Hyster Převodovky

CALIBRATION
PROCEDURES
S30-35FT, S40FTS [E010, F010];
H1.6-1.8FT, H2.0FTS (H30-35FT, H40FTS)
[F001, G001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187, G187];
S2.0-3.5FT (S40-70FT) [H187];
S4.0-5.5FT, S5.5FTS (S80-120FT;
S80-100FTBCS; S120FTS; S120FTPRS)
[G004, H004, J004];
H2.0-3.5FT (H40-70FT) [L177, N177, P177];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80-120FT) [N005, P005, R005, S005, U005];
H6.0-7.0FT; (H135-155FT)
[H006, J006, K006, L006];
S6.0-7.0FT, (S135-155FT)
[D024, E024, F024, G024];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) [A299, B299, C299]
This manual contains information that is confidential and/or proprietary to Hyster
Company, its subsidiaries and/or vendors. Copying or distribution of any sections
of this manual marked "Confidential/Proprietary" is prohibited.
PART NO. 1580528 8000 SRM 1134

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 in-
structions 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 ex-
ceed 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 flamma-
ble. 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
Description ...............................................................................................................................................................1
Proc_Cal_001: Service Password Entry ................................................................................................................. 3
When to Perform ................................................................................................................................................. 3
Why Perform ....................................................................................................................................................... 3
How to Perform ................................................................................................................................................... 3
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed .................................................................4
When to Perform ................................................................................................................................................. 4
Calibration Order ................................................................................................................................................4
Why Perform ....................................................................................................................................................... 4
How to Perform ................................................................................................................................................... 5
Proc_Cal_003: Save and Exit ..................................................................................................................................6
When to Perform ................................................................................................................................................. 6
Why Perform ....................................................................................................................................................... 6
How to Perform ................................................................................................................................................... 6
Proc_Cal_004: Lift Valve Output Threshold ..........................................................................................................8
When to Perform ................................................................................................................................................. 8
Calibration Order ................................................................................................................................................8
Why Perform ....................................................................................................................................................... 8
How to Perform ................................................................................................................................................... 8
Proc_Cal_005: Lower Valve Output Threshold ................................................................................................... 10
When to Perform ............................................................................................................................................... 10
Calibration Order ..............................................................................................................................................10
Why Perform ..................................................................................................................................................... 10
How to Perform ................................................................................................................................................. 10
Proc_Cal_006: Tilt Back Valve Output Threshold .............................................................................................. 13
When to Perform ............................................................................................................................................... 13
Why Perform ..................................................................................................................................................... 13
How to Perform ................................................................................................................................................. 13
Proc_Cal_007: Tilt Forward Valve Output Threshold ........................................................................................ 16
When to Perform ............................................................................................................................................... 16
Why Perform ..................................................................................................................................................... 16
How to Perform ................................................................................................................................................. 16
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold ..........................................................................................19
When to Perform ............................................................................................................................................... 19
Why Perform ..................................................................................................................................................... 19
How to Perform ................................................................................................................................................. 19
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold ..........................................................................................22
When to Perform ............................................................................................................................................... 22
Why Perform ..................................................................................................................................................... 22
How to Perform ................................................................................................................................................. 22
When to Perform ............................................................................................................................................... 25
Why Perform ..................................................................................................................................................... 25
How to Perform ................................................................................................................................................. 25
©2017 HYSTER COMPANY i

Table of Contents
TABLE OF CONTENTS (Continued)

When to Perform ............................................................................................................................................... 28
Why Perform ..................................................................................................................................................... 28
How to Perform ................................................................................................................................................. 28
When to Perform ............................................................................................................................................... 31
Why Perform ..................................................................................................................................................... 31
How to Perform ................................................................................................................................................. 31
When to Perform ............................................................................................................................................... 34
Why Perform ..................................................................................................................................................... 34
How to Perform ................................................................................................................................................. 34
Proc_Cal_014: Load Weight Zero Point ................................................................................................................37
When to Perform ............................................................................................................................................... 37
Why Perform ..................................................................................................................................................... 37
How to Perform ................................................................................................................................................. 37
Proc_Cal_015: Loaded Weight Calibration .......................................................................................................... 39
When to Perform ............................................................................................................................................... 39
Why Perform ..................................................................................................................................................... 39
How to Perform ................................................................................................................................................. 39
Proc_Cal_016: Transmission Valve Calibration .................................................................................................. 42
Applicable System/Option ................................................................................................................................ 42
When to Perform ............................................................................................................................................... 42
Why Perform ..................................................................................................................................................... 42
How to Perform ................................................................................................................................................. 42
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function .............................................44
When to Perform ............................................................................................................................................... 44
Why Perform ..................................................................................................................................................... 44
How to Perform ................................................................................................................................................. 44
Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electronic Extended Function ............................... 46
When to Perform ............................................................................................................................................... 46
Why Perform ..................................................................................................................................................... 46
How to Perform ................................................................................................................................................. 46
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment .....................................................................48
Required Tools ...................................................................................................................................................48
When to Perform ............................................................................................................................................... 48
Why Perform ..................................................................................................................................................... 49
How to Perform ................................................................................................................................................. 49
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation .............................................................................. 50
When to Perform ............................................................................................................................................... 50
ii
Table of Contents
TABLE OF CONTENTS (Continued)

Why Perform ..................................................................................................................................................... 50
How to Perform ................................................................................................................................................. 50
Proc_Cal_026: Travel Speed Calibration ............................................................................................................. 52
When to Perform ............................................................................................................................................... 52
Why Perform ..................................................................................................................................................... 52
How to Perform ................................................................................................................................................. 52
This section is for the following models:
(S30-35FT, S40FTS) [E010, F010];

H1.6-1.8FT, H2.0FTS (H30-35FT, H40FTS) [F001, G001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187, G187];
S2.0-3.5FT (S40-70FT) [H187];
S4.0-5.5FT, S5.5FTS (S80-120FT; S80-100FTBCS; S120FTS; S120FTPRS) [G004,
H004, J004];
H2.0-3.5FT (H40-70FT) [L177, N177, P177];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80-120FT) [N005, P005, R005,
S005, U005];
H6.0-7.0FT; (H135-155FT) [H006, J006, K006, L006];
S6.0-7.0FT, (S135-155FT) [D024, E024, F024, G024];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299, C299]
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
8000 SRM 1134 Description
Description
This section is written assuming no experience with NOTE: The calibration procedures described in this
electronic controllers. The menu progressions SRM may have to be repeated when any on-board
indicate how many key presses it will take to get to controllers, sensors, or related components are
a given screen, versus detailing out every screen replaced.
you would see. Refer to Table 1 for calibration
procedures. Refer to Table 2 for an example of how
to read calibration procedures.
Table 1. Calibration Procedures

When Procedure is Used:
Proc_Cal/Procedure All Units 3 4 5 Mazda Units w/ Electronic Electronic
Functions Functions Functions Engine w/ Load Transmiss Extended
Electronic Electronic Electronic Electronic Weight ion (Basic Function
- - - 1-Speed Display & L1) (L2)
Hydraulic Hydraulic Hydraulic Transmiss
Valves Valves Valves ion
001 Service Password Entry X
002 Hydraulic Valve X X X
Calibration Warm Up and Air
Bleed
003 Save and Exit X
004 Lift Valve Output X X X
Threshold
005 Lower Valve Output X X X
Threshold
006 Tilt Back Valve Output X X X
Threshold
007 Tilt Forward Valve Output X X X
Threshold
008 Aux 1 Dir A Valve Output X X X
Threshold
009 Aux 1 Dir B Valve Output X X X
Threshold
010 Aux 2 Dir A Valve Output X X
Threshold
011 Aux 2 Dir B Valve Output X X
Threshold
012 Aux 3 Dir A Valve Output X
Threshold
013 Aux 3 Dir B Valve Output X
Threshold
014 Load Weight Zero Point X
015 Loaded Weight Calibration X
016 Transmission Valve X
Calibration (Basic & L1)
016A Transmission Valve X
Calibration (L2)
Confidential/Proprietary - Do Not Copy or Duplicate 1

Description 8000 SRM 1134
Table 1. Calibration Procedures (Continued)

When Procedure is Used:
Proc_Cal/Procedure All Units 3 4 5 Mazda Units w/ Electronic Electronic
Functions Functions Functions Engine w/ Load Transmiss Extended
Electronic Electronic Electronic Electronic Weight ion (Basic Function
- - - 1-Speed Display & L1) (L2)
Hydraulic Hydraulic Hydraulic Transmiss
Valves Valves Valves ion
016B Transmission Valve X X
Calibration (L1 & L2)
019 Mazda LP and Gas X
Acceleration Pedal Adjustment
025 Hydraulic Valve Pressure X X X
Gage Installation
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 Calibration procedures that must be completed before this
Proc_Cal_002: Hydraulic Valve Calibration procedure, if any.
Warm Up
Action Actions to perform other than calibration steps. Numbered
when needed for clarification.
A. TYPICAL DISPLAY WITHOUT KEY, 1. SYMBOLS USED IN CALIBRATION

WITH OPTIONS PROCEDURES
B. TYPICAL DISPLAY WITH KEY, 2. NUMBERS FOR SERVICE PASSWORD ENTRY -
WITHOUT OPTIONS SEE PROC_CAL_001
NOTE: Perform all actions and calibration steps in the order shown.
2 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1134 Description
Table 2. How to Read Calibration Procedure (Continued)
Step 1: Press * One Time Calibration steps.
You will see:

Passwords
Enter Password
Step 2: Press * One Time
You will see:
Enter Password
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

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

Proc_Cal_001: Service Password Entry 8000 SRM 1134
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
WHEN TO PERFORM WHY PERFORM
Performed when any hydraulic calibration items Hydraulic calibrations are the process of setting the
are performed. hydraulic current levels that result in initial func-
tion movement. Pressure and flow are directly rela-
CALIBRATION ORDER ted to the hydraulic fluid viscosity which is a func-
tion of the fluid temperature. Air, trapped within
1. Proc_Cal_025 the lift valve assembly, may produce slight mast
movement at engine start. This process ensures
2. Proc_Cal_001 that the hydraulic fluid achieves an optimum tem-
perature, and that the air is bled out of the lift
3. Proc_Cal_002
valve and cylinders prior to performing calibra-
tions.

8000 SRM 1134 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed
HOW TO PERFORM helper. A helper must not be near the load or the
handle a load. The lift mechanism has moving
WARNING parts with close clearances that can cause seri-
Keep yourself and all others clear of the lift mech- ous injury.
Refer to Table 4 for the procedures on how to per-
Never put hands, arms, head, or legs through the form Proc_Cal_002: Hydraulic Valve Calibration
mast or near the carriage or lift chains. This warn- Warm Up and Air Bleed.
ing applies not only to the operator but also the
Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed
A. E-HYD CONTROL LEVERS

1. LIFT/LOWER 2. TILT 3. *AUX 1 OR AUX 2 4. *AUX 2 OR AUX 3 5. *FOURTH LEVER
DIRECTION LIFT ↓ DIRECTION BACK ↓ DIRECTION A ↑ DIRECTION A ↑ 6. *THIRD LEVER
DIRECTION LOWER ↑ DIRECTION FWD ↑ DIRECTION B ↓ DIRECTION B ↓
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 3. LIFT ↓ 5. AUX 2 6. TILT FORWARD
DIRECTION A ↑ 4. ↑ LOWER DIRECTION A ↑ 7. SEAT ARMREST
DIRECTION B ↓ DIRECTION B ↓
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.

Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 8000 SRM 1134
Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed (Continued)
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 (122 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 neu-
tral 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 neces-
sary.
NOTE: Optional for initial manufacture.
Step 3: (Required warm up for service): Activate tilt at relief pressure until the hydraulic fluid tem-
perature 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.
Proc_Cal_003: Save and Exit

Must be performed after any calibration except Pro- ing applies not only to the operator but also the
cedure 016, Transmission Valve Calibration. helper. A helper must not be near the load or the
Calibration processes do not automatically save ous injury.
their results until this routine is run.
form Proc_Cal_003: Save and Exit.
HOW TO PERFORM
WARNING

8000 SRM 1134 Proc_Cal_003: Save and Exit
Table 5. Proc_Cal_003: Save and Exit

Information: You can enter this process from any of the sub menu levels. As such, you will be asked to
press the up or down arrow until you get to the Save and Exit Screen for the item you are working
on.
Step: Until You See: Save and Exit
Press or
If you want to Save...
Step 1: Press * One Time You Will See: Save all changes
and exit Menu - Yes
If you DO NOT want to Save...
Step 1: Press * One Time You Will See: Save all changes
and exit Menu - Yes
Step 2: Press One Time You Will See: Cancel Save

Return to Menu
You will return to the menu level where you last were.

Proc_Cal_004: Lift Valve Output Threshold 8000 SRM 1134
Proc_Cal_004: Lift Valve Output Threshold

WHEN TO PERFORM HOW TO PERFORM
Performed when troubleshooting procedures indi-

cate, when lift valve components have been serv- WARNING
iced, or when the lift valve is replaced. Keep yourself and all others clear of the lift mech-
CALIBRATION ORDER Never put hands, arms, head, or legs through the
1. Proc_Cal_025
2. Proc_Cal_001 helper. A helper must not be near the load or the
3. Proc_Cal_002 handle a load. The lift mechanism has moving
4. Proc_Cal_004 ous injury.
WHY PERFORM Refer to Table 6 for the procedures on how to per-
form Proc_Cal_004: Lift Valve Output Threshold.
All electro-hydraulic valves have different operat-
ing characteristics. One of the key characteristics is
the point at which hydraulic flow begins for a given
command current. This cracking’ current is deter-
mined by this process.
Table 6. Proc_Cal_004: Lift Valve Output Threshold

Perform Proc_Cal_025: Hydraulic Valve Pressure Gage Installation, Proc_Cal_001: Service Pass-
word Entry, and Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed before pro-
ceeding.
Information: "Creep" is defined as the threshold when a function first starts to move very slowly (barely
perceptible motion). The identification of this motion is defined as the "visual method." The method that
provides more consistent calibration is by monitoring the change in pressure when the function is activated;
this is defined as the "pressure method."

8000 SRM 1134 Proc_Cal_004: Lift Valve Output Threshold
Table 6. Proc_Cal_004: Lift Valve Output Threshold (Continued)
Information: Pressure Method: Perform actions 1, 2, 3, 4, and 6.

Visual Method: Perform actions 2, 3, 5, and 6.
Information: Leave truck running at idle after performing Proc_Cal_002.
Action 1: With the truck running, note the pressure reading (standby pressure).
Action 2: Activate Lift Control to Position Attachment You Will See: Main Menu
0.6 m (2 ft) up with no load on the forks/attachment. Passwords
Step 1: Press or Until You See: Main Menu

Calibrations
Step 2: Press * One Time You Will See: Calibrations
Lift Valve Output
Step 3: Press * One Time You Will See: Lift Valve Output
Press * at Creep

7. SEAT ARMREST
B. JOYSTICK
Action 3: SLOWLY Activate (Feather) Lift Control.....

Action 4: Until the pressure is 0.7 MPa (100 psi) above the standby pressure. Note that the pressure read-
ing may oscillate. Hold control steady and.....
Action 5: WATCH for Attachment Movement. When it first starts to move slowly, HOLD control steady
and.....

Proc_Cal_004: Lift Valve Output Threshold 8000 SRM 1134
Table 6. Proc_Cal_004: Lift Valve Output Threshold (Continued)
Press * One Time while holding control.

Action 6: STOP activating the Lift Control. LOOK at the display.
Go to the calibration step below that matches your display.
If You See..... Result out of range
Repeat Calibration
Press * One Time You Will See: Lift Valve Output
Press * at Creep
Return to Action 3.
Pressure Method: Perform Actions 3, 4, and 6 again.
Visual Method: Perform Actions 3, 5, and 6 again.
If You See..... Lower Valve Output
Press * at Creep
To Continue with Calibrations.....
Go to Action 2 of Proc_Cal_005.
To Quit and Save....
Step 1: Press or Until You See: Lower Valve Out-

put
Back 1 Level
Back 1 Level
Perform Proc_Cal_003: Save and Exit.
Proc_Cal_005: Lower Valve Output Threshold


cate, when lower valve components have been serv- WARNING
iced, or when the lower valve is replaced. Keep yourself and all others clear of the lift mech-
1. Proc_Cal_001
WHY PERFORM ous injury.
All electro-hydraulic valves have different operat- Refer to Table 7 for the procedures on how to per-
ing characteristics. One of the key characteristics is form Pro_Cal_005: Lower Valve Output Threshold.
command current. This cracking' current is deter-

8000 SRM 1134 Proc_Cal_005: Lower Valve Output Threshold
Table 7. Proc_Cal_005: Lower Valve Output Threshold

Perform Proc_Cal_001: Service Password Entry and Proc_Cal_002: Hydraulic Valve Calibration
Warm Up and Air Bleed before proceeding.
perceptible motion). The identification of this motion is defined as the "visual method." This procedure can-
not be performed by using the pressure method.
0.6 m (2 ft) up with no load on the forks/attachment. If the forks/ Passwords
attachment are/is not installed, ensure that the attachment will
lower when the control is activated. It may be necessary to apply
a load (approximately 90 kg (200 lb) to the attachment.

Calibrations
Lift Valve Output

Proc_Cal_005: Lower Valve Output Threshold 8000 SRM 1134
Table 7. Proc_Cal_005: Lower Valve Output Threshold (Continued)
Step 3: Press or Until You See: Calibrations

Lower Valve Out-
put
Step 4: Press * One Time You Will See: Lower Valve Out-
put
Press * at Creep

7. SEAT ARMREST
B. JOYSTICK
Action 2: SLOWLY Activate (Feather) Lower Control.

and.....
Press * One Time while holding the control.
Action 4: STOP activating the Lower Control. LOOK at the display.
Go to the Calibration Step below that matches your display.

8000 SRM 1134 Proc_Cal_005: Lower Valve Output Threshold
Table 7. Proc_Cal_005: Lower Valve Output Threshold (Continued)

Repeat Calibration
Press * One Time You Will See: Lower Valve Out-
put
Press * at Creep
Return to Action 2. Perform Actions 2 through 4 again.
If You See..... Tilt Bk Valve Output
Press * at Creep
Step 1: Press or Until You See: Tilt Bk Valve Out-

put
Back 1 Level
Back 1 Level
Proc_Cal_006: Tilt Back Valve Output Threshold


cate, when tilt back valve components have been WARNING
serviced, or when the tilt back valve is replaced. Keep yourself and all others clear of the lift mech-
1. Proc_Cal_025
form Proc_Cal_006: Tilt Back Valve Output
All electro-hydraulic valves have different operat- Threshold.

Proc_Cal_006: Tilt Back Valve Output Threshold 8000 SRM 1134
Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold

ceeding.
Information: Pressure Method: Perform Actions 1, 2, 3, 4, and 6.
Visual Method: Perform Actions 2, 3, 5, and 6.
0.6 m (2 ft) up with no load on the forks/attachment. Activate the Passwords
tilt control to position the function in the middle of the range
(mast is vertical).

Calibrations
Lift Valve Output

Tilt Bk Valve Out-
put
Step 4: Press * One Time You Will See: Tilt Bk Valve Out-
put
Press * at Creep

8000 SRM 1134 Proc_Cal_006: Tilt Back Valve Output Threshold
Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold (Continued)

7. SEAT ARMREST
B. JOYSTICK
Action 3: SLOWLY Activate (Feather) Tilt Back Control.....

Action 4: Until the pressure is just above the standby pressure (as the needle moves on an analog gage).
Note that the pressure reading may oscillate. Hold control steady and.....
and.....
Action 6: STOP activating the Tilt Bk Control. LOOK at the display.
Repeat Calibration

Proc_Cal_006: Tilt Back Valve Output Threshold 8000 SRM 1134
Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold (Continued)
Press * One Time You Will See: Tilt Bk Valve Out-

put
Press * at Creep
Return to Action 3.
If You See..... Tilt Fw Valve Output
Press * at Creep
Step 1: Press or Until You See: Tilt Fw Valve Out-

put
Back 1 Level
Back 1 Level
Proc_Cal_007: Tilt Forward Valve Output Threshold


cate, when tilt forward valve components have been WARNING
serviced, or when the tilt forward valve is replaced. Keep yourself and all others clear of the lift mech-
1. Proc_Cal_025
form Proc_Cal_007: Tilt Forward Valve Output
All electro-hydraulic valves have different operat- Threshold.

8000 SRM 1134 Proc_Cal_007: Tilt Forward Valve Output Threshold
Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold

ceeding.
Information:
Pressure Method: Perform Actions 1, 2, 3, 4, and 6.
0.6 m (2 ft) up with no load on the forks/attachment. Activate Passwords
the tilt control to position the function in the middle of the
range (mast is vertical).

Calibrations
Lift Valve Output

Tilt Fw Valve Output
Step 4: Press * One Time You Will See: Tilt Fw Valve Output
Press * at Creep

Proc_Cal_007: Tilt Forward Valve Output Threshold 8000 SRM 1134
Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold (Continued)

7. SEAT ARMREST
B. JOYSTICK
Action 3: SLOWLY Activate (Feather) Tilt FWD Control.....

and.....
Action 6: STOP activating the Tilt Fw Control. LOOK at the display.
Repeat Calibration
Press * One Time You Will See: Tilt Fw Valve Output
Press * at Creep
Return to Action 3.

8000 SRM 1134 Proc_Cal_007: Tilt Forward Valve Output Threshold
Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold (Continued)
If You See..... Aux 1 Valve Output Dir A

Press * at Creep
Step 1: Press or Until You See: Aux 1 Valve Output Dir A

Back 1 Level
Back 1 Level
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold


cate, when Aux 1 Dir A valve components have WARNING
been serviced, or when the Aux 1 Dir A valve is re- Keep yourself and all others clear of the lift mech-
placed. anism. Never allow anyone under or on the forks.
Never put hands, arms, head, or legs through the

CALIBRATION ORDER mast or near the carriage or lift chains. This warn-
1. Proc_Cal_025
helper. A helper must not be near the load or the
2. Proc_Cal_001 lift mechanism while the operator is attempting to
3. Proc_Cal_002 parts with close clearances that can cause seri-
ous injury.
4. Proc_Cal_008
WHY PERFORM form Pro_Cal_008: Aux 1 Dir A Valve Output
Threshold.

Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 8000 SRM 1134
Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold

ceeding.
Information:
0.6 m (2 ft) up with no load on the forks/attachment. Activate Passwords
the Aux 1 control to position the function in the middle of the
range.

Calibrations
Lift Valve Output

Aux 1 Valve Output Dir A
Step 4: Press * One Time You Will See: Aux 1 Valve Output Dir A
Press * at Creep

8000 SRM 1134 Proc_Cal_008: Aux 1 Dir A Valve Output Threshold
Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold (Continued)

7. SEAT ARMREST
B. JOYSTICK
Action 3: SLOWLY Activate (Feather) Aux 1 Dir A Control.....

NOTE: Optional for initial manufacture: Use the same pressure setting for both Dir A and Dir B of this
function to provide uniform flow outputs.
and.....

Action 4: STOP activating the Aux 1 Dir A Control. LOOK at the display.
Repeat Calibration
Press * One Time You Will See: Aux 1 Valve Output Dir A
Press * at Creep
Return to Action 3.
If You See..... Aux 1 Valve Output Dir B
Press * at Creep
Step 1: Press or Until You See: Aux 1 Valve Output Dir B

Back 1 Level
Back 1 Level
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold


cate, when Aux 1 Dir B valve components have WARNING
been serviced, or when the Aux 1 Dir B valve is re- Keep yourself and all others clear of the lift mech-

1. Proc_Cal_025
ous injury.
4. Proc_Cal_009
WHY PERFORM form Proc_Cal_009: Aux 1 Dir B Valve Output
Threshold.

8000 SRM 1134 Proc_Cal_009: Aux 1 Dir B Valve Output Threshold
Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold

ceeding.
Information:
Action 2: Activate Lift Control to Position Atachment You Will See: Main Menu
Aux 1 control to position the function in the middle of the range.

Calibrations
Lift Valve Output

Aux 1 Output Dir B
Step 4: Press * One Time You Will See: Aux 1 Output Dir B
Press * at Creep

Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 8000 SRM 1134
Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold (Continued)

7. SEAT ARMREST
B. JOYSTICK
Action 3: SLOWLY Activate (Feather) Aux 1 Dir B Control.....

and.....
Action 6: STOP activating the Aux 1 Dir B Control. LOOK at the display.
Repeat Calibration

Press * One Time You Will See: Aux 1 Valve Output

Dir B
Press * at Creep
Return to Action 3.
Press * at Creep
Step 1: Press or Until You See: Aux 2 Valve Output

Dir A
Back 1 Level
Back 1 Level



1. Proc_Cal_025
ous injury.
4. Proc_Cal_010
WHY PERFORM form Proc_Cal_010: Aux 2 Dir A Valve Output
Threshold.


ceeding.
Information:

Calibrations
Lift Valve Output

Aux 2 Valve Output
Dir A
Step 4: Press * One Time You Will See: Aux 2 Valve Output
Dir A
Press * at Creep


7. SEAT ARMREST
B. JOYSTICK

and.....
Repeat Calibration


Dir A
Press * at Creep
Return to Action 3.
Press * at Creep

Dir B
Back 1 Level
Back 1 Level



1. Proc_Cal_025
ous injury.
4. Proc_Cal_011
Threshold.


ceeding.
provides more consistent calibration is by monitoring the change in pressure when the function is activated.
This is defined as the "pressure method."
Information:

Calibrations
Lift Valve Output

Aux 2 Output Dir B
Press * at Creep


7. SEAT ARMREST
B. JOYSTICK

and.....
Repeat Calibration


Dir B
Press * at Creep
Return to Action 3.
Press * at Creep

Dir A
Back 1 Level
Back 1 Level



1. Proc_Cal_025
ous injury.
4. Proc_Cal_012
WHY PERFORM form Proc_Cal_012: Aux 3 Dir A Valve Output
Threshold.


ceeding.
Information:
Action 2 Activate Lift Control to Position Attachment You Will See: Main Menu

Calibrations
Lift Valve Output

Aux 3 Output Dir A
Step 4: Press * One Time You Will See: Aux 3 Output Dir A
Press * at Creep


7. SEAT ARMREST
B. JOYSTICK

and.....
Repeat Calibration


Dir A
Press * at Creep
Return to Action 3.
Press * at Creep

Dir B
Back 1 Level
Back 1 Level



1. Proc_Cal_025
ous injury.
4. Proc_Cal_013
Threshold.


ceeding.
Information:

Calibrations
Lift Valve Output

Aux 3 Output Dir B
Press * at Creep


7. SEAT ARMREST
B. JOYSTICK

and.....
Repeat Calibration
Dir B
Press * at Creep

Return to Action 3.
If You See..... Calibrations
Aux 3 Valve Output Dir B
You May Quit and Save.....
Proc_Cal_014: Load Weight Zero Point

Performed by the operator when the no-load weight

displayed on the screen with the forks in the WARNING
"weighing position" is not within ±2 percent of Keep yourself and all others clear of the lift mech-
truck capacity. (This is ±45.4 kg (100 lb) for a anism. Never allow anyone under or on the forks.
2268 kg (5,000 lb) truck).
This procedure will write a value to the Tare
Weight memory location. If you are going to per-
form Proc_Cal_015 Loaded Weight Calibration, you
can skip this procedure as its value will be over-
written.
ous injury.
CALIBRATION ORDER
1. Proc_Cal_001
form Proc_Cal_014: Load Weight Zero Point.
2. Proc_Cal_014
WHY PERFORM
Allows the system to take into account the weight

of the carriage assembly for weight displays.

Proc_Cal_014: Load Weight Zero Point 8000 SRM 1134
Table 16. Proc_Cal_014: Load Weight Zero Point

Proc_Cal_001: Service Password Entry before proceeding.
Action 1: Start Engine.
Action 2: Position Mast Vertical.
Action 3: With No Load, Activate Lift Control to Raise You Will See: Main Menu
Forks/Attachment Approximately 0.6 m (2 ft), But If Freelift Passwords
Is Present, Not More Than Maximum Freelift.

7. SEAT ARMREST

8000 SRM 1134 Proc_Cal_014: Load Weight Zero Point
Table 16. Proc_Cal_014: Load Weight Zero Point (Continued)

B. JOYSTICK

Calibrations
Lift Valve Output

Load Weight Set Zero
Step 4: Press * One Time You Will See: Load Weight Set Zero
Press * with No Load
Action 4: Lower The Empty Forks/Attachment Approximately 51 mm (2 in.), Wait One Second And Imme-
diately Press * One Time.
Perform Proc_Cal_003: Save and Exit if not performing additional calibration procedures.
Proc_Cal_015: Loaded Weight Calibration

WHEN TO PERFORM 2. Proc_Cal_015
1. Perform when the pressure transducer is re- WHY PERFORM

placed.
Because known load weights are not weighing
OR within ±2 percent of truck capacity.
2. Perform the calibration when the following pro- HOW TO PERFORM

cedure does not pass.
Lift a load equal to approximately 3/4 the
WARNING
lift truck capacity or more and raise the
load in the same manner as when per- Keep yourself and all others clear of the lift mech-
forming the Proc_Cal_014: Load Weight anism. Never allow anyone under or on the forks.
Zero Point several times to ensure the Never put hands, arms, head, or legs through the
system repeats within approximately ±2 mast or near the carriage or lift chains. This warn-
percent of truck capacity. If it does not, ing applies not only to the operator but also the
then remove the load and recheck the helper. A helper must not be near the load or the
Proc_Cal_014: Load Weight Zero Point. If lift mechanism while the operator is attempting to
the load weights are then within toler- handle a load. The lift mechanism has moving
ance, continue using the system. If not parts with close clearances that can cause seri-
within tolerance, then proceed to perform ous injury.
the Loaded Weight Calibration.
CALIBRATION ORDER form Proc_Cal_015: Loaded Weight Calibration.
1. Proc_Cal_001

Proc_Cal_015: Loaded Weight Calibration 8000 SRM 1134
Table 17. Proc_Cal_015: Loaded Weight Calibration

Proc_Cal_001: Service Password Entry before proceeding.
Action 1: Start Engine.
Action 2: Position Mast Vertical.
Action 3: With No Load, Activate Lift Control to Raise You Will See: Main Menu
Forks/Attachment Approximately 0.6 m (2 ft), But If Freelift Passwords

7. SEAT ARMREST

8000 SRM 1134 Proc_Cal_015: Loaded Weight Calibration
Table 17. Proc_Cal_015: Loaded Weight Calibration (Continued)

B. JOYSTICK

Calibrations
Lift Valve Output

Load Weight Calibration
Step 4: Press * One Time You Will See: Load Weight Set Zero
Press * with No Load
Action 4: Lower The Empty Forks/Attachment Approxi- You Will See: Lift Known Load To
mately 51 mm (2 in.), Wait One Second And Immediately Weighing Height
Press * One Time.
Action 5: Safely Raise A Load Of Known Weight Equal To 3/4 Or More Of Rated Lift Truck Capacity. Lift
To A Height Of Approximately 0.6 m (2 ft), But If Freelift Is Present, Not More Than Maximum Freelift.
Ensure Mast Is Vertical.
Step 6: Press * One Time You Will See: Scroll to Correct Weight
with #### lbs.
Step 7: Press or Until You See: Weight On Display Equal

To Weight On Forks/
Attachment.
Action 6: Lower Known Weight Load.
Action 7: Safely Raise A Load Of Known Weight To A Height Of Approximately 0.6 m (2 ft), But If Freelift
Action 8: Lower Known Weight Load Approximately 51 mm (2 in.), Wait One Second, Read The Load
Weight.
Step 8: Press or Until You See: The Weight Displayed

One Second After Stop-
ping Is Within 2% Of
Weight On Forks.
Action 9: Repeat Action 6 Through 8 Until 2% Noted In Step 8 Is Achieved. The load may have to be raised
several times and it may take several presses of the scroll and buttons before the correct weight is
displayed.
Action 10: Lower Known Weight Load.
Action 11: Safely Raise A Load Of Known Weight To A Height Of Approximately 0.6 m (2 ft), But If Free-
lift Is Present, Not More Than Maximum Freelift.
Action 12: Lower Known Weight Load Approximately 51 mm (2 in.), Wait One Second And Immediately
Press * One Time.
Perform Proc_Cal_003: Save and Exit if not performing additional calibration procedures.

Proc_Cal_016: Transmission Valve Calibration 8000 SRM 1134
Proc_Cal_016: Transmission Valve Calibration

NOTE: The information contained in the transmis- 2. Proc_Cal_016
sion calibration procedures described below, apply
to all lift trucks covered in this SRM EXCEPT lift WHY PERFORM
truck models:
• S6.0FT, S7.0FT (S135FT,S155FT) (D024, Performed to compensate for clutch pack control
E024, F024, G024) valve pressure in relation to valve command cur-
rent tolerances.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006, L006)
HOW TO PERFORM
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299, C299)
WARNING
Calibration procedures for the following lift truck Keep yourself and all others clear of the lift mech-
models can be found in Table 20: anism. Never allow anyone under or on the forks.
• S6.0FT, S7.0FT (S135FT,S155FT) (D024,
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, ing applies not only to the operator but also the
J006, K006, L006) helper. A helper must not be near the load or the
• H8.0FT, H8.0FT9, H9.0FT (H170FT, lift mechanism while the operator is attempting to
H175FT36, H190FT) (A299, B299, C299) handle a load. The lift mechanism has moving
APPLICABLE SYSTEM/OPTION ous injury.
Basic Power Shift Transmission

WARNING
Keep park brake applied, full service brake ap-
WHEN TO PERFORM
plied, and full accelerator applied during entire
time that automated transmission valve calibra-
Performed whenever disassembling or replacing
tion is occurring.
the transmission, the transmission valve, or the
transmission pressure sensors.
form Proc_Cal_016: Transmission Valve Calibra-
CALIBRATION ORDER tion.
1. Proc_Cal_001
NOTE: Brakes must be properly adjusted and func-

tioning prior to performing this procedure.

8000 SRM 1134 Proc_Cal_016: Transmission Valve Calibration
Table 18. Proc_Cal_016: Transmission Valve Calibration

Information: Parking Brake and Service Brakes MUST be properly adjusted and functioning before per-
forming this procedure.
Perform Proc_Cal_001: Service Password Entry before proceeding.
Action: Start Engine. You Will See: Main Menu
Passwords

Calibrations
Lift Valve Output

Calibrate Xsmn Valve
Step 4: Press * One Time You Will See: Calibrate Xsmn Valve
Press * to Begin
Action 1: APPLY Parking Brake and leave on throughout process.
Action 2: FULLY APPLY Service Brakes and HOLD during process.
Action 3: FULLY Depress Accelerator Pedal and HOLD during process.
Action 4: Allow for the transmission to warm up to 46°C (115°F).
Information: This is an automated process. The Engine, Park Brake, and Service Brake must all be ON
for the process to start.
If either Parking or Service Brake is NOT applied, you Apply Parking Brake
will see..... Apply Service Brake

Proc_Cal_016: Transmission Valve Calibration 8000 SRM 1134
Table 18. Proc_Cal_016: Transmission Valve Calibration (Continued)
If both Parking and Service Brakes are applied, you will Calibrate Xmsn Valve
see..... Press * to Begin.
NOTE: Keep park brake applied, full service brake applied, You Will See: Calibrate Xmsn Valve
and full accelerator applied during entire time that automated Done in 15
transmission valve calibration is occurring.
Press * One Time

Watch display countdown. When completed success- You Will See: Calibrations
fully..... Calibrate Xmsn Valve
Proc_Cal_016A: Transmission Valve Calibration-Electronic

Extended Function
NOTE: The information contained in the transmis- WHY PERFORM
to all lift trucks covered in this manual EXCEPT Performed to compensate for clutch pack control
lift truck models: valve pressure in relation to valve command cur-
• S6.0FT, S7.0FT (S135FT,S155FT) (D024, rent tolerances.
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, HOW TO PERFORM
J006, K006, L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, WARNING
H175FT36, H190FT) (A299, B299, C299) Keep yourself and all others clear of the lift mech-
For the models listed above, see Proc_Cal_016B:
Trans. Valve Calibration-Electronic and Electronic Never put hands, arms, head, or legs through the
Extended Function for calibration procedures. mast or near the carriage or lift chains. This warn-
APPLICABLE SYSTEM/OPTION helper. A helper must not be near the load or the
Duramatch and Duramatch Plus Transmission handle a load. The lift mechanism has moving
WHEN TO PERFORM ous injury.
Performed whenever disassembling or replacing

the transmission, the transmission valve, or the WARNING
transmission pressure sensors. Keep park brake applied, full service brake ap-
plied, and full accelerator applied during entire
CALIBRATION ORDER time that automated transmission valve calibra-
tion is occurring.
1. Proc_Cal_001
NOTE: Brakes must be properly adjusted and func- form Proc_Cal_016: Transmission Valve Calibra-
tioning prior to performing this procedure. tion.
2. Proc_Cal_016A

8000 SRM 1134 Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function
Table 19. Proc_Cal_016A: Transmission Valve Calibration

Passwords

Calibrations
Lift Valve Output

Press * to Begin

Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 8000 SRM 1134
Table 19. Proc_Cal_016A: Transmission Valve Calibration (Continued)
NOTE: Keep park brake applied, full service brake applied, You Will See: Calibrate Xmsn Valve
and full accelerator applied during entire time that automated Done in 35
transmission valve calibration is occurring. If you release the
service brake at any time during L2 calibration, the calibration
will start over from the beginning.
Press * One Time

Watch display countdown. When completed success- You Will See: Calibrate Xmsn Valve
fully..... The engine will go to idle and you will see for approxi- Xmsn Calibration 0
mately 2 minutes:
Watch display. When completed successfully..... You will You Will See: Calibrate Xmsn Valve
see for approximately 2 minutes: Xmsn Calibration 1
Watch display. When completed successfully..... You Will See: Calibrations
Calibrate Xmsn Valve
Proc_Cal_016B: Trans. Valve Calibration-Electronic and

Electronic Extended Function
NOTE: The information contained in the transmis- CALIBRATION ORDER
to the following lift truck models covered in this 1. Proc_Cal_001
SRM:
NOTE: Brakes must be properly adjusted and func-
• S6.0FT, S7.0FT (S135FT,S155FT) (D024, tioning prior to performing this procedure.
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 2. Proc_Cal_016B
J006, K006, L006)
WHY PERFORM
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299, C299) Performed to compensate for clutch pack control
valve pressure in relation to valve command cur-
APPLICABLE SYSTEM/OPTION rent tolerances.
Duramatch and Duramatch Plus Transmission
HOW TO PERFORM
WHEN TO PERFORM
WARNING
Performed whenever disassembling or replacing Keep yourself and all others clear of the lift mech-
the transmission, the transmission valve, or the anism. Never allow anyone under or on the forks.
transmission pressure sensors.

8000 SRM 1134 Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electronic Extended
Function

mast or near the carriage or lift chains. This warn- WARNING
ing applies not only to the operator but also the Keep park brake applied, full service brake ap-
helper. A helper must not be near the load or the plied, and full accelerator applied during entire
lift mechanism while the operator is attempting to time that automated transmission valve calibra-
handle a load. The lift mechanism has moving tion is occurring.
ous injury. Refer to Table 20 for the procedures on how to per-
form Proc_Cal_016: Transmission Valve Calibra-
tion.
Table 20. Proc_Cal_016B: Transmission Valve Calibration

Passwords

Calibrations
Lift Valve Output

Press * to Begin

Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electronic Extended 8000 SRM 1134
Function
Table 20. Proc_Cal_016B: Transmission Valve Calibration (Continued)

NOTE: Keep park brake applied, full service brake applied, You Will See: Xmsn Oil Temp
and full accelerator applied during entire time that automated xxx°
transmission valve calibration is occurring. If you release the
service brake at any time during L2 calibration, the calibration
will start over from the beginning.
Press * One Time

Watch display countdown. When completed success- You Will See: Calibrate Xmsn Valve
fully..... The engine will go to idle and you will see for approxi- Xmsn Calibration 0
mately 5 minutes:
Watch display. When completed successfully..... You Will See: Calibrations
Calibrate Xmsn Valve
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment

REQUIRED TOOLS WHEN TO PERFORM
LPG: Perform when adjusting or first installing an accel-

• 13mm Open-End Wrench erator pedal assembly on fork trucks equipped with
the Mazda LP and Mazda gas engines and elec-
Gas: tronic control transmission.
• #3 Phillips Head Screwdriver

CALIBRATION ORDER
• 10mm Open-End Wrench
• 13mm Open-End Wrench 1. Proc_Cal_001
2. Proc_Cal_019

8000 SRM 1134 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment
WHY PERFORM Never put hands, arms, head, or legs through the
Sets the lost motion in the throttle assembly for the ing applies not only to the operator but also the
proper operation of the clutch pack braking and in- helper. A helper must not be near the load or the
ching functions. lift mechanism while the operator is attempting to
HOW TO PERFORM parts with close clearances that can cause seri-
ous injury.
WARNING Refer to Table 21 for the procedures on how to per-

Keep yourself and all others clear of the lift mech- form Proc_Cal_019: Mazda LP and Gas Accelerator
anism. Never allow anyone under or on the forks. Pedal Adjustment.
Table 21. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment

Perform: Proc_Cal_001 Service Password Entry.
Action: Ignition switch ON.
Action: Transmission in neutral.
Action: Park brake applied. You Will See: Main Menu
Passwords

Calibrations
Lift Valve Output

Accelerator Pedal
Step 4: Press * One Time You Will See: Accel Pedal xx%
Xxx RPM
Information: Top line will show numbers for percent of pedal travel. Bottom line is engine RPM.
Action 1: With the engine warm (80°C (176°F) You Will See: Accel Pedal 25%
minimum coolant temperature) and at idle, 850 RPM
slowly press the throttle pedal until the engine
RPM reaches 850. The accelerator pedal value
should be between 22 and 27 percent.

Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 8000 SRM 1134
Table 21. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment (Continued)
Action 2 (LPG) : If this value is below 22 percent, then adjust slack into the cable by adjusting the
nuts on the engine throttle cable bracket. If the value is above 27 percent, remove the slack in the
cable by adjusting the same nuts. If there is not enough adjustment, verify that the bell crank to cowl
clearance is correct. When adjustment is complete, tighten throttle cable adjusting screws to 8 to
15 N•m (6 to 11 lbf ft). Refer to the Frame section for your lift truck for complete adjustment proce-
dures.
Action 2 (Gas) : If this value is below 22 percent, increase the clearance between the bellcrank
screw and the bellcrank follower by adjusting the bellcrank screw. If the value is above 27 percent,
decrease the clearance between the bellcrank screw and the bellcrank follower by adjusting the bell-
crank screw. When adjustment is complete, lock the adjusting screw with the jam nut. Refer to the
Frame section for your lift truck for complete adjustment procedures.
Action 3: Adjust bumper on the underside of the throttle pedal and tighten jam nut as shown in the
Frame section for your lift truck.
Action: Ignition OFF.
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation

Perform whenever any hydraulic calibration items ing applies not only to the operator but also the
are performed by using the pressure method. helper. A helper must not be near the load or the
Installation of a pressure gage will allow for the ous injury.
pressure method to be used whenever any hy-
draulic calibration items are performed. Refer to Table 22 for the procedures on how to per-
form Proc_Cal_025: Hydraulic Valve Pressure Gage
Installation.
HOW TO PERFORM
WARNING

8000 SRM 1134 Proc_Cal_025: Hydraulic Valve Pressure Gage Installation
Table 22. Proc_Cal_025: Hydraulic Valve Pressure Gage Installation
1. EF PORT
2. DIAGNOSTIC FITTING
3. PRESSURE GAGE
Action: With the ignition turned OFF, install a 24 MPa (3500 psi) minimum analog pressure gage in the
EF Port. (See illustration above.) It is highly recommended to use a small diameter hose (approximately 2
to 3 mm ID) to minimize pressure variation seen at the gage.
Information: It is recommended that the diagnostic fitting installed in the EF Port is used. This fitting is
a Parker EMA3/3/7/16-20UNF-2A or HYDAC 06003735. A gage can be connected to this fitting by using a
flexible hose (Parker SMA3-200, SMA3-400, SMA3-800, SMA3-2000, SMA3-4000, or equivalent). The alter-
native is to remove the diagnostic fitting and connect directly to the EF Port; port size: SAE #4 O-ring Port
(7/16-20UNF). If this is done, ensure that the fitting is tightened to the torque specified per HC-712, and
that the connection is leak-free after the calibrations are completed and the gage is removed. Preceding pro-
cedure is the same for lift trucks equipped with OPS solenoids.

Proc_Cal_026: Travel Speed Calibration 8000 SRM 1134
Proc_Cal_026: Travel Speed Calibration

For trucks with electronic or enhanced electronic

transmissions that perform advanced functions, WARNING
perform the calibration process whenever changing Keep yourself and all others clear of the lift mech-
the drive tire size or if the truck travel speed diag- anism. Never allow anyone under or on the forks.
nostic display is not reading correctly.
CALIBRATION ORDER ing applies not only to the operator but also the
No prior calibration required. lift mechanism while the operator is attempting to
WHY PERFORM parts with close clearances that can cause seri-
ous injury.
Advanced function transmission control decisions
are based on travel speed. The VSM needs accurate Refer to Table 23 for the procedures on how to per-
travel speed information for advanced functions form Proc_Cal_026: Travel Speed Calibration.
such as enhanced power reversals, auto-decel, and
travel speed limiting, to work correctly.
Table 23. Proc_Cal_026: Travel Speed Calibration

Action 1: Make two marks 15 m (50 ft) apart on level ground.
Action 2: Drive truck up to the first mark. Be sure to choose a reference point on the truck to line up with
the mark on the ground. Also be sure that the steer tires are aligned straight ahead.
Action 3: Shut the engine OFF and enter the service password in the dash.
Action 4: Start the engine.
Action 5: Scroll to the Calibrations Menu and press *.
Action 6: Scroll to the Travel Speed Sensor and press *.

8000 SRM 1134 Proc_Cal_026: Travel Speed Calibration
Table 23. Proc_Cal_026: Travel Speed Calibration (Continued)
Action 7: Press * when ready to begin.

Action 8: Drive to the second mark 15 m (50 ft), stopping when the reference point you made lines up with
the 15 m (50 ft) mark. Be sure to drive straight as possible. Travel speed will not have any affect on the
outcome of the calibration.
Action 9: Press *.
Action 10: The display should say "Save and Exit" if the calibration process was performed properly.
Action 11: Press * twice to save the calibration.
Verification: Access the speed indicator by using the or , or by performing Action 12 through Ac-
tion 15.
Action 12: Press *.
Action 13: Scroll to the Diagnostics Menu and press *.
Action 14: Scroll to the XMSN/Brake Data Disp Menu and press *.
Action 15: Scroll to Travel Speed Sensor Menu and press *.

Drive the truck at top speed and verify that the top speed agrees with the model truck within
±1.61 km/h (±1 mph).
NOTE: The travel speed diagnostic display in 1.61 km/h (1 mph) increments. Any speed between whole
numbers is always rounded down to the nearest whole number.

NOTES
54
TECHNICAL PUBLICATIONS
8000 SRM 1134 1/17 (9/15)(3/15)(12/14)(4/14)(3/13)

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Hyster Převodovky

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CALIBRATION

PART NO. 1580528 8000 SRM 1134

©2017 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

(S30-35FT, S40FTS) [E010, F010];

Table 1. Calibration Procedures

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Table 1. Calibration Procedures (Continued)

Table 2. How to Read Calibration Procedure

Proc_Cal_XXX Number and title of calibration procedure.

A. TYPICAL DISPLAY WITHOUT KEY, 1. SYMBOLS USED IN CALIBRATION

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Table 2. How to Read Calibration Procedure (Continued)

Step 1: Press * One Time Calibration steps.

You will see:

Proc_Cal_001: Service Password Entry

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Table 3. Proc_Cal_001: Service Password Entry

A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS

Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air

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Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed

A. E-HYD CONTROL LEVERS

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NOTE: Optional for initial manufacture.

Proc_Cal_003: Save and Exit

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Table 5. Proc_Cal_003: Save and Exit

A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS

Step 2: Press One Time You Will See: Cancel Save

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Proc_Cal_004: Lift Valve Output Threshold

Performed when troubleshooting procedures indi-

Table 6. Proc_Cal_004: Lift Valve Output Threshold

A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS

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Table 6. Proc_Cal_004: Lift Valve Output Threshold (Continued)

Information: Pressure Method: Perform actions 1, 2, 3, 4, and 6.

Step 1: Press or Until You See: Main Menu

A. E-HYD CONTROL LEVERS

Action 3: SLOWLY Activate (Feather) Lift Control.....

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Table 6. Proc_Cal_004: Lift Valve Output Threshold (Continued)

Press * One Time while holding control.

Step 1: Press or Until You See: Lower Valve Out-

Proc_Cal_005: Lower Valve Output Threshold

Performed when troubleshooting procedures indi-

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Table 7. Proc_Cal_005: Lower Valve Output Threshold

A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS

Step 1: Press or Until You See: Main Menu

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Table 7. Proc_Cal_005: Lower Valve Output Threshold (Continued)

Step 3: Press or Until You See: Calibrations

A. E-HYD CONTROL LEVERS

Action 2: SLOWLY Activate (Feather) Lower Control.

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