Manitou MT6034, MT6642 & MT8044 RADIO REMOTE BOOM CONTROL SYSTEM Operator's Manual - PDF DOWNLOAD

CONTENTS

MANITOU NORTH AMERICA, INC. 6401 Imperial Drive Waco, TX 76712-6803

For Parts Orders contact your Manitou North America Dealer or call: Manitou North America Parts Dept. (800) 425-3727 or (254) 799-0232.

Parts Dept. Fax (254) 867-6504 Website: www.manitou-na.com

MT6034, MT6642 & MT8044 RADIO REMOTE BOOM CONTROL SYSTEM OPERATOR’S MANUAL PARTS MANUAL

THIS OPERATOR'S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS. CATALOG 809767 R09-06

CONTENTS

CONTENTS

Table of Contents Chapter

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1 2 3 4 5 6 7 8 9

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Factory Installed Service Parts - All Models . . . . . . . . . . . . . . . . . . . . . . .26 Field Installed Kits - 806841 & 806842 Model MT6034 . . . . . . . . . . . . .33 Field Installed Kits - 806621, 806622 & 806623 Models MT6642 & MT8044 . . . . . . . . . .49

1

CONTENTS

INTRODUCTION The information in this manual was written to give the owner/operator assistance in preparing, adjusting, maintaining and servicing the Radio Remote Boom Control. More important, this manual provides information on the safe and proper use of the Radio Remote Boom Control System. Major points of safe operation are detailed in the SAFETY chapter of this manual.

Be sure to read and understand the contents of this manual COMPLETELY and become familiar with the Radio Remote Boom Control System BEFORE operating it.

This Radio Remote Boom Control System allows the operator to remotely start the engine and operate the boom lift, lower, extend and retract functions. The operator can position a loaded attachment or raise personnel in an approved work platform from a safe position outside the operator’s station or from within the work platform. Lift personnel only with an approved work platform, and in full compliance with the “Mandatory Work Platform Safety Rules” (see SAFETY chapter).

The use of this Radio Remote Boom Control is subject to certain hazards that cannot be eliminated by mechanical means, but only by the exercise of intelligence, care and common sense. It is therefore essential to have competent and careful operators, who are not physically or mentally impaired, and who are thoroughly trained in the safe operation of the Radio Remote Boom Control and the handling of the loads.

A storage pocket in the back of the seat of the telescopic handler is provided for storing this manual. After using the manual, please return it to the pocket and keep it with the unit at all times! If the machine is resold, give this manual to the new owner.

The manufacturer reserves the right to make changes or improvements in the design or construction of any part without incurring the obligation to install such changes on any unit previously delivered.

In cooperation with the Society of Automotive Engineers, this

Safety Alert Symbol has been adopted to pinpoint characteristics which, if NOT properly followed, can create a safety hazard. When you see this symbol in this manual or on the machine itself, you are reminded to BE ALERT! Your personal safety is involved!

2

CONTENTS

Chapter 1 SPECIFICATIONS RECEIVER

TRANSMITTER

Size

5.1” x 4.7” x 1.4” (130 mm x 119 mm x 36 mm)

7.9” x 4.2” x 4.1” (200 mm x 125 mm x 105 mm)

Weight

0.65 lbs. (295 gm)

1.8 lbs. (817 gm)

Construction

High-impact plastic, weatherproof

High-impact, low-temp. plastic, weatherproof

Input Power

+9V to 30VDC

4 AA alkaline batteries

Battery Life

N/A

>120 hours (continuous use)

Operating Temp. Range -40°F to 158°F (-40°C to 70°C)

-40°F to 158°F (-40°C to 70°C)

Outputs

3A (max) each (sourcing), 10A (max) each (combined)

N/A

Antenna

Internal

Internal

Approvals

USA - FCC part 15.247; Canada - ISC RSS 2210; Europe - EN 440; Australia - C-Tick

3

CONTENTS

Chapter 2

SAFETY REMEMBER! It is the owner’s responsibility for communicating information on the safe use and proper maintenance of the Radio Remote Boom Control System! This includes providing an understandable interpretation of these instructions for operators who are not fluent in reading English.

Before using the Radio Remote Boom Control, read and study the following safety information. In addition, be sure that everyone who operates the Radio Remote Boom Control is familiar with these safety precautions.

WARNING

Manitou North America Inc., ALWAYS takes safety into consideration when designing its machinery. The Operator’s Manual, Safety Manual and decals on the machine warn of hazards and should be read and observed closely.

ALWAYS maintain a safe distance from electric power lines and avoid contact with any electrically charged conductor. It is not necessary to make direct contact with a power line for power to ground through the structure of the machine. Keep the boom at least 10 ft. (3 m) from all power lines. Accidental contact can result in electrocution.

DANGER “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING

U.S. OSHA regulations require employers in general industry and the construction, shipyard and cargo-handling industries (excepting agricultural operations) to ensure that forklift operators are competent, as demonstrated by successful completion of a training course.

“WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

The training course must consist of a combination of formal instruction and practical training, including both forklift-related and workplace-related topics, and evaluation of the operator’s performance in the workplace.

CAUTION “CAUTION” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also alert to unsafe practices.

All operator training and evaluation is to be conducted by persons who have the knowledge, training and experience to train and evaluate operators.

It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided, and use correct operating procedures.

Machines should be operated only by qualified operators.

4

CONTENTS

Safety Reminders

It is essential that operators be trained in the safe operation of the machine and the Radio Remote Boom Control System. Such training should be presented completely to all new operators and not condensed for those claiming previous experience.

Make sure machinery and the surrounding area are clear before operating. Do not activate the Radio Remote Boom Control unless it is safe to do so.

Turn off the receiver power before working on the machine. Always disconnect the Radio Remote Boom Control before doing any maintenance to prevent accidental operation of the machine.

User/operator safety practices, as established by industry standards, are included in this Operator’s Manual and intended to promote safe operation of the machine. These guidelines do not, of course, preclude the use of good judgment, care and common sense as may be indicated by the particular jobsite work conditions.

Before Operation Safety Reminders

ALWAYS wear appropriate personal protective equipment for the job and working conditions.

Hard hats, goggles, protective shoes, gloves, reflector-type vests, respirators and ear protection are examples of types of equipment that may be required. DO NOT wear loose fitting clothing, long hair, jewelry or loose personal items while operating or servicing the machine.

Study the load charts carefully. They show maximum capacity to be lifted and placed at specific outward and upward distances. ALWAYS be aware of load weights prior to attempting lift and placement with this machine.

DO NOT exceed the machine’s rated operating capacity for the type of attachment tool being used.

DO NOT allow minors or any unqualified personnel to operate or be near the machine unless properly supervised.

DO NOT run the engine in an enclosed area without providing proper ventilation for the exhaust.

Exhaust gases contain carbon monoxide, an odorless and deadly gas. Internal combustion engines deplete the oxygen supply within enclosed spaces and may create a serious hazard unless the oxygen is replaced. This includes the atmosphere within the cab when equipped.

To ensure continued safe operation, replace damaged or worn-out parts BEFORE using this equipment.

Modifications, Nameplates, Markings and Capacities

ALWAYS check the job site for terrain hazards, obstructions and people. Remove all objects that do not belong in or on the machine and its equipment.

Walk around the machine and warn all personnel who may be servicing the machine or who are in the machine path prior to starting. DO NOT start until all personnel are clearly away from the machine.

Operation Safety Reminders

DO NOT raise or drop a loaded fork or bucket suddenly. Abrupt movements under load can cause serious instability.

IF YOU ARE NOT CAREFUL WHILE OPERATING THIS MACHINE, ANY OF THE FOLLOWING FACTORS COULD CAUSE THE MACHINE TO TIP: terrain, engine speed, type of load being carried and placed, improper tire inflation, weight of the attachment tool, and abrupt movement of any control lever may affect the stability of the machine, WHICH COULD RESULT IN SERIOUS BODILY INJURY OR DEATH!

5

Modifications and additions that affect capacity or safe operation shall not be performed without the manufacturer’s prior written approval. Where such authorization is granted, tags or decals shall be changed accordingly.

All attachment tools MUST be marked to identify the attachment tool and the total capacity with attachment tool at maximum elevation with load laterally centered.

ALWAYS be sure all nameplates, warnings and instruction markings are in place and legible.

Local government regulations may require specific decals, which then become the responsibility of the local owner to provide.

CONTENTS 10. Be sure that the forklift has a firm footing.

Radio Remote Boom Control System

11. Be sure that any required restraining means (railings, chains, harnesses, etc.) are in place and properly used.

WARNING

12. Before lifting personnel, shift the transmission into Neutral, apply the parking brake, and activate the "Radio Remote Boom Control System" switch.

Always activate the Radio Remote Boom Control System when lifting or carrying personnel, or using the machine with a personnel work platform.

13. Before lifting personnel, the area should be marked to warn others of work by elevated personnel.

The Mandatory Work Platform Safety Rules must be adhered to at all times while elevating personnel.

These rules are based on ANSI/ITSDF Standard B56.6-2005, “Safety Standard for Rough Terrain Forklift Trucks.” (A copy of this and related standards can be obtained from the Industrial Truck Standards Development Foundation, 1750 K Street NW, Suite 460, Washington D.C. 20009; or downloaded from: www.itsdf.com) The rules apply to the owner, operator and the personnel in the work platform.

14. Be sure the path of platform travel is clear of hazards, such as scaffolds, electrical wires and overhead obstructions.

15. The operator must keep hands and feet clear of controls that are not in use.

16. Lift and lower the platform smoothly and cautiously and only after all personnel have been notified.

MANDATORY WORK PLATFORM SAFETY RULES

17. The platform must be lowered fully before moving the forklift. Do not drive the forklift with personnel on the platform.

1. The work platform must comply with ANSI/ITSDF B56.6-2005, Sec. 8.24, “Platforms for Elevating Personnel.” (See “Work Platform Design Requirements.”)

18. The radio remote operator must always alert elevated personnel before raising or lowering the platform.

2. The platform must be securely attached to the carriage or forks, and the carriage securely attached to the boom.

19. A trained operator must be in position to operate the forklift and boom controls at all times.

20. The combined weight of the platform, personnel and load must not exceed one-third of the material handling capacity of the forklift.

3. The carriage and forks must be secured to prevent them from pivoting upward.

4. If the machine is equipped with a rotating or swinging carriage, the rotation or swing must be deactivated. (This occurs automatically when the “Radio Remote Boom Control System” is switched on.)

21. Platform personnel must maintain firm footing on the platform floor, unless secured by harness and lanyard. A harness is to be worn and a lanyard attached to the platform or boom when working from an elevated work platform, in accordance with OSHA regulations. Use of railings, planks, ladders, etc. on platform for the purpose of achieving additional reach or height is prohibited.

5. Personnel on the platform must be provided protection from any moving parts on the forklift that may present a hazard.

6. If overhead hazards exist for platform personnel, overhead protection must be provided.

22. Workers on the platform must keep all parts of their bodies inside the work platform during raising and lowering.

7. Be sure that the lifting mechanism is operating smoothly throughout its entire range, both empty and loaded, and that any lift-limiting devices and latches are functional.

23. Be sure that the personnel and equipment on the platform do not exceed the available space.

24. The platform must be fully lowered for personnel to enter and exit. Personnel must not climb on any part of the forklift in attempting to enter and exit.

8. Be sure that the frame is level, to ensure a vertical lift.

9. Be sure the platform is horizontal before lifting.

6

CONTENTS 25. Any harness, body belt, lanyard, or deceleration device that has sustained permanent deformation or is otherwise damaged must be replaced.

Work Platform Design Requirements (Per ANSI/ITSDF B56.6-2005, Sec. 8.24)

1. A platform floor having a slip-resistant surface located not more than 8 inches (200 mm) above the normal load supporting surface of the forks.

26. Modifications to the platform that are detrimental to its safe use are prohibited.

2. Floor dimensions that shall not exceed two times the load center distance of 24 inches (610 mm) listed on the forklift nameplate, measured parallel to the longitudinal center plane of the forklift, nor have a width greater than the overall width of the forklift [measured across the load-bearing tires] plus 10 inches (250 mm) on either side. Minimum space for each person on the platform shall not be less than 18 inches (450 mm) in either direction.

WARNING Use ONLY an approved work platform for elevating personnel.

NEVER move the machine with the work platform in a raised position or with personnel on board.

3. A 4 inch (100 mm) minimum height toe plate, which may be omitted at the access opening.

NEVER tilt the platform forward, rearward, or to the side with personnel aboard.

4. An overhead protective device, when requested by the user.

ALWAYS engage the Radio Remote Boom Control System and follow the Mandatory Work Platform Safety Rules when lifting personnel.

5. Protection for personnel in their normal working position on the platform from moving parts of the forklift that may present a hazard.

6. Information prominently indicated on the platform: a. maximum work load including personnel and equipment, and b. weight of empty platform.

Radio Remote System Switch

7. Means so that the platform can only be centered laterally on the forklift, and retained against the vertical face of the forks, carriage, or lifting mechanism.

8. A means to securely attach the platform to the lifting mechanism, and to prevent the platform from inadvertently pivoting.

9. Restraining means such as a guard rail or a means for securing personnel such as a body harness and lanyard. A guard rail or similar structure shall have a nominal height to the platform floor of 42 inches (1066 mm) around its upper periphery and include a midrail. It may be hinged, removable, or of chains, and used to provide an access opening if proper positioning is easily accomplished and a secure condition is discernable. Such restraining means shall be capable of withstanding a concentrated horizontal force of 200 lbs. (890 N) applied at the point of least resistance without permanent deformation. A body harness and lanyard is to have an attachment point provided overhead for freedom of movement, and its length is to limit freefall to 5 feet (1500 mm) measured from the point

Radio Remote Boom Control Transmitter

7

CONTENTS of attachment to the operator. The complete system shall be capable of withstanding three consecutive drop tests to simulate a 250 lbs. (113 kg) person falling 6 feet (1800 mm) without allowing the test weight to fall free to the ground. A deceleration device may be included.

10. Lanyards, when provided, shall be arranged so as not to cause a tripping hazard.

11. Body harnesses, when provided, should have a width of at least 1.75 inches (44 mm).

12. Structural safety factor - all load-supporting structural elements of the work platform shall have a structural safety factor of not less than 2 - to - 1 based on the minimum yield strength of the materials used.

NOTE: Fall protection should comply with applicable U.S. OSHA regulations: 1910.67 (c)(2)(v) (for General Industry) or 1926.453 (b)(2)(v) (for Construction).

Radio Remote Boom Control System Decals (for machines with 42’ or 44’ lift height)

809723 - Decal Set Diagnostics / Precaution Under Tool Box Cover

8

CONTENTS

Radio Remote Boom Control System Decals (for machines with 42’ or 44’ lift height)

808041

808041

808039 809724

808040

808042

808039

809724

PWP/WPS cab decals

809725 808039 808040 808042

9

CONTENTS

Radio Remote Boom Control System Decals (for machines with center-mounted engine and 34’ lift height)

809723 - Decal Set Diagnostics / Precaution Under Battery Access Cover

10

CONTENTS

Radio Remote Boom Control System Decals (for machines with 34’ lift height)

808041

808041

808039 809724

808042

808039 808040

809724

PWP/WPS cab decals

809725 808039 808040 808042

11

CONTENTS

Chapter 3 CONTROLS AND INDICATORS Transmitter 2

3

7

4

Receiver 5

6 10

11

9

12

8

Radio Remote System Switch 13

REF.

CONTROLS / INDICATORS

1 01 02 03 04 05 06 07 08 09 10 11 12 13

12

PROPORTIONAL TRIGGER ACTIVATE SWITCH BATTERY LOW LED EMERGENCY STOP (E-STOP) BUTTON SYSTEM ACTIVE LED ENGINE SWITCH BOOM EXTEND/RETRACT SWITCH BOOM RAISE/LOWER SWITCH EMERGENCY STOP LED FAULT LED LINK LED STATUS LED RADIO REMOTE SYSTEM SWITCH

CONTENTS 11 - Link LED: This LED indicates the condition of the communication link between the Receiver and the Transmitter.

Transmitter Controls and Indicators The Transmitter controls and indicator lights (shown on the previous page) are described as follows:

12 - Status LED: This LED indicates the status of the Radio Remote System, based upon the color and condition of the LED.

1 - Proportional Trigger: This trigger is used to control the speed of the selected boom function. The further the trigger is pulled, the faster the function will operate.

Radio Remote System Switch

2 - Activate Switch: Pressing this switch up in conjunction with the Emergency Stop button will activate the Radio Remote System.

13 - Radio Remote System Switch: This switch is used to activate the Radio Remote System. It is a red switch located in the dash area of the cab. When activated, an amber lamp lights on the switch.

3 - Battery Low LED: This LED, when on, indicates a low battery condition in the Transmitter.

NOTE: This LED will flash on and off, indicating that the system is not yet fully functional (or not fully de-activated), until the brakes are held on for two or more seconds.

NOTE: The Transmitter will continue to operate approximately 10 hours after the LED comes on.

See battery replacement procedure on page 17.

4 - Emergency Stop (E-STOP) Button: This red button must be cycled between “off” and “on” to turn on the Transmitter. Pressing in this button turns off the Transmitter.

5 - System Active LED: This LED flashes to indicate the Radio Remote System is activated.

6 - Engine Switch: When the Radio Remote System is activated, press and momentarily hold this switch up to start the engine, and press it down to stop the engine.

7 - Boom Extend/Retract Switch: Press this switch up and simultaneously pull the proportional trigger to extend the boom; press the switch down to retract the boom.

8 - Boom Raise/Lower Switch: Press this switch up and simultaneously pull the proportional trigger to raise the boom; press the switch down to lower the boom.

Receiver Indicators 9 - Emergency Stop LED: This LED indicates the condition of the emergency stop button, based upon the color of the LED. 10 - Fault LED: When this LED is on, a fault condition is indicated.

13

CONTENTS

Chapter 4 OPERATION ACTIVATE SWITCH Radio Remote System Switch

E-STOP BUTTON

BATTERY LED

SYSTEM ACTIVE LED

ACTIVATING THE RADIO REMOTE SYSTEM To activate the Radio Remote System, apply and hold the service brakes on for two or more seconds, and press the top of the Radio Remote System rocker switch. The system is activated when the lamp in the Radio Remote System rocker switch is on continuously.

EXTEND / RETRACT BOOM SWITCH

transmission is de-clutched into Neutral,

parking brake is applied,

rear axle stabilizer cylinder is locked,

frame leveling speed is reduced,

auxiliary hydraulic and carriage tilt and swing functions are disabled,

machine inclination sensor is activated, with the result that the Telescopic Handler must be level laterally (side-to-side) and longitudinally (front-toback) to the factory pre-set limits before the boom controls will function, and

ENGINE SWITCH

TURNING ON THE TRANSMITTER The Transmitter must be turned on before the Radio Remote System will function. To turn on the system:

When the Radio Remote System is active:

RAISE / LOWER BOOM SWITCH

1. Press down the E-STOP button 2. Press up the ACTIVATE switch.

3. Twist the E-STOP button clockwise and release it.

NOTE: Be sure to twist the E-STOP button to release it. Do not pull on the button, because this may damage it.

The Transmitter ACTIVE LED should now be flashing to indicate the Radio Remote System is active.

Press down the E-STOP button to turn off the Transmitter.

the Transmitter can be activated, to operate the boom functions remotely.

OPERATING THE RADIO REMOTE SYSTEM

To de-activate the system, apply the service brakes and press the bottom of the Radio Remote System rocker switch. The system is de-activated when the LED in the rocker switch is OFF.

Starting and Stopping the Engine Press and momentarily hold the engine switch up to start the engine. Press the engine switch down to stop the engine.

NOTE: If the LED in the Radio Remote System rocker switch is flashing, apply the service brakes until the LED is off.

14

CONTENTS

Boom Operation

Procedure to test the transmission and joystick control lockout:

To raise the boom, first press the right boom switch “UP”. With the switch held in the “UP” position, pull the trigger to increase the speed at which the boom is raised.

3. Shift transmission into “FORWARD” and increase the engine speed slightly.

The transmission should remain de-clutched and allow the engine to gain speed easily.

Return the transmission selector to “NEUTRAL” to complete the check.

4. Activate the Transmitter.

The hydraulic joystick should now be disabled such that boom raise/lower and extend/retract no longer function.

Press the E-STOP button on the Transmitter after completion of the check.

5. Tilt the frame to the right slightly more than two degrees.

The hydraulic joystick should now be disabled such that boom raise/lower and extend/retract no longer function.

Repeat the procedure with the frame tilted to the left.

Return the frame to a level position after completion of the check.

To lower the boom, first press the right boom switch “DOWN”. With the switch held in the “DOWN” position, pull the trigger to increase the speed at which the boom is lowered.

To extend the boom, first press the left boom switch to “OUT”. With the switch held in the “OUT” position, pull the trigger to increase the speed at which the boom is extended.

To retract the boom, first press the left boom switch to “IN”. With the switch held in the “IN” position, pull the trigger to increase the speed at which the boom is retracted.

NOTE: Only one boom function can be operated at a time.

CHECK RADIO REMOTE SYSTEM (if to be used)

Procedure to test the Radio Remote System mode disable logic:

The following must be performed before beginning the Radio Remote System checking procedures: 1.

2.

3.

4.

5.

6.

7.

6. Turn the ignition key switch to “OFF” and wait for the engine to stop completely. Then turn the key switch to “ON”.

The Radio Remote System mode lamp and the parking brake lamp should be illuminated.

7. Turn the key switch “OFF” and then turn the Radio Remote System rocker switch “OFF”. Turn the key switch back “ON”.

The Radio Remote System mode lamp should be flashing and the park brake lamp should be on continuously.

8. Start the engine and apply the service brakes.

The Radio Remote System mode lamp and the parking brake lamp should go off after approximately two seconds of service brake application.

Machine on level surface, Boom fully lowered, Frame level, Transmission in “NEUTRAL”, Parking brake switch “OFF”, Radio Remote System switch “OFF”, and Press the E-STOP button.

Procedure to test the Radio Remote System mode enable logic: 1. Start the engine and turn the Radio Remote System switch “ON”.

Radio Remote System mode lamp in the switch should be flashing.

2. Apply the service brakes.

After two seconds, the Radio Remote System mode lamp should be on continuously, indicating that the system has been activated.

Parking brake should engage, as indicated by the lamp on the parking brake switch lighting.

The carriage tilt and auxiliary functions should now be disabled. The hydraulic joystick should function as normal for boom raise/lower and extend/retract.

WARNING If the Radio Remote System fails to operate properly during any of the Radio Remote System checks, DO NOT USE the machine until the cause has been corrected. Contact your dealer for service information and parts.

15

CONTENTS

Chapter 5 SERVICE TESTING THE TRANSMITTER / RECEIVER LINK

Transmitter. (Refer to the LED Legend below for diagram explanations.)

Follow these steps to ensure that a radio link has been established between the Transmitter and Receiver.

NOTE: It is necessary to download the ID Code when either the Transmitter or the Receiver has been replaced.

(Refer to the LED Legend below for diagram explanations.)

1. Open the Receiver case to access the Setup Mode button.

1. Press the E-STOP button.

NOTE: The cap is held on by two plastic tabs on opposite sides, which can be unlatched as shown using a screwdriver. Once the cap is free, the Receiver can slide open. Use a small slotted screwdriver to press the side tabs inward.

2. Power the Radio Remote System, by activating the Radio Remote System rocker switch.

2. Prepare the Transmitter and power the Receiver: A. Press the E-STOP. B. Twist clockwise and release the E-STOP. A B 3. Power the Transmitter.

If the Active LED on the Transmitter is flashing and the Link LED on the Receiver is flashing GREEN, a link between the two has been established.

If the Receiver's Link LED does not flash GREEN, follow the steps under “Downloading ID Code,” below.

C. Supply power to the Receiver (by activating the Radio Remote System switch).

C

3. Power the Transmitter into Configuration Mode:

DOWNLOADING ID CODE

A. Press and hold the engine switch UP.

Follow these steps to download the Transmitter’s unique ID Code into the Receiver. This will allow the Receiver to establish a radio link with that specific

B. Press the E-STOP.

16

CONTENTS A

B

A

B. LINK LED changes to GREEN. Once complete, the LINK LED changes to RED as the Transmitter turns OFF.

C. Twist clockwise and release the E-STOP. D. Release the engine switch.

C

D

B

4. Put the Receiver into Setup Mode:

IMPORTANT: When replacing the Receiver cover, ensure that the cover snaps completely into place to create a weatherproof seal around the base of the Receiver.

A. Press and hold the SETUP button until the STATUS LED changes from slow flash to fast flash.

A

CALIBRATING THE PROPORTIONAL CONTROLS The Transmitter trigger controls the Receiver’s proportional output. The trigger is used in conjunction with the Transmitter’s boom control switches. The proportional output can be activated when a switch is held UP or DOWN; it will activate at an increasingly higher level as the trigger is pulled. The minimum and maximum levels of the proportional output can be calibrated by following these steps. (Refer to the LED Legend below for diagram explanation.)

B. Release the SETUP button. The STATUS LED changes to solid GREEN, and the LINK LED turns OFF. B

NOTE: Calibration settings can be reset to factory default settings in Steps 4 and 5 by holding the engine switch UP or DOWN for 5 seconds.

1. Prepare the Transmitter, power the Receiver: NOTE: If left idle in Setup Mode for more than 30 seconds, the Receiver will “time out”. The Link LED and Status LED will flash RED rapidly. To return to Setup Mode, repeat Step 4.

.

A. Press the E-STOP, B. Twist clockwise and release the E-STOP. A

5. Download the ID code: A. Press the engine switch UP.

17

B

CONTENTS C. Supply power to the Receiver by activating the Radio Remote System rocker switch.

4. Set the minimum level: A. Keep the trigger released to set the minimum level.

C

B. Press the engine switch UP to increase the minimum level, or DOWN to decrease it.

A B

2. Power the Transmitter into Calibration Mode: A. Hold the engine switch DOWN. B. Press the E-STOP. A

NOTE: All switches, except the engine switch, remain active in Calibration Mode. A switch can be activated during calibration to help determine the desired levels.

B

5. Set the maximum level: A. Keep the trigger fully engaged to set the maximum level.

C. Twist clockwise and release the E-STOP.

B. Press the engine switch UP to increase the maximum level or DOWN to decrease it.

D. Release the engine switch.

C

D

A

3. Set up the Transmitter:

B

6. Power OFF:

A. Press the engine switch DOWN. A

A. Press the E-STOP. A

18

CONTENTS Stuck switch detected.

Ensure that all switches are in a centered position. The Transmitter will not power up when a function is ON.

TRANSMITTER DIAGNOSTICS On Power Up Press and release the ESTOP button within 10 seconds to power up the transmitter, or the unit will power down.

On Power Down Unit is still powered. Check for stuck switches. The Transmitter will not power down when a function is ON. Alternating flash means that the Transmitter is in Calibration Mode.

Release the E-STOP button within 10 seconds to power up the Transmitter, or the unit will power down.

Transmitter Battery Replacement

During Normal Operation The Transmitter Download Mode.

is

1. Remove the battery cover on the back of the transmitter by removing the four screws.

in

2. Insert four “AA” alkaline batteries. Battery orientation is embossed inside the battery housing.

3. Replace the cover and install the screws to secure the cover in place.

The Active LED will flash several times per second, indicating that the Transmitter is sending signals to the Receiver. The Active LED will remain on momentarily whenever a function changes.

NOTE: For operation at temperatures below 14° F (-10° C), lithium batteries are recommended. Low temperatures reduce battery performance for both alkaline and lithium types. Refer to the battery manufacturer’s specifications for detailed information on low temperature performance.

Indicates low battery. Unit will run approximately 10 hours after the Battery LED starts flashing.

See Transmitter Battery Replacement” procedure on this page.

Battery LED flashing rapidly for 10 seconds indicates a Transmitter failure.

19

CONTENTS

RECEIVER DIAGNOSTICS Normal Operation Transmitter is OFF. If the Transmitter is OFF, this LED pattern indicates the Receiver is operating properly.

Transmitter is ON. When the Transmitter is turned ON, a fast flashing Link LED and a GREEN E-Stop LED indicate the Receiver is operating properly.

Transmitter is in Operation.

When a function is activated on the Transmitter, the Fault LED will turn on GREEN. This indicates the Receiver is operating properly.

Transmitter is OFF. If a latched function is activated, and the Transmitter is turned OFF, the Fault LED will stay on GREEN. The Receiver should be operating properly; if not, call for service.

Trouble Indicators NOTE: In some cases, the indicator LED will be different depending on whether the Transmitter is ON or OFF, so note the Transmitter status in the “Description” column for each case.

Indicator Light Description Solution Transmitter is ON. This pattern indicates the Transmitter is not communicating with the Receiver.

Refer to Troubleshooting Chart 3 for solutions.

Transmitter is ON. A low battery condition has been detected.

To detect intermittent conditions caused by poor or corroded ground or power circuits, the GREEN LED will continue to flash for 30 seconds after the condition has been removed.

Transmitter is ON. An internal fault with the ESTOP has been detected.

Inspect E-STOP wiring for short circuit. Disconnect ESTOP wire as close to the Receiver output as possible.

If the Status LED: • changes to GREEN, this means a short is present after the disconnection point, which must be repaired.

• Stays flashing RED, call for service.

Transmitter is ON. This pattern indicates a short to ground or excessive current draw on an output. It is most likely caused by a wiring fault.

Ensure Transmitter is functioning properly. Check status of each output connection: Press each function button and observe Fault LED. • If GREEN, everything is OK. • If RED, there is a short in that connection that must be repaired.

20

CONTENTS Indicator Light

Description

Solution

Transmitter is ON. This pattern indicates the ESTOP output has been connected with one of the other outputs.

Follow the wire and check for connections with other wires. Disconnect to see if condition clears. If not, call for service.

Transmitter is OFF. A wiring short to the battery has been detected.

Refer to Troubleshooting Chart 1 for solutions.

Transmitter is OFF. The Receiver has detected an internal fault.

Refer to Troubleshooting Chart 1 for solutions.

Transmitter is OFF. Blown fuse detected.

Refer to Page 14 for instructions on how to open the Receiver case to access the fuse. Check wiring for shorts or bare spots. If fuses continue to blow, call for service.

Transmitter is ON. A Setup failure has occurred.

Either hold the Setup button for five seconds to return to Setup Mode or cycle power to return to the normal operating mode.

Transmitter is OFF. The Receiver is powered incorrectly.

The most likely cause of this condition is that an output wire or the E-STOP wire has been connected to the power supply while the power wire was disconnected from the power supply.

21

CONTENTS

Chapter 6 TROUBLESHOOTING Test the Receiver

CHART 1

Start Initial Condition Turn Transmitter OFF (all LEDs are off - press the E-STOP button).

Cycle power to Receiver (turn OFF and back ON).

What is the state of the LEDs on the Receiver?

NOTE: If there is a short to ground on an output, it is not indicated at this stage. To test for short to ground, refer to the “Fault LED is RED” procedure at the bottom of this page and follow the instructions.

Problem state: Status - RED

Problem state: Status - flashing GREEN & RED

Is the Status LED flashing RED?

OK state: Status - GREEN Link - RED Fault - OFF E-STOP - RED

YES

The system is wired incorrectly.

The most likely cause is one of the input/output wires has been connected to the power source.

Go to Chart 2.

Fuse is blown. Change fuse.

1. Inspect wiring looking for short circuits (e.g. bare wires).

2. If problem recurs, call for service.

NO

What is the state of the ESTOP LED?

OK state: E-STOP - RED.

What is the state of the Fault LED?

Problem state: E-STOP - flashing RED.

Inspect E-STOP wiring looking for short circuits (e.g. bare wires).

Disconnect the E-STOP output as close to the Receiver output as possible.

If the Status LED:

Changes to GREEN, there is a short in the wiring after the disconnection point.

Stays flashing RED, call for service.

Fault LED is OFF.

Call for service.

Fault LED is flashing RED.

There is a short to supply.

1. Disconnect A & B connectors from Receiver and check all outputs for power (e.g. bare wires, improper connections) and make any necessary repairs.

2. Call for service.

There is a short to ground.

Note: This should only occur when the Transmitter is ON and a function button is pressed. In this case, the Status LED will be GREEN and will turn RED at the same time as the Fault LED. Go to Chart 2 to test the Transmitter. If the Transmitter is functioning properly, proceed to check the status of each of the output connections: Press each of the function buttons and observe the Fault LED. If the LED turns GREEN, everything is OK. If the LED turns RED, there is a short in that connection.

Fault LED is RED.

22

CONTENTS

Test the Transmitter

CHART 2

Turn off the Receiver.

Ensure there are good batteries in the Transmitter.

Turn on the Transmitter.

What is the state of the LEDs?

OK state: Active LED - steady for about 3 seconds then changes to fast flash.

Battery LED - OFF E-STOP LED - OFF

Activate a function.

Go to Chart 3.

No LED comes on at any time.

Complete the following steps in order: 1. Check battery orientation.

2. Clean battery contacts.

3. Check or replace batteries.

4. Call for service.

Both the Active LED and the Battery LED flash at the same time.

Stuck switch: 1. Return all switches to neutral (OFF) position.

2. Toggle the switch a few times.

3. Call for service.

Active LED is flashing rapidly and Battery LED is flashing slowly.

Low battery - Change batteries.

Replace batteries by next shift.

Note: Low batteries will last approximately 10 hours once the Battery LED begins to flash.

Battery LED flashes for 10 seconds then all LEDs are OFF.

Press and release E-STOP if the condition persists, then either there is a faulty E-STOP or Transmitter failure - call for service.

Battery LED and Active LED flash alternately.

The Transmitter is in Calibration Mode 1. Turn unit OFF, then turn back ON. 2. If condition persists, call for service.

23

YES

Does the Active LED change to solid YELLOW?

NO Either the switch/trigger is defective or the switch/trigger connection to the circuit board is broken.

Call for service.

CONTENTS

Test the Transmitter / Receiver Communication Transmitter: Active LED is flashing.

CHART 3 Transmitter: Active LED is flashing.

What is the status of the Transmitter and Receiver LEDs?

Receiver: Status - GREEN Link - RED Fault - OFF E-STOP - RED

Receiver: Status - GREEN Link - Flashing GREEN Fault - OFF E-STOP - GREEN

Transmitter and Receive should be working properly.

The problem may be with the machine instead of the Radio Remote Control System.

Call for service.

There is no link between the Transmitter and Receiver.

Do you have a matched set? (i.e. the Transmitter and Receiver should have identical ID Codes.)

YES

Call for service.

NO

Was the Transmitter accidentally swapped with another one on the job site?

POSSIBLY

NO

Search the job site for the correct Transmitter.

Was it found?

NO

YES

Turn on the Transmitter to check if the units function correctly. If not, proceed to Chart 1.

The Transmitter ID code may need to be re-loaded to the Receiver.

WARNING: Be very cautious before proceeding with the Downloading ID Code procedure.

If by accident the Transmitter has been switched with another unit, by downloading the ID code to a new Receiver, it is possible for the Transmitter to operate two units at the same time (if the original Receiver unit is still on the job site). Therefore, it must be certain that the Transmitter / Receiver pair are the correct set.

Second, once the download procedure is completed, ensure all other units on the job site are stopped. Test the operation of the newly configured set to ensure that no other machines on the site are activated by the same Transmitter.

Only after it is certain that the Transmitter / Receiver pair are a unique set can normal operations continue.

24

CONTENTS

Reprogramming the System

Potential Reprogramming Issues:

WARNING

If testing of the Receiver and Transmitter both yield positive results (Charts 1 and 2), then the Transmitter and Receiver will both go into Download/Calibration Mode.

Before attempting the reprogramming procedure with another Transmitter, understand that reprogramming the Receiver with another Transmitter could result in having two Receivers on the job site responding to one Transmitter, with the potential for unexpected machine actions, and possible personal injury or damage. If the original Transmitter is sent in for repair, be sure to disconnect the Receiver (disconnect connector A) to continue using the machine without the remote control capability and without the risk of inadvertently operating the machine with the other Transmitter.

Possible issues will arise during Step 4, the download phase of reprogramming. In this case there are two symptoms to look for: 1. The Link LED on the Receiver will not turn GREEN when the power switch is toggled on the Transmitter to Download Mode.

2. The Receiver will “time out,” indicating that it did not receive a signal from the Transmitter within 30 seconds after the Receiver was switched into Setup Mode.

If all indications appear normal during the download phase, test the link by turning on the Transmitter.

NOTE: The Transmitter shuts off after transmitting the ID Code in Step 4.

Reprogramming Tips: 1. Use a pointed instrument to depress the Setup button on the Receiver (e.g., a pen), because the button is relatively small.

If the Link LED on the Receiver does not turn GREEN, this indicates the Receiver did not receive all of the information that was sent from the Transmitter.

2. Follow each step as described in the procedure.

Possible Solutions: IMPORTANT: Never set down the Receiver circuit board on anything metallic, because there are contact points on the back that could contact the metal and result in damage to the Receiver.

1. Try the reprogramming procedure again.

2. If this does not correct the problem, send in both the Transmitter and Receiver for service.

NOTE: To determine whether the fault is with the Transmitter or Receiver, try repeating the reprogramming procedure using a different Transmitter. If this works, then the fault is with the original Transmitter. If not, the fault may be with the Receiver.

25

CONTENTS

FACTORY INSTALLED PARTS (ALL MODELS)

Chapter 7 FACTORY INSTALLED SERVICE PARTS Transmitter and Receiver

7

3

2

1

4

5

6 To solenoid valves on hydraulic remote control manifold

26

CONTENTS

FACTORY INSTALLED PARTS (ALL MODELS)

Transmitter and Receiver Ref. No.

Part No.

00

Note a

01

809726

02 03 04b 05 06 07

809727 NSS NSS 809728 809729 809724

00

809731

00

808394

Description

Qty. NOTES:

COMPLETE, RADIO REMOTE . . . . 1 (Includes items 1-4 shown) REMOTE TRANSMITTER. . . . . . . . 1 (includes item 2) SWITCH, TOGGLE 3 POS. MIL . . . 4 REMOTE RECEIVER . . . . . . . . . . . 1 ENCLOSURE / CIRCUIT BOARD. . 1 LANYARD (wire cable) . . . . . . . . . . 1 SNAP RING, LANYARD . . . . . . . . . 1 DECAL - REMOTE TRANSMITTER 1 (not included with item 1) -- ITEMS NOT SHOWN -WIRE HARNESS. . . . . . . . . . . . . . . 1 (to existing PWP/WPS wire harness) FUSE, MINI 15 AMP . . . . . . . . . . . . 1

a

809741 on machines with 34’ lift height.

809730 on machines with 42’ or 44’ lift height.

b

27

Includes wire harnesses, to Receiver (item #3 - shown), and to hydraulic manifold valves, with DIN connectors on hydraulic manifold valves (shown on next page).

CONTENTS

FACTORY INSTALLED PARTS (ALL MODELS)

Manifold and Valves

2 2

1

4

28

3

CONTENTS

FACTORY INSTALLED PARTS (ALL MODELS)

Manifold and Valves Ref. No. 00 01 02a 03 04

Part No. 809732 809733 809734 809735 809736 809737 NSS

Description

Qty.

Ref. No.

COMPLETE VALVE. . . . . . . . . . . . . 1 (includes all items shown and listed) 2/4 WAY SOLENOID VALVE . . . . . . 1 SEAL KIT FOR VALVE . . . . . . . . . . 1 12 VDC COIL (DIN CONN.) . . . . . . 5 PROPORTIONAL PRESS. VALVE . 4 SEAL KIT FOR VALVE . . . . . . . . AR MANIFOLD . . . . . . . . . . . . . . . . . . . 1

00 00

a

29

Part No. 809738 809739 809740

Description

Qty.

-- ITEMS NOT SHOWN -SHUTTLE VALVE . . . . . . . . . . . . . . 4 SEAL KIT FOR VALVE . . . . . . . . AR MOUNT, MANIFOLD . . . . . . . . . . . . 1

The wire harness that attaches to these coils with DIN connectors is not sold separately. It is part of item #4 shown on page 27.

CONTENTS

FACTORY INSTALLED PARTS (ALL MODELS)

Decals Ref. No.

Part No.

01

809723

02 03 04 05 06 07

809724 808042 808039 808040 808041 809725

Description

Qty.

DIAGNOSTIC / PRECAUTION . . . . 1 (3 decal set) REMOTE TRANSMITTER. . . . . . . . 1 PWP/WPS SWITCH INSTRUC. . . . 1 WORK PLATFORM . . . . . . . . . . . . . 2 CAB WORK PLATFORM RULES . . 1 BOOM WORK PLATFORM RULES 1 RADIO CONTROLLED . . . . . . . . . . 1

1

30

CONTENTS

FACTORY INSTALLED PARTS (ALL MODELS)

Decals

2

6

3

4

7

5

31

CONTENTS

Intentionally Blank

32

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

Chapter 8 Instructions to Install Radio Remote Control System Kits

FOR FORKLIFT MODEL MT6034 KIT 806841 WITH PWP KIT 806842 WITHOUT PWP

INTRODUCTION These instructions provide procedures for field installation of the Radio Remote Control System.

IMPORTANT: These kits should only be installed by competent and experienced service technicians.

PARTS LIST Kit 806841, which is intended for use on machines that already have the optional work platform system installed, does not contain the items marked with an asterisk (*). Kit 806842 contains all of the items listed.

Part No. *808443 808451 *808455 808464 809506 809742 *808601

Description Qty. Adap., -6orm-6jicm Str . . . . . . . . . .2 Adap., -4orm -6jicm Str . . . . . . . . .5 Adap., -6orm-6jicm 90 deg . . . . . . .2 Adap., -6jic swivel run tee . . . . . . .2 Adap., -4orm-6jicm 90 deg . . . . . . .6 Bolt, 1/4”-20x1/2” . . . . . . . . . . . . .2 Bolt, 1/4”-20x1” . . . . . . . . . . . . . . .2

33

*808644 808603 809743 809744 *808945 809724 *808042 809725 809723 *808039 *808040 *808041 809304 809731 809763 *809353 809764 *808715 808850 809765 809766 809728 *808127 809732 809767 809740 809770 808545 808555 *808649 809741 *809771 *808935 *808946 809729 *808938 *808588 *808589

Bolt, 1/4”-20x2” . . . . . . . . . . . . . . .2 Bolt, 5/16”-18x3/4” . . . . . . . . . . . . .2 Bolt, 5/16”-18x3-1/2” . . . . . . . . . . .2 Bracket, receiver mounting . . . . . . .1 Chain, 5/16" (16 links) . . . . . . . . . .1 Decal, remote transmitter . . . . . . . .1 Decal, PWP/WPS switch instruc. . .1 Decal, radio control . . . . . . . . . . . . .1 Decal, diagnostics and safety . . . . .1 Decal, work platform . . . . . . . . . . .2 Decal, work platform rules canopy .1 Decal, work platform rules boom . .1 Decal, Load Chart (w/kit 820308) . .1 Harness, radio remote control . . . . .1 Harness, PWP/WPS option . . . . . . .1 Hose, 1/4”x52" . . . . . . . . . . . . . . . .1 Hose, 1/4”x109" . . . . . . . . . . . . . . .1 Hose, 1/4”x15" . . . . . . . . . . . . . . . .2 Hose, 1/4”x26" . . . . . . . . . . . . . . . .4 Hose, 1/4”x20" . . . . . . . . . . . . . . . .4 Hose, 1/4”x130" . . . . . . . . . . . . . . .2 Lanyard, remote control . . . . . . . . .1 Manifold, PWP/WPS joystick . . . . .1 Manifold, radio remote control . . . .1 Manual, radio remote control . . . . .1 Mount, radio manifold . . . . . . . . . .1 Module, PWP/WPS control . . . . . .1 Nut, 1/4”-20 whiz-loc . . . . . . . . .AR Nut, 5/16”-18 whiz-loc . . . . . . . . . .2 Nut, #10-24 . . . . . . . . . . . . . . . . . . .2 Receiver, radio remote w/harness . .1 Screw, #10-24x1/2” . . . . . . . . . . . . .2 Sensor, LS-60 level . . . . . . . . . . . . .1 Shackle, 5/16" chain . . . . . . . . . . . .1 Snap Ring, remote control lanyard .1 Switch, work platform . . . . . . . . . . .1 Washer, 1/4" . . . . . . . . . . . . . . . . . .2 Washer, 1/4" lock . . . . . . . . . . . . . .2

806948 806947

Registration Warranty

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

INSTALLATION PROCEDURE IMPORTANT: Before beginning the installation, the machine must be level both laterally (side-toside) and longitudinally (front-to-back).

Radio Remote Control Receiver Installation 1. Raise the boom to gain access to the area around the transmission access cover (Figure 1).

WARNING Before performing any installation, modification or adjustment on a unit, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE described in the Operator’s Manual.

Figure 1 - Transmission Access

2. Remove the access cover and disconnect the battery cables.

Battery

1 2

3. Install the receiver mounting bracket (809744) to the bottom of the battery support plate using the existing threaded rods (1) and nuts (2). Figure 2.

809744

Figure 2 - Battery / Receiver mount bracket

1

4. Bolt the radio remote control receiver 809741 (1), including the attached harness, to the radio remote control receiver mounting bracket 809744 (2) using two 1/4”x1/2” bolts (809742) and two 1/4” whiz-loc nuts (808545). See Figure 3.

2

Figure 3 - Radio Remote Control Receiver

34

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034 Rear Hood

5. Remove the rear hood bolts; slide back far enough to disconnect the tail light wire harness. Remove the rear hood. See Figure 4.

Figure 4 - Rear Hood

6. Route the portion of the harness identified as “Connectors in the pump area” in Figure 5 through the existing hose loops on the frame up to the area near the hydraulic pump between the engine and the transmission as shown in Figure 6.

809741 Manifold connectors at the rear of the machine

Connectors in the pump area

Radio Remote Receiver

Figure 5 - Radio Remote Control Harness Cab wire harness

Hydraulic Pump Connectors from Remote Receiver (809741)

Figure 6 - Receiver Harness Connectors

7. Route the remainder of the radio remote receiver wire harness identified as “Manifold connectors at the rear of the machine” in Figure 5 along the left inside frame to the rear of the machine in the area (1) alongside the main hydraulic control valve. See Figure 7. Secure the wire harness to the frame and existing hoses with nylon wire ties.

1

Main Hydraulic Valve

Figure 7 - Main Hydraulic Valve

35

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

Install Wire Harness 809731 1

NOTE: For 99 h.p. engines skip to Step 8b.

8a. For 115 h.p. engines, refer to Figure 8-A. Locate the engine harness at the back of the engine. Cut the 12-gauge red wire (1) 4 inches from the engine harness connector, and crimp the two butt connectors (2) and (3) from the radio remote wire harness (809731) to each end of the 12-gauge wire.

115 hp Engine Shown

2 3 Radio Remote Harness

8b. For 99 h.p. engines, refer to Figure 8-B. Route the end of the radio remote harness with the two black w/yellow stripe 14 gauge wires (2) and (3) around the front of the engine to the fuel injection pump.

Remove the wire (1) from the injection pump and cut the terminal end off. Strip the end of this wire (1) and crimp it into a butt connector (2). Cut the butt connector (3) off the end of the wire. Strip the wire and crimp a ring terminal (not included) to this wire, then put back on the injection pump and tighten.

Figure 8-A Radio Remote Harness

99 hp Engine Shown

2

1

3

Injector Pump

Figure 8-B 9. Route the 16-gauge white wire to the starter solenoid located on the left side of the engine. Attach the wire terminal to the “S” (Start) terminal of the solenoid. See Figure 9.

Starter Solenoid

“S” Terminal (Start)

White wire - Radio Remote Harness

Figure 9 - Starter Solenoid PWP/WPS Harness 809763

10. Plug the connectors of the 809731 wire harness into the connectors of the radio remote receiver harness (809741) as shown in Figure 10.

Black and White/Green

Brown and Lt. Blue

White and Black/White

NOTE: If the machine is already equipped with a PWP/WPS system, then disconnect the brown and light blue wire connector (Figure 10) from the existing two-piece (boom) wire harness (not shown) that runs from the end of the boom to the hydraulic pump area. The radio remote control system does not use the existing (boom) harness.

Black and White

Radio Remote Receiver (809741) Harness

Harness 809731

Black

Green

Red and Orange

Figure 10 - Wire Harnesses 36

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

Control Module 809770 Installation 11. Remove the joystick access panel (inside cab), and retain the bolts for re-installation. See Figure 11.

NOTE: If the machine already has a PWP/WPS system installed, replace the control module and PWP/WPS wire harness with the control module and wire harness included with this kit (refer to Step 12 and 16), and then skip to Step 27.

Figure 11 - Joystick Access Panel

12. Position the PWP/WPS Control Module (809770) inside the area under the joysticks and align with the pre-drilled holes as shown in Figure 12.

NOTE: Some earlier units do not have pre-drilled

Control Module 809770

holes. If the unit does not have pre-drilled holes, it will be necessary to drill two 7/32” holes. Use the PWP/WPS Control Module as a template; position it so the leading hole is 6” back from the front inside edge of the outer cab wall and 1-3/4” up from the bottom inside edge of the outer cab wall. See Figure 12.

11”

6” 1-3/4”

13. Use two #10-24 bolts (809771) and nuts (808649) to secure the module to the cab.

Figure 12 - Control Module Location

Work Platform Switch 808938 Installation

Work Platform Switch 808938

14. Remove the six screws that secure the dash panel and save for re-installation. See Figure 13.

Dash panel bolts

15. Lift the dash panel high enough to remove the plastic switch plug, and then install the Work Platform Switch (808938) into the open slot. See Figure 13.

Figure 13

37

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

PWP/WPS Wire Harness 809763 Installation 16. Working from inside the cab, through the access opening shown in Figures 11 - 12, feed the front half of wire harness 809763 (Figure 14) up to the dash area following the existing wire harness.

Connect the work platform switch connector into the work platform switch (808938). Connect the control module connector into the control module (809770). Connect the canopy harness connector into the existing canopy harness.

17. Feed the back half of the harness out of the cab and into the area under the transmission access cover near the hydraulic pump. Connect all applicable connectors as shown in Figure 10.

18. Re-install the dash panel removed in Step 14.

19. Add the applicable load chart plate (included in all kits except 820305) to the end of the load chart assembly, .

PWP/WPS Joystick Manifold Connectors

Grounding Terminals

Control Module Connector

Level Sensor Connector

PWP/WPS Switch Connector To Canopy Harness

Connects to Radio Remote Receiver (809741) Harness

Connects to 809731 Harness

Figure 14 - Wire Harness 809763 Connections

38

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

Level Sensor 808935 Installation Level Sensor Mount

20. Locate the level sensor mounting bracket in the area beneath the transmission access cover. See Figure 15.

21. Attach the level sensor (808935) to the level sensor mount bracket with two1/4”-20x1” bolts (808601) and two 1/4”-20 whiz-loc nuts.

IMPORTANT: Verify that the “Y” marking on the level sensor is pointed toward the front of the machine. See Figure 16.

Battery

Figure 15 - Level Sensor Mount

22. Adjust the sensor, using the three spring-tensioned adjusting screws to center the bubble within the circle on top of the sensor. See Figure 16.

Level Sensor Bubble

IMPORTANT: The machine must be level both Adjusting Screws

laterally (side-to-side) and longitudinally (front-toback). The PWP/WPS system will not operate properly if the level sensor is not adjusted (leveled) properly.

23. Connect the level sensor wire to the mating connector on wire harness 809763. See Figure 14.

“Y” axis mark

PWP/WPS Joystick Manifold Installation

Figure 16 - Level Sensor

NOTE: If the PWP/WPS manifold is already installed on the machine, it will be necessary to swap the straight (1) and 90-degree (2) fittings as shown in Figure 17.

24. Install the hydraulic fittings: two straight 808443 (1) and two 90-degree 808455 (2) adapters into the PWP/WPS joystick manifold 808127 as shown in Figure 17.

25. Mount the PWP/WPS joystick manifold (808127) to the existing bracket on the frame near the flow divider with two 1/4”-20x2” bolts (808644), two 1/4” lock washers (808589), and two flat washers (808588). For a secure ground, attach the ground wire terminals from the PWP/WPS wire harness (809763) to the upper bolts before installing the bolt.

26. Connect the PWP/WPS joystick manifold connectors from wire harness 809763 to the PWP/WPS joystick manifold connectors. Connect the terminal with the orange and black wires to the connector for the Lift Solenoid (Figure 17) and connect the terminal with the gray and black wires to the other solenoid.

(Orange wire) Lift Solenoid PWP/WPS Manifold (808127)

2

1

Figure 17 - Radio Remote PWP/WPS

39

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

Hydraulic Hose Installation IMPORTANT: When disconnecting hydraulic hoses, catch and dispose of spilled oil according to local waste disposal regulations. DO NOT discharge oil onto the ground.

27. Access the joysticks from the panel inside the cab as shown in Figure 11.

28. Refer to Figure 18. Remove the swivel tee (1) and the hydraulic hose (2) from the Lift/Extend joystick controller. Remove the other end of the hydraulic hose (2) from the Tilt/Level joystick controller. Discard the hydraulic hose (2).

1

2 29. Connect the existing hydraulic hose (3) to the straight adapter on the Lift/Extend controller “P” port (where the swivel tee was removed). Locate hydraulic hose 809764 from the kit and mark both ends of the hose with “AA.” Attach and tighten one end of this hose to the existing hose (3). Refer to item “AA” in Figure 19.

30. Refer to Figure 19. Add hydraulic hose 809353 (item “DD” in Figure 19). Connect and tighten one end of the hose to the Tilt/Level joystick “P” port and route the other end out of the cab following existing joystick hoses and connect and tighten to the PWP/WPS valve “J2” port.

Hydraulic Tank

3

31. Locate one of the 809766 hydraulic hoses from the kit and mark both ends “CC.” Connect and tighten one end to the “J1” port of the PWP/WPS valve “FF”; do not attach the other end at this time. See Figure 19.

Figure 18 - Standard Configuration

32. Install two swivel tee adapters (808464) to the “T” port on the flow divider. Re-connect the hose to the outer swivel adapter as shown in Figure19.

from the kit. Connect and tighten one hose to the swivel tee just installed at port “T” and connect and tighten the other end to the PWP/WPS valve“T” port “EE” as shown in Figure 19.

33. Locate the remaining 809766 hydraulic hose from the kit and mark both ends “BB.” Connect and tighten one end of the hose to the swivel run tee as shown in Figure 19.

35. Connect and tighten one end of the other hose 808715 to port “J” on the flow divider and the other end to port “P” on the PWP/WPS valve as shown in Figure 19.

NOTE: If unit is already equipped with

36. Route the loose ends of hydraulic hose “AA” 809764 and the two “BB” and “CC” 809766 hydraulic hoses along the inside of the right side of the frame to the rear of the machine to the main valve area under the rear hood. Secure the hoses with nylon wire ties .

PWP/WPS, the existing hose on the “T” port of the PWP/WPS “EE” manifold will remain. In addition, it will not be necessary to add the second swivel adapter to the flow divider. If already equipped with PWP/WPS, then skip to Step 36.

34. Locate one of the two 808715 hydraulic hoses

40

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

TILT LEVEL

LIFT EXTEND

Existing Hose New Hose P

T P

T

DD 809353

WPS Manifold (808127) T

Flow Divider P

EE

HYDRAULIC TANK

808715 J

T

J1

3

J2

FF

(2) 808464

809764 809766

AA

BB

809766

CC

Figure 19 - Joystick / Hydraulic Hose Configuration

41

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

Install Radio Remote Manifold 3 37. Install the manifold mount 809470 (1) to the main valve mount plate. Using two 808603 5/16”-18 x 3/4” bolts (2) and two 808555 5/16”-18 whiz-loc nuts. If the main valve has an auxiliary hydraulics valve section installed (not shown), it will be necessary to remove the bolts (3) and use two 809743 5/16”-18x3-1/2”bolts to go through the main valve and the radio remote conrol manifold mount bracket.

2

1

Figure 20 - Main Valve Mount Plate

Boom Up

38. Mount the radio remote control manifold 809732 to the manifold mount 809470 using two 808603 5/16” x 3-1/2” bolts and two 808555 5/16-18” whiz-loc nuts. See Figure 21.

Boom Down

39. Connect the radio remote receiver harness connectors from Step 6 to the radio remote control manifold solenoid as shown in Figure 21.

Boom In

Boom Out

Manifold mount (809470)

40. Refer to Figures 21 - 22 as a guide to install the hydraulic fittings for radio remote manifold 809732. Use the following hydraulic fittings: five 808451 -4orm x -6jicm straight adapters and six 809506 -4orm x -6jicm 90-degree adapters.

Radio Remote Manifold (809732)

UP

41. Connect and tighten the hoses from the WPS valve and joystick (AA, BB and CC) to the radio remote manifold ports “JS,” “T” and “P” as shown in Figure 22.

RET

EXT

DN

INL

Figure 21 - Radio Remote Control Manifold 42. Mark the ends of the boom-up, boom-down, boomin, and boom-out hoses and then remove them from the main valve. Locate the four 809765 hydraulic hoses from the kit. Connect and tighten each of the 809765 hoses to boom-up, boomdown, boom-in and boom-out hoses and the other ends to the radio remote manifold as shown in Figure 22. Tighten all hose connections.

43. Locate the four 808850 hydraulic hoses from the kit and connect and tighten one end of each to the main valve where the boom-up, boom-down, boom-in and boom-out hoses were removed and then connect and tighten the other end to the radio remote control manifold as shown in Figure 22.

42

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

JS

809764 E1

AA

809766

E2

CC 809766

BB

E3 E4

808850

P INL T

DN EXT RET

J1

UP J2 J4 Boom Out

J3 Boom Down Boom In

Tilt

808850 809765

Level Boom Up

809765

FRONT

Boom Down Boom In

Boom Out

Boom Up Existing Hose

FROM JOYSTICKS

New Hose

Figure 22 - Radio Remote / Hydraulic Valve Hose Routing

43

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

45. Remove decal 808031 from the front of the boom and apply decals 808039 and 808041 as shown in Figure 25.

New Decal Application Surfaces must be free from dirt, dust, grease and other foreign material before applying the new decals. To apply a decal, remove the smaller portion of the decal backing paper and apply this part of the exposed adhesive backing to the clean surface while maintaining proper position and alignment. Slowly peel off the other portion of the backing paper while applying hand pressure to smooth out the decal surface.

46. Apply remaining decals in locations as shown in Figures 25-27.

808040

808042

808039

Decal Installation 44. Remove decal 808031 from the right side of the dash and replace it with decal 808039. Apply decals 808042 and 808040 as shown in Figure 23.

Figure 23 - WPS Cab Decals

808040 808042

2

808041

808039

808039

Figure 24 - WPS Front of Boom Decals

808041

44

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

Radio Remote Control System Decals 809725

809724

809724

Figure 26 Place the diagnostics and warning decals (809723) under the access hood.

Figure 25

Figure 27

45

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

Finalize Installation

Procedure to test the Radio Remote System mode enable logic:

47. Re-connect the battery cables that were removed in Step 1.

1. Start the engine and turn the Radio Remote System switch “ON”.

Radio Remote Control System mode lamp in the switch should be flashing.

2. Apply the service brakes.

After two seconds, the Radio Remote System mode lamp should be on continously, indicating that the system has been activated.

Parking brake should engage as indicated by the lamp on the parking brake switch lighting.

The carriage tilt and auxiliary functions should now be disabled. The hydraulic joystick should function as normal for boom raise/lower and extend/retract.

48. Start the machine and check all hydraulic connections for leaks. Correct any leaks as necessary.

49. Replace the joystick access panel inside the cab.

50. Check the hydraulic fluid level and fill to operating level as required.

51. Replace the rear hood and transmission access cover.

CHECK RADIO REMOTE CONTROL SYSTEM

Procedure to test the transmission and joystick control lockout: 3. Shift transmission into “FORWARD” and increase the engine speed slightly.

The transmission should remain de-clutched and allow the engine to gain speed easily.

Return the transmission selector to “NEUTRAL” to complete the check.

4. Activate the Transmitter.

The hydraulic joystick should now be disabled such that boom raise/lower and extend/retract no longer function.

Press the E-STOP button on the Transmitter after completion of the check.

5. Tilt the frame to the right slightly more than two degrees.

The hydraulic joystick should now be disabled such that boom raise/lower and extend/retract no longer function.

Repeat the procedure with the frame tilted to the left.

Return the frame to a level position after completion of the check.

WARNING To avoid injury due to incorrect installation, after the installation procedures are completed by a competent and experienced service technician, the WPS System must be checked for proper operation.

WARNING Do not use the machine after the WPS System kit has been installed until the installation has been verified as correct. Contact your dealer for service information and parts.

The following must be performed before beginning the Radio Remote System checking procedures: 1.

2.

3.

4.

5.

6.

7.

Machine on level surface, Boom fully lowered, Frame level, Transmission in “NEUTRAL”, Parking brake switch “OFF”, Radio Remote System switch “OFF”, and Press the E-STOP button.

Procedure to test the Radio Remote System mode disable logic: 6. Turn the ignition key switch to “OFF” and wait for the engine to stop completely. Then turn the key switch to “ON”.

The Radio Remote Control System mode lamp and the parking brake lamp should be illuminated.

46

CONTENTS

FIELD INSTALLED KITS - 806841 & 806842 FOR MODEL MT6034

7. Turn the key switch “OFF” and then press the Radio Remote System rocker switch “OFF”. Turn the key switch back “ON”.

The Radio Remote Control System mode lamp should be flashing and the park brake lamp should be on continously.

8. Start the engine and apply the service brakes.

The Radio Remote System mode lamp and the parking brake lamp should go off after the service brake is applied for two or more seconds.

Work Platform Installation The chain (808945) and the shackle (808946) are used to secure the personnel work platform (not included) to the bottom of the carriage. This will keep the forks from pivoting upward in case the work platform is lowered onto an obstruction. See Figure 28.

Chain - 808945 and Shackle - 808946

WARNING If the Radio Remote System fails to operate properly during any of the Radio Remote System checks, DO NOT USE the machine until the cause has been corrected. Contact your dealer for service information and parts.

Figure 28 - Chain and Shackle Radio Remote Control Transmitter

IMPORTANT: Only after the Radio Remote Control System installation has successfully passed these verification checks, can the machine be put into use.

Complete and sign the Radio Remote Control System Registration form (806948), and return it to Manitou North America. Present the Radio Remote Control Warranty (806947) to the customer. Remind the customer of the importance of and the requirement for operator training.

Attach the remote control lanyard (809728) to the handle of the radio remote transmitter; place one end of the cable through the handle and place one loop inside of the other. Attach the snap ring (809729) to the loop.

MT6034 LOAD CHART - 809304 47

CONTENTS

INTENTIONALLY BLANK

48

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Chapter 9 Instructions to Install Radio Remote Control System Kits

*808601 *808644 809743 *808945 809772 809724 809723 *808042 809725 *808039 *808040 *808041 808091 809731 809763 *808265 809764 *808715 808850 809765 809766 809773 809728 *808127 809732 809767 809770 809774 808545 808555 *808649 809775 *809771 *808935 *808946 809729 *808938 *808588 *808589 808014 808007 806948 806947

FOR FORKLIFT MODELS MT6642 & MT8044 KIT 806621 WITH PWP, MODEL MT6642 & MT8044 KIT 806622 WITHOUT PWP, MODEL MT6642 KIT 806623 WITHOUT PWP, MODEL MT8044

INTRODUCTION These instructions provide procedures for field installation of the Radio Remote Control System.

IMPORTANT: These kits should only be installed by competent and experienced service technicians.

PARTS LIST Kit 806621, which is intended for use on machines that already have the optional work platform system installed, does not contain the items marked with an asterisk (*). Kits 806622 & 806623 contain all of the items listed.

Part No.

Description

*808443 808451 *808455 808464 809506 809742

Adap., -6orm-6jicm Str . . . . . . . . . .2 Adap., -4orm -6jicm Str . . . . . . . . .5 Adap., -6orm-6jicm 90 deg . . . . . . .2 Adap., -6jic swivel run tee . . . . . . .2 Adap., -4orm-6jicm 90 deg . . . . . . .6 Bolt, 1/4”-20x1/2” . . . . . . . . . . . . .2

Qty.

49

Bolt, 1/4”-20x1” . . . . . . . . . . . . . . .2 Bolt, 1/4”-20x2” . . . . . . . . . . . . . . .2 Bolt, 5/16”-18x3-1/2” . . . . . . . . . . .2 Chain, 5/16" (16 links) . . . . . . . . . .1 Cover, tool box bottom . . . . . . . . . .1 Decal, transmitter . . . . . . . . . . . . . .1 Decal, diagnostics and warning . . .1 Decal, PWP/WPS switch instruc. . . .1 Decal, radio control . . . . . . . . . . . . .1 Decal, work platform . . . . . . . . . . .2 Decal, work platform rules canopy .1 Decal, work platform rules boom . .1 Grommet . . . . . . . . . . . . . . . . . . . . .1 Harness, radio remote . . . . . . . . . . .1 Harness, PWP/WPS option . . . . . . .1 Hose, 1/4”x54" . . . . . . . . . . . . . . . .1 Hose, 1/4”x109" . . . . . . . . . . . . . . .1 Hose, 1/4”x15" . . . . . . . . . . . . . . . .2 Hose, 1/4”x26" . . . . . . . . . . . . . . . .4 Hose, 1/4”x20" . . . . . . . . . . . . . . . .4 Hose, 1/4”x130" . . . . . . . . . . . . . . .1 Hose, 1/4”x110" . . . . . . . . . . . . . . .1 Lanyard, remote control . . . . . . . . .1 Manifold, PWP/WPS joystick . . . . .1 Manifold, radio remote . . . . . . . . . .1 Manual, radio remote control . . . . .1 Module, PWP/WPS control . . . . . .1 Mount, radio receiver . . . . . . . . . . .1 Nut, 1/4”-20 whiz-loc . . . . . . . . .AR Nut, 5/16”-18 whiz-loc . . . . . . . . . .2 Nut, #10-24 . . . . . . . . . . . . . . . . . . .2 Receiver, radio remote / harness . . .1 Screw, #10-24x1/2” . . . . . . . . . . . . .2 Sensor, LS-60 level . . . . . . . . . . . . .1 Shackle, 5/16" chain . . . . . . . . . . . .1 Snap Ring, remote control lanyard .1 Switch, work platform . . . . . . . . . . .1 Washer, 1/4" . . . . . . . . . . . . . . . . . .2 Washer, 1/4" lock . . . . . . . . . . . . . .2 Decal, MT6642 load chart . . . . . . .1 Decal, MT8044 load chart . . . . . . .1 Registration . . . . . . . . . . . . . . . . . . .1 Warranty . . . . . . . . . . . . . . . . . . . . .1

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

WARNING

Tool box

Before performing any installation, modification or adjustment on a unit, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE described in the Operator’s Manual.

Battery access

Figure 1 - Fuel Tank / Battery Compartment

INSTALLATION PROCEDURE IMPORTANT: Before beginning the installation, the machine must be level both laterally (side-toside) and longitudinally (front-to-back).

2-1/4” diameter

5”

Radio Remote Control Receiver Installation 7”

1. Open the tool box access cover and remove the tool box floor panel and discard. Disconnect the battery cables. Remove the wing nuts and battery holddown bracket. Remove the battery access panel located on the side of the battery compartment; remove the battery from the battery storage compartment. See Figure 1.

Radio Remote Control Harness access hole

Existing battery cable hole

Figure 2

NOTE: If the machine already has two holes as shown in Figure 2, then skip to Step 3.

Radio Remote Receiver (809775)

2. Drill a 2-1/4” diameter hole 5” from the center of the existing battery cable hole and 7” up from the floor of the battery box as shown in Figure 2.

Install grommet (808091) into the hole.

809774

3. Bolt the radio remote control mount (809774) to the bottom of the radio remote control receiver (809775) using two 1/4”x1/2” bolts (809742) and two 1/4” whiz-loc nuts (808545). See Figure 3.

Figure 3

4. Place the battery back into the battery storage compartment. Place the battery holddown bracket (809774) on top of the battery and over the battery holddown threaded rods.

Threaded rod and wing nut

5. Route the battery cables to the battery posts on top of the battery, but do not connect them to the battery at this time.

6. Place the radio remote control receiver and mounting bracket on top of the battery holddown bracket (Figure 4) and fasten to the battery holddown bracket using the wing nuts that were removed from the battery in Step 1.

Holddown Bracket

Figure 4 - Radio Remote Receiver

50

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Transmission access

7. Remove the transmission access cover (Figure 5).

Figure 5 Rear Hood

8. Remove the rear hood bolts; slide back far enough to disconnect the tail light wire harness. Remove the rear hood. See Figure 6.

Figure 6 9. Route the wire harness of the radio remote receiver (Figure 7) out of the battery storage compartment through the radio remote harness access hole (Figure 2).

Manifold connectors at the rear of the machine

10. Route the portion of the harness identified as “Connectors in the pump area” in Figure 7 up to the area near the hydraulic pump shown in Figure 8. Secure the wire harness to the frame and existing hoses with nylon wire ties.

Connectors in the pump area

Figure 7 - Radio Remote Control Harness

11. Continue routing the remainder of the radio remote receiver wire harness identified as “Manifold connectors at the rear of the machine” in Figure 7 along the left inside frame to the rear of the machine. Secure the wire harness to the frame and existing hoses with nylon wire ties.

115 hp Engine Shown Connectors from Remote Receiver (809775)

Figure 8

51

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Wire Harness 809731 Installation 1

NOTE: For 99 h.p. engines skip to Step 13.

12. For 115 h.p. engines, refer to Figure 9-A. Locate the engine harness at the back of the engine. Cut the 12-gauge red wire (1) four inches from the engine harness connector, and crimp the two butt connectors (2) and (3) from the radio remote wire harness (809731) to each end of the 12-gauge wire.

115 hp Engine Shown

2 3 Radio Remote Harness

13. For 99 h.p. engines, refer to Figure 9-B. Route the end of the radio remote harness with the two black w/yellow stripe 14-gauge wires (2) and (3) around the front of the engine to the fuel injection pump.

Remove the wire (1) from the injection pump and cut off the terminal end. Strip the end of this wire (1) and crimp it into a butt connector (2). Cut the butt connector (3) off the end of the wire. Strip the wire and crimp a 14-gauge ring terminal on to this wire, and then attach the terminal back on to the injection pump and tighten.

Figure 9-A Radio Remote Harness

99 hp Engine Shown

2

1

3

Injector Pump

Figure 9-B 14. Route the 16-gauge white wire back to the starter solenoid located on the left side of the engine.

Attach the wire terminal to the “S” (Start) terminal of the solenoid. See Figure 10.

Starter Solenoid

“S” Terminal (Start)

White wire - Radio Remote Harness

Figure 10 PWP/WPS Harness 809763

15. Plug the connectors of the 809731 wire harness into the connectors of the 809775 radio remote receiver harness as shown in Figure 11.

Black and White/Green

Brown and Lt. Blue

Black and White

White and Black/White

NOTE: If the machine is already equipped with a PWP/WPS system, then disconnect the brown and light blue wire connector (Figure 11) from the existing two-piece (boom) wire harness (not shown) that runs from the end of the boom to the hydraulic pump area. The radio remote control system will not use the existing (boom) harness.

Radio Remote Receiver (809775) Harness

Harness 809731

Black

Green

Red and Orange

Figure 11 - Wire Harnesses 52

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Control Module 809770 Installation NOTE: If the machine already has a PWP/WPS system installed, it will be necessary to replace the existing control module and the PWP/WPS wire harness with the control module (809770) and PWP/WPS wire harness (809763) included in the kit. Refer to steps 16-18 and steps 21-23; when completed, skip to Step 32.

16. Remove the joystick access panel (inside cab), and retain the bolts for re-installation. See Figure 12.

Figure 12

17. Position the PWP/WPS Control Module (809770) inside the area under the joysticks and align with the pre-drilled holes as shown in Figure 13.

Control Module 809770

11”

NOTE: Some earlier units do not have pre-drilled holes. If the unit does not have pre-drilled holes, it will be necessary to drill two 7/32” holes. Use the PWP/WPS Control Module as a template; position it so the leading hole is 6” back from the front inside edge of the outer cab wall and 1-3/4” up from the bottom inside edge of the outer cab wall. See Figure 13.

6” 1-3/4”

Figure 13 18. Use two #10-24 screws (809771) and nuts (808649) to secure the module to the cab.

Work Platform Switch 808938 Installation

Work Platform Switch 808938

19. Remove the six bolts that secure the dash panel and save for re-installation. See Figure 14.

Dash panel bolts

20. Lift the dash panel high enough to remove the plastic switch plug, and then install the Work Platform Switch (808938) into the open slot. See Figure 14.

Figure 14

53

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

PWP/WPS Wire Harness 809763 Installation 21. Working from inside the cab, through the access opening shown in Figures 12 - 13, feed the front half of wire harness 809763 (Figure 15) up to the dash area following the existing wire harness.

Connect the work platform switch connector into the work platform switch (808938). Connect the control module connector into the control module (809770). Connect the canopy harness connector into the existing canopy harness.

22. Feed the back half of the harness out of the cab and into the area under the transmission access cover near the hydraulic pump. Connect all applicable connectors as shown in Figure 11.

23. Re-install the dash panel bolts removed in Step 19.

24. Add the applicable load chart plate to the end of the load chart assembly (included in all kits except 806621).

PWP/WPS Joystick Manifold Connectors

Grounding Terminals

Control Module Connector

Level Sensor Connector

PWP/WPS Switch Connector To Canopy Harness

Connects to Radio Remote Receiver (809775) Harness

Connects to 809731 Harness

Figure 15 - Wire Harness 809763 Connections

54

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Level Sensor 808935 Installation Level Sensor Mount

25. Locate the level sensor mounting bracket in the area beneath the transmission access cover. See Figure 16.

26. Attach the level sensor (808935) to the level sensor mount bracket with two 1/4”-20 x 1” bolts (808601) and two 1/4”-20 whiz-loc nuts (808545).

IMPORTANT: Verify that the “Y” marking on the level sensor is pointed toward the front of the machine.

Figure 16

27. Adjust the sensor, using the three spring-tensioned adjusting screws to center the bubble within the circle on top of the sensor. See Figure 17.

Level Sensor Bubble Adjusting Screws

IMPORTANT: The machine must be level both laterally (side-to-side) and longitudinally (front-toback). The PWP/WPS system will not operate properly if the level sensor is not adjusted (leveled) properly.

“Y” Mark

28. Connect the level sensor wire to the mating connector on wire harness 809763. See Figure 15.

Figure 17

PWP/WPS Joystick Manifold Installation 29. Install the hydraulic fittings: two 808443 straight and two 808455 90-degree adapters into the PWP/WPS joystick manifold (808127) as shown in Figure 18.

Front

30. Mount the PWP/WPS joystick manifold to the existing bracket on the frame near the flow divider with two 1/4”-20x2” bolts (808601), two 1/4” lock washers (808589), and two 808588 flat washers.

For a secure ground, attach the ground wire terminals from the PWP/WPS wire harness (809763) to the upper bolt before installing the bolt. See Figure 18.

Lift Solenoid (Orange wire)

Flow Divider

Ground wires

808455 90 deg fitting

808443 straight fitting

31. Connect the PWP/WPS joystick manifold connectors from wire harness 809763 to the PWP/WPS joystick manifold connectors. Connect the terminal with the orange and black wires to the connector for the Lift Solenoid (Figure 18) and connect the terminal with the gray and black wires to the other solenoid.

Figure 18

55

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Hydraulic Hose Installation IMPORTANT: When disconnecting hydraulic hoses, catch and dispose of spilled oil according to local waste disposal regulations. DO NOT discharge oil onto the ground.

32. Access the joysticks from the access panel inside the cab as shown in Figure 12.

33. Refer to Figure 19. Remove the swivel tee (1) and the hydraulic hose (2) from the Lift/Extend joystick controller. Remove the other end of the hydraulic hose (2) from the Tilt/Level joystick controller. Discard the hydraulic hose (2).

34. Connect the existing hydraulic hose (3) to the straight adapter on the Lift/Extend controller “P” port (where the swivel tee was removed). Locate hydraulic hose (809764) from the kit and mark the each end of the hose with “AA.” Attach one end of this hose to the existing (3) hose. Refer to item AA in Figure 20.

3

35. Refer to Figure 20. Add hydraulic hose 808265 (“EE” in Figure 20). Connect one end of the hose to the Tilt/Level joystick “P” port and route the other end out of the cab following existing joystick hoses and connect to the PWP/WPS valve “J2” port.

Figure 19 36. Locate one of the 809773 hydraulic hoses from the kit and mark both ends “CC.” Connect one end to the “J1” port of the PWP/WPS valve; do not attach the other end at this time. See Figure 20.

37. Install two swivel tee adapters (808464) to the “T” port on the flow divider. Re-connect the hose to the outer swivel adapter as shown in Figure 20.

main valve area under the rear hood. Secure the hoses with nylon wire ties.

38. Locate the remaining 809773 hydraulic hose from the kit and mark both ends “BB.” Connect one end of the hose to the swivel run tee as shown in Figure 20.

40. Refer to Figure 20. Locate the two (808715) hydraulic hoses from the kit. Connect one hose to the swivel tee just installed at port “T” and connect the other end to the PWP/WPS valve “T” port.

Connect the other hose to port “J” on the flow divider and the other end to port “P” on the PWP/WPS valve as shown in Figure 20.

39. Route hydraulic hose 809764 and the two 809773 hydraulic hoses along the inside of the right side of the frame toward the rear of the machine to the

56

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Tilt/Level

FRONT

Lift/Extend

P

Existing hose

T

EE

P

808265 T

Hydraulic Tank

808464

DD

FLOW DIVIDER

FRONT

T

808455 PWP/WPS VALVE 808127 J T

808443

P

808715 J1

809766

809764

J2

809773

AA

BB

(See Figure 21)

CC

808265

Figure 20

57

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Radio Remote Control Manifold Installation NOTE: Early machines do not have pre-drilled holes to mount the radio remote manifold to the rear weight. If the unit has pre-drilled holes in the rear weight, skip to Step 42.

FRONT Drill two 3/8” diameter holes 3/4”

41. Use the measurements shown in Figure 22, or use the radio remote control manifold (809732) as a template (placed in center of the rear weight as shown in Figure 23), to drill two 3/8” diameter holes into the rear weight.

7-1/2”

1-7/16”

13-3/4”

Top View Rear Weight

Figure 22 - Top View of Rear Weight

42. Mount the radio remote manifold (809732) to the rear weight using two 5/16”x 3-1/2” bolts (809743) and two 5/16” lock nuts (808555) to the rear weight as shown in Figure 23.

43. Refer to Figures 21 and 24 as a guide to install the hydraulic fittings for radio remote control manifold (809732). Use the following hydraulic fittings: five (808451) -4orm x -6jicm straight adapter, six (809506) -4orm x -6jicm 90-degree adapter.

Radio Remote Manifold

Figure 23

44. Connect the hoses from the PWP/WPS valve and joystick (AA, BB, CC) to the radio remote control manifold ports “JS,” “T” and “P” as shown in Figure 21.

INL

DN

45. Disconnect the existing hoses from the main valve pilots 1, 2, 3, and 4. Locate the four (809765) hydraulic hoses from the kit. Connect each of the (809765) hoses to the main valve and radio remote manifold as shown in Figure 21.

UP

46. Connect the radio remote receiver harness connectors to the radio remote manifold solenoid as shown in Figure 24.

Radio Remote Receiver Harness

Figure 24

58

RET EXT

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

(See Figure 20, for matching AA, BB, CC hoses) AA

CC

809764

BB 809773

EXT

(5) 808451 RET

DN

UP

808850 808850 E2

(6)809506

809766

E3 E1 E4

JS P J2

J4

J1

809732 Radio Remote Control Manifold

T

J3

4

BOOM UP/DOWN

1

809765

2

809765 Main Valve

3

BOOM IN/OUT

Previously connected to main valve

Previously connected to main valve

Previously connected to main valve

2

4

Previously connected to main valve 3

1

Figure 21

59

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

48. Remove decal 808031 from the front of the boom and apply decals 808039 and 808041 as shown in Figure 26.

New Decal Application Surfaces must be free from dirt, dust, grease and other foreign material before applying the new decals. To apply a decal, remove the smaller portion of the decal backing paper and apply this part of the exposed adhesive backing to the clean surface while maintaining proper position and alignment. Slowly peel off the other portion of the backing paper while applying hand pressure to smooth out the decal surface.

49. Apply remaining decals in location shown in Figures 25 - 29.

808040

808042

808039

Decal Installation 47. Remove decal 808031 from the right side of the dash and replace it with decal 808039. Apply decals 808042 and 808040, refer to Figure 25.

Figure 25 - PWP/WPS cab decals 808040 808042

2

808041

808039

808039

Figure 26 -PWP/WPS Front of Boom Decals

808041

60

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Radio Remote Control System Decals 809725

809724 809724

Figure 27

Figure 29

Place the diagnostics and warning decals (809723) under the access hood.

Figure 28

61

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

Finalize Installation

Procedure to test the Radio Remote System mode enable logic:

50. Re-connect the battery cables that were removed in Step 1. Leave the tool box floor cover off until the machine has been started and the radio remote control system has been checked for proper operation, and then install the new tool box floor cover (809772) included with the kit.

1. Start the engine and turn the Radio Remote System switch “ON”.

Radio Remote Control System mode lamp in the switch should be flashing.

2. Apply the service brakes.

After two seconds, the Radio Remote System mode lamp should be on continously, indicating that the system has been activated.

Parking brake should engage as indicated by the lamp on the parking brake switch lighting.

The carriage tilt and auxiliary functions should now be disabled. The hydraulic joystick should function as normal for boom raise/lower and extend/retract.

51. Start the machine and check all hydraulic connections for leaks. Correct any leaks as necessary.

52. Replace the rear hood and transmission access cover.

53. Replace the joystick access panel inside the cab.

54. Check the hydraulic fluid level and fill to operating level as required.

Procedure to test the transmission and joystick control lockout: 3. Shift transmission into “FORWARD” and increase the engine speed slightly.

The transmission should remain de-clutched and allow the engine to gain speed easily.

Return the transmission selector to “NEUTRAL” to complete the check.

4. Activate the Transmitter.

The hydraulic joystick should now be disabled such that boom raise/lower and extend/retract no longer function.

Press the E-STOP button on the Transmitter after completion of the check.

5. Tilt the frame to the right slightly more than two degrees.

The hydraulic joystick should now be disabled such that boom raise/lower and extend/retract no longer function.

Repeat the procedure with the frame tilted to the left.

Return the frame to a level position after completion of the check.

CHECK RADIO REMOTE CONTROL SYSTEM

WARNING To avoid injury due to incorrect installation, after the installation procedures are completed by a competent and experienced service technician, the PWP/WPS System must be checked for proper operation.

WARNING Do not use the machine after the PWP/WPS System kit has been installed until the installation has been verified as correct. Contact your local dealer for service information and parts.

The following must be performed before beginning the Radio Remote System checking procedures:

Procedure to test the Radio Remote System mode disable logic:

1.

2.

3.

4.

5.

6.

7.

6. Turn the ignition key switch to “OFF” and wait for the engine to stop completely. Then turn the key switch to “ON”.

The Radio Remote Control System mode lamp and the parking brake lamp should be illumi nated.

Machine on level surface, Boom fully lowered, Frame level, Transmission in “NEUTRAL”, Parking brake switch “OFF”, Radio Remote System switch “OFF”, and Press the E-STOP button.

62

CONTENTS FIELD INSTALLED KITS - 806621, 806622 & 806623 FOR MODELS MT6642 & MT8044

7. Turn the key switch “OFF” and then press the Radio Remote System rocker switch “OFF”. Turn the key switch back “ON”.

The Radio Remote Control System mode lamp should be flashing and the park brake lamp should be on continously.

8. Start the engine and apply the service brakes.

The Radio Remote System mode lamp and the parking brake lamp should go off after the service brake is applied for two or more seconds.

Work Platform Installation The chain (808945) and the shackle (808946) are used to secure the personnel work platform (not included) to the bottom of the carriage. This will keep the forks from pivoting upward in case the work platform is lowered onto an obstruction. See Figure 30.

Chain - 808945 and Shackle - 808946

WARNING If the Radio Remote System fails to operate properly during any of the Radio Remote System checks, DO NOT USE the machine until the cause has been corrected. Contact your dealer for service information and parts.

Figure 30

IMPORTANT: Only after the Radio Remote Control System installation has successfully passed these verification checks can the machine be put into use. Complete and sign the Radio Remote Control System Registration (form 806948), and the Radio Remote Control Warranty (806947). Remind the customer of the importance of and the requirement for operator training.

Radio Remote Control Transmitter Attach the remote control lanyard (809728) to the handle of the radio remote transmitter; place one end of the cable through the handle and place one loop inside of the other. Attach the snap ring (809729) to the loop.

MT6642 LOAD CHART - 808014

MT8044 LOAD CHART - 808007 63

CONTENTS

WARNING THIS MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THE MACHINE Do not start, operate or work on this machine until you have carefully read and thoroughly understand the contents of this manual.

Failure to follow safety, operating and maintenance instructions could result in serious injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of this machine, contact your dealer before starting or continuing operation.

64