ELECTRICAL SYSTEM N30-40-45 XMR N25-30 XMDR N50 XMA HYSTERSAFETY PRECAUTIONS MAINTENANCE AND REPAIR ‘When lifting parts or assemblies, make sure that all slings, chains or cables are correctly fastened and thatthe load being lifted is balanced. Make sure that the crane, cables and chains have the capacity to support the weight of the Toad. Do not lift heavy parts by hand. Use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR befoe 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 and working area clean and in order. Use the correct tools for the job. Keep the tools clean and in good condition. Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment ‘manufacturer. Make sure that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when making repairs or if the unit needs repairs, Make sure you follow the DANGER, WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels. Make sure that you follow the ne and when working on these fuel systems, ry safety precautions when handling these fuels Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area, Make sure the area has ventilationCONTENTS INTRODUCTION GENERAL COMPONENT REPAIR AND TESTING GENERAL CONTACTOR PANEL ASSEMBLY Description/Features Removal Installation . . CONTACTORS ...... Description/Features Testing Removal vee ceeeees Installation... “BE” CONTACTORS . FUSES RELAYS Description/Features Coil testing Contact testing .. Removal and Installation HEIGHT LIMIT SWITCH Removal ...... Installation . KEY SWITCH . Removal Installation ceeeees BATTERY DISCONNECT SWITCH . Removal Installation eee PROPORTIONAL ELECTRO-HYDRAULIC VALYI Description/Features ‘Testing/Removal/Installation Manual LoweringSELECTOR VALVES .. cee ceceeeeeeees a nl Description/Features . cee ceee ou Testing/Removal/Installation ..... 5 n MULTI-FUNCTION CONTROL HANDLE . cee teeeees 12 Description/Features ........000000+ 12 MFCH TRACTION CONTROL ......... cee e eee we 12 Disassembly... 12 Assembly ... 13 ‘TRACTION, LIFI/LOWER AND TILT LEVER POTENTIOMETER 15 Testing 15 Installation . cece IS Adjustment wee - we - . 15 OMNITROL LEVER CONTROL ........0000000000cee essen - 16 Testing . cee 16 Removal . - : cee 1B: Installation 20 SINGLE SPEED LIFT/LOWER CONTROL (SEPARATE LEVER CONTROL) veceeeeeeee ees 20 Testing, 20 Removal . we 20 Installation cee a SEPARATE LEVER CONTROL ..... cee . a Removal 2 Disassembly cee coos 2B Assembly . . - : - 2B Installation . 2B MAIN INTERFACE BOARD ..... - : 25 DESCRIPTION/FEATURES ....... . 25 OPERATION ..... oe - 25 DISPLAY 25 PRIORITIES ....... - 6 REMOVAL 26 INSTALLATION .. cee . . 7 CHECKING THE MODEL CODE AND PROGRAM STATUS .. 27 GENERAL : 28 CUSTOM PROGRAMMING 28MAIN INTERFACE BOARD ADJUSTMENTS, Beene 21229 GENERAL ........ : cee cee 2.29 MIB SET-UP SEQUENCE .........000++ : . 29 MIB SET-UP PROCEDURE, vee tteeeettneees . 30 Incteasing/Decreasing The Function Number ......+..000++ meets) Increasing/Decreasing The Function Value 30 STEP 1 ENTERING THE SET-UP MODE = 30 STEP2 ERASING THE MODEL CODE ... cee eetee cece 30 STEP 3 SETTING THE MODEL CODE ... 31 STEP 4 HYDRAULIC CONTROL SET-UP 31 Step4A OMNITROL Lever Set-Up cee 31 LifvLower cect BI Sideshift 000... ooo eee teeeeeeee 32 Setting Reach Function .........060.ccceeeeeeeee 32 Setting Tilt Function 32 Evaluating the OMNITROL Lever Set-Up 3 Step 4B _Lift/Lower Lever Potentiometer Set-Up Step 4C Tilt Lever Potentiometer Set-Up . STEP 5 TRACTION POTENTIOMETER SET-UP 34 STEP 6 EXITING THE SET-UP MODE . cee cee . 35 Exit and Save New Values ...00.0.00000:0000008 ceteteeeeeeeeeerees 38 MIB STATUS, WARNING AND FAULT CODE TROUBLESHOOTING 41 MIB FUNCTION DESCRIPTIONS. 83 This section is forthe following models: 30-40-45 XMR, N25-30 XMDR, NSO XMA @HYSTER COMPANY 1996INTRODUCTION GENERAL This electrical system for the N30-40-45XMR, N25-30XMDR and NSOXMA lift trucks is new to Hys- ter trucks. The electrical control system consists of the following major components: + Main Interface Board (MIB) + Proportional Electro-Hydraulic Valve * Traction Motor Controller + Dash Display Assembly ‘+ Multi-function Control Handle Assembly (MECH) + Contactor Panel Assembly r MAIN INTERFACE BOARD (SYSTEM SUPERVISOR + OMNITROL Lever or Separate Lever Hydraulic Control Each of the major components will first be discussed in ‘general, Later in this section complete instructions re~ ‘garding removal, disassembly, repair, assembly, instal- lation, adjustments and specifications are provided. See the section, DLAGRAMS, 8000 SRM 579 for addi- tional wiring details. NOTE: Throughout this manual the terms right, left, front and rear relate to the viewpoint of an operator standing in the truck facing the forks. veto \ FIGURE 1 - LOGIC DIAGRAMCOMPONENT REPAIR AND TESTING GENERAL 1. Tocheck for wire connections to the frame, discon- nect the battery so that the connector is completely free and use an ohmmeter to check the circuits. Check for 50,000 ohms or more between each terminal of the part of the battery connector on the lift truck and aclean con- nection on the frame. Make sure there are no electrical ‘connections tothe frame of the lift truck. Wires or termi- nals without insulation can cause these connections. Isolators for circuit boards that are missing, broken or not installed correctly can also cause these connections. 2. Checkfor voltage between each terminal of the con- rector on the battery and a clean metal connection on the frame ofthe lift truck. Itis normal to measure some volt- age between the battery and the frame even if the resis- tance checks are correct. Ifa voltage is measured, use an ammeter to determine if the level is acceptable. Current in excess of 100 milliamperes can cause a problem. ‘There can be a voltage on the frame ifthe battery is dirty or if the battery has a defect. Clean the battery and bat- tery compartment as necessary. There can also be a volt age on the frame if there is carbon dust in the motors. Use dry compressed air to remove the carbon dust from all motors. CONTACTOR PANEL ASSEMBLY Description/Features ‘The contactor panel assembly is supplied as asubassem- bly complete with wiring. It contains the main, forward/ reverse and steering pump contactors, all fuses, and the associated wiring and components. The lift pump con- tactoris mounted separately. All ofthe components used are commen for all of this series of lift trucks, whether the lift truck is using a 24 volt or 36 volt battery. All of the components are located so that they are easy to see, test and maintain, ‘The contactor panel assembly is located behind the op- erator’ compartment cover on the right hand side of the truck. Access to the contactor panel requires removing, the cover. The fuses, “ER” (enable relay), main contac- tor, power steering contactor and the forward/reverse contactor are mounted on this panel assembly. 2 NOTE: The lift pump motor contactor, the “HMR” (hour meter relay) and the “HR” (hom relay) are located in the drive unit compartment. |. PLUG . RESISTOR 9, FWD, REV. CONTACTOR FUSE 400 AMPS 10. MIB ENABLE RELAY FUSE 325AMPS 11. FUSE BLOCK BUSS BAR 12. POWER STEERING ‘CONTROL PANEL FUSE 100AMPS _ CONTACTOR BUSS BAR 13, MAIN COVTACTOR FIGURE 2~ CONTACTOR PANEL ASSEMBLY Removal 1. Move the lift truck toa safe level crea. Turn the key switch off and remove the key. Put a “DO NOT OPER- ATE” tag on the MFCH. Put blocks under the drive wheels to keep the lift truck from moving. See the sec- tion, PERIODIC MAINTENANCE, 8000 SRM 578. Refer to HOW TO PUT A LIFT TRUCK ONTO BLOCKS,A warnine Disconnect the battery and separate the connector before opening the compartment cover or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage. 2. Disconnect the battery and separate the connectors. 3. Remove the socket head capscrews retaining the coverto the frame. Remove the operator’s compartment cover for access to the contactor panel assembly. A WwaRNING ‘The capacitor in the traction motor controller can hold an electrical charge after the battery is discon- nected. To prevent electrical shock and injury, dis- charge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the ca- pacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B— terminals (center 2 terminals). DO NOT use a screwdriver to discharge the traction mo- tor controler. 4, Discharge the controller by connecting load across terminals B+ and B—. Disconnect the plug to the main wiring harness. NOTE: The contactor panel assembly does not nor- mally have to be removed from the lift truck. The steps listed above must be done to service any item that is at- tached to the contactor panel assembly. 5. To remove the panel assembly, tag and disconnect, the power wires to the contactors and the fuses. 6. Unplug the control wires from the main wire har- ness at the X-5 connector. 7. Remove the capscrew, flat washer, lockwasher and ‘nut retaining the top of the panel assembly to the frame. Remove the two nuts, lockwashers, and flat washers re- taining the bottom of the panel assembly to the frame. Remove the contactor panel assembly. Installation 1. Align the contactor panel with the mounting holes in the frame. Install the two flat washers, lockwashers and nuts on the bottom of the panel assembly. Install the capscrew, flat washer, lockwasher and nut to retain the top of the panel assembly. 2. Install the power wires and fuses. See the section, DIAGRAMS, 8000 SRM 579 for additional informa- tion. 3. Reconnect the control wires. 4, Connect the battery and test the operation of the truck. 5. Remove the blocks from under the drive wheels, re- move the “DO NOT OPERATE” tag and install the key. CONTACTORS Contactors are switches, controlled by electromagnets (coils), that close and open a power circuit, The MIB and traction motor controller have internal electronic driv- €ers to control the current to the coils of the contactors. ‘The electromagnetic field in the coil moves the armature against spring pressure to close the contact. When the coil is deenergized, the spring pressure moves the arma- ture and opens the contacts. When a spring holds the contacts of a switch open, the switch is called normally open (NO). If a spring holds the contacts of a switch closed, the switch is called normally closed (NC) FIGURE 3 - TYPICAL SPNO CONTACTOR ASSEMBLY ‘The contactor contacts are made of special silver alloy The contacts will normally look black and rough from normal operation, This condition does not cause prob- 3lems with the operation of the lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CON- TACTS. DO NOT LUBRICATE THE CONTACTS. Replace the contacts when the silver alloy is worn away to the base support metal. Lift trucks equipped with a power steering circuit have contactors with one set of single pole normally open ‘contacts (SPNO). See FIGURE 3. FIGURE 4 ~ DIRECTION CONTACTOR A typical set of direction contactors is shown in FIGURE 4. The direction contactors (FORWARD and REVERSE) each have two sets of NC and NO contacts. When a coil for a direction contactor is energized, the NO contac's close and the NC contacts open. This de- sign preveats the contacts from being closed in the wrong sequence. Testing A warNinc Parts of this procedure requires working on the lift truck with full electrical current present. Do not wear any rings, a watch or any other Jewelry while working around the contactor panel assembly. When manually closing a contactor with the power connected, use a properly insulated tool. 1, Block the lift truck so that the drive wheels are off the floor. See the section, PERIODIC MAINTE- NANCE, 8000 SRM 578. Refer to HOW TO PUT A LIFT TRUCK ONTO BLOCKS. Make certain that the hydraulic controls are in the neutral position. 4 2, Remove the operator's compartment cover. & caution Never operate the traction motor at full speed for more than a few seconds without a load when the drive wheels are off the floor. A series wound DC mo- tor will continue to accelerate indefinitely until it ex- ceeds its designed maximum rpm, at which point it will self-destruct. 3. Check the condition of the battery. If it is not fully charged, charge or replace the battery with a fully charged battery before continuing, 4, Visually check to see if the contactor closes when the circuit is energized. If the contactor closes, skip to Step 10. Ifthe contactor does not close, proceed to Step 5. 5. Connect a voltmeter across the coil terminals. Verify that the correct voltage is being applied to the coil with the circuit energized. See TABLE 1 CONTACTOR COR | agoroximate | Approximate Foward/Reverse 2avots | _24,volts Main-24 volt tuck 24voits | 8 vols Main-36 volt tuck 36 volts | 12 vols Lit Pump 2avots | 12 volts Power Steering/Aux.Pump | 24vots | 12 volts NOTE: Pullin voltage occurs for only approximately 1 ‘second. Some voltmeters may not display this voltage. TABLE I - CONTACTOR COIL VOLTAGES 6. Check the contactor for loose, broken or corroded connections at the contactor. 7. Check the mechanical function of the contactor. Use an insulated tool, such as an electricians screwdriver to ‘manually close the contactor tips. Check for looseness or binding of the moving parts of the contactor. The parts should move freely, but the parts must not be so loose that the movement is sloppy. 8. Visually check the tips for pitting, burning or wear. 9. Ifan external suppressor is attached to the coil, re- move the suppressor. Check the ohm value of the con- tactor coil. Compare the reading against the ohm values for the type of contactor being tested. See TABLE 2,Page 8 for coil resistance values. Readings not within the listed limits indicate the following: High Resistance . Corrosion or an open coil Low Resistance .. Shorted or a burnt coil NOTE: No external suppressors are used on contac- tor coils which are controlled by the MIB or the traction ‘motor controller. The MIB and traction motor controller have internal suppressors for these contactor coils. 10. If the contactor closes but the truck does not work properly, check the electrical function of the high cur- rent section of the contactor (the tips and buss bars). With the lift truck battery connected and all switches closed, connect a volt ohmmeter across the high current terminals of the contactor. Set the voltage scale of the meter to the lowest range higher than battery voltage (50 volts for a 36 volt bat- tery, etc.). On forward and reverse contactors, with the contactor open, a reading of zero volts should be ob- tained. As the contactor closes, the meter should jump then immediately drop to zero or close to zero. This is the voltage drop across the contactor. On pump contac~ tors, read the voltage across the contactor with the tips open. Battery voltage should drop to zero or near zero as the tips close. A voltage drop of 2 volts or more across the tips indi- cates a poor contact or high resistance. Check for burned or wom tips, incorrect size or mismatched tips and for an incorrect gap setting on contactors with adjustable point gaps. Removal A WARNING ‘The capacitor in the traction motor controller can hold an electrical charge after the battery is discon- nected. To prevent electrical shock and injury, dis- charge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the ca- pacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B— terminals (center 2 terminals). DO NOT usea screwdriver to discharge the traction mo- tor controller. 1. Disconnect the battery and separate the connectors. 2. Refer to CONTACTOR PANEL ASSEMBLY, RE- OVAL for access o the main, power steering and for- wward/reverse contactors mounted on the contactor pan- el. The pump contactor is located on a bracket located in the drive unit compartment. To access the pump contac~ tor, open the drive unit compartment door. 3, Discharge the controller by connecting a load across terminals B+ and B— 4, Tag and disconnect the wires and/or buss bars to the contactor. 5, Remove the capscrews, flat washers and lockwash- ers retaining the contactor to the contactor panel assem- bly. For the pump contactor, remove the capscrews, lockwashers, flat washers and nuts. Installation 1, Forthe contactors on the contactor panel assembly, align the contactor to the contactor panel assembly. Install the contactor using the capscrews, flat washers and lockwashers. For the pump contactor, align the con- tactor with the bracket in the drive unit compartment. Install the capscrews, flat washers, lockwashers and nuts, 2. Connect the wires and/or buss bars to the contactor. See the section, DIAGRAMS, 8000 SRM 579 for wit- ing connections. 3. Close the drive unit compartment door for the pump contactor. Install the operator's compartment cover for the contactors mounted on the contactor panel assem- bly. 4. Connect the battery and test the operation of the truck, “EE” CONTACTORS ‘When “EB” contactors are used, additional steps are re- quired to service the contactors as the contactors are covered by an enclosure shroud. 1, Remove the capscrews retaining the enclosure shroud to the contactor. Remove the shroud. 2, Remove the insulator. 3, Service the contactor. 4, Install the insulator. 5. Position the enclosure shroud over the contactor and fasten the shroud to the coil and frame assembly, 5ENCLOSURE SHROUD CAPSCREW INSULATOR . FIXED CONTACT . CAPSCREW . COVER RETURN SPRING MOVING CONTACT . BASE . PLUNGER |. COIL AND FRAME, FIGURE 5 - TYPICAL “EE” CONTACTOR FUSES ‘The fuses for these lift trucks are located on the contac- tor panel assembly. See CONTACTOR PANEL AS- SEMBLY, REMOVAL to access the contactor panel as- sembly. A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage. ‘When the lift truck has the provision for “EE” the fuses FUI through FUS are enclosed in a fuse box on the con- tactor panel assembly. For access to the fuses, see FIGURE 6. Remove the capscrews and lockwashers re- taining the floor insulator, wall insulator and the fuse box enclosure to the base plate to test or remove the fuses. ‘The fuses may be checked for continuity if it cannot be determined visually that a fuse has failed. Make certain toreplace any failed fuse with one ofthe same amperage when replacing a fuse. FUL TRACTION MOTOR 205 AMPS FU2_LIFTPUMP MOTOR 400 AMPS FU3 POWER STEERING MOTOR 100 AMPS FU4 DASH DISPLAY/BDI 10 AMPS FUS KEY SWITCH 10 AMPS FU6 CONTROL CIRCUITS 10 AMPS FU7 HORN ANDOPTIONAL FANS 10 AMPS FU OPERATOR COMPARTMENT LAMP (OPTIONAL) 10 AMPS RELAYS Description/Features ‘There are three relays used oa the standard N30-40-45XMR, N25-30XMDR and NSOXMA model lift trucks. The “ER” (enable relay) is mounted on the contactor control panel. The “HMR” ihourmeter relay) and “HR” (hom relay) are mounted below the lift con- tactor in the drive unit compartment. ‘The “HMR” (hour meter relay) isusedto senda signal to the dash display whenever the lift pump is activated.‘When the signal is present, pump hours accumulate on the dash display hourmeter. ‘The “HR” (horn relay) supplies battery volts to the horn ‘when the hom button is depressed, ‘The relay mounted near the bottom of the contactor pan- el is designated as the “ER” (enable relay). The enable 4. INSULATOR-TERMINAL, 2. ENCLOSURE-FUSE BOX 3. NUT, 4, LOCKWASHER, 5. SPACER, 6. LOCKNUT 7. FUSE 100 AMPS 8. SCREW 9. WASHER 10. TERMINAL POST 11, CAPSCREW 12. 13, 14. 16. 16. 17. 18, 19, \\ ”. FUSE 325 AMPS |. INSULATOR-WALL ). LOCKWASHER . CAPSCREW FIGURE 6 - ENCLOSED FUSE BOX “EE” APPLICATION Coil testing ‘The “ER”, “HMR” and “HR” relay coils can be tested for resistance across terminals 85 and 86. See FIGURE 7 for test point locations. Replace any relay which has a coil resistance value outside of specifica- tions. See TABLE 2 for coil resistance values. NOTE: The “ER” (enable relay) “HMR” (hourmeter relay) and “HR” (hom relay) are both single pole, double throw (SPDT) type relays. They are manufac- tured by either The Bosch Company or Potter & Brumfield. When testing these relays, itis important to identify the manufacturer due to different coil resistance values. The name of the manufacturer is stamped on the relay. 18 17, INSULATOR-FLOOR, SPACER SF |. WASHER NUT. 8 . FUSE 400 AMPS fi 9 relay iscontrolled by the MIB. The enable relay supplies battery volts tothe the lift pump contactor coil, the pow- er steering contactor coil, the hydraulic control valve coils, the selector valve coils and to certain MIB input switches. The relay will deenergize these circuits if cer- tain fault conditions occur. See MIB fault codes 70, 71, T2and 73. 16, BOSCH AND POTTER BRUMFIELD RELAYS PIN ARRANGEMENT ‘SCHEMATIC FIGURE 7 — “ER”, “HMR”AND “HR” RELAYSContact testing ‘The normally open contacts of the “ER”, “HMR” and “HR” relays are checked at terminals 30 and 87. Check fora voltage drop across the N.O. contacts with the relay energized. Replace any relay which has a voltage drop exceeding 2 volts. See FIGURE 7 for test point loca- tions. Removal and Installation _ ‘To remove the relays, tag and disconnect the wires. Re~ ‘move the capscrews and lockwashers etaining the relay to the contactor panel assembly or the mounting brack- et Replace the relays by aligning the relay with the mount- ing holes in the contactor panel assembly or mounting bracket and installing the capscrews end lockwashers, COIL RESISTANCE cou Location | wanuracrunen [OE RESSTANCE | Test powrs “TAF and LOWER a 65 5 ohms | Collen “AUX UP" (auxiliary up) and | Hydraulic Control ro “AUXDOWNE (aula down) | Va tar zone | cotteads cole Faber ach Gap] BE Teak “ERT enable ey col . wet | conctreat |Peeré Bunt | an as anne | mean Saaum | Rab boscn Gap] S055 Sams "HMR" (nourmeter relay) coil Compartment Potter See ‘360 + 35 ohms ‘Teminals 85 and 86 Saeum | Rares Cap | 205 ms “HRY (hom il rive Uni Terminals 85 and 86 (rome cxt | compartnent_ | Pater Bumfotd | sep = a5 hme _| Toms “SS (aac as [Een Raven | Polaron ne [9+ dots | Cotas "REACH cols Cr Trp ie Un FT PUMP" ol come u tt 18 1ohms | Collease “PS power doo) Contactor Paret | —_ Abit 323 the | Cotten "HAIN col ContacorPanot [ Abit 20 Thins | Collate "FID and "RE (om aeTRE [ comacor tara | __ Abn 7 tots | _Collease ‘TABLE 2 - COIL RESISTANCE VALUES HEIGHT LIMIT SWITCH Removal 1. Move the lift truck to a safe level area. Raise the ‘mast high enough to obtain access to the height limit switch, SAFETY CHAIN THE MAST. See the section, PERIODIC MAINTENANCE, 8000 SRM 578. Refer to SAFETY PROCEDURES WHEN WORKING NEAR THE MAST. Tur the key switch off and remove the key. Puta “DO NOT OPERATE” tag on the MFCH. Put blocks under the drive wheels to keep the Tift truck from moving. See the section, PERIODIC MAINTE- NANCE, 8000 SRM 578. Refer to HOW TO PUT A. LIFT TRUCK ONTO BLOCKS 8 A WARNING Do not raise the frame of the truck with the forks raised. Raising the forks will reduce the stability of the truck and could cause it to tip over. Tipping of the truck can cause personal injury or property damage. A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage. 2. Disconnect the battery and separa‘e the connectors. 3. Disconnect the plug X-11.4, Remove the two capscrews retaining the cover to the switch body. Remove the cover from the switch body. 5. Test the switch for continuity. 6. If the switch must be replaced, tag and disconnect the wires. 7. Remove the switch by removing the mounting caps- crews, lockwashers and nuts. Installation 1. Position the new switch on the bracket. Install the mounting capscrews, lockwashers and nuts. 2. Connect the wires to the switch, 3. Install the cover using the two capscrews. 4, Connect plug X-11 5. Remove the safety chains from the mast. Connect the battery, install the key and check the mast for proper operation. 6. Remove the blocks from under the drive wheels. Remove the “DO NOT OPERATE” tag from the MECH. 7. Check the truck for proper operation. Maximum travel speed must be limited with the mast elevated above free lft. KEY SWITCH Removal 1. Move the lift truck to a safe level area. Tum the key switch off and remove the key. Put a“DO NOT OPER- ATE” tag on the MFCH. Put blocks under the drive wheels to keep the lift truck from moving. See the sec- tion, PERIODIC MAINTENANCE, 8000 SRM 578. Refer to HOW TO PUT A LIFT TRUCK ONTO BLOCKS. & warnina Disconnect the battery and separate the connector before opening the compartment cover or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can canse an injury or parts damage. 2. Disconnect the battery and separate the connectors, 3, Remove the hydraulic tank dipstick. 4, Remove the socket head capscrews retaining the battery compartment cover to the frame. Remove the battery compartment cover for access to the wiring to the key switch, 5. Tag and disconnect the electrical wires to the key switch, 6. Remove the nut retaining the key switch to the mounting bracket and remove the key switch. Installation 1. Position the new switch in the mounting bracket. Install the nut to retain the key switch. 2. Install the electrical wires to the key switch. See the section, DIAGRAMS, 8000 SRM 579. 3. Install the battery compartment cover. 4, Install the hydraulic tank dipstick. 5. Connect the battery 6. Remove the blocks from under the drive wheels, re- move the "DO NOT OPERATE” tag and install the key. BATTERY DISCONNECT SWITCH Removal 1. Move the lift truck to a safe level area. Turn the key switch off and remove the key. Put a “DO NOT OPER- ATE” tag on the MFCH. Put blocks under the drive wheels to keep the lft truck from moving. See the sec- tion, PERIODIC MAINTENANCE, 8000 SRM 578. Refer to HOW TO PUT A LIFT TRUCK ONTO BLOCKS. A warning Disconnect the battery and separate the connector before opening the compartment cover or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery ‘can cause an injury or parts damage. 2. Disconnect the battery and separate the connectors. 3. Remove the hydraulic tank dipstick. 4, Remove the socket head capscrews retaining the battery compartment cover to the frame. Remove the battery compartment cover for access to the wiring to the battery disconnect switch,5. Tagand disconnect the electrical wires tothe battery disconnect switch. 6. Remove the nut retaining the battery disconnect switch to the mounting bracket and remove the battery disconnect switch. Installation 1. Position the new battery disconnect switch in the ‘mounting bracket. Install the nut to retain the battery disconnect switch. 2. Install the electrical wires to the battery disconnect switch. See the section, DIAGRAMS, 8000 SRM 579. 3. Install the battery compartment cover. 4, Install the hydraulic tank dipstick, 5. Connect the battery. 6. Remove the blocks from under the drive wheels, re- move the “DO NOT OPERATE” tag and install the key. PROPORTIONAL ELECTRO-HYDRAULIC VALVE Description/Features ‘There are four electrically operated proportional valves located on the main hydraulic control valve. These pro- portional valves are controlled by solenoids. Valve openings are controlled by varying the electrical current in the solenoid coils, al FIGURE 8 ~ PROPORTIONAL ELECTRO-HYDRAULIC VALVE Testing/Removal/installation Solenoid coils can be checked by removing the leads to the solenoid coil and testing the coil resistance using a volt ohmmeter. See TABLE 2 for coil resistance values. If a reading other than those listed is obtained, replace the solenoid coil. 10 See the section, HYDRAULIC SYSTEM, 2000 SRM (607 for instructions on removal and installation of the. proportional valves. Manual Lowering A warRNiNG Allow no one under or near the lift mechanism or load during the manual lowering procedure. & warnine Always verify that there are no obstructions beneath the lift mechanism or load before attempting to low- er manually ‘A provision is provided on the lowering valve to allow ‘manual lowering of the forks if necessary. Manual low- ering is accomplished by inserting an 1/8 inch allen ‘wrench into the manual lowering screw (located in the center of the lowering valvistor) and slowly turning it clockwise until the forks begin to lower. See FIGURE 9. Be sure to return the screw to the original position once the manual lowering process is complete by slowly turn- ing the screw counterclockwise unt PROPORTIONAL ELECTRO-HYDRAULIC ‘SOLENOIDS 1. AUXILIARY UP. 2. AUXILIARY DOWN 3. LIFT 4. LOWER MANUAL LOWERING SCREW FIGURE 9 - HYDRAULIC CONTROL VALVE A warnine Failure to return the manual lowering screw to the full counterclockwise position will cause the forks to lower unexpectedly.SELECTOR VALVES Description/Features (Used on N30-40-45XMR and N25-30XMDR model trucks only.) If the lift truck has provisions for tilt, sideshift and reach there are solenoids used to operate these functions lo- cated on selector valves. One selector valve assembly, containing two selector valves and two solenoids is lo- cated on the mast assembly and used to select between reach or tilt. See FIGURE 11. A second selector valve assembly, also containing two selector valves and two solenoids is located on the reach assembly and used to select between tilt and sideshift. See FIGURE 10. The second selector valve assembly is only fitted on reach model trucks equipped with an optional sideshifter. ‘When tit is selected by the operator, neither of the two selector valve assemblies is energized. When reach is selected, the coils are energized on the reach selector valve. When sideshift is selected the coils on the option- al sideshift selector valve are energized. 1. SOLENOID 2. VALVE BODY FIGURE 10 - SIDESHIFTER SELECTOR VALVE, Testing/Removal/installation Solenoid coils can be checked by removing the leads to the solenoid coil and testing the coil resistance using a volt ohmmeter. See TABLE 2 for coil resistance values. If a reading other than those listed is obtained, replace the solenoid coil See the section HYDRAULIC SYSTEM, 2000 SRM 6607, for information on removing and installing the sideshift and reach solenoids. . HYDRAULIC FITTING . SOLENOID |. VALVE BODY . HOSE 5. INNER FRAME . PORT TUBES. |. CHECK VALVE ASSEMBLY FIGURE 11 - REACH SELECTOR VALVE uMULTI-FUNCTION CONTROL HANDLE Description/Features ‘The MFCH (multi-function contro! handle) is located in the operator’s compartment with the handle positioned toafford the operatora comfortable position from which to operate the lft truck. Traction control, horn operation and certain hydraulic functions (depending on hydraulic control option) are controlled by using this single han- dle Rotating the MFCH forward activates travel in the for- ward direction. Rotating the MFCH backward activates travel in the reverse direction. Travel speed is also con- trolled by the MFCH. Faster travel speeds are provided as the MFCH is moved further from the neutral position. ‘The MFCH is spring loaded to allow handle to return to the center (neutral position) when there is no pressure applied, ‘The MFCH is designed so that the forward and reverse switches are activated and the traction potentiometer is turned when the MECH is rotated. FIGURE 12 - MFCH WITH OMNITROL LEVER ‘The MFCH also provides a means to control hydraulic functions. On OMNITROL lever equipped lift trucks, all hydraulic functions are controlled by the OMNITROL lever located on the MECH. See FIGURE 12. On separate lever equipped lift trucks, there are thumb actuated push button switches for single speed lift or single speed lower located on the MFCH. See FIGURE 13. ‘The travel, flower, tlt and reach functions will oper- ‘ate when the MFCH and/or OMNITROL leveris moved in accordance with the directions specified in ANSI BS6.1 2 FIGURE 13 - MFCH WITH SINGLE SPEED LIFTLOWER MFCH TRACTION CONTROL, Disassembly A caution ‘The gear segment is held to the T-plate with a special ‘epoxy. Never disturb the gear segment mounting, unless adjustment or replacement is necessary. Al- ‘ways install the gear segment using the proper pro- cedure and epoxy. ‘The numbers in the ( ), in the following procedures re- fer to item numbers in FIGURE 14. A warninc Disconnect the battery and separate the connector before opening the compartment coyer or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage. 1. Disconnect the battery and separae the connectors 2. Remove the socket head capscrews retaining the cpereor’s compartment cover tthe fane, Remove the cover. 3, Remove the potentiometer mounting plate (16) from the mounting weldment (6) by removing the two capscrews (20) and lockwashers (21), A cauTIon Pulling the potentiometer gear from the potentiome- ter assembly can cause damage tothe potentiometer. 4. Loosen the setscrew holding the gear (22) to the po- tentiometer shaft and remove the potentiometer gear by using a screwdriver positioned in the slot ofthe poten- tiometer shaft (14). Push the potentiometer shaft through the gear while holding the gear stationary.5. Remove the nut and lockwasher retaining the poten- tiometer (14) to the mounting plate (16). 6. If gear segment adjustment or replacement is neces- 4. HEX NUT 15. 2. SPRING RETAINER 16. 3. EQUALIZER TUBE 17, 4, CAPSCREW 18, 5. WASHER 19. 6. MOUNTING WELDMENT 20. 7. CLAMP. 21. 8. STUD PLATE 22. 9. SWITCH 23. 10. LOCKWASHER 24, 11. GEAR SEGMENT 25. 12. CAPSCREW 26. 13, WASHER, 27. 14, POTENTIOMETER 28. FIGURE 14 — MULTI-FUNCTION CONTROL Assembly ‘The numbers in the ( ), in the following procedures re- fer to item numbers in FIGURE 14. 1. Before assembling the spring retainer assembly, ap- ply anti-seize to the thicker center part of the equalizer sary remove the two countersunk screws (27) retaining, the gear segment (I1) to the T-plate (26). Break the epoxy seal between the gear segment and the T:plate. 18 17 NUT PLATE, POTENTIOMETER MOUNTING PLATE WASHER LOCKWASHER SCREW CAPSCREW LOCKWASHER GEAR MULTI-FUNCTION CONTROL HANDLE (MFCH) MOVING COVER RETURN BLOCK T-PLATE COUNTERSUNK SCREW HEX NUT HANDLE ASSEMBLY WITH OMNITROL LEVER tube (3). The spring retainer (2) should be held firmly against the equalizer tube by inside nuts (1) on either end. Adjust the location of the return block (25) by tun- ing the spring assembly clockwise or counterclockwise until the leg ofthe T-plate assembly (26) is approximate- ly parallel (A) tothe left side of the mount weldment (6). 3BThis provides the initial adjustment for the neutral posi- tion, 2. Remove all traces of epoxy from the gear segment (11) and the T-plate (26) using a scraper and a wire brush. Wipe the areas to be joined clean with isopropyl alcohol. Clean both the gear segment and the T-plate, 3. Installthe gear segment (11) tothe T-plate assembly (26) making sure that the area of the gear segment above the countersunk screws (27) is flush with the top of the bottom right side extension of the T-plate. The cam on the gear segment should be positioned between the directional switches (9). Secure the two countersunk screws to hold the gear segment in place. 4, Install the potentiometer (14) into the mounting plate (16) using the lockwasher and nut. Be sure to align the location pin of the potentiometer into the slot. 5, Attach the potentiometer mounting plate (16) to the mounting weldment (6) using capscrews (20) and lock- washers (21). Position the upper left comer of the mounting plate approximately 1/16” away from the gear segment tooth tip (in the neutral position). Secure the two capscrews to hold the mounting plate in place. Slowly move the multi-function control handle (23) ful- ly forward and fully backward while checking the gear segment to mounting plate clearance. Adjust the gear segment and/or the potentiometer mounting plate to in- sure 1/16” clearance in all positions (forward, neutral, and reverse). Scribe a line on the T-plate assembly (26) marking the left edge of the gear segment (1), A caution Clean the area where the gear segment meets the T- plate. Wipe both the gear segment and the T-plate with isopropyl alcohol. Allow the adhesive to set for at least three (3) minutes. 6. Remove the gear segment (11) from the T:plate. Clean the areas where the gear segment meets the T- plate with isopropyl alcohol. 7. Apply (Locktite Speed Bonder 324) Hyster P/N 2032538 to the right of the mark on the T-plate (26) only, in the areato be covered by the gear segment (11). 8. Apply (Locktite Activator 7075) Hyster P/N 2032539 to the gear segment (11) only, in the area that will contact the T-plate (26). Be sure to allow activator 4 to flash off per manufacturers instructions before as- sembly. 9. Assemble gear segment (11) to the T-plate (26) us- ing two countersunk screws (27). Before tightening the screws make sure that the gear segment is aligned with the scribe mark on the T-plate and is still 1/16” from the potentiometer mounting plate at all, forward, neutral and reverse positions. Tighten the two countersunk serews and allow the adhesive to set for atleast three (3) minutes. 10. Install the forward switch with the stud plate (8) positioned in the center of the mounting holes. 11. Install the reverse switch with the stud plate (8) positioned in the center of the mounting holes. 12. Adjust the neutral position of the the gear segment by rotating the spring assembly to position the gear seg- ‘ment (11) an equal distance from eack direction switch. ‘Tighten the lock nut (1) on the spring assembly against the return block (25) when the adjustment is complete 13. Adjust each direction switch (9) so it is activated ‘when the multi-function control handle is moved in the appropriate direction and not activated when in neutral. The switch rollers are positioned approximately 1/16” from each end of the gear segment cam, when the multi- function control handle assembly is inneutral. When the switches are activated the switch arm must not bottom out against the body of the switch or bind the multi-func- tion control handle assembly. NOTE: Loosen screws (20) and move potentiometer mounting plate away from the gear segment before installing the gear, if necessary. 14, Install the potentiometer gear (22) with the setscrew facing the gear segment and perpendicular to the gear ‘segment (11). Do not tighten the setscrew in the gear at this time. If necessary, adjust the potentiometer mount- ing plate to provide adequate tooth clearance. Gear lash ‘must be checked at full Forward, full reverse and neutral. ‘There must be a small amount of lash in all positions to prevent binding and side loading of the potentiometer (14), After setting the gear lash, tighten the two caps- crews (20) to lock the potentiometer mounting plate (16), 15. Adjust the traction potentiometer. Refer to POTEN- TIOMETER, Adjustment, Page 15.TRACTION, LIFT/LOWER AND TILT LEVER POTENTIOMETER Testing Potentiometer’s operation can be verified by discon- necting the wiring and checking resistance. Use an ana- Jog volt ohmmeter. Watch the needle on the meter while slowly rotating the potentiometer shaft. Look for a smooth sweep of the needle from minimum to maxi- mum values. Replace any potentiometer with erratic readings or operation. Potentiometer specifications are listed in TABLE 3. Test Points Resistance Value Between pot terminals 1 and 3 10KQ + 10% Between pot terminals 1 and 2 | From Oto 10KA + 10% From 010 10K@ 10% Between pot terminals 2 and 3 NOTE: Potentiometers can be supplied with or without rotational stops. ‘TABLE 3 - POTENTIOMETER SPECIFICATIONS, Install 1. Install the potentiometer through the mounting hole aligning the locating pin into the slot in the mounting bracket. See FIGURE 15. Fasten the potentiometer to the bracket using the lockwasher and nut. A cauTION Potentiometers can be supplied with or without rota- tional stops. Potentiometers with internal rotational stops will be damaged if they are rotated beyond the stops. 2. Install the gear on the potentiometer. Do not tighten the setscrew in the gear at this time. If the setscrew is tightened before the potentiometer is centered, the po- tentiometer can be damaged. Adjustment A caution ‘The wires to the potentiometer must be disconnected during Step 1. 1. Adjust the potentiometer for mid-range. Compare the resistance measured between terminals 1 and 2 with the resistance measured between terminals 2 and 3. The potentiometer is at the mid-range position when the re- sistance readings are equal within 100 ohms. Rotate the potentiometer shat while holding the gear in the neutral position for the correct resistance readings. Tighten the setscrew in the gear at this time. NOTE: Failure to properly center the potentiometer can cause a fault code to occur. The fault code may occur immediately or intermittently. 2. Connect the wires to the potentiometer terminals as shown in TABLE 4. 3. Calibrate the MIB to the potentiometer. Refer to MIB SET-UP PROCEDURE. A caution ‘Whenever adjusting or replacing a potentiometer the MIB must be calibrated to the potentiometer. Wire Number Pot Terminal | rraten pot | Letvtower | Tit Lover 1 2 3H 38 2 2 4 2 3 2 50 3 ‘TABLE 4 - POTENTIOMETER WIRING [i~ \ ee L@ XS OR ‘TERMINAL 2 ‘TERMINAL 1 LocaTine PN 10K0 + 10% ‘NY TERMINAL 1 cw TERMINALS ‘TERMINAL 2 (WIPER) FIGURE 15 - TRACTION AND HYDRAULIC POTENTIOMETER SPECIFICATIONS 1sOMNITROL LEVER CONTROL A warNinG Attempting to disassemble the OMNITROL lever equipped MFCH may alter the internal calibration ‘and will damage the internal shielding. Tampering with an OMNITROL lever equipped MFCH can ‘cause unexpected truck operation. Testing Ifthe OMNITROL components are suspected to be de- fective, the OMNITROL, MIB and interconnecting wir- ing can be functionally tested using the following proce- dure. 1, Remove the battery compartment cover and the clear plastic MIB cover to expose the MIB program- ming buttons. With the brake applied (brake pedal up), ‘tum the key switch tothe “ON” position (main contactor energized, MIB display shows “0200”). Push and hold button B to enter the TEST MODE. The left two digits will show the horizontal axis, and the right two digits will show the vertical axis. The numbers will change as the OMNITROL lever is moved. Generally these num- bers are approximately relative to a full scale of 0 to 99 in each axis, where 5050 is the approximate center val- ues. The acceptable values for each position are shown in TABLE 5. NOTE: Values over 99 are displayed as AO. In the TEST MODE, the decimal point between the left two digits is used to indicate operation of the OMNITROL intemal neutral switch. It should be off when the stick is in the center position. It will illuminate when the stick is moved away from the center, and it will remain on while the OMNITROL lever is moved to the end of the function gate. 2. If the MIB display readings match those listed in ‘TABLE 5 under TEST MODE, the OMNITROL and all of the associated wiring to the MIB is functioning prop- erly. If operational problems exist withthe lft truck, the OMNITROL set-up and/or the hydraulic components are suspect. Refer to MIB SET-UP PROCEDURE for the OMNITROL set-up procedure. See the section, HY- DRAULIC SYSTEM, 2000 SRM 607 for additional information on the hydraulic components. 16 NOTE: This procedure can be performed even if the OMNITROL lever set-up procedure has not been per- formed, orif it has been performed incorrectly. This test is completely independent of any calibration and works the same regardless of MIB setup. 3. If the MIB display readings are not correct, the MIB, OMNITROL lever/module andior wiring may be faulty. Further testing should be performed using a volt ‘meter to verify the output volages from the OMNITROL. Proceed to Step 4. 4. Check the OMNITROL voltages by back probing the X-8 molex connector of the main wire hamess (plugs into molex connector of the OMNITROL mod- ule interconnecting harness) Correct voltages are listed in TABLE 6. NOTE: The brake must be applied (brake pedal up), key switch on, main contactor energized and the respec tive function activated as shown in TABLE 6 to check the output voltages. 5. Ifthere are any problems with inputs or outputs, re~ move the OMNITROL module interconnecting harness and verify the integrity of each wire with an ohmmeter. See FIGURE 16 for pin out information. If this harness is defective replace it. 6. Ifthe inputs are not correct atthe X-8 connector, use an ohmmeter to check the respective circuit for an open. Locate and repair the open. A waRNING Never attempt to probe through the back of the J1 or J2MIB plugs. These plugs are special sealed plugs. If circuit must be tested for voltage, check for voltage at an “amp” type plug, a switch or a component. If the circuit to the MIB is suspect, check the circuit for continuity by removing the MIB and then discon- necting the J1 and J2 plugs. See MIB REMOVAL, Page 26. Test continuity from the front (pin end) of the plugs. See FIGURE 17, Page 19. 7. If the inputs are correct, but the outputs are not cor- rect at the X-8 connector, replace the MFCH assembly complete with OMNITROL lever and OMNITROL module,MIB in Test Mode MB in MIB in Run Mode x pe MIB In Any Mode Set-Up Mode oMNiTROL Function 2 Lever selected with Pecliin [Horizontal] vertical | Horizontal | _ Vertical aeceaee ‘xis | Axis | Axle Output | Axis Output | ash olpiay | MB | Depressed Display Display Volts Volts Y | Display ‘See NOTES) Lot bigts [Right ois | wheres | Whe #32 c ) POWERON | 0200 Neural | 401060 | 401060 | 2000 | 201000 0300 READY | 0900 atone fences! een Rises maze =o tower | 0700 | o705woo790 Fun | aswes | owa7 | 18was | ow20 uF (0500__| 0605 to 0690 FulT# | 751099 | saioo | a75w50 | astoso | Turoown | 1300 | 1395101390 FulTup | 7090 | owar | avsws0 | wis TuruP | 1200 | 1205t0 1299 Fulenend | 0125 | 68099 | ow125 | aswso | extend | 0900 | ooastoom9 Fuimotact | owes | owsi | ows2s | ovis | RETAACT | 1000 | 1095t0 1090 Furssrigt| ow10 | e769 | 005 | 19.92 |siDEsHIFTAIGHT| 1500 | _16Xxx Fulsstet | sos | artes | ssws0 | i9wa2 | sDESHFTLERT | 1600 | _i6Kx NOTE: Values listed are for an OMNITROL lever which has been set-up (MIB has been calibrated to OMNITROL lever). NOTE: _XXis equal to the programmed value of function 42 (default value is 99). ‘TABLE 5 - OMNITROL LEVER OUTPUT VALUES. SEE DETAIL & @ 9 PIN D-CONNECTOR 408 DETAIL & MOLEX PLUG —see FIGURE 16 ~ OMNITROL MODULE INTERCONNECTING HARNESS 7wire | toler | ani Connect Votimeter | Connect Voimeter "| Gomector | rgrminat | Funetion oativeto: Tiegeive to: Value 120 | x01 | soe | patrynegatveinput | BateryPostve | *®.1!atmain Batery vols 25 | _¥8-0 | NONE | Battery postive nput [XE@atmainhamess | Batley Negaive | Battery vols 3 | x65 | 222 | v2voninpua _|xeSatmainhamess | BatloryNegaive | 10010140 vole Less than 1 volt neutral 40 | x86 | 1-2 | Neutral Switch output | x8-6 at mainhamess | Battery Negative | Greater than 12.0 volts function activated 32 | x82 | 2-16 | Vertical Axis output |X8-2 at main hamess | Battery Negative ‘See TABLE 5 34 | xe-4 | 2-19 | Horizontal Axis output | X8-4 at main hamess | Battery Negative ‘See TABLE 5 43. | x81 | NONE Horn output | X8-1 at main hamess | Battery Negative | Batteyy votts with hom ‘bution depressed NOTE: Measure all volages with key switch on (main contactor energized) and brake pedal up. ‘TABLE 6 - OMNITROL MODULE TEST POINTS. 8, Ifthe inputs and the outputs at the X-8 connector are correct as shown in TABLE 6, repeat Step 1. Ifthe hori- zontal axis and/or vertical axis values do not match the values in TABLE 5, the wiring from the OMNITROL, ‘module to the MIB and/or the MIB is suspect. Discon- nect the battery. Disconnect the J-1 and J-2 plugs at the MIB and the X-8 connector at the OMNITROL module interconnecting harness. Verify the continuity of wires #40, #32 and #34 from the X-8 plug to the respective MIB pin. See FIGURE 17, Page 19. Repair any opens. 9. If no wiring problems are located, the MIB is sus- pect. Replace the MIB. Removal A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage. 1. Turn the key switch to OFF. Disconnect the battery. Position blocks on both sides (front and back) of the drive tire and the caster wheel. Put a block on each side (front and back) of the load wheels. 18 A WARNING ‘Make sure the brake pedal is up and the brake is ap- plied. Put blocks on both sides (frontand back) of the drive tire and the caster wheel to prevent movement of the lft truck. Puta block on each side (front and back) of the load wheels to prevent movement of the lift truck. 2. Remove the socket head capscrews retaining the ‘compartment cover to the frame. 3. Remove the socket head capscrews retaining the side cover to the frame. A WARNING ‘The OMNITROL lever and OMNITROL module are a matched set. The MFCH with OMNITROL le- ver is not serviceable component. The complete MECH including OMNITROL lever and OMNI- TROL module must be replaced if there is a problem with the any part MFCH or OMNITROL module. A warnina Attempting to disassemble the OMNITROL lever equipped MFCH may alter the internal calibration and will damage the internal shielding. Tampering with an OMNITROL lever equipped MFCH can cause unexpected truck operation.8 23 # FRONT VIEW FIGURE 17 - MIB J1 AND J2 PLUGS-PIN IDENTIFICATION A warnine Do not repair the teflon coated wire that is part of the OMNITROL lever assembly. 4, Remove the two screws between the shielded cable connector of the OMNITROL module and the OMNITROL module interconnecting harness. Discon- nect the connectors. 5. Remove the capscrews, washers, lockwashers and nuts retaining the MFCH and the mounting weldment to the lift truck frame. There are shims used on the front ‘mounting location. Remove the shims note their loca- tion and save them for reuse at assembly. Move the MECH and the mounting weldment away from the lift ‘ruck frame. A caution Before removing the MFCH note the manner in which the harness from the handle is installed. Dur- ing assembly, the harness must be installed in the same manner to avoid premature wear. 6. Remove the clamps retaining the MFCH wiring hamess to the mounting weldment. Disconnect the ‘MECH harness from the control module. 7. Remove two screws, washers, lockwashers and the rut plate holding the control module to the mounting plate. A caution ‘The OMNITROL module can be damaged by im- proper handling. To prevent damage from static electrical discharge, never touch the OMNITROL 1»module connector pins or the exposed componentsin the rear ofthe case. Handle the OMNITROL module by the metal case and connector housing only. 8. Remove the four capscrews and lockwashers retain- ing the multi-function control handle to the T-plate. Installation & warRNiNG The OMNITROL lever and OMNITROL module are a matched set. The MFCH with OMNITROL le- ver is not serviceable component. The complete MFCH including OMNITROL lever and OMNI- TROL module must be replaced if there is a problem with the any part MFCH or OMNITROL module. Refer to FIGURE 14 1, Install the multi-function control handle to the T- plate with four capscrews and lockwashers. 2. Replace two screws, washers, lockwashers and the nut plate holding the control module to the mounting, plate. A cauTION ‘The harness in the new handle must be installed in the same manner as the original harness to avoid premature wear. 3. Align the hamess and install the clamps using the capscrews and lockwashers. 4, Align the shims between the lift truck frame and install the capscrew, washer, lockwasher and nut. Install the remaining two capscrews, washers, lockwashers and nuts. 5. Connect the MFCH’s wire hamess connector to the control module. 6. Calibrate the MAIN INTERFACE BOARD to the new MECH. Refer to MIB SET-UP PROCEDURE. 7. Replace the socket head capscrews retaining the top and side covers. 8. Remove the blocks from in front and in back of the rive wheels and caster wheel. Connect the battery. SINGLE SPEED LIFT/LOWER CONTROL (SEPARATE LEVER CONTROL) Testing 2» ‘Testing of the MFCH with single speed lift lower is lim- ited to verifying the continuity of the three normally ‘open push buttons and their respective circuits. Discon- nect the battery. Disconnect the J-1 and J-2 plugs at the MIB. Check the circuits as shown in TABLE 7. The cir- cuits should test normally open. Continuity will exist on each circuit when the respective buttonis depressed. See the section, DIAGRAMS, 8000 SRM 579 for addition- al information, Service parts are available for the MECH with single speed lift/ower. A WARNING Never attempt to probe through the back of the J1 or J2MIB plugs. These plugs are special sealed plugs. If acircuit must be tested for voltage, check for voltage at an “amp” type plug, a switch or a component. If the circuit to the MIB is suspect, check the circuit for continuity by removing the MIB and then discon- necting the J1 and J2 plugs. See MIB REMOVAL, Page 26. Test continuity from the front (pin end) of the plugs. See FIGURE 17, Page 19. Function ‘Check Continuity from: ‘Terminal 30 (wire #10) at Enable Relay to J1-6 Terminal 30 (wire #10) at Enable Single Speed Lower | Ferm'ta srs Single Speed Litt Fuse FU7 to Terminal 86 (wire #43) athor relay ‘TABLE 7 - MFCH WITH SINGLE SPEED LIFT/LOWER Hom Removal A warNiNG Make sure the brake pedal is up and the brake is ap- plied. Put blocks on both sides (frontand back) of the drive tire and the caster wheel to prevent movement of the lift truck. Put a block on each side (front and back) of the load wheels to prevent movement of the lift truck. A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage. 1. Tum the key switch to OFF. Disconnect the battery and separate the connectors. Position blocks on both