1600691, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}INTRODUCTIONGENERALThis section contains procedures for adjustment, repairand troubleshooting of the Electric Power Steering(EPS III) System. The EPS III system controls the steermotor used to turn the master drive unit. The lift truck issteered by turning the master drive unit.There are three types of Electric Power Steering Sys-tems available: the standard system called the Return-to-Center Steering System (RTC), the optional TachGenerator Steering System (TGS), and the optionalWire Guidance Steering System. This section pertainsto the Return-to-Center and Tach Generator SteeringSystems only.NOTE:This section is NOT applicable to lift truckswith the optional Wire Guidance Steering System. Seethe sectionWIRE GUIDANCE – DESCRIPTION,2200 SRM 421for checks and adjustments and the sec-tionWIRE GUIDANCE – REPAIR, 2200 SRM 422for repairs to the steer system of trucks equipped withthe Wire Guidance Steering System.The TGS system has a steering wheel coupled to a belt-driven tach generator. The steering wheel does NOTautomatically return to the center position.The steering handle and command potentiometer for theRTC system are located in the operator’s compartment.Similarly, the steering wheel and tach generator for theTGS system are located in the operator’s compartment.The Electronic Control Module and steer motor are inthe motor compartment beside the master drive unit.The feedback potentiometer is connected to the steermotor below the steer sprocket. The steering chain con-nects the steer sprocket at the gear motor to the sprocketof the master drive unit. The Electronic Control Moduleis also located in the steer motor compartment.The command potentiometer attached to the steeringhandle provides a signal to the Electronic Control Mod-ule corresponding to the operator input. Similarly, thetach generator coupled to the steering wheel on the op-tional TGS system provides a signal to the ElectronicControl Module corresponding to the operator input.The Electronic Control Module processes the signal toascertain the steer angle selected by the operator.The feedback potentiometer is connected to the steermotor. The feedback potentiometer provides a signal tothe Electronic Control Module that corresponds to theposition of the master drive unit.The signal from the command potentiometer (or tachgenerator) and the signal from the feedback potentiome-ter are sent simultaneously to the Electronic ControlModule. If the master drive unit is not at the operator-se-lected angle, the Electronic Control Module provideselectrical output to the steer motor.The steer motor is coupled to the master drive unit with asprocket and chain. The electrical output to the steer mo-tor causes the motor to rotate the sprocket and chain andturn the master drive unit. As the master drive unit ap-proaches the selected angle, the signal from the feed-back potentiometer changes to instruct the ElectronicControl Module to slow and then stop the rotation of thesteer motor.1DESCRIPTIONThe Electric Power Steering System is comprised of thefollowing components:a. Steering handle (RTC system) OR steeringwheel (TGS system)b. Command potentiometer (RTC system) OR thetach generator (TGS system)c. Feedback potentiometerd. Steer system wire harnesse. Electronic Control Module (ECM)f.Lift truck batteryg. Steer motorh. Steering sprocket and chainThe RTC system has a steering handle that returns to thecenter position when released. The handle moves 100°each side of center for the full range of steering control.CHECKS AND ADJUSTMENTSGENERALDo not make adjustments to a properly operating steersystem.WARNINGDo not operate a lift truck that needs adjustments orrepairs. Report the need for adjustments or repairsimmediately. If adjustment or repair is necessary,put a “DO NOT OPERATE” tag in the operator’sarea. Remove the key from the key switch.WARNINGSome of the checks and adjustments are done withthe battery connected. Never have any metal on yourfingers, arms or neck. During some checks or adjust-ments, the operator must move the lift truck. Theperson doing the adjustments must make the adjust-ments with the system energized. Make sure the op-erator does not move the lift truck to cause an injuryFIGURE 1 – DIPSWITCHES – FACTORYSETTINGOn trucks equipped with the optional TGS steer system,an adjustment can be made to the settings of dipswitches5, 6, and 7 to alter the sensitivity of the tach generatorinput scaling, if desired. Refer to Tach Generator Steer-ing System – Sensitivity Adjustment in the ADJUST-MENTS section following.LED IndicatorsThe Electronic Control Module continuously monitorsthe steering system. Problems detected by the Electron-ic Control Module are indicated by 5 LEDs. Refer toFIGURE 2. These vehicles equipped with electric steer-ing systems are designed to stop automatically when afault occurs. The brake relay, located in the ElectronicControl Module, applies the brake to stop the vehicle if afault condition is detected.LED 1 on (green)(with motor clicking sound)LED 2 on (red)LED 3 on (red)Controller activeLeft limit reachedRight limit reachedError in sensor circuitError in controller or motorcircuitError in controllerSupply contactor fault orvoltage on emergencybrake coil (the controllermust remain off for a mini-mum of 2 seconds before anew startup to avoid an er-ror condition)CHECKSThree test points are provided for adjustment of theElectronic Control Module. TP1 is the feedback poten-tiometer input adjusted by P2. TP2 is the command po-tentiometer input adjusted by P1. TP3 is the analog andlogic common. Light Emitting Diodes (LEDs) 1through 5, located on the ECM circuit board, are used toindicate steer system faults.DipswitchesLED 4 on, LED 5 offLED 4 off, LED 5 onCAUTIONThe dipswitches are factory-set and should not need tobe adjusted.If the Electronic Control Module is replaced or the set-tings of the dipswitches are inadvertently changed, referto FIGURE 1 to set the position of the dipswitches to thefactory settings.2LED 4 on, LED 5 onLED 4, LED 5 off, and LED1 on (with no sound frommotor)TABLE 1 – LED INDICATORSLED’SDIPSWITCHESTEST POINTSPOTENTIOMETERSTP3TP2TP1 P2 P1 P3FIGURE 2 – ELECTRONIC CONTROL MODULEChecking the Steering System for CorrectOperationThe Electronic Control Module check includes checksfor the command potentiometer and the feedback poten-tiometer.1. Open the motor compartment door. Move the keyswitch to the “ON” position and push the foot switch.2. Make sure the battery has a corrected specific grav-ity of at least 1.250. To check the system for correct op-eration, move the steering handle or steering wheel froma full left turn position to a full right turn position. Themaster drive unit should move 85° to 95° in each direc-tion from straight travel.3. If the master drive unit moves less than 90°〈"5°)in either direction, the steering is incorrectly adjusted ormay have a mechanical problem. Refer to ADJUST-MENTS.4. Check that the master drive unit moves through thefull range of rotation in five seconds or less. The lifttruck must be on smooth concrete with a fully chargedbattery and no load.5. If the master drive unit requires greater than 5 se-conds to move through the full range of rotation, checkfor a mechanical problem or defective Electronic Con-trol Module.Checking Slow Travel SpeedNOTE:The slow travel speed is checked during theadjustment procedure. Refer to ADJUSTMENTS.Checking High Lift Traction Shut-Off1. Instruct the operator to raise the platform above3810 mm (150 in).2. The traction system shouldNOToperate with theoperator platform above 3810 mm (150 in) unless thetruck is equipped with the high lift travel-enable option.If the unit is so equipped, check that the traction systemoperates normally EXCEPT when the steering is set for7° or more from center and the operator platform isabove 3810 mm (150 in). If the steering is set for morethan 7° and the operator platform is above 3810 mm(150 in), the traction system should NOT operate.3ADJUSTMENTSGeneralNOTE:This section is NOT applicable to lift truckswith the optional Wire Guidance Steering System. SeeWIRE GUIDANCE – DESCRIPTION, 2200 SRM421for checks and adjustments to the Wire GuidanceSteering System.Make sure the battery has a corrected specific gravity ofat least 1.250. Move the lift truck to an open area whereit can be driven in a straight line for a distance of at least9 metres (30 ft).NOTE:Do not make adjustments to a properly oper-ating steer system. The following adjustments must bedone in the order specified. Do not move the steeringwheel or handle after it has been accurately centered un-less instructed to move it in the following procedures.1. Set the key switch in the “OFF” position.2. Unplug the connector from the command poten-tiometer. Refer to FIGURE 3.3. Use an ohmmeter to measure the resistance betweenwires 19 (black) and 20 (green). Measure the resistancebetween wires 20 (green) and 21 (white).4. Adjust the command potentiometer until the resis-tance values measured in Step 3 are equal (±50 ohms).Adjust the potentiometer by loosening the retaining nutand moving the potentiometer body to attain the desiredresistance readings. Tighten the retaining nut withoutmoving the potentiometer body.5. Attach the plug removed in Step 2 to the commandpotentiometer.6. Set the key switch to the “ON” position.7. Measure the voltage across TP3 and TP2 on theElectronic Control Module circuit board by insertingthe negative probe into TP3 and the positive probe inTP2. Refer to FIGURE 2. Adjust potentiometer P1 onthe Electronic Control Module circuit board to a valueof 0 Volts DC (± 0.05 VDC).Feedback Potentiometer AdjustmentRETURN-TO-CENTER STEERINGSYSTEMCommand Potentiometer AdjustmentThe RTC command potentiometer is located at the steer-ing mechanism in the instrument panel. Refer toFIGURE 3. Remove the screws at the top of the instru-ment panel. Tilt the panel to the open (down) positionfor access to the potentiometer.CAUTIONMake sure the Return-to-Center command poten-tiometer is properly adjusted before adjusting thefeedback potentiometer.1. Center the drive tire and steer handle for straighttravel. After the drive tire and handle are centered, donot adjust the steer handle again until specificallyinstructed to do so in this procedure.2. Refer to FIGURE 4 to identify the feedback poten-tiometer. Unplug the connector from the feedback po-tentiometer.3. Measure the resistance between wires 16 and 17.Measure the resistance between wires 17 and 18.4. Adjust the feedback potentiometer until the resis-tance values measured in Step 3 are equal (±50 ohms).Adjust the potentiometer by loosening the retaining nutand moving the potentiometer body to attain the desiredresistance readings. Tighten the retaining nut withoutmoving the potentiometer body.5. Attach the plug removed in Step 2 to the feedbackpotentiometer.2150.25-2.3 mm(0.01-0.09 in)341.2.3.4.5.RTC STEERING HANDLEINSTRUMENT PANELCOMMAND POTENTIOMETERRETAINING NUTCOWL CAPSCREWS12361FIGURE 3 – RETURN-TO-CENTER STEERING46. Set the key switch to the “ON” position.NOTE:If there are no steering changes within a 10second period, the Electronic Control Module removespower to the steer motor. To restore power to the steermotor, cycle the key from the “ON” position to the“OFF” position, and then back to the “ON” position.MOTORMOTORMOUNTINGBRACKET7. Measure the voltage across TP3 and TP1 on theElectronic Control Module circuit board by insertingthe negative probe into TP3 and the positive probe inTP1. Refer to FIGURE 2. Ensure that the ElectronicControl Module has not removed power to the steer mo-tor. Adjust potentiometer P2 on the Electronic ControlModule circuit board to a value of 0 Volts DC (± 0.05VDC).WARNINGDuring the following check, the operator must movethe lift truck. Use caution to avoid injury.8. Operate the lift truck in a straight line for at least 30feet, without touching the steer handle. Adjust poten-tiometer P2 again as necessary to ensure the lift trucktravels in a straight line within 152 mm (6 in) in 9 metres(30 ft).9. To verify that the lift truck is traveling in a straightline, install a pointer at the center of the front (masterdrive unit end) of the lift truck. Make a mark on the floorunder the point of the pointer.10. Operate the lift truck straight forward 5 metres (15ft). Make a mark on the floor under the point of thepointer.11. Operate the lift truck straight forward 5 more metres(15 ft). Make another mark on the floor under the pointof the pointer.12. Draw a straight line between the first and last marks.The center mark must be within 76 mm (3 in) of the line.If the center mark is within this specification, P2 is cor-rectly adjusted. If the mark isNOTwithin the specifica-tion, adjust P2 until the trial is successful.CHAINSPROCKETPOTENTIOMETERMOUNTINGBRACKETFEEDBACKPOTENTIOMETERFIGURE 4 – MOTOR MOUNTING ASSEMBLY5

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