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005 Joystick 2

The document provides instructions for removing and installing remote control valves (joysticks) that control hydraulic functions on equipment. It describes disconnecting electrical and hydraulic connections, removing mounting hardware, cleaning the valves before installation, and ensuring proper reconnection and operation by checking for leaks during testing. Troubleshooting tips are also included to diagnose issues like a lack of response or incorrect joystick movement by checking for causes like low pilot pressure, leaks, or incorrect line connections.

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350 views

005 Joystick 2

The document provides instructions for removing and installing remote control valves (joysticks) that control hydraulic functions on equipment. It describes disconnecting electrical and hydraulic connections, removing mounting hardware, cleaning the valves before installation, and ensuring proper reconnection and operation by checking for leaks during testing. Troubleshooting tips are also included to diagnose issues like a lack of response or incorrect joystick movement by checking for causes like low pilot pressure, leaks, or incorrect line connections.

Uploaded by

JonathanDavidDeLosSantosAdorno
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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HYDRAULIC REMOTE CONTROL

VALVE (JOYSTICK)
The remote control (joystick) valves supply pressure to the main directional valve. This pilot
pressure shifts the main valve spools which direct oil to the cylinders.
The remote control valves are mounted in front of the arm rest, in the operators
compartment.

REMOVAL OF REMOTE CONTROL VALVES


1. Disconnect the battery ground (-) cable.
2. Remove the console cover by taking off the two wing nuts that hold on the arm rest
and lift the cover off.
3. Thoroughly clean the valves and hydraulic connections with an approved cleaning
solvent.
4. Match-mark the hydraulic lines and valve ports to ensure correct connections during
installation.
5. Disconnect hydraulic lines from joystick. Cap the lines and valve ports to prevent
contamination.
6. Disconnect the joystick electrical wire underneath the mounting bracket.
7. Remove the four (4) socket head fasteners on each of the joysticks, and remove the
joysticks.

JOYSTICKS, FIXED BOOM

Page 23

JOYSTICKS, TRAVERSING BOOM

Pettibone/Traverse Lift, LLC

INSTALLATION OF REMOTE CONTROL VALVE


1. Install the valves onto the mounting bracket with the four (4) socket head fasteners for
each joystick.
2. Connect the joystick wires to the terminal.
3. Connect the hydraulic lines to the valves.
4. Connect the ground (-) cable to the battery.
5. Start engine and actuate joystick to ensure
correct operation. Be sure to check for leaks as the joysticks are operated.
6. Replace console cover and armrest with the two wing nuts.

Page 24

Pettibone/Traverse Lift, LLC

REMOTE CONTROL (JOYSTICK) TROUBLESHOOTING


SYMPTOM

CAUSE

REMEDY

Pilot operated spools in


main valve do not shift
when joystick is actuated
Not enough pilot pressure
supplied to main valve

Pilot pressure should


be within the range of
500 psi (25 psi). If it is
not, clean filter and
clean or replace pilot
spool.

Leak(s) in pilot lines from


remote control valve

Tighten pilot hose


couplings or replace
defective hoses.

Blocked pilot lines.

Remove
contamination and
flush pilot lines with
clean hydraulic oil.

Joystick chatters

Pilot pressure too high

Check pilot pressure


using a 600 psi pressure
gauge. Correct pressure
should be within the
range of 500 psi (25
psi). If pressure is too
high, clean or replace
pressure reducing valve.

Wrong response to
Joystick movement

Pilot lines connected to


wrong valve ports

Reconnect lines to
correct ports

Joystick does not center

Broken centering springs

Replace springs.

Oil leaks between sections


Of remote control valve

Defective section O-ring

Replace o-ring.

Page 25

Pettibone/Traverse Lift, LLC

FORK TILT AND AUXILIARY HYDRAULIC


JOYSTICK WITH TOC 2 MODULE
OVERVIEW
The Fork Control consists of two rocker control buttons mounted in the joystick handle, the
TOC 2 module, the solenoid operated fork up/down section of the main valve, and the
auxiliary fork rotate solenoid operated section of the main valve.
1. The fork up and down buttons supply an analog voltage reference to the TOC 2 module
proportional to button depression, varying approximately 0.5VDC to 4.5VDC, to control
the speed of operation.

TOC 2 MODULE
2. The TOC 2 module is located under the armrest bracket, underneath the fiberglass
console on the RH side of the operator compartment.
3. The TOC 2 module is a current compensated output control which maintains a constant
level of current to the solenoid coils, proportional to an input signal from the joystick
ensuring constant hydraulic operation regardless of system temperature and voltage
variations. The driver is equipped with monitor LEDs.

Operation
1. With no buttons pressed, there should be no voltage at pins 11 and 12.
2. With a button pressed, depending on the axis, Vbatt minus of about 1VDC will be
present at either pin 11 or 12.
3. Normal standby reference voltage of the four control input may range from 1.0 to
1.2VDC approximately.

Page 26

Pettibone/Traverse Lift, LLC

TOC 2 MODULE

HARNESS PLUG

BOTTOM VIEW

INDICATOR LIGHTS

SIDE VIEW

Page 27

Pettibone/Traverse Lift, LLC

Indicator lit green with


secondary indicator
blinking green. Normal
function.

Tilt down -
Side-Tilt CCW -

Tilt up +
Side-Tilt CW +

Indicator lit green with


secondary indicator
blinking green twice,
then red. Open circuit
(as if the joystick were
unplugged).

Page 28

Pettibone/Traverse Lift, LLC

Joystick PWM Theory of Operation


A +5VDC reference voltage is sent from the PWM to the joystick buttons
which operate independently of each other but share a common ground. As the
rocker switch is depressed, the reference voltage is changed to an output
generated by an IC chip in the rocker. The neutral position output voltage of the
switch is 2.5VDC. As the switch is depressed the voltage changes depending on
which direction the switch is activated; if the lower part of the rocker is pressed the
output voltage will range between 2.5VDC and .5VDC and if the top portion of the
switch is activated the output voltage will range from 2.5VDC to 4.5VDC. The
output voltage from the switch is then compared to the reference voltage in the
PWM.
Upon comparison the PWM determines if the output voltage is + or of
neutral and applies an output phase shift to the appropriate A or B coil. The voltage
present at the valve solenoid coil is always 12VDC but the time that the voltage is
applied to the coil can vary. The amount of time the 12VDC is applied to the coil is
dependant on the output voltage from the PWM. If you were to use a voltmeter to
read the voltage available to the coil you should see approximately 0VDC with the
rocker in the neutral position and .6VDC with the switch fully depressed; polarity
depending on the direction of switch actuation. You would, in effect, be reading the
RMS value of the voltage.

Page 29

Pettibone/Traverse Lift, LLC

Joystick & Module Test Procedure


FL-13202 Test Harness

TEST PROCEDURE: (tests to be performed in machine or on bench w/ external power)


With no buttons pushed on Joystick1. Check voltage between terminal 5 and 6, it should be about 5 VDC.
2. Check voltage between terminal 5 and 3, and 5 and 1. It should read 2.5VDC on both with
the rocker in the neutral position.
Pushing buttons on joystick- (slowly vary pressure from slight pressure to firm pressure)
3. Check voltage between terminal 5 and 3 and push left rocker up & down (fork tilt fwd/back)
4. Check voltage between terminal 5 and 1 and push right rocker up & down (Aux CW/CCW)
On tests 3, 4 above, voltage should slowly and smoothly vary as you vary pressure on
button, starting at the range noted in step 2 and rising from 2.5VDC to 4.5VDC. Pressing the
switch in the opposite direction should vary the voltage from 2.5VDC to .5VDC
If the results measured do not correspond to stated voltages, the joystick is faulty.
Note: It is recommended that these tests be performed in the forklift with its onboard power.

Please see the appendix section for a detailed installation and


troubleshooting guide for the TOC2 module.

Page 30

Pettibone/Traverse Lift, LLC

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