CALIBRAÇÕES

CALIBRATION
PROCEDURES
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]; H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) [A299]
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
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
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
Why Perform .................................................................................................................................................. 10
How to Perform.............................................................................................................................................. 10
Proc_Cal_005: Lower Valve Output Threshold ................................................................................................ 12
When to Perform............................................................................................................................................ 12
Why Perform .................................................................................................................................................. 12
How to Perform.............................................................................................................................................. 12
Proc_Cal_006: Tilt Back Valve Output Threshold ........................................................................................... 16
When to Perform............................................................................................................................................ 16
Why Perform .................................................................................................................................................. 16
How to Perform.............................................................................................................................................. 16
Proc_Cal_007: Tilt Forward Valve Output Threshold ..................................................................................... 18
When to Perform............................................................................................................................................ 18
Why Perform .................................................................................................................................................. 18
How to Perform.............................................................................................................................................. 19
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold....................................................................................... 22
When to Perform............................................................................................................................................ 22
Why Perform .................................................................................................................................................. 22
How to Perform.............................................................................................................................................. 22
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold....................................................................................... 26
When to Perform............................................................................................................................................ 26
Why Perform .................................................................................................................................................. 26
How to Perform.............................................................................................................................................. 26
When to Perform............................................................................................................................................ 28
Why Perform .................................................................................................................................................. 28
How to Perform.............................................................................................................................................. 29
When to Perform............................................................................................................................................ 32
©2009 HYSTER COMPANY i

Table of Contents Calibration Procedures
TABLE OF CONTENTS (Continued)

Why Perform .................................................................................................................................................. 32
How to Perform.............................................................................................................................................. 32
When to Perform............................................................................................................................................ 34
Why Perform .................................................................................................................................................. 34
How to Perform.............................................................................................................................................. 35
When to Perform............................................................................................................................................ 38
Why Perform .................................................................................................................................................. 38
How to Perform.............................................................................................................................................. 38
Proc_Cal_014: Load Weight Zero Point ............................................................................................................ 40
When to Perform............................................................................................................................................ 40
Why Perform .................................................................................................................................................. 40
How to Perform.............................................................................................................................................. 40
Proc_Cal_015: Loaded Weight Calibration....................................................................................................... 42
When to Perform............................................................................................................................................ 42
Why Perform .................................................................................................................................................. 42
How to Perform.............................................................................................................................................. 42
Proc_Cal_016: Transmission Valve Calibration ............................................................................................... 45
Applicable System/Option ............................................................................................................................. 45
When to Perform............................................................................................................................................ 45
Why Perform .................................................................................................................................................. 45
How to Perform.............................................................................................................................................. 45
When to Perform............................................................................................................................................ 46
Why Perform .................................................................................................................................................. 46
How to Perform.............................................................................................................................................. 47
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Funtion ........................................... 48
When to Perform............................................................................................................................................ 48
Why Perform .................................................................................................................................................. 48
How to Perform.............................................................................................................................................. 49
Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electronic Extended Function ............................ 50
When to Perform............................................................................................................................................ 50
Why Perform .................................................................................................................................................. 50
How to Perform.............................................................................................................................................. 51
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment................................................................. 52
Required Tools................................................................................................................................................ 52
When to Perform............................................................................................................................................ 52
Why Perform .................................................................................................................................................. 52
ii
Calibration Procedures Table of Contents
TABLE OF CONTENTS (Continued)

How to Perform.............................................................................................................................................. 53
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
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];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299]
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 indi- SRM may have to be repeated when any on-board
cate how many key presses it will take to get to a controllers, sensors, or related components are re-
given screen, versus detailing out every screen you placed.
would see. Refer to Table 1 for calibration proce-
dures. 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 3 4 5 Mazda Engine Units Electronic Electronic

Units Functions Functions Functions w/Electronic w/Load Transmission Extended
Electronic- Electronic- Electronic- 1-Speed Weight (Basic & L1) Function
Hydraulic Hydraulic Hydraulic Transmission Display (L2)
Valves Valves Valves
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 X X X

Output 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 X

Calibration
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 3 4 5 Mazda Engine Units Electronic Electronic

Units Functions Functions Functions w/Electronic w/Load Transmission Extended
Electronic- Electronic- Electronic- 1-Speed Weight (Basic & L1) Function
Hydraulic Hydraulic Hydraulic Transmission Display (L2)
Valves Valves Valves
016 Transmission Valve X

Calibration (Basic & L1)
016A Transmission Valve X

Calibration (L2)
016B Transmission Valve X X

Calibration (L1 & L2)
019 Mazda LP and X

Gas Acceleration Pedal
Adjustment
025 Hydraulic Valve Pressure X X X

Gage Installation
026 Travel Speed Calibration X X
2 Confidential/Proprietary - Do Not Copy or Duplicate

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

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 HOW TO PERFORM
Performed when any hydraulic calibration items are
performed.
WARNING
CALIBRATION ORDER mechanism. Never allow anyone under or on
the forks.
1. Proc_Cal_025
Never put hands, arms, head, or legs through
2. Proc_Cal_001 the mast or near the carriage or lift chains.
This warning applies not only to the opera-
3. Proc_Cal_002 tor but also the helper. A helper must not be
Hydraulic calibrations are the process of setting the
hydraulic current levels that result in initial function
movement. Pressure and flow are directly related to Refer to Table 4 for the procedures on how to perform
the hydraulic fluid viscosity which is a function of the Proc_Cal_002: Hydraulic Valve Calibration Warm
fluid temperature. Air, trapped within the lift valve Up and Air Bleed.
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.
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

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)
*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.
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.

Proc_Cal_003: Save and Exit 8000 SRM 1134
Proc_Cal_003: Save and Exit

Must be performed after any calibration except Pro- This warning applies not only to the opera-
cedure 016, Transmission Valve Calibration. tor but also the helper. A helper must not be
Calibration processes do not automatically save their
results until this routine is run.
Refer to Table 5 for the procedures on how to perform
HOW TO PERFORM Proc_Cal_003: Save and Exit.
WARNING
the forks.

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

Performed when troubleshooting procedures indi-
cate, when lift valve components have been serviced,
WARNING
or when the lift valve is replaced. Keep yourself and all others clear of the lift
CALIBRATION ORDER the forks.
1. Proc_Cal_025 Never put hands, arms, head, or legs through

2. Proc_Cal_001 This warning applies not only to the opera-
tor but also the helper. A helper must not be
3. Proc_Cal_002 near the load or the lift mechanism while the
operator is attempting to handle a load. The
4. Proc_Cal_004
WHY PERFORM
All electro-hydraulic valves have different operating
Proc_Cal_004: Lift Valve Output Threshold.
characteristics. One of the key characteristics is the
point at which hydraulic flow begins for a given com-
mand current. This ‘cracking’ current is determined
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
Password Entry, and Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed before
proceeding.
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."
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.

8000 SRM 1134 Proc_Cal_004: Lift Valve Output Threshold
Table 6. Proc_Cal_004: Lift Valve Output Threshold (Continued)
Action 1: With the truck running, note the pressure reading (standby pressure).
Action 2: Activate Lift Control to Position Attachment 0.6 m You Will See: Main Menu
(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

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
reading 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_005: Lower 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 Output

Back 1 Level

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

Performed when troubleshooting procedures in-
dicate, when lower valve components have been
WARNING
serviced, or when the lower valve is replaced. Keep yourself and all others clear of the lift

WHY PERFORM lift mechanism has moving parts with close
characteristics. One of the key characteristics is the Refer to Table 7 for the procedures on how to perform
point at which hydraulic flow begins for a given com- Pro_Cal_005: Lower Valve Output Threshold.
by this process.

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
cannot be performed by using the pressure method.
Action 1: Activate Lift Control to Position Attachment 0.6 m (2 ft) You Will See: Main Menu
up with no load on the forks/attachment. If the forks/attachment Passwords
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
Step 3: Press or Until You See: Calibrations

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

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

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.
Repeat Calibration
Press * One Time You Will See: Lower Valve Output

Press * at Creep
Return to Action 2. Perform Actions 2 through 4 again.
If You See..... Tilt Bk Valve Output
Press * at Creep

8000 SRM 1134 Proc_Cal_005: Lower Valve Output Threshold
Table 7. Proc_Cal_005: Lower Valve Output Threshold (Continued)
Step 1: Press or Until You See: Tilt Bk Valve Output

Back 1 Level

Back 1 Level

Proc_Cal_006: Tilt Back Valve Output Threshold 8000 SRM 1134
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

4. Proc_Cal_006
WHY PERFORM
Proc_Cal_006: Tilt Back Valve Output Threshold.
by this process.
Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold

proceeding.
Information: Pressure Method: Perform Actions 1, 2, 3, 4, and 6.
Visual Method: Perform Actions 2, 3, 5, and 6.

8000 SRM 1134 Proc_Cal_006: Tilt Back Valve Output Threshold
Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold (Continued)
(2 ft) up with no load on the forks/attachment. Activate the tilt Passwords
control to position the function in the middle of the range (mast
is vertical).

Calibrations

Lift Valve Output

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

B. JOYSTICK

Action 3: SLOWLY Activate (Feather) Tilt Back Control.....

Proc_Cal_007: Tilt Forward Valve Output Threshold 8000 SRM 1134
Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold (Continued)
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
Press * One Time You Will See: Tilt Bk Valve Output

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

Output
Back 1 Level

Back 1 Level
Proc_Cal_007: Tilt Forward Valve Output Threshold

WHEN TO PERFORM 4. Proc_Cal_007
Performed when troubleshooting procedures indi- WHY PERFORM

cate, when tilt forward valve components have been
serviced, or when the tilt forward valve is replaced. All electro-hydraulic valves have different operating
CALIBRATION ORDER point at which hydraulic flow begins for a given com-
1. Proc_Cal_025 by this process.
2. Proc_Cal_001
3. Proc_Cal_002

8000 SRM 1134 Proc_Cal_007: Tilt Forward Valve Output Threshold
HOW TO PERFORM near the load or the lift mechanism while the
WARNING lift mechanism has moving parts with close
mechanism. Never allow anyone under or on Refer to Table 9 for the procedures on how to perform
the forks. Proc_Cal_007: Tilt Forward Valve Output Thresh-
old.
Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold

proceeding.
Information:
Pressure Method: Perform Actions 1, 2, 3, 4, and 6.
(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

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

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

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

8000 SRM 1134 Proc_Cal_007: Tilt Forward Valve Output Threshold
Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold (Continued)
Press * One Time You Will See: Tilt Fw Valve Output

Press * at Creep
Return to Action 3.
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 8000 SRM 1134
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold

cate, when Aux 1 Dir A valve components have been
WARNING
serviced, or when the Aux 1 Dir A valve is replaced. Keep yourself and all others clear of the lift

4. Proc_Cal_008
WHY PERFORM
Refer to Table 10 for the procedures on how to
perform Pro_Cal_008: Aux 1 Dir A Valve Output
Threshold.
by this process.

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

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

Calibrations

Lift Valve Output

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

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

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 func-
tion 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 8000 SRM 1134
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold

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

4. Proc_Cal_009
WHY PERFORM
perform Proc_Cal_009: Aux 1 Dir B Valve Output
Threshold.
by this process.
Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold

proceeding.
Information:

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 (Continued)

Action 2: Activate Lift Control to Position Atachment 0.6 m (2 ft) You Will See: Main Menu
up with no load on the forks/attachment. Activate the Aux 1 Passwords
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

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

Performed when troubleshooting procedures indi- 4. Proc_Cal_010

serviced, or when the Aux 2 Dir A valve is replaced. WHY PERFORM
CALIBRATION ORDER All electro-hydraulic valves have different operating

1. Proc_Cal_025 point at which hydraulic flow begins for a given com-

mechanism. Never allow anyone under or on Refer to Table 12 for the procedures on how to
the forks. perform Proc_Cal_010: Aux 2 Dir A Valve Output
Threshold.

proceeding.
Information:
(2 ft) up with no load on the forks/attachment. Activate the Aux 2 Passwords

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

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


WARNING

4. Proc_Cal_011
WHY PERFORM
Threshold.
by this process.

proceeding.
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

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

Performed when troubleshooting procedures indi- WHY PERFORM

serviced, or when the Aux 3 Dir A valve is replaced. All electro-hydraulic valves have different operating
CALIBRATION ORDER point at which hydraulic flow begins for a given com-
2. Proc_Cal_001
3. Proc_Cal_002

HOW TO PERFORM This warning applies not only to the opera-

WARNING near the load or the lift mechanism while the
the forks.
perform Proc_Cal_012: Aux 3 Dir A Valve Output
Threshold.

proceeding.
Information:
Action 2 Activate Lift Control to Position Attachment 0.6 m (2 ft) You Will See: Main Menu
up with no load on the forks/attachment. Activate the Aux 3 Passwords

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

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


WARNING

4. Proc_Cal_013
WHY PERFORM
Threshold.
by this process.

proceeding.
Information:



Calibrations

Lift Valve Output

Aux 3 Output Dir B
Press * at Creep

B. JOYSTICK


Proc_Cal_014: Load Weight Zero Point 8000 SRM 1134
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 "weigh-
WARNING
ing position" is not within ±2 percent of truck capac- Keep yourself and all others clear of the lift
ity. (This is ±45.4 kg (100 lb) for a 2268 kg (5,000 lb) mechanism. Never allow anyone under or on
truck). the forks.
This procedure will write a value to the Tare Weight Never put hands, arms, head, or legs through
memory location. If you are going to perform the mast or near the carriage or lift chains.
Proc_Cal_015 Loaded Weight Calibration, you can This warning applies not only to the opera-
skip this procedure as its value will be overwritten. tor but also the helper. A helper must not be
CALIBRATION ORDER operator is attempting to handle a load. The
1. Proc_Cal_001 clearances that can cause serious injury.
2. Proc_Cal_014 Refer to Table 16 for the procedures on how to per-

form Proc_Cal_014: Load Weight Zero Point.
WHY PERFORM
Allows the system to take into account the weight of
the carriage assembly for weight displays.

8000 SRM 1134 Proc_Cal_014: Load Weight Zero Point
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.


Proc_Cal_015: Loaded Weight Calibration 8000 SRM 1134
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
Immediately 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 WHY PERFORM
1. Perform when the pressure transducer is re- Because known load weights are not weighing within
placed. ±2 percent of truck capacity.
OR HOW TO PERFORM
2. Perform the calibration when the following pro-
cedure does not pass. WARNING
Lift a load equal to approximately 3/4 the lift Keep yourself and all others clear of the lift
truck capacity or more and raise the load in mechanism. Never allow anyone under or on
the same manner as when performing the the forks.
Proc_Cal_014: Load Weight Zero Point sev-
eral times to ensure the system repeats within Never put hands, arms, head, or legs through
approximately ±2 percent of truck capacity. If the mast or near the carriage or lift chains.
it does not, then remove the load and recheck This warning applies not only to the opera-
the Proc_Cal_014: Load Weight Zero Point. tor but also the helper. A helper must not be
If the load weights are then within tolerance, near the load or the lift mechanism while the
continue using the system. If not within tol- operator is attempting to handle a load. The
erance, then proceed to perform the Loaded lift mechanism has moving parts with close
Weight Calibration. clearances that can cause serious injury.
Refer to Table 17 for the procedures on how to per-

CALIBRATION ORDER form Proc_Cal_015: Loaded Weight Calibration.
1. Proc_Cal_001
2. Proc_Cal_015

8000 SRM 1134 Proc_Cal_015: Loaded Weight Calibration
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


Proc_Cal_015: Loaded Weight Calibration 8000 SRM 1134
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 You Will See: Lift Known Load To
Approximately 51 mm (2 in.), Wait One Second And Weighing Height
Immediately 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 Stopping 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 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.

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

NOTE: The information contained in the transmis- WHY PERFORM
sion calibration procedures described below, apply to
all lift trucks covered in this SRM except lift truck Performed to compensate for clutch pack control
models S6.0FT, S7.0FT (S135FT,S155FT) (D024, valve pressure in relation to valve command current
E024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, tolerances.
J006), and H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299). Calibration proce- HOW TO PERFORM
dures for S6.0FT, S7.0FT (S135FT,S155FT) (D024,
E024) and H6.0FT, H7.0FT (H135FT, H155FT) WARNING
(H006, J006) can be found in Table 19. Keep yourself and all others clear of the lift
APPLICABLE SYSTEM/OPTION the forks.
Electronic Power Shift Transmission Never put hands, arms, head, or legs through
WHEN TO PERFORM This warning applies not only to the opera-
Performed whenever disassembling or replacing the
transmission, the transmission valve, or the trans-
mission pressure sensors.
CALIBRATION ORDER
1. Proc_Cal_001 WARNING
NOTE: Brakes must be properly adjusted and func- Keep park brake applied, full service brake
tioning prior to performing this procedure. applied, and full accelerator applied during
entire time that automated transmission valve
2. Proc_Cal_016 calibration is occurring.
Refer to Table 18 for the procedures on how to per-

form 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
performing this procedure.

Proc_Cal_016: Transmission Valve Calibration 8000 SRM 1134
Table 18. Proc_Cal_016: Transmission Valve Calibration (Continued)
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
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, and You Will See: Calibrate Xmsn Valve
full accelerator applied during entire time that automated trans- Done in 15
mission valve calibration is occurring.
Press * One Time
Watch display countdown. When completed You Will See: Calibrations
successfully..... Calibrate Xmsn Valve
NOTE: The information contained in the transmis- CALIBRATION ORDER

lift truck models S6.0FT, S7.0FT (S135FT,S155FT) 1. Proc_Cal_001
(D024, E024) and H6.0FT, H7.0FT (H135FT,
NOTE: Brakes must be properly adjusted and func-
H155FT) (H006, J006).
tioning prior to performing this procedure.
APPLICABLE SYSTEM/OPTION 2. Proc_Cal_016
Electronic Power Shift Transmission.
WHY PERFORM
WHEN TO PERFORM Performed to compensate for clutch pack control
valve pressure in relation to valve command current
tolerances.

8000 SRM 1134 Proc_Cal_016: Transmission Valve Calibration
HOW TO PERFORM operator is attempting to handle a load. The

WARNING clearances that can cause serious injury.
mechanism. Never allow anyone under or on WARNING
the forks. Keep park brake applied, full service brake
applied, and full accelerator applied during
Never put hands, arms, head, or legs through entire time that automated transmission valve
the mast or near the carriage or lift chains. calibration is occurring.
tor but also the helper. A helper must not be Refer to Table 19 for the procedures on how to per-
near the load or the lift mechanism while the form Proc_Cal_016: Transmission Valve Calibration.
Table 19. Proc_Cal_016: Transmission Valve Calibration (S6.0FT, S7.0FT (S135FT,S155FT)

(D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006))

Passwords

Calibrations

Lift Valve Output

Press * to Begin
Action 3: FULLY Depress Accelerator Pedal and HOLD during heating mode.

Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Funtion 8000 SRM 1134
Table 19. Proc_Cal_016: Transmission Valve Calibration (S6.0FT, S7.0FT (S135FT,S155FT)

(D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)) (Continued)
Action 4: Allow for the transmission to warm up to 60 C (140 F) (automatic operation).

for the process to start. The calibration process will begin automatically after the transmission has fully
warmed up. The accelerator pedal can then be released. The operator must be in the seat during the
duration of the calibration process which takes approximately 25 minutes (5 minutes per clutch pack).
If transmission temperature drops below 40 C (104 F) calibration will stop and heating mode will start up
again. Press and hold the accelerator pedal down until transmission temperature reaches 60 C (140 F). The
calibration process will then continue from where it left off.
If a fault occurs during the calibration process, press the * button once to continue the calibration process.
Recover and troubleshoot all faults after the calibration process has been completed.
NOTE: Keep park brake applied and full service brake applied You Will See: Xmsn Calibration X
during entire time that automated transmission valve calibra- (X Represents the
tion is occurring. Calibration starts automatically after heating Clutch Pack Being
mode. Calibrated)
When calibration is completed successfully..... You Will See: Calibrations
Calibrate Xmsn Valve
Proc_Cal_016A: Transmission Valve Calibration-Electronic

Extended Funtion
all lift trucks covered in this SRM except lift truck 1. Proc_Cal_001
models S6.0FT, S7.0FT (S135FT,S155FT) (D024,
E024), H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006), and H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299). 2. Proc_Cal_016A
APPLICABLE SYSTEM/OPTION WHY PERFORM

Electronic Power Shift Transmission Performed to compensate for clutch pack control
WHEN TO PERFORM tolerances.

8000 SRM 1134 Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Funtion

Table 20. Proc_Cal_016A: Transmission Valve Calibration

Passwords

Calibrations

Lift Valve Output

Press * to Begin

Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electronic Extended Function 8000 SRM 1134
Table 20. Proc_Cal_016A: Transmission Valve Calibration (Continued)
NOTE: Keep park brake applied, full service brake applied, and You Will See: Calibrate Xmsn Valve
full accelerator applied during entire time that automated trans- Done in 35
mission 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 You Will See: Calibrate Xmsn Valve
successfully..... The engine will go to idle and you will see for Xmsn Calibration 0
approximately 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
Proc_Cal_016B: Trans. Valve Calibration-Electronic and

Electronic Extended Function
the following lift truck modelscovered in this SRM 1. Proc_Cal_001
S6.0FT, S7.0FT (S135FT,S155FT) (D024, E024),
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006),
and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299). 2. Proc_Cal_016B
APPLICABLE SYSTEM/OPTION WHY PERFORM

Electronic Power Shift Transmission Performed to compensate for clutch pack control
WHEN TO PERFORM tolerances.

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

Table 21. Proc_Cal_016B: Transmission Valve Calibration

Passwords

Calibrations

Lift Valve Output

Press * to Begin

Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 8000 SRM 1134
Table 21. Proc_Cal_016B: Transmission Valve Calibration (Continued)
NOTE: Keep park brake applied, full service brake applied, and You Will See: Xmsn Oil Temp
full accelerator applied during entire time that automated trans- xxx
mission 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 You Will See: Calibrate Xmsn Valve
successfully..... The engine will go to idle and you will see for Xmsn Calibration 0
approximately 2 minutes:
Watch display. When completed successfully..... You Will See: Calibrations
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment

REQUIRED TOOLS the Mazda LP and Mazda gas engines and electronic
control transmission.
LPG:
• 13mm Open-End Wrench CALIBRATION ORDER
Gas: 1. Proc_Cal_001
• #3 Phillips Head Screwdriver
• 10mm Open-End Wrench 2. Proc_Cal_019
• 13mm Open-End Wrench
WHY PERFORM
WHEN TO PERFORM
Sets the lost motion in the throttle assembly for the
Perform when adjusting or first installing an accel- proper operation of the clutch pack braking and inch-
erator pedal assembly on fork trucks equipped with ing functions.

8000 SRM 1134 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment
mechanism. Never allow anyone under or on Refer to Table 22 for the procedures on how to per-
the forks. form Proc_Cal_019: Mazda LP and Gas Accelerator
Pedal Adjustment.
Table 22. 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, slowly 850 RPM
press the throttle pedal until the engine RPM
reaches 850. The accelerator pedal value should
be between 22 and 27 percent.

Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 8000 SRM 1134
Table 22. 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 procedures.
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 bellcrank 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 This warning applies not only to the opera-
are performed by using the pressure method. tor but also the helper. A helper must not be
Installation of a pressure gage will allow for the pres-
sure method to be used whenever any hydraulic cal-
ibration items are performed. Refer to Table 23 for the procedures on how to per-
form Proc_Cal_025: Hydraulic Valve Pressure Gage
HOW TO PERFORM Installation.
WARNING
the forks.

8000 SRM 1134 Proc_Cal_025: Hydraulic Valve Pressure Gage Installation
Table 23. 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
alternative 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
procedure 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, per-
WARNING
form the calibration process whenever changing the Keep yourself and all others clear of the lift
drive tire size or if the truck travel speed diagnostic mechanism. Never allow anyone under or on
display is not reading correctly. the forks.

CALIBRATION ORDER the mast or near the carriage or lift chains.
No prior calibration required. This warning applies not only to the opera-
WHY PERFORM near the load or the lift mechanism while the
Advanced function transmission control decisions lift mechanism has moving parts with close
are based on travel speed. The VSM needs accurate clearances that can cause serious injury.
travel speed information for advanced functions
such as enhanced power reversals, auto-decel, and Refer to Table 24 for the procedures on how to per-
travel speed limiting, to work correctly. form Proc_Cal_026: Travel Speed Calibration.
Table 24. 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 *.
Action 7: Press * when ready to begin.

8000 SRM 1134 Proc_Cal_026: Travel Speed Calibration
Table 24. Proc_Cal_026: Travel Speed Calibration (Continued)
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
Action 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 num-
bers is always rounded down to the nearest whole number.

NOTES
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58
TECHNICAL PUBLICATIONS
8000 SRM 1134 4/09 (2/09)(7/08)(6/07)(3/07)(9/06)(6/06)(4/06)(11/05)(6/05)(5/05) Printed in U.S.A.

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CALIBRAÇÕES

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CALIBRATION

This manual contains information that is confidential and/or proprietary to Hyster

PART NO. 1580528 8000 SRM 1134

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2009 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

Table 1. Calibration Procedures

When Procedure is Used:

Proc_Cal/Procedure All 3 4 5 Mazda Engine Units Electronic Electronic

001 Service Password Entry X

002 Hydraulic Valve X X X

003 Save and Exit X

004 Lift Valve Output X X X

005 Lower Valve Output X X X

006 Tilt Back Valve Output X X X

007 Tilt Forward Valve X X X

008 Aux 1 Dir A Valve Output X X X

009 Aux 1 Dir B Valve Output X X X

010 Aux 2 Dir A Valve Output X X

011 Aux 2 Dir B Valve Output X X

012 Aux 3 Dir A Valve Output X

013 Aux 3 Dir B Valve Output X

014 Load Weight Zero Point X

015 Loaded Weight X

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Table 1. Calibration Procedures (Continued)

When Procedure is Used:

Proc_Cal/Procedure All 3 4 5 Mazda Engine Units Electronic Electronic

016 Transmission Valve X

016A Transmission Valve X

016B Transmission Valve X X

019 Mazda LP and X

025 Hydraulic Valve Pressure X X X

026 Travel Speed Calibration X X

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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

Step 1: Press * One Time Calibration steps.

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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

Step 1: Press * One Time. You Will See: Main Menu

Step 2: Press * One Time. You Will See: Passwords

Step 3: Press * One Time. You Will See: Enter Password

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Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed

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

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1. LIFT/LOWER 2. TILT 3. AUX 1 OR AUX 2 4. AUX 2 OR AUX 3 5. *FOURTH LEVER

1. LIFT/LOWER 2. TILT 3. AUX 1 OR AUX 2 4. AUX 2 OR AUX 3 5. *FOURTH LEVER

1. LIFT/LOWER 2. TILT 3. AUX 1 OR AUX 2 4. AUX 2 OR AUX 3 5. *FOURTH LEVER

1. LIFT/LOWER 2. TILT 3. AUX 1 OR AUX 2 4. AUX 2 OR AUX 3 5. *FOURTH LEVER