Hyster Forklift Calibration Procedures Manual

Calibration Procedures Table of Contents TABLE OF CONTENTS Description ......................................................................................................................................................... 1 Proc_Cal_001: Service Password Entry............................................................................................................ 4 When to Perform............................................................................................................................................ 4 Why Perform .................................................................................................................................................. 4 How to Perform.............................................................................................................................................. 4 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed............................................................ 6 When to Perform............................................................................................................................................ 6 Calibration Order .......................................................................................................................................... 6 Why Perform .................................................................................................................................................. 6 How to Perform.............................................................................................................................................. 6 Proc_Cal_003: Save and Exit ............................................................................................................................ 8 When to Perform............................................................................................................................................ 8 Why Perform .................................................................................................................................................. 8 How to Perform.............................................................................................................................................. 8 Proc_Cal_004: Lift Valve Output Threshold .................................................................................................... 10 When to Perform............................................................................................................................................ 10 Calibration Order .......................................................................................................................................... 10 Why Perform .................................................................................................................................................. 10 How to Perform.............................................................................................................................................. 10 Proc_Cal_005: Lower Valve Output Threshold ................................................................................................ 12 When to Perform............................................................................................................................................ 12 Calibration Order .......................................................................................................................................... 12 Why Perform .................................................................................................................................................. 12 How to Perform.............................................................................................................................................. 12 Proc_Cal_006: Tilt Back Valve Output Threshold ........................................................................................... 16 When to Perform............................................................................................................................................ 16 Calibration Order .......................................................................................................................................... 16 Why Perform .................................................................................................................................................. 16 How to Perform.............................................................................................................................................. 16 Proc_Cal_007: Tilt Forward Valve Output Threshold ..................................................................................... 18 When to Perform............................................................................................................................................ 18 Calibration Order .......................................................................................................................................... 18 Why Perform .................................................................................................................................................. 18 How to Perform.............................................................................................................................................. 19 Proc_Cal_008: Aux 1 Dir A Valve Output Threshold....................................................................................... 22 When to Perform............................................................................................................................................ 22 Calibration Order .......................................................................................................................................... 22 Why Perform .................................................................................................................................................. 22 How to Perform.............................................................................................................................................. 22 Proc_Cal_009: Aux 1 Dir B Valve Output Threshold....................................................................................... 24 When to Perform............................................................................................................................................ 24 Calibration Order .......................................................................................................................................... 24 Why Perform .................................................................................................................................................. 24 How to Perform.............................................................................................................................................. 24 Proc_Cal_010: Aux 2 Dir A Valve Output Threshold....................................................................................... 28 When to Perform............................................................................................................................................ 28 Calibration Order .......................................................................................................................................... 28 Why Perform .................................................................................................................................................. 28 How to Perform.............................................................................................................................................. 28 Proc_Cal_011: Aux 2 Dir B Valve Output Threshold ....................................................................................... 30 When to Perform............................................................................................................................................ 30

Table of Contents Calibration Procedures TABLE OF CONTENTS (Continued) Calibration Order .......................................................................................................................................... 30 Why Perform .................................................................................................................................................. 30 How to Perform.............................................................................................................................................. 31 Proc_Cal_012: Aux 3 Dir A Valve Output Threshold....................................................................................... 34 When to Perform............................................................................................................................................ 34 Calibration Order .......................................................................................................................................... 34 Why Perform .................................................................................................................................................. 34 How to Perform.............................................................................................................................................. 34 Proc_Cal_013: Aux 3 Dir B Valve Output Threshold....................................................................................... 36 When to Perform............................................................................................................................................ 36 Calibration Order .......................................................................................................................................... 36 Why Perform .................................................................................................................................................. 36 How to Perform.............................................................................................................................................. 37 Proc_Cal_014: Load Weight Zero Point ............................................................................................................ 40 When to Perform............................................................................................................................................ 40 Calibration Order .......................................................................................................................................... 40 Why Perform .................................................................................................................................................. 40 How to Perform.............................................................................................................................................. 40 Proc_Cal_015: Loaded Weight Calibration....................................................................................................... 42 When to Perform............................................................................................................................................ 42 Calibration Order .......................................................................................................................................... 42 Why Perform .................................................................................................................................................. 42 How to Perform.............................................................................................................................................. 42 Proc_Cal_016: Transmission Valve Calibration ............................................................................................... 44 Applicable System/Option ............................................................................................................................. 44 When to Perform............................................................................................................................................ 44 Calibration Order .......................................................................................................................................... 44 Why Perform .................................................................................................................................................. 45 How to Perform.............................................................................................................................................. 45 Applicable System/Option ............................................................................................................................. 46 When to Perform............................................................................................................................................ 46 Calibration Order .......................................................................................................................................... 46 Why Perform .................................................................................................................................................. 46 How to Perform.............................................................................................................................................. 46 Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function .......................................... 48 Applicable System/Option ............................................................................................................................. 48 When to Perform............................................................................................................................................ 48 Calibration Order .......................................................................................................................................... 48 Why Perform .................................................................................................................................................. 48 How to Perform.............................................................................................................................................. 48 Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electronic Extended Function ............................ 50 Applicable System/Option ............................................................................................................................. 50 When to Perform............................................................................................................................................ 50 Calibration Order .......................................................................................................................................... 50 Why Perform .................................................................................................................................................. 50 How to Perform.............................................................................................................................................. 50 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment ................................................................. 52 Required Tools................................................................................................................................................ 52 When to Perform............................................................................................................................................ 52 Calibration Order .......................................................................................................................................... 52 Why Perform .................................................................................................................................................. 52

Calibration Procedures Table of Contents TABLE OF CONTENTS (Continued) How to Perform.............................................................................................................................................. 52 Proc_Cal_025: Hydraulic Valve Pressure Gage Installation ........................................................................... 54 When to Perform............................................................................................................................................ 54 Why Perform .................................................................................................................................................. 54 How to Perform.............................................................................................................................................. 54 Proc_Cal_026: Travel Speed Calibration .......................................................................................................... 56 When to Perform............................................................................................................................................ 56 Calibration Order .......................................................................................................................................... 56 Why Perform .................................................................................................................................................. 56 How to Perform.............................................................................................................................................. 56 This section is for the following models: S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT, S55FTS ) [F187]; S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) [G004]; H2.0-3.5FT (H40-70FT) [L177]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005]; H6.0FT, H7.0FT; (H135FT, H155FT) [H006, J006]; S6.0FT, S7.0FT, (S135FT,S155FT) [D024, E024]

8000 SRM 1134 Description Description This section is written assuming no experience with electronic controllers. The menu progressions indi- cate how many key presses it will take to get to a given screen, versus detailing out every screen you would see. Refer to Table 1 for calibration procedures. Refer to Table 2 for an example of how to read calibration procedures. NOTE: The calibration procedures described in this SRM may have to be repeated when any on-board controllers, sensors, or related components are re- placed. Table 1. Calibration Procedures When Procedure is Used: Proc_Cal/Procedure All Units 3 Functions Electronic- Hydraulic Valves 4 Functions Electronic- Hydraulic Valves 5 Functions Electronic- Hydraulic Valves Mazda Engine w/Electronic 1-Speed Transmission Units w/Load Weight Display Electronic Transmission (Basic & L1) Electronic Extended Function 2-Speed (L2-2) 001 Service Password Entry X 002 Hydraulic Valve Calibration Warm Up and Air Bleed X X X 003 Save and Exit X 004 Lift Valve Output Threshold X X X 005 Lower Valve Output Threshold X X X 006 Tilt Back Valve Output Threshold X X X 007 Tilt Forward Valve Output Threshold X X X 008 Aux 1 Dir A Valve Output Threshold X X X 009 Aux 1 Dir B Valve Output Threshold X X X 010 Aux 2 Dir A Valve Output Threshold X X 011 Aux 2 Dir B Valve Output Threshold X X 012 Aux 3 Dir A Valve Output Threshold X 013 Aux 3 Dir B Valve Output Threshold X 014 Load Weight Zero Point X 015 Loaded Weight Calibration X 016 Transmission Valve Calibration (Basic & L1) X 016A Transmission Valve Calibration (L2) X 019 Mazda LP and Gas Acceleration Pedal Adjustment X

Description 8000 SRM 1134 Table 1. Calibration Procedures (Continued) When Procedure is Used: Proc_Cal/Procedure All Units 3 Functions Electronic- Hydraulic Valves 4 Functions Electronic- Hydraulic Valves 5 Functions Electronic- Hydraulic Valves Mazda Engine w/Electronic 1-Speed Transmission Units w/Load Weight Display Electronic Transmission (Basic & L1) Electronic Extended Function 2-Speed (L2-2) 025 Hydraulic Valve Pressure Gage Installation X X X 026 Travel Speed Calibration X X Table 2. How to Read Calibration Procedure Proc_Cal_XXX Number and title of calibration procedure. Calibration Order Calibration procedures that must be completed before this procedure, if any. When to Perform Performed either during initial manufacture or after component changes. Why Perform Description of why the procedure is performed. Proc_Cal_001: Service Password Entry Proc_Cal_002: Hydraulic Valve Calibration Warm Up Calibration procedures that must be completed before this procedure, if any. Action Actions to perform other than calibration steps. Numbered when needed for clarification. A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS B. TYPICAL DISPLAY WITH KEY, WITHOUT OPTIONS 1. SYMBOLS USED IN CALIBRATION PROCEDURES 2. NUMBERS FOR SERVICE PASSWORD ENTRY - SEE PROC_CAL_001 NOTE: Perform all actions and calibration steps in the order shown.

8000 SRM 1134 Description Table 2. How to Read Calibration Procedure (Continued) Step 1: Press * One Time You will see: Passwords Enter Password Step 2: Press * One Time You will see: Enter Password Calibration steps. Information Information to assist in completion of calibration procedure. NOTE: Perform all actions and calibration steps in the order shown.

Proc_Cal_001: Service Password Entry 8000 SRM 1134 Proc_Cal_001: Service Password Entry WHEN TO PERFORM Performed when any service menu-related items must be performed. WHY PERFORM Service-related items are protected from inadvertent access. This procedure allows the service menus to be accessed. HOW TO PERFORM WARNING Keep yourself and all others clear of the lift mechanism. Never allow anyone under or on the forks. Never put hands, arms, head, or legs through the mast or near the carriage or lift chains. This warning applies not only to the operator but also the helper. A helper must not be near the load or the lift mechanism while the operator is attempting to handle a load. The lift mechanism has moving parts with close clearances that can cause serious injury. Refer to Table 3 for the procedures on how to perform Pro_Cal_001: Service Password Entry.

8000 SRM 1134 Proc_Cal_001: Service Password Entry Table 3. Proc_Cal_001: Service Password Entry A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS B. TYPICAL DISPLAY WITH KEY, WITHOUT OPTIONS NOTE: The password entry can only be done with the ignition ON and the engine OFF. If the engine is started, and then turned OFF, the password will have to be re-entered. Action: Ignition ON/EngineOFF Step 1: Press * One Time. You Will See: Main Menu Passwords Step 2: Press * One Time. You Will See: Passwords Enter Password Step 3: Press * One Time. You Will See: Enter Password Information: Refer to Number Location on Keypad and Enter Service Password (Default Service Password is 55555). Step 4: Press * One Time. You Will See: Passwords or Main Menu Enter Password

Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 8000 SRM 1134 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed WHEN TO PERFORM Performed when any hydraulic calibration items are performed. CALIBRATION ORDER 1. Proc_Cal_025 2. Proc_Cal_001 3. Proc_Cal_002 WHY PERFORM Hydraulic calibrations are the process of setting the hydraulic current levels that result in initial function movement. Pressure and flow are directly related to the hydraulic fluid viscosity which is a function of the fluid temperature. Air, trapped within the lift valve assembly, may produce slight mast movement at engine start. This process ensures that the hydraulic fluid achieves an optimum temperature, and that the air is bled out of the lift valve and cylinders prior to performing calibrations. HOW TO PERFORM WARNING Keep yourself and all others clear of the lift mechanism. Never allow anyone under or on the forks. Never put hands, arms, head, or legs through the mast or near the carriage or lift chains. This warning applies not only to the operator but also the helper. A helper must not be near the load or the lift mechanism while the operator is attempting to handle a load. The lift mechanism has moving parts with close clearances that can cause serious injury. Refer to Table 4 for the procedures on how to perform Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed. Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed

8000 SRM 1134 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed (Continued) A. E-HYD CONTROL LEVERS 1. LIFT/LOWER DIRECTION LIFT ↓ DIRECTION LOWER ↑ 2. TILT DIRECTION BACK ↓ DIRECTION FWD ↑ 3. *AUX 1 OR AUX 2 DIRECTION A ↑ DIRECTION B ↓ 4. *AUX 2 OR AUX 3 DIRECTION A ↑ DIRECTION B ↓ 5. *FOURTH LEVER 6. *THIRD LEVER 7. SEAT ARMREST *AUX 2 IS IN THE FOURTH LEVER LOCATION EXCEPT AS FOLLOWS: WITH 5 FUNCTION VALVE WITH CLAMPING ATTACHMENT, AUX 2 IS IN THE THIRD LEVER LOCATION. B. JOYSTICK 1. TILT BACK 2. AUX 1 DIRECTION A ↑ DIRECTION B ↓ 3. LIFT ↓ 4. ↑ LOWER 5. AUX 2 DIRECTION A ↑ DIRECTION B ↓ 6. TILT FORWARD 7. SEAT ARMREST Perform Proc_Cal_025: Hydraulic Valve Pressure Gage Installation and Proc_Cal_001: Service Password Entry before proceeding. Information: First determine if it is necessary to bleed the air out of the lift valve and cylinders. The hoist valve air bleed procedure is necessary if the carriage moves slightly (approximately 1/4 inch) when the engine is started, without activation of the lift control. The cylinder air bleed procedure is necessary if the cylinders have not been previously cycled, or if the left function is not operating smoothly. NOTE: Optional for initial manufacture. Information: To ensure that the oil temperature is optimal, warm up the hydraulic fluid until it is within a range of 50 to 65 C (12 to 149 F). Action: • Ignition: ON • Engine: High Idle • Transmission: Neutral • Park Brake: ON Step 1: (Optional hoist valve air bleed): Activate Lift Control from neutral to full lift and back to neutral at a rate of one or two times per second. Repeat until the lift function is operating smoothly and there is no mast movement upon engine start. Step 2: (Optional cylinder air bleed): Cycle function completely two or three times; repeat if necessary. NOTE: Optional for initial manufacture. Step 3: (Required warm up for service): Activate tilt at relief pressure until the hydraulic fluid temperature is within the optimum range 50 to 65 C (12 to 149 F). Step 4: Proceed to calibrate desired electro-hydraulic functions. Information: You do not need to START or turn OFF the vehicle if you are performing other procedures.

Hyster Forklift Calibration Procedures Manual

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