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Sistema Elã©ctrico Raya 2

Hister

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mantenimiento.montacargas2015
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223 vistas112 páginas

Sistema Elã©ctrico Raya 2

Hister

Cargado por

mantenimiento.montacargas2015
Derechos de autor
© © All Rights Reserved
Nos tomamos en serio los derechos de los contenidos. Si sospechas que se trata de tu contenido, reclámalo aquí.
Formatos disponibles
Descarga como PDF o lee en línea desde Scribd
ELECTRICAL SYSTEM N30-40 XMR2 N25XMDR2 N50XMA2 N30XMXDR, N45XMXR UNIT CODE B470, B471, F138, A264 HYSTER PART NO. 1459000 100 SRM 719 SAFETY PRECAUTIONS MAINTENANCE AND REPAIR ‘When lifting parts or assemblies, make sure that all slings, chains and cables are correctly fastened and that the load being lifted is balanced. Make sure that 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 onelectrilift trucks. Disconnectthe 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 and working area clean and in order. 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 that all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when making repairs or if the unit needs repairs. Make sure you follow the DANGER, WARNING and CAUTION notes in the instructions. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area has ventilation, CONTENTS INTRODUCTION COMPONENT REPAIR AND TESTING GENERAL cette CONTACTOR PANEL ASSEMBLY Description'Features Removal ... Installation CONTACTORS .. DescriptioniFeatures Auxiliary Switch Testing . Removal ... Installation... . “EE” Contactors FUSES SIDACTOR RELAYS ......0005 Description/Features Enable .... Hourmeter Coil testing Contact testing . Removal and Installation . HEIGHT LIMIT SWITCH Removal ... Testing .. Installation . KEY SWITCH Removal .. Installation ; BATTERY DISCONNECT SWITCH Removal ... Installation Boosen506 cee : PROPORTIONAL ELECTRO-HYDRAULIC CONTROL VALVES . . Manual Lowering, Operation .... ‘SELECTOR VALVES Testing/Removal/Installation CONTROL HANDLE . 213 Description/Features 1B CONTROL HANDLE ASSEMBLY 4 Removal . : weld Installation severed CONTROL HANDLE TRACTION AND HYDRAULIC POTENTIOMETERS ....... 15 Removal... we Installation and Adjustment... Testing HORN BUTTON Removal Installation ........ . MAIN INTERFACE BOARD (MIB) DESCRIPTION/FEATURES . OPERATION : LED DISPLAY «2.00.00 cccecceeee . 19 MIB REMOVAL... cee pee ved MIB INSTALLATION we 20 MAIN INTERFACE BOARD (MIB) ADJUSTMENTS 22 GENERAL 6.000.020 ceeeeeeeeeecees a DEFAULT VALUES . cee beet teeeeeeeeeeee ee 2d CHECKING THE MODEL CODE AND SET-UP STATUS ..... a MIB CALIBRATION PROCEDURE Step 1 Entering the Set up Mode Step 2. Erasing the Model Code Step 3 Setting the Model Code Step4 Calibrating the Hydraulic Potentiometer Range Step 5 Calibrating the Traction Potentiometer Range Step 6 Exiting the Set up Mode and Saving the New Values . . CUSTOMIZING MIB FUNCTIONS MIB FUNCTION DESCRIPTIONS a Function 01 Model Code Default Values ........0000000000se005 Function 02 Lift - Minimum Rate Function 03. Lift - Maximum Rate Function 04 Lower - Minimum Rate . Function 05 Lower - Maximum Rate Function 06 Extend ~ Rate ...... Function 07 Extend - Rate . Function 08 Retract - Rate ...... Function 09 Retract ~ Rate ...... Function 10 Tilt Up - Rate .. Function 11 Tilt Up - Rate Function 12 Tilt Down - Rate Function 13 Tilt Down - Rate BYRERBBE Function 14 Sideshift Right - Rate ....... Function 15 Sideshift Right - Rate Function 16 Sideshift Left ~ Rate Function 17 Sideshift Left - Rate Function 18 Auxiliary Hydraulic Function ~ Starting Rate Function 19 Auxiliary Hydraulic Function - Stopping Rate Function 20 Maximum Travel Speed - Mast Elevated Function 21 Model Code - MTVED . Function 22. Model Code - MTVRD Function 23. Power Steering Contactor - Minimum Current - Function 24 Power Steering Contactor - Maximum Current Function 25. Lift Pump Contactor ~ Minimum Current Function 26 Lift Pump Contactor - Maximum Current Function 27 Auxiliary Function Coils - Minimum Current .. Function 28 Auxiliary Function Coils - Maximum Current . Function 29 Steering Pump Time Delay Function 30 Exit and Save New Values . Function 31 Erase ..... feos Function 32 _Lift/Lower Potentiometer - Set up. Function 33 Not Used Function 34 Traction Potentiometer - Set up .. Functions 35 to. 56 NOT USED Function 57. Extend/Retract Equalization Time Function 58. Lift Ramp Up - Function 59 Lift Ramp Down Function 60 Lower Ramp Up - Function 61 Lower Ramp Down Function 62 Traction Potentiometer Neutral Band Adjustment . Function 63 _Lift/Lower Potentiometer Neutral Band Adjustment Function 64 Tilt Speed % ......- Function 65 Reach Low Speed % Function 66 Reach High Speed % .. Function 67 Sideshift Speed % Function 68 Sideshift Equalization Time . MIB STATUS, WARNING, AND FAULT CODES GENERAL . ‘TROUBLESHOOTING CHARTS ..... . BLANK OR UNDEFINED CODE CONDITIONS STATUS CODES WARNING CODES FAULT CODES RBEBRRBRRBRBRERERS "This section is for the following models: N2SXMDR2, N30/40XMR2, NSOXMA2, N30XMDR2, N4SXMR2 N30XMXDR,N4SXMXR GHYSTER COMPANY 1999 QRRRKRK BEssssssER 30 “THE QUALITY KEEPERS” HYSTER APPROVED PARTS INTRODUCTION GENERAL + Control Handle Assembly + Contactor Panel Assembl ‘The electrical control system consists of the following, te Cane Sen ‘major components: See the section DIAGRAMS, 8000 SRM 690 and * Main Interface Board (MIB) 8000 SRM 748 for additional information. + Proportional Electro-Hydraulic Valve NOTE: Throughout this manual the terms right, left, ‘+ SEM Traction Motor Controller front, and rear relate to the viewpoint of an operator * Dash Display Assembly standing in the truck facing the forks. OPERATOR CONTROLS ia | Hobe SELECTS MIB MAIN INTERFACE BOARD (SYSTEM 5 150R) | logs (es J FIGURE | - LOGIC DIAGRAM COMPONENT REPAIR AND TESTING GENERAL 1. Tocheck for wire connections to the frame, discon- nect the battery connector completely and use an ohm- meter to check the circuits. Check for resistance of ‘50,000 ohms or more between each terminal of the lift truck portion of the battery connector and a clean con- nection point onthe frame of the lift truck. There should benoelectrical connections to the frame of the lift truck. ‘Wires or terminals without insulation can cause elect cal connections to the frame, Isolators used to insulate circuit boards from the frame that are missing, broken or installed incorrectly can also cause these connections. 2. Check for voltage between each terminal of the con- nector onthe battery anda clean metal connection onthe frame of the lifttruck. Itis normal to measure some volt- age between the battery and the frame even if the resi tance checks are correct. If voltage is detected, use an ammeter to measure current flow. The current must not exceed 100 milliamperes. Current in excess of 100 mi liamperes can cause a problem. If voltage is detected at the frame, check to be sure the battery is clean and is not defective. Clean the battery and battery compartment as required. A build-up of car- ‘bon dust in the electric motors can also cause measur- able voltage at the frame. Wear appropriate safety equipment and remove carbon dust from motors using, dry compressed air. CONTACTOR PANEL ASSEMBLY ‘The contactor panel assembly is located in the front compartment. The contactor panel assembly contains the following major components: + Traction Contactor + Lift Pump Contactor + Steer/Auxiliary Pump Contactor + 3 Power Fuses + 4 Control Fuses 2 + “ER” Enable Relay) + “HR” (Hourmeter Relay) “EE” trucks only + Sidactor (for dash display protection) + 6 Amp Diode (for reverse polarity protection) Components used in the contactor panel assembly are common to both the 24 volt truck and the 36 volt truck options. POWER FUSES CONTROL FUSES: TRACTION MOTOR CONTROLLER ‘TRACTION CONTACTOR POWER STEERING CONTACTOR LIFT PUMP CONTACTOR: mis. FIGURE 2 - ELECTRICAL COMPARTMENT Removal 1. Move the lift truck toa safe level area. Tum the key switch off and remove the key. Put a“DO NOT OPER- ATE” tag on the control handle. Put blocks under the drive wheels to keep the lift truck from moving. See the PERIODIC MAINTENANCE MANUAL. Refer to HOW TO PUT THE LIFT TRUCK ON BLOCKS. A warning Disconnect the battery by separating the connector before opening the compartment cover or inspect- ing/repairing the electrical system. Ifa tool causes a short circuit, the high current flow from the battery can cause an injury or parts damage. 2. Disconnect the battery and separate the connectors. 3. Lift off the cover for access to the compartment. A WARNING The capacitor in the traction motor controller can hold an electrical charge after the battery is discon- nected. To prevent electrical shock and injury, dis- charge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the ca- pacitors in the controller by connecting a load (such as a contactor coil ora horn) across the controller's B+ and B— terminals. DO NOT use a screwdriver to discharge the traction motor controller. 4, Discharge the controller by connecting a load across terminals B+ and B=. NOTE: The contactor panel assembly does not nor- mally have to be removed from the lift truck. The steps listed above must be done to service any item that is at- tached to the contactor panel assembly. 5. To remove the panel assembly, tag and disconnect the power wires to the contactors and the fuses. 6. Unplug the control wires from the main wire har- ness at the P-1 connector. 7. Remove the capscrews, flat washer, lockwasher, and nut retaining the top of the panel assembly to the frame, Remove the two nuts, lockwashers, and flat washers retaining the bottom of the panel assembly to the frame, Remove the contactor panel assembly. 8. For the A264, remove the three nuts, lockwashers and flat washers retaining the panel assembly to the frame. Remove the contactor panel assembly. Installation 1. Align the contactor panel with the mounting holes in the frame. Install the two flat washers, lockwashers, and nuts on the bottom of the panel assembly. Install the capscrew, flat washer, lockwasher, and nut to retain the top of the panel assembly. 2. For the A264, replace the contactor panel on the three mounting capscrews. Install the flat washers, lock- ‘washers, and nuts fo retain the panel assembly. FIGURE 3 - ELECTRICAL COMPARTMENT 3. Install the power wires and fuses. See the section DIAGRAMS, 8000 SRM 690 and 8000 SRM 748 for additional information. 4, Reconnect the control wires. 5. Connect the battery. 6. Remove the blocks from under the drive wheels, re- move the “DO NOT OPERATE” tag and install the key. CONTACTORS Description/Features Contactors are switches, controlled by electromagnets (coils), that close and open power circuit. The MIBand traction motor controller have internal electronic driv- ers to control the current to the coils of the contactors. ‘The electromagnetic field in the coil moves the armature against spring pressure to close the contact. When the coil is deenergized, the spring pressure moves the arma- ture and opens the contacts. When a spring holds the 3 contacts of a switch open, the switch is called normally open (NO). If a spring holds the contacts of a switch closed, the switch is called normally closed (NC).. FIGURE 4 - TYPICAL SPNO CONTACTOR ASSEMBLY The contactor contacts are made of special silver alloy. ‘The contacts will normally look black and rough from normal operation. This condition does not cause prob- lems with the operation of the lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CON- ‘TACTS. DO NOT LUBRICATE THE CONTACTS. Replace the contacts when the silver alloy is worn away to the base support metal. ‘The traction, lift pump and steer pump contactors are SPNO (single pole normally open) contactors. SPNO contactors have one set of normally open contacts. S FIGURE 4. Auxiliary Switch (On non “EE” rated trucks, there is an auxiliary switch ‘mounted on the lift pump contactor. A mechanical con- nection between the lift pump contactor and the auxilia- ry switch causes the contacts of the auxiliary switch to close when the lift pump contactor is closed. ‘The lift pump contactor auxiliary switch is used to send signal to the dash display whenever the lift pump is ac- tivated. When the signal is present, pump hours accu- mulate on the dash display hourmeter. NOTE: The lift pump contactor auxiliary switch is not present on “EE” rated trucks. On “EE” rated trucks a hourmeter relay is used tosend a signal to the dash, play. Refer to RELAYS for additional information on the hourmeter relay. Testing A WARNING Parts of this procedure requires working on the lift truck with full electrical current present. Do not wear any rings, watches or any other jewelry while working around the contactor panel assembly. When manually closing a contactor with the power connected, use a properly insulated tool. 1. Lift off the cover for access to the compartment, 2. Check the condition of the battery. If it is not fully charged, charge or ceplace the battery with a fully charged battery before continuing, 3. Visually check to see if the contactor closes when the circuit is energized. If the contactor closes, skip to ‘Step 9. Ifthe contactor does not close, proceed to Step 4. 4, Connect a voltmeter across the coil terminals. Verify that the correct voltage is being appliedto the coil with the circuit energized. See TABLE 1. ‘TABLE 1 - CONTACTOR COIL VOLTAGES contactor con | PUL. | storonimate Traction 2avoits | 12volts Lift Pump 2avorts | 12volts Power Steering/Aux. Pump | 24 volts 12 volts NOTE: Pullin voltage occurs for only approximately 1 ‘second. Some voltmeters may not display this voltage. 5. Check the contactor for loose, broken or corroded connections at the contactor. 6. Check the mechanical function of the contactor. Use an insulated tool, such as an electricians screwdriver to manually close the contactor tips. Check for looseness or binding of the moving parts of the contactor. The parts should move fieely, but the parts must not be so loose that the movement is sloppy. 7. Visually check the tips for pitting, burning or wear. 8. Ifa external suppressor is attached to the coil, re- move the suppressor. Check the resistance of the contac- tor coil. Compare the reading against the values for the type of contactor being tested. See TABLE 3, Page 8 forcoil resistance values. Readings not within the listed limits indicate the following: High Resistance-Corrosion or an open coil Low Resistance-Shorted or a burnt coil NOTE: No external suppressors are used on contac- tor coils which are controlled by the MIB or the traction ‘motor controller. The MIBand traction motor controller have internal suppressors for these contactor coils. 9. Ifthe contactor closes but the truck does not work properly, check the electrical function of the high cur- rent section of the contactor (the tips and buss bars). With the lift truck battery connected and all switches ‘closed, connect a volt ohmmeter across the high current terminals of the contactor. Check the voltage drop across the contactor tips. Set the voltage scale of the metertothe lowestrange higher than battery voltage (50 volts for a 36 volt battery, etc.). On ‘SPNO contactors, read the voltage across the contactor with the tips open. Battery voltage should drop to zero or near zero as the tips close. A voltage drop of 2 volts or more across the closed tips indicates a poor contact or high resistance. Check for burned or worn tips, incorrect size or mismatched tips and for an incorrect gap setting on contactors with ad- justable point gaps. Removal Disconnect the battery and separate the connectors. A WARNING ‘The capacitor in the traction motor controller can hold an electrical charge after the battery is discon- nected. To prevent electrical shock and injury, dis- charge the capacitor before inspecting or repairing ‘any component. Wear safety glasses. Make certain. the battery has been disconnected. Discharge the ca- pacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B — terminals. DO NOT use a screwdriver to discharge the traction motor controller. 2. Discharge the controller by connecting a load across terminals B+ and B—. 3. Refer to CONTACTOR PANEL ASSEMBLY, RE- MOVAL for access to the contactors. 4, Tag and disconnect the wires and/or bus bars to the contactor. 5. Remove the capscrews, flat washers and lockwash- ers retaining the contactor to the contactor panel assem- bly. For the pump contactor, remove the capscrews, lockwashers, flat washers and nuts. Installation 1. Alignthe contactorto the contactor panel assembly. Install the contactor using the capscrews, flat washers and lockwashers, 2. Connect the wires and/or bus bars to the contactor. See the section DIAGRAMS, 8000 SRM 690 and 8000 SRM 748 for additional information. 3. Install the cover on the front compartment. 4. Connect the battery and test the operation of the truck. “EE” Contactors When “EE” contactors are used, additional steps are re- quired to service the contactors as the contactors are covered by an enclosure shroud. 1. Remove the capscrews retaining the enclosure shroud to the contactor. Remove the shroud. 2. Remove the insulator. 3. Service the contactor. 4, Install the insulator. 5. Position the enclosure shroud over the contactor and fasten the shroud to the coil and frame assembly. 1. ENCLOSURE 6. COVER ‘SHROUD 7. RETURN SPRING 2. CAPSCREW 8 MOVING CONTACT 3. INSULATOR 9. BASE 4, FIXED CONTACT 10. PLUNGER. 5, CAPSCREW 11. COIL AND FRAME FIGURE 5 - TYPICAL “EE” CONTACTOR FUSES ‘The fuses for these lift trucks are located on the contac- tor panel assembly. Lift off the cover for access to the contactor panel assembly. A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspect ing/repairing the electrical system. If.a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage. ‘TABLE 2 - FUSES rae oar = Fut ‘Traction 325 Amp Be ee om | Sao coe eine co vu [ Speyer | same Se Bs maa cana ‘When the lift truck has the provision for “EE” the fuses FUI, FU2, and FU3 are enclosed in a fuse box on the contactor panel assembly. For access to the fuses, see FIGURE 6. Remove the capscrews and lockwashers re- taining the floor insulator, wall insulator and the fuse box enclosure to the base plate to test or remove the fuses. ‘The fuses may be checked for continuity ifit cannot be determined visually that a fuse has failed. Make certain toreplace any failed fuse with one of the same amperage ‘when replacing a fuse. See TABLE 2. SIDACTOR ‘The sidactor is used to protect the dash display from voltage spikes or excessive voltage, which can occur ifa battery charger is accidently connected to the lift truck. ‘The sidactor is normally open and connected between, fuse FU4 (battery +) and battery —. Battery + to the dash display is also supplied through FU. The sidactor is designed to momentarily short when higher than nor- detected. This will cause the 1 amp fuse (FU4) to fail before damage to the dash display occurs. mal voltas ‘Always replace fuse FU4 with a 1-amp fuse. The sidac- tormust be checked whenever the 1-amp fuse has failed. INSULATOR-TERMINAL ENCLOSURE-FUSE BOX NUT LOCKWASHER ‘SPACER LOCKNUT FUSE 100 AMPS ‘SCREW WASHER ‘TERMINAL POST ‘CAPSCREW INSULATOR-FLOOR ‘SPACER WASHER NUT FUSE 400 AMPS FUSE 325 AMPS INSULATOR-WALL LOCKWASHER CAPSCREW Check the sidactor by disconnecting it and measuring the resistance. Replace the sidactor if it tests shorted. FIGURE 6 - ENCLOSED FUSE BOX “EE” APPLICATION ‘The “ER” (enable relay) is found on all narrow aisle model ifttrucks. The “HMR” (hourmeter relay) is pres- ent only on “EE” rated trucks. Both relays are mounted on the contactor panel assembly. Enable ‘The enable relay is controlled by the MIB. The enable relay supplies battery volts to the lift pump contactor coil, the power steering contactor coil, the hydraulic control valve coils, the selector valve coilsand ocertain MIBinput switches. The relay will deenergize these cir- cuits if certain fault conditions occur. Refer to MIB. codes 70, 71, 72 and 73. Hourmeter ‘The“HMR” (hourmeter relay) isused to senda signal to the dash display whenever the lift pump is activated. ‘When the signal is present, pump hours accumulate on the dash display hourmeter. The “HMR” (hourmeter relay) is present only on “EE” rated trucks. NOTE: Onnon“EE” rated trucks, there isan auxilia- zy switch mounted on the lift pump contactor. Refer to CONTACTORS, AUXILIARY SWITCH for addition- al information. BOSCH AND POTTER BRUMFIELD RELAYS PIN ARRANGEMENT ‘SCHEMATIC FIGURE 7 - “ER” AND “HMR” RELAYS ‘TABLE 3 - HYDRAULIC CONTROL VALVE/RELAY COIL RESISTANCE VALUES ‘COIL RESISTANCE con. LocaTion | manuractunen |°CL AESISACE | Test Points “LIFT and “LOWER cols 65 + 05 ohms Coit feads a ooo He Cont AUUP (aay w») — LHyrauie Consol] Yrers “AUX DOWN" (auxiliary down) 18 £ 02ohms eT coils Robert Bosch Garp. | 305 + 15 ohms “ERT (enable relay) coil | Contactor Panel | “Bote & Brum Terminals 85 and 86 Prater & Buell T 360 « 35 ohms Robert Bosch Corp, | 905 + 15 ohms HM (hourmeter relay) colt | Drive Unt (CEE trucks only) Compartment | Potter & Brumfield | 365. 35 ohme | Terminals 85 and 86 Go. "SS" (sideshift) coils Extend Assembly | _ HydraForce inc. 39 + 4ohms: Coil leads “EX” (reach) coils Mast HydraForce Inc. 39 + 4 ohms: Coil leads "it pum) Contactor Pant ‘Albright 13 + 2 ohms Coit feads "PS" (power steering) | Contactor Panel ‘Abright 52 + 4 ohms Coit leads Traction - B470, B471" ‘Contactor Panel Albright 17 + 2ohms Coil leads Traction -F1982, A268" | Contactor Pane! “Albright 13 + 2ohms Coil leads N25XMDR2, N30/40XMR2, NSOXMA2 2 N3OXMDR2, N45XMR2 S.N3OXMXDR, N45XMXR Coil testing ‘The “ER” and “HMR” relay coils can be tested forresis tance across terminals 85 and 86. ee FIGURE 7 fortest point locations. Replace any relay which hasa coil resis tance value outside of specifications. See TABLE 3 for coil resistance values NOTE: The “ER” (enable relay) and “HMR” (hour- ‘meter relay) are both single pole, double throw (SPDT) type relays. They are manufactured by either The Bosch, ‘Company or Potter & Brumfield. When testing these re- lays, itis important to identify the manufacturer due to different coil resistance values. The name of the manufacturer is stamped on the relay. Contact testing ‘The normally open contacts of the “ER” and “HMR” re- lays are checked at terminals 30 and 87. Check for a voltage drop across the NO contacts with the relay ener- gized. Replace any relay which has a voltage drop ex- ceeding 2 volts. See FIGURE 7 for test point locations. Removal and Installation ‘To remove the relays, tag and disconnect the wires. Re- move the capscrews and lockwashers retainingthe relay to the contactor panel assembly or the mounting bracket. Replace the relays by aligning the relay with the mount- ing holes in the contactor panel assembly or mounting bracket and installing the capscrews and lockwashers. HEIGHT LIMIT SWITCH Removal 1. Move the lift truck to a safe level area. Raise the mast high enough to obtain access to the height limit switch, SAFETY CHAIN THE MAST. See the PE- RIODIC MAINTENANCE MANUAL. Refer to SAFETY PROCEDURES WHEN WORKING NEAR ‘THE MAST. Turn the key switch off and remove the key. Puta “DO NOT OPERATE” tagon the control han- dle, Put blocks under the drive wheels to keep the lift truck from moving, See the PERIODIC MAINTE- NANCE MANUAL. Refer to HOW TO PUT THE LIFT TRUCK ON BLOCKS. A WaRNING ‘Do not raise the frame of the truck with the forks raised. The stability of the truck is reduced. Raising the frame of the truck with the forks raised could cause it to tip over. Tipping of the truck can cause personal injury or property damage. A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspect- ing/repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery ‘can cause an injury or parts damage. 2. Disconnect the battery and separate the connectors. 3. Disconnect the X-11 plug. 4, Remove the two capscrews retaining the cover to the switch body. Pry the cover from the switch. 5. If the switch must be replaced, tag and disconnect the wires. 6. Remove the switch by removing the mounting caps- crews, lockwashers and nuts. Testing 1. Remove wires #56 and #74 from the switch and check the resistance between switch terminals 7 and 8. 2. Replace any switch that does not read continuity be- tween switch terminals 7and 8 with the switch activated and no continuity with the switch not activated. NOTE: The switch is not activated (switch arm out) ‘when the inner mast is elevated. The switch is activated (switch arm depressed) when the inner mast is lowered. Installation 1. Position the new switch on the bracket. Install the mounting capscrews, lockwashers and nuts. 2. Connect wire #56 to terminal 8 and wire #74 to terminal 7. 3. Install the cover using the two capscrews. 4, Connect the X-11 plug, 5. Remove the safety chains from the mast. Connect the battery, install the key and check the mast for proper operation. 6. Remove the blocks from under the drive wheels. Remove the “DO NOT OPERATE” tag from the control handle, 7. Verify that the switch is activated with the inner mast lowered and not activated with the inner mast ele- vated. Check wire #74 at the X-11 plug. Battery volts, should be present at wire #74 with the inner mast low- ered, Near O volts should be present at wire #74 with the inner mast elevated. 8 Check the truck for proper operation. Maximum travel speed must be limited with the mast elevated above free lift. KEY SWITCH Removal 1. Move the lift truck toa safe level area. Turn the key switch off and remove the key. Put a “DO NOT OPER- ATE” tag on the control handle. Put blocks under the drive wheels to keep the lift rick from moving. See the PERIODIC MAINTENANCE MANUAL. Refer to HOW TO PUT THE LIFT TRUCK ON BLOCKS. A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspect- ing/repairing the electrical system. Ifa tool causes a short- ‘the high current flow from the battery can cause an injury or parts damage, 2. Disconnect the battery and separate the connectors. 3. Remove the cover for access tothe wiring to the key switch. 4, Tag and disconnect the electrical wires to the key switch, 5. Remove the nut retaining the key switch to the mounting bracket and remove the key switch. Installation 1. Position the new switch in the mounting bracket Install the nut to retain the key switch. 2. Install the electrical wires tothe key switch. See the section DIAGRAMS, 8000 SRM 690 and 8000 SRM 748 for additional information. 3. Install the cover. 4, Connect the battery. 5. Remove the blocks from under the drive wheels, re- ‘move the “DO NOT OPERATE” tag and install the key. BATTERY DISCONNECT SWITCH Removal 1. Move the lift trick toa safe level area. Turn the key switch off and remove the key. Put a“DO NOT OPER- ATE” tag on the control handle. Put blocks under the drive wheels to keep the lift truck from moving, See the PERIODIC MAINTENANCE MANUAL. Refer to HOW TO PUT THE LIFT TRUCK ON BLOCKS. A WaRNING Disconnect the battery and separate the connector before opening the compartment cover or inspect- ing/repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage. 2. Disconnect the battery and separate the connectors. 3. Remove the cover foraccess to the wiringtothe bat- tery disconnect switch. 4, Tagand disconnecttthe electrical wires tothe battery disconnect switch, 5. Pull the battery disconnect switch up to the “ON” position. 6. Rotate the red knob to align the hole in the housing the hole in the shaft. 7. Insert a 4.0 mm (0.15 in) diameter rod through the hole in the housing and into the hole in the shaft, to pre- vent the shaft from rotating. 8 Rotate the red knob counterclockwise to remove it. 9, Remove the two screws retaining the battery dis- connect switch to the mounting bracket and remove the switch, Installation 1. Ensure the replacement battery disconnect switchis in the “ON” (up) position and that the red knob is removed. 2. Position the new battery disconnect switch in the mounting bracket, Install the two screws retaining the battery disconnect switch to the mounting bracket. 10 3. Install the red knob by threadingiit clockwise. Insert 24.0 mm (0.15 in) diameter rod through the hole in the housing and into the hole in the shaft, to prevent the shaft from rotating while installing the knob. Remove the rod from the housing once the red knob is tightened securely, 4, Install the electrical wires to the battery disconnect, switch. 5. Install the cover. 6. Connect the battery. 7. Remove the blocks from under the drive wheels, re- move the “DO NOT OPERATE” tag and install the key. PROPORTIONAL ELECTRO-HYDRAULIC CONTROL VALVES ‘There are four electrically operated proportional valves located on the main hydraulic control valve, These pro- portional valves are controlled by solenoids. Valve openings are controlled by varying the electrical current in the valve coils, See the section HYDRAULIC SYSTEM, 1900 SRM (689 for instructions for testing, removal and replace- ‘ment of the proportional valves. FIGURE 8 - PROPORTIONAL ELECTRO-HYDRAULIC VALVE Manual Lowering A WaRNING Always verify that no one is under or near the lift mechanism or load during the manual lowering pro- cedure. Verify that there are no obstructions beneath the lift mechanism or load. If the mast does not lower when the manual lowering valve is activated, deacti- vate the valve immediately and determine the cause. A provision is provided on the lowering valve to allow ‘manual lowering of the forks if necessary. Manual low- ering is accomplished by inserting a 1/8 inch allen wrench into the manual lowering screw (located in the center of the lowering valvistor) and slowly turning it clockwise until the forks begin to lower. On the A264 the manual lowering screw has been replaced by aknob, itoperates just like the screw. See FIGURE 9. Be sure to return the screw/knob to the original position once the ‘manual lowering process is complete by slowly turning the screw/knob counterclockwise until it stops. & WARNING Failure to return the manual lowering screw or knob to the full counterclockwise position will cause the forks to lower unexpectedly. 1. AUXILIARY UP 2. AUXILIARY DOWN. 3. LIFT 4. LOWER, MANUAL, LOWERING KNOB OR SCREW FIGURE 9 - HYDRAULIC CONTROL VALVE, Operation ‘The four electrically operated proportional valves lo- cated on the main hydraulic control valve are controlled by solenoids. These solenoids can be checked for resis- tance by removing the leads to the solenoids and tested 1g a volt ohmmeter. See TABLE 3, Page 8 for coil resistance values. Ifa reading other than those listed are obtained, replace the solenoid. See the section HYDRAULIC SYSTEM, 1900 SRM 689 for information on removing and instal- ling the solenoids. SELECTOR VALVES HYDRAULIC FITTING SOLENOID VALVE BODY HOSE INNER FRAME PORT TUBES (CHECK VALVE ASSEMBLY FIGURE 10 - REACH SELECTOR VALVE (Used on REACH model trucks only.) Ifthe lifttruckhas provisions for tilt, sideshift, and reach there are solenoids used to operate these functions lo- cated on selector valves. One selector valve assembly, containing two selector valves and two solenoids is lo- cated on the mast assembly and used to select between reach or tilt. See FIGURE 10. A second selector valve assembly, also containing two selector valves and two solenoids, is located on the reach assembly and used to select between tilt and sideshift. See FIGURE 11. The second selector valve assembly is only fitted on reach model trucks equipped with an optional sideshifter. When tilt is selected by the operator at the control han- dle, neither of the two selector valve assemblies is ener- gized. When reach isselected, the coils are energized on the reach selector valve, When sideshift is selected the u coils on the optional sideshift selector valve are ener- ized. Testing/Removal/installation Solenoids can be checked for resistance by removing, the leadstothe solenoids and tested usinga volt ohmme- ter. See TABLE 3, Page 8 for coil resistance values. Ifa readingother than those listed are obtained, replace the solenoid. See the section HYDRAULIC SYSTEM, 1900 SRM 689 for additional information. n 1. SOLENOID 2. VALVE BODY FIGURE 11 - SIDESHIFTER SELECTOR VALVE CONTROL HANDLE Description/Features ‘The contro! handle controls the direction and speed of the lift truck. See FIGURE 12. Travel is activated by ‘moving the entire control handle in the desired direction of travel. Pushing the control handle toward the forks makes the lift truck travel toward the forks. To change direction, move the control handle in the opposite direc- tion of lift truck travel, regardless of travel speed. The lifttruck will come toa stop, then accelerate in the oppo- site direction. This controlis proportional; therefore, the farther the control handle is pushed, the faster the lift truck will decelerate or acvelerate. Ifthe control handle is released, it will return to neutral, and the truck will coast to a stop. ‘The control handle controls the direction and speed at which the carriage moves vertically on the mast. Lift/ lower is activated by moving the entire control handle toward the left orright side of the lift truck. Ifthe control handle is moved to the right, the carriage lifts; if the con- trol handle is moved to theleft, the carriage lowers. This control is also proportional. The farther the lever is moved, the faster the carriage lifts or lowers. HORN TILT/SIDESHIFT EXTEND RETRACT FIGURE 12 - CONTROL HANDLE SIDESHIFT LEFT TILT FORWARD SIDESHIFT RIGHT TILT BACK 2 BY \ fg FIGURE 13 - TILT/SIDESHIFT DISK ‘The Tilt/Sideshift disk, located atthe top of the control handle lever, controls the tilting of the forks and side- shifting of the carriage. See FIGURE 13. The diskis op- crated with the thumb of the right hand. To tilt forward, press the top of the disk. To tilt back, press the bottom of the disk. On lift trucks equipped with a sideshifting car- riage, press the left side of the disk to move the carriage to the left and press the right side of the disk to move the carriage tothe right. Unlike the variablespeed travel and liftvlower functions, tilt and sideshift are single speed functions. ‘The Horn button is located on the side of the control handle facing the operator, just below the tiltsideshift disk. The horn is activated by pressing the button with the thumb. ‘The Extend and Retract buttons are located on the shaft of the control handle. The buttons are used to extend or retract the reach attachment. When the upper button is pressed, extend is activated at low speed. To continue extending at high speed, the operator simultaneously presses the upper and lower auxiliary buttons. To re~ tract, the operator presses only the bottom auxiliary but- ton. Tocontinue retracting athigh speed, the operatorsi- multaneously presses the lower and upper auxiliary buttons. B TILTISIDESHIFT SELECT DISK FORWARD, TRAVEL STEERING. DISK BATTERY DSCONNECT ‘SWITCH HORN EXTEND BUTTON RETRACT FIGURE 14 - OPERATOR CONTROLS CONTROL HANDLE ASSEMBLY Removal 1. Move the lift ruck toa safe level area. Turn the key switch off and remove the key. Put blocks under the drive wheels to keep the lift truck from moving, See the PERIODIC MAINTENANCE MANUAL. Refer to HOW TO PUT THE LIFT TRUCK ON BLOCKS. connect the battery and separate the connectors. 3. Remove the cover. A WARNING The capacitor in the traction motor controller can hold an electrical charge after the battery is discon- nected. To prevent electrical shock and injury, dis- charge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the ca- pacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B+ and B— terminals. DO NOT usea screwdriverto discharge the traction motor controller. 4, Discharge the controller by connecting a load across terminals B+ and B=. 5. Disconnect the X7, X8, and X9 connectors cable at the control handle wiring harness. 6. Remove the socket head screws and lockwashers, securing the control handle to the frame and remove the control handle assembly. Installation 1. Position the control handle assembly on the frame and secure in place with four screws and lockwashers. 2. Route the cable as shown in FIGURE 15. Connect plugs X7, X8, and X9. See the section DIAGRAMS, 8000 SRM 690 and 8000 SRM 748 ‘or additional in- formation. 3. Connect the battery. 4, Calibrate the MIB to the potentiometers. Refer to MIB CALIBRATION, 5. Install the cover. TY-WRAP THE WIRES FROM THE POTENTIOMETER TO THE BRACKET STANDOFF GUIDE ‘THE WIRES FROM THE HANDLE MUST BE FREE TO SLIDE THROUGH THE UPPER CLIP ‘TY-WRAP THE WIRES FROM THE POTENTIOMETER TO THE BRACKET THREADED SHAFT MUST BE FLUSH WITH UNDERSIDE OF BRACKET TO PREVENT WIRES FROM RUBBING ON MECHANISM FIGURE 15 - CONTROL HANDLE WIRING ROUTING CONTROL HANDLE TRACTION AND HYDRAULIC POTENTIOMETERS Removal 1. Disconnect the battery and discharge the capacitors. 2, Remove the cover. 3. Grip the bottom of the control handle boot and roll it upward to access the dual axle mechanism. See FIGURE 16. 4, Unplug the potentiometer wire harness from the truck wire harness. 5. Loosen the setscrew holding the potentiometer in the dual axle. See FIGURE 16. 6. Remove the screw holding the bracket to the dual axle mechanism. 7. Remove the potentiometer/wire harness assembly from the dual axle mechanism. 8, Remove the locknut on the collar ofthe potentiome- ter and remove the potentiometer from the mounting bracket. 1s DUAL AXIS MECHANISM CONTROL HANDLE BOOT BRACKET WASHER ‘SCREW ‘TRACTION POTENTIOMETER LOCKNUT SETSCREW BRACKET 10. HYDRAULIC POTENTIOMETER 11. SCREW 12. WASHER 13, SETSCREW FIGURE 16 - CONTROL HANDLE DUAL AXIS MECHANISM - EXPLODED VIEW Installation and Adjustment NOTE: |The traction potentiometer wire harness and the hydraulic potentiometer wire harness must remain disconnected through Step 7. 1. Place the mounting bracket over the collar of the potentiometer and secure with the locknut. See FIGURE 16. 2. Adjust the potentiometers to the mid-range posi- tion. Compare the resistance measured between poten tiometer wires BROWN and RED with the resistance measured between potentiometer wires BLACK and RED. ‘The potentiometer is at the mid-range position when the resistance readings are equal within 100 ohms. Rotate the potentiometer shaft while holding the potentiometer body forthe correct resistance readings. Tighten the set- screw in the gear at this time. 3. Without rotating the potentiometer shaft, install the potentiometer and bracket onto the dual axle mechanism. 16 4, Tighten the setscrew securing the shaft of the poten- tiometer in the dual axle. TABLE 4 - POTENTIOMETER WIRING Potterminal | WireNumber_| We Number igh 21 (BRN) 31 GLK) Wiper 22 (RED) 32 (RED) Low 23 (BL) 33 (BAN) 5. Use an ohmmeter to compare the resistance mea sured between potentiometer wires BROWN and RED with the resistance measured between potentiometer wires BLACK and RED. Verify thatthe resistance read- ings are equal within 100 ohms. 6. If the resistance values are not correct, loosen the hex. nut securing the potentiometer to the mounting bracket and rotate the body of the potentiometer slightly while monitoring the resistance. Once the calculated value is reached, tighten the hex nut. See FIGURE 16. NOTE: Failure to properly center the potentiometer can cause a fault code to occur. The fault code may occur immediately or intermittently. 7. Route and secure the control handle wires as shown in FIGURE 15. 8. Plug the potentiometer wire harness into the maii wire harness. See the section DIAGRAMS, 8000SRM (690 and 8000 SRM 748 for additional information. 9. Connect the battery. 10. Calibrate the MIB to the potentiometers. Refer to MIB CALIBRATION. A caution Whenever adjusting or replacing a potentiometer the MIB must be calibrated to the potentiometer. 11. Return the control handle boot to the normal operat- ing position. 12, Install the cover. Testing ‘The potentiometer is rated at 1OKQ + 10% and has a 180° sweep. Potentiometer operation canbe verified by checking resistance with an analog volt ohmmeter. 1. Unplug the potentiometer and remove it from the control handle. Refer to REMOVAL. 2. Connect the ohmmeter to the potentiometer. See ‘TABLE S for test points and specifications. TABLE 5 - POTENTIOMETER SPECIFICATIONS Test Test Points 1_| Between BROWN and BLACK 2 [Between BROWN and RED [Between BLACK and RED 7As the potentiometer is rotated through its 160° range Resistance Value TOKO = 10% *0-10KQ # 10% NOTE: When performing test 2 and test 3, watch the needle on the meter while slowly rotating the poten- tiometer shaft. Look for a smooth sweep of the needle from minimum to maximum values. Replace potentiometers that do not meet the specifica tions in TABLE 5. Also replace any potentiometer with erratic readings or operation, HORN BUTTON & WARNING ‘The capacitor in the traction motor controller can hold an electrical charge after the battery is discon- nected. To prevent electrical shock and injury, dis- charge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certai the battery has been disconnected. Discharge the ca- pacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B— terminals. DO NOT use a screwdriver to sharge the traction motor controller. Removal 1. Disconnect the battery and discharge the controller by connecting a load across terminals B+ and B= 2. Locate the horn button on the front of the control handle. See FIGURE 17. 3. Remove (2) button head bezel attaching screws from under the control handle. See FIGURE 17. 4, Remove the bezel, rocker and keypad switch, 5. Lift out the horn button and spring, Installation 1. Install the horn button and spring. See FIGURE 17. 2. Install the keypad switch, rocker and bezel, 3. Install and tighten the two button head screws toat- tach the bezel. 4, Reconnect the battery. 5. Verify the operation of the horn, uv LOCKWASHER, BEZEL ROCKER KEYPAD SWITCH HORN BUTTON HORN BUTTON SPRING BUTTON HEAD SCREW FIGURE 17 - CONTROL HANDLE - EXPLODED VIEW MAIN INTERFACE BOARD (MIB) DESCRIPTION/FEATURES ‘The main interface board (MIB) is a printed circuit board that directs communication between the electrical components of the truck. The MIB provides inputs and outputs to the control handle, variable valves, solenoid valves, contactor coils, relay coils, throttle, speed limit switch, brake switch, operator sensing switch and the dash display. Pushbuttons on the MIB provide for ser~ vice level diagnostics and set-up capability. A four-digit LED display on the MIB shows real-time truck function “STATUS,” “WARNINGS”, and “FAULTS.” See STA- TUS, WARNING, AND FAULT CODE TROUBLE- _- FIGURE 18 - MAIN INTERFACE BOARD (MIB) SHOOTING. 18 OPERATION When the key switch is in the “ON? position and the op- eratorisnoton the truck, the MIB should display “0200” and the dash display should read “POWER ON.” If the operator is present on the truck, and the brake pedal is pressed (operator sensing switch and brake switch closed), the MIB should display “0300” and the dash display should read “READY.” NOTE: When the operator enters the operator's ‘compartment, the operator sensing switch (under right foot) and the brake switch (under left foot) must both be closed to change the MIB display to"0300” and the dash display to “READY.” Afterwards, either of the two switches may be opened at any one time as long as both switches are not opened simultaneously. Ifthe operator steps off the truck, and the key switch re- mains in the “ON” position, the MIB will display “0200” and the dash display will read “POWER ON” {after a 3 second delay). LED DISPLAY ‘The four digit LED display is capable of displaying two ‘truck function status, warning, or fault codes simulta- neously. Refer to MIB STATUS, WARNING, AND. FAULT CODES for a comprehensive explanation of each code. One code is displayed by the left two digits and the other code is displayed by the right two digits. It is important to read the left two digits as one code and the right two digits asa separate code. The LED display is also used during the calibration procedure. Refer to MIB ADJUSTMENTS. During normal operation, the left two digits show the “STATUS” code of the truck and the right two digits show “00.” Whenever a truck function is selected, the left two digits are updated to display the selected function. ‘The two digits on the right side ofthe display are used to display eithera “WARNING” code or a “FAULT” code. If neither a“WARNING” code nor a “FAULT” code is present, the right two digits continue to display “00.” If multiple faults are present, the highest priority “FAULT” code is displayed. After the highest priority fault is repaired, the next highest priority “FAULT” code will be displayed. If a “WARNING?” code and a “FAULT” code are re- ceived at the same time, the left two digits will display the “WARNING” code, the right two digits will display the “FAULT” code, and the “STATUS” code will not be displayed. Always troubleshoot the code shown on the right side of the display first. Codes are displayed as follows: + “STATUS” codes —+ numbers 01 to 16. + “WARNING” codes—+ numbers 34 to 38. + “FAULT” codes —+ numbers 40 to 85. FIGURE 19 - MIB PUSHBUTTONS A, B, C, AND D AND LED DISPLAY MIB REMOVAL ‘The main interface board (MIB) is located in the front compartment. The MIBis nota repairable item and must be replacedif troubleshooting determines the MIB to be faulty. A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspect- ing/repairing the electrical system. Ifa tool causes a short-circuit, the high current flow from the battery. can cause an injury or parts damage. 1» 1. Move the lift truck toa safe level area. Turn the key switch off and remove the key. Put a “DO NOT OPER- ATE? tag on the control handle. Put blocks under the rive wheels to keep the lift truck from moving. See the PERIODIC MAINTENANCE MANUAL. Refer to HOW TO PUT THE LIFT TRUCK ON BLOCKS. 2. Disconnect the battery and separate the connectors. 3 Liftoff the cover for access to the compartment. & WARNING The capacitor in the traction motor controller can hold an electrical charge after the battery is discon- nected. To prevent electrical shock and injury, dis- charge the capacitor before inspecting or repairing ‘any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the ca- pacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B— terminals. DO NOT use a screwdriver to discharge the traction motor controller. 4. Discharge the controller by connecting a load across terminals B + andB —. Disconnectthe two plugs, from the main interface board (MIB). 5. Remove the screws retaining the MIB to the MIB bracket. 6. Remove the capscrews and lockwashers retaining, the MIB bracket to the lift truck frame. 7. Usea screwdriver inthe slot of the lock on the con- rector to release the male plug. Pull and hold the lock away from the latch while pulling the J plug from the MIB. See FIGURE 20. Disconnect both the J1 and J2 plugs from the MIB. 8. Lift the MIB bracket high enough to allow removal of the MIB, NOTE: The MIBisnct arepairable item and must be replaced if there is a problem with the board itself. MIB INSTALLATION A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspect- ing/repairing the electrical system. Ifa tool causes short circuit, the high current flow from the battery ‘can cause an injury or parts damage. 1. Move the lift truck to a safe level area. Turn the key ‘switch off and remove the key. Put a“DO NOT OPER- 20 ATE” tag on the control handle. Put blocks under the drive wheels to keep the lift truck from moving, See the PERIODIC MAINTENANCE MANUAL. Refer to HOW TO PUT THE LIFT TRUCK ON BLOCKS. 2. Disconnect the battery and separate the connectors. 3. Align the plugs with the connectors located on the bottom of the MIB. Connect the two plugs J1 and J2 to the bottom of the main interface board. Make certain that the lock on each plug is engaged with the latch. 4, Align the new main interface board with the holes in the MIB bracket and install the screws. 5. Align the MIB bracket with the lift truck frame and install the capscrews and lockwashers. INSERT SCREWDRIVER INTO SLOT PULL LOCK AWAY FROM THE CONNECTOR TO DISCONNECT FIGURE 20 - MIB “J” CONNECTOR 6. Before installing the cover, the MIB must be pro- grammed for the lift truck that it is being installed in. ‘The MIB must also be calibrated to the traction and hy- draulic potentiometers. Refer to MAIN INTERFACE BOARD ADJUSTMENTS. 7. Install the cover and connect the battery. Remove the blocks from under the drive wheels, remove the “DO NOT OPERATE” tag and install the key. MAIN INTERFACE BOARD (MIB) ADJUSTMENTS GENERAL ‘The MIB must be calibrated whenever any of the fol- lowing occur: + Anew MIB is installed or a MIB is transferred from one truck to another. + Traction potentiometer is adjusted or replaced. + Hydraulic potentiometer is adjusted or replaced. + Troubleshooting indicates that any of the above components may be out of adjustment. A caution ‘Turning the key switch off or disconnecting the bat- tery when the MIB is being calibrated will result in the MIB returning to the run mode without saving. any new values. DEFAULT VALUES Every MIB installed in a new truck by the factory is pro- ‘grammed with the recommended factory default values forthat model truck In addition, the MIRis calibrated to the specifictraction and hydraulic potentiometers onthe truck. ‘Whenever a replacement MIB is installed in a truck, the appropriate model code must be programmed into the MIB. This automatically sets the recommended factory default values for all functions except functions 30 through 34. Functions 30 and 31 are programming utili- ties and do not require value entries. Function 33 is not used. Functions 32 and 34 are used to calibrate the trac- tion and hydraulic potentiometers. The replacement MIB must be manually calibrated tothe specifictraction and hydraulic potentiometers installed on the truck. NOTE: The MIB must be calibrated to the traction and/or hydraulic potentiometer whenever a traction or hydraulic potentiometer is adjusted, repaired or replaced. CHECKING THE MODEL CODE AND. SET-UP STATUS ‘Turn the key switch to the “ON? position. Press button “A” onthe MIB. Refer to FIGURE 19. The LED display will show either “Fnn0” or “FanA,” where ‘nn’ indi- cates the model code number currently programmed into the MIB and the “0” or “A” indicates the MIB pro- ‘gram status. A model code of “00” indicates that the MIB has not been programmed for any truck model. See ‘TABLE 6 for model code information. ‘The MIB programstatusisshownas““0” or“A.”The“O” indicates that the settings correspond to the default val- ues for the truck model listed (‘nn’), The “A” stands for “altered,” and indicates that one or more of the function values have beenset toa value other than the default val- ue for the truck model listed. NOTE: A fault code can occur if the truck model is not selected properly or if the traction and/or hydraulic potentiometers are not properly calibrated to the MIB. Pressing button “C” or “D” will show the software ver- sion (i.e. “C600” for version 6.10). MIB CALIBRATION PROCEDURE ‘The four-digit LED display on the MIB is used during the calibration procedure to display the function num- ber and the function value + The function number is displayed by the left two digits. * The function value is displayed by the right two digits. During normal operation, the left two digits show the status code of the truck and the right two digits show 00, ora warning or fault code, as applicable. During the set- up procedure, the LED is used to display function num- ber and function value information. Step 1 Entering the Set up Mode NOTE: Toexit the set-up procedure at any time with- ‘out saving new values, turn the key switch to the “OFF” position. 1. Tum the key switch to the “ON” position. 2. Refer to FIGURE 19 for the location of the MIB buttons. Press and hold buttons “A” and “C” simulta- neously until the LED display shows a series of dashes “ ~ ”,then release. Upon release, the left two digits will display function number“01” and the right two dig- its will display the corresponding function value. Func~ tion number “01” is the truck model code function. The a function value shown should correspond to one of the truck model code values shown in TABLE 6. ‘TABLE 6 - TRUCK MODEL CODE FUNCTION ‘VALUES Function |-type| Truck Model | Battery 00 | WA | __NONE NA © NaoxMna 24 61 NAOXMR 24 2 NAOXMR 3 a NASXMR2 36 | ve [_NasxwRe 24 e N25xMOR2 36 66 NGOXMOR2 36 7 NSOXMAZ 24 NSOXMAZ 36 mo |e | meses | 88 nf aes 73 ve | Noon 36 © NGOKMR 2a ar TaORMRa 2a e2 NAOxMR 36 @ NASXMR2 36 4] ee | asxwore 24 3 N2SXMOR2 36 3 NGOXMOR2 36 87 NGOXMAR 24 38 NGOXMAR 36 NOTE: A value of 00 indicates a new MIB with no program or a MIB whict has had the program erased. 3. Ifthe model code is incorrect or the MIBis to be re- set to the factory default settings, proceed to Step 2, ERASING THE MODEL CODE. If the model code is correct, proceed to Step 4, CALIBRATING THE HY- DRAULIC POTENTIOMETER RANGE. Step 2 Erasing the Model Code 1. Select function number 31 by pressing and holding button “A,” then pressing button “C” or “D” until the left two digits of the LED show 31. Release button “A” when the desired function number is reached. 2 A cauTION After erasing the model code it will be necessary to perform Steps 3 through Step 6 before the lift truck will be operational. 2. Verify that the LED display shows “3150.” 3. Change the function value (the right two digits) toa value of 75. The function value is changed by pressing either button “C” or “D” until the desired value is obtained. 4, Press and hold button “B.” Pressbutton “D” toerase the model code and all programmed values. Release both buttons. The MIB display will show “0110” toindi- cate that Function 01 has reset to a starting value of 10. Proceed to STEP 3 to change the model code function value. Step 3 Setting the Model Code 1. Change the function value (the right two digits) to the value assigned for the correct truck model. See ‘TABLE 6. The function value is changed by pressing ei- ther button “C” or “D” until the desired value is dis- played Step 4 Calibrating the Hydraulic Potentiometer Range 1. Center the hydraulic potentiometer manually using an ohmmeter before proceeding. Refer to HY- DRAULIC POTENTIOMETER, INSTALLATION AND ADJUSTMENT. 2. Select function number 32 by pressing and holding button “A,” then pressing button “C” or “D” until the left two digits of the LED show 32. Release button “A” when the desired function number is reached. The MIB display should show “3210.” 3. Press button “D” until the function value is de- creased to 2er0. Once the value reaches zero, press but- ton “D” at least one more time. 4, Verify that the MIB display shows “3200.” Move the control handle tothe full speed lift posi- tion. Hold for 2 seconds. 6. Move the control handle to the full speed lower position, Hold for 2 seconds. 7. Repeat Step 5. 8, Repeat Step 6. 9, Return the control handle to the neutral position. 10. Press button “C” to increase the function value (the right two digits) to any value greater than “00.” 11, Press and hold button “B.” Move the control handle through the full range of full speed lft to full speed low- er while holding button “B.” Notice that the function value digits (right two digits) remain at the value set in Step 10 above, but that the left two digits changeas the control handle is moved. Check the calibration by watching the left two digits, while holding button “B” and cycling the control handle through the full range of lift and lower. The left two dig- its should be nearly zero in the neutral position. When the handle is moved tothe full speed lift position, the left two digits should increase to a value of atleast 94, ideal- y 99 (the value “AO” representsa value of 100 and is ac- ceptable). Similarly, when the handle is moved to the full speed lower position, the left two digits should in- crease toa value of atleast 94, ideally 99 the value“A0” represents a value of 100 and is acceptable). Ifthe left ‘two digits do not exceed 94 when the control handle is moved to the full speed (lift or lower) position, the cal- ibration must be repeated. Ifthe proper values cannot be ‘obtained, check the potentiometer. Step 5 Calibrating the Traction Potentiometer Range 1. Put blocks under the drive wheels to keep the lift truck from moving. See the PERIODIC MAINTE- NANCE MANUAL. Refer to HOW TO PUT THE LIFT TRUCK ON BLOCKS. 2. Center the traction potentiometer manually usingan ohmmeter before proceeding. Refer to TRACTION POTENTIOMETER, INSTALLATION AND AD- JUSTMENT. 3, Select function number 34 by pressing and holding, button “A,” then pressing button “C” or “D” until the left two digits of the LED show 34. Release button “A” ‘when the desired function number is reached. The MIB. display should show “3410.” 4, Press button “D” until the function value is de- creased to 2er0. Once the value reaches zero, press but- ton “D” atleast one more time, 5. Verify that the MIB display shows “3400.” 6. Press the brake pedal, A CAUTION ‘The brake pedal must remain pressed during the traction potentiometer calibration procedure. 7. Move the control handle to the full speed forward position. Hold for 2 seconds. 8. Move the control handle to the full speed reverse position. Hold for 2 seconds. 9. Repeat Step 7. 10. Repeat Step 8, 11. Return the control handle to the neutral position. 12. Press button “C” to increase the function value (the right two digits) to any value greater than “00.” 13, Pressand hold button “B.” Move the control handle through the full range of full speed forward to full speed reverse while holding button“B.” Notice that the fune- tion value digits (right two digits) remainat the value set in Step 12 above, but that the left two digits change as the control handle is moved. Check the calibration by watching the left two digits, while holding button “B” and cycling the control handle through the full range of forward and reverse. The left two digits should be nearly zero in the neutral position. ‘When the handle is moved to the full speed forward position, the left two digits should increase to a value of at least 89, ideally 99 (the value “AO” represents a value of 100 and is acceptable). Similarly, when the handle is moved to the full speed reverse position, the left two digits should increase toa value of at least 89, ideally 99 (the value “AO” represents a value of 100 and is accept- able). Ifthe left two digits do not exceed 89 when the control handle is moved to the full speed (forward or re- verse) position, the calibration must be repeated. Ifthe proper values cannot be obtained, check the potentiometer. 2B Step 6 Exiting the Set-up Mode and Saving the New Values A cauTION Failure to perform this step will result in the loss of all new settings. 1. Select function number 30 by pressing and holding button “A,” then pressing button “C” or “D” until the left two digits of the LED show 30. Release button “A” ‘when the desired function number is reached. The MIB display should show “3050.” 2. Verify that the MIB display shows “3050.” 3. Press and hold button “B,” then press and hold but- ton“C” 4, Release both buttons. After several seconds the

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