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For use in service manual

form SB4176E
SB4183E00
Feb. 2005

SERVICE MANUAL CONTENTS


NOTICE
This form lists the contents of the complete Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers listed with mark(*) are, they are not available for the initial release of the
manual. When items are updated, or supplements added, they will be announced in
preview and should be ordered as they become available.

TITLE
Service Manual Contents
Safety
Torque Specifications

FORM NUMBER
SB4183E00
SB2003E00
SB2004E00

DIRVE & CONTROL SYSTEM


MicroController Control Systems

SB4177E00

POWER TRAIN
Power Train

SB4185E00

VEHICLE SYSTEMS
Vehicle Systems
Vehicle Systems D & A
Hydraulic System Schematic
Electric Systems Schematic
Mast Systems

SB4186E00
SB4187E00
SB4182E00
SB4181E00
SB2143E03

OPERATION & MAINTENANCE


Operation & Maintenance Manual
Operation & Maintenance Manual

Models ; B15T-5, B18T-5, B20T-5 (AC 36V, 48V)


B16X-5, B18X-5, B20X-5 (AC 48V)

SB2339E01
SB2340E01

For use in service manual


form SB4176E
SB4183E00
Feb. 2005

SERVICE MANUAL CONTENTS


NOTICE
This form lists the contents of the complete Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers listed with mark(*) are, they are not available for the initial release of the
manual. When items are updated, or supplements added, they will be announced in
preview and should be ordered as they become available.

TITLE
Service Manual Contents
Safety
Torque Specifications

FORM NUMBER
SB4183E00
SB2003E00
SB2004E00

DIRVE & CONTROL SYSTEM


MicroController Control Systems

SB4177E00

POWER TRAIN
Power Train

SB4185E00

VEHICLE SYSTEMS
Vehicle Systems
Vehicle Systems D & A
Hydraulic System Schematic
Electric Systems Schematic
Mast Systems

SB4186E00
SB4187E00
SB4182E00
SB4181E00
SB2143E03

OPERATION & MAINTENANCE


Operation & Maintenance Manual
Operation & Maintenance Manual

Models ; B15T-5, B18T-5, B20T-5 (AC 36V, 48V)


B16X-5, B18X-5, B20X-5 (AC 48V)

SB2339E01
SB2340E01

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Feb. 2005
SB4145E00
Jun. 2004

Specifications
Systems Operation
Testing & Adjusting
MicroController Control Systems
B15T-5, B18T-5, B20T-5 (AC 36V/48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
for Electric Lift Trucks

Important Safety Information


Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as WARNING as
shown below.

The meaning of this safety alert symbol is as follows:


Attention ! Become Alert ! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.

Index
Specifications

Instrument Panel

Assembly Layout of Controller (4 Wheel)...................9


Assembly Layout of Motors........................................9
Component Measurements........................................5
Control Panel Layout................................................10
Controller AS Specification.........................................6
Drive Motor Specification ...........................................7
Fuses .........................................................................9
Instrument Panel Layout ............................................8
Pump Motor Specification ..........................................7

Accessing Stored Error Codes ...............................109


Default Setting........................................................106
Diagnostic Mode.....................................................107
Display Keys Utilization ..........................................102
Instrument Panel ......................................................99
LED Indicators........................................................101
Lift truck operation mode........................................100
List of diagnostic.....................................................108
Parameter Calibration ............................................103
Sensor Initial Setting ..............................................106

Systems Operation
Eye Software Interface
General Information .................................................13
Advantage of AC motor.........................................13
Basic ITC ..............................................................16
Comparison between AC and DC motor...............13
ITC system characteristics....................................16
Main ITC(Intelligent Torque Control) features .......15
Glossary ................................................................... 11
Installation and Wiring..............................................17
Accessory Circuits ................................................26
General .................................................................17
Hydraulic Pump Motor Circuit ...............................25
K1 connector: list of all terminals ..........................19
System Circuit.......................................................23
Thermal protection circuit......................................26

Features .................................................................114
General Information................................................112
Installation ..............................................................113
Main Menu..............................................................115
Calibration ...........................................................124
Configuration Menu (Setup) ................................119
Data Logging.......................................................144
Flash ...................................................................146
Not Actual Software / Eeprom Crc Fault..............118
Password Insertion..............................................116
Submenus ...........................................................118
Test......................................................................120

Troubleshooting of Eye Program


Testing and Adjusting
Flash Programmation .............................................147
Generality ...............................................................147
Other Problems ......................................................147
Serial Communication ............................................147
Software Installation ...............................................147

Preparation Tests and Check ...................................27


Programmable Parameters ......................................30
Adjustable Parameters Description.......................30
E-S-H Energetic Modes Parameters.....................37
Some Functions Management .................................38
B.D.I. Measure Management................................38
Buzzer Management.............................................38
Pump Motor Modes...............................................38
Static Return to Off................................................38

Appendix
Appendix A : 48[V] Parameter List..........................148
Appendix B : 36[V] Parameter List .........................151
Appendix C : Error Code List..................................154
Appendix D : Contraction for dot matrix display......160
1. Alarm Code .....................................................160
2. Calibration Code .............................................161
3. Diagnostic Code..............................................162

Diagnostic and Troubleshooting


Alarm List .................................................................39
Electrical System Adjustment...................................95
General Description .................................................39
System Tests and Adjustments ................................94
Troubleshooting Problem List...................................48

Specifications
G

Component Measurements

SPECIFICATIONS
Multimeter Setting

(+) Test Lead

(-) Test Lead

Results

Resistance

+BATT

Each U,V,W

Over 1.4 Mohms

Resistance

-BATT

Each U,V,W

Over 1.4 Mohms

Resistance

U Termina

V Terminal

Below 0.5 ohms

Resistance

U Termina

W Terminal

Below 0.5 ohms

Resistance

V Termina

W Terminal

Below 0.5 ohms

Controller AS Specification
BATTERY VOLTAGE

24-60 V

MAXIMUM IMPULSIVE DRIVE INVERTER CURRENT

325 A

MAXIMUM IMPULSIVE PUMP INVERTER CURRENT

400 A

SWITCHING FREQUENCY

3-6-9 KHz

EFFICIENCY

95 %

PROTECTION LEVEL
MECHANICAL SIZE

IP51
580x248x187

WEIGHT

24 Kg

VIBRATION

5g 10-500Hz in X,Y,Z axis

TEMPERATURE RANGE

- 30 C + 40 C

MAXIMUM MODULE TEMPERATURE


CONTROLLER

100C
Complies with EN 1175-1 EN 12895-1

MAIN CONTACTOR

250A

MAIN FUSE
KEY FUSE

700A
10A

Drive Motor Specification


POWER

5 KW

POWER

12 KW

VOLTAGE

32 V

VOLTAGE

30.5 V

CURRENT

157 A

CURRENT

335 A

RATED SPEED

1500 RPM

RATED SPEED

2200 RPM

MAXIMUM SPEED

4500 RPM

MAXIMUM SPEED

4500 RPM

FREQUENCY
Cos G

75 Hz
0,72

FREQUENCY
Cos G

SERVICE

S2 60'

SERVICE

INSULATION CLASS
PROTECTION DEGREE
BEARINGS
WEIGHT

Pump Motor Specification

INSULATION CLASS

IP 10

PROTECTION DEGREE

6206 2RS
38.5 Kg

BEARINGS
WEIGHT

73 Hz
0.84G
S3 15%
F
IP 20
6206 2RS
43.5 Kg

Instrument Panel Layout


TYPE A

TYPE B

Fuses

Assembly Layout of Motors

Line ..................................................................... 700A


Key ........................................................................ 10A
Horn ...................................................................... 10A
DC / DC Converter................................................ 10A
Light ..................................................................... 10A
Option light............................................................ 10A

Assembly Layout of Controller


(4 Wheel)

Control Panel Layout

NOTE: Apply a small amount of D557047 Thermal Joint Compound on control panel plate and mating surface
prior to assembly. Communication cables assembly with power units and logic control unit uses the micro
screw driver(2.5*100mm)
Communication cable's assembly with Power Unit and Logic Control Unit uses Micro Screw Driver
(1) Logic Control Unit. Use a socket wrench(7mm) to hold bolts
(2) Left Drive Motor Power Unit. Use a hex bit socket(5mm) wrench(100mm) or L-wrench to hold bolts
(3) Pump Motor Power Unit
(4) Right Drive Motor Power Unit
(5) FUSE. Use a socket wrench(13mm) and a wrench(13mm) to hold bolts
(6) Line Contactor
(7) Bus Bar. Use a socket wrench(13mm) and a socket wrench(17mm) to hold bolts

10

Systems Operation
Glossary

NAME

DESCRIPTION

Accelerator

A device that converts mechanical movement into a analog voltage pattern to the
logics for variable drive motor speed.

Ampere (or Amp)

The unit of measurement of current flow. The amount of current that one volt can
push through a resistance of one ohm.

Analog to Digital
Converter

A device that converts an analog voltage into a pattern of digital HIGH and LOW
voltage signals.

Battery

Two or more cells connected together for a supply of electric current.

BDI

Battery Discharge Indicator - An electrically controlled display showing the operator


the state of batter y charge.

Bus Bar

A heavy electrical conductor to which other smaller wires are connected.

Capacitor

Device used to store electrical energy for short periods of time.

Circuit

A way for current to go from the positive (+) side of an electrical power source to the
negative (-) side of an electrical power source. This can be through wires and
electrical components.

Coil

A component made from many circles or turns of wire used to concentrate a


magnetic field.

Connector

Part of a wire assembly or harness that connects with another wire assembly or
harness. Used for ease of assembly and disassembly.

Contactor Assembly

An electrical component consisting of an electromagnetic coil and a set of heavy


contact tips. Control current passes through the coil, building a magnetic field which
closes or opens the contact tips.

Contactor Coil

An electromagnet used to close or open contact tips in a contactor assembly.

Contact Tips or Contacts

The portion of a switch, relay or contactor where the circuit can be opened or closed.

Current

The movement or flow of electricity through a conductor. A circuit must be complete


for current to flow.

Current Limit

The maximum allowable armature current of a stalled drive motor during pulsing.

Digital Signal

A signal in which the elements may be either of two distinct values.


For example high voltage, low voltage.

Diode

A semiconductor device that allows current to flow in one direction, from the anode to
the cathode.

Display

An electrical device that converts voltage inputs to a visual output.

Electrical Assist Braking


(EAB)

Electrically trying to rotate the drive motor opposite to the direction of truck
movement.

Fuse

A component in an electrical circuit that will open the circuit if too much current goes
through it.

Harness

An assembly made of two or more wires that are held together.

Heat Sink

A mounting frame used for semiconductor cooling.

Indicator

LCD that gives an indication of some vehicle condition when it turns on or flashes.

LCD

Liquid Crystal Display.

Logic Control Unit

The main printed circuit board containing a microprocessor and circuits to condition
the voltage signals that go into or come out of the logics. It electronically monitors
and controls the truck's functions.

11

NAME

DESCRIPTION

Microprocessor

A small computer chip preprogrammed to control the various electrical functions on a


lift truck.

Normal Condition

Words used with a switch or relay. Their normal condition is their condition when they
are not controlled by the application of force, temperature, pressure, or electricity.

MOSFET

A semiconductor component used in electric lift trucks as an electronic switch. A


MOSFET most often has three terminals, a GATE(G), a DRAIN(D), a SOURCE(S). A
MOSFET is a voltage-controlled device and required only a small input current. The
switching speed is very high.

Ohm

The unit of measurement of resistance. The amount of resistance that will let one volt
push only one ampere of current through it.

ON-Time

The amount of time current flows through a transistor.

Open Circuit

Wiring or components of a circuit that have no continuity.

Overload

The presence of voltage or current which is greater than an electrical circuit or


component is designed to handle.

Plugging

A portion of electrical braking where the generated current is directed back through
the armature.

Relay

An electrical component consisting of an electromagnetic coil and a set of small


contact tips. Control current passes through the coil, building a magnetic field which
closes or opens the contact tips. When the contact tips are closed, low current can
flow in a separate isolated circuit.

Resistor

A component made of a material that has a specific resistance to the flow of current.

Rotor

Part that rotate of motor

Schematic

A line drawing of an electrical or electronic assembly which uses symbols to show


individual components. It shows how the components, wires and connectors function
electrically.

Short Circuit

An electrical connection between two or more components that is not desired.

Socket

The female contact of a connector that slips over a male contact (pin) of another
connector.

Solid State

Reference to semiconductor components or circuits that use semiconductor


components that have no moving parts, such as diodes and transistors.

Stator

Fixed part in driving state of motor

Switch

A component used to control an electric circuit. It can close or open a circuit.

Systems

The electrical components, circuits, and connections that deliver power to perform
specific tasks.

Terminal

An electrical connection point on an electrical component.

Thermal Sensor

A sensor that activates at a set temperature.

Volt

The unit of measurement of electromotive force. One volt is the force needed to
make one ampere of current flow through one ohm of resistance in a circuit.

Watt

The unit of measurement of power. The amount of power used when one volt pushes
one ampere of current through a resistance of one ohm. The result of amperes
(current) multiplied by volts (voltage) is watts (power).

Wire

A conductor used to provide a path for current to flow to and from electrical
components.

Wiring Diagram

A drawing using visual representation of components the way they actually look. It is
used to show the locations of components and the connections between them.

Zener Diode

A special diode used to regulate voltage or as an over-voltage (too high a voltage)


protector.

12

General Information
Advantage of AC motor

Comparison between AC and DC


motor
Motor Characteristics
AC Motor systems

DC Motor system

Little components

More complex

Decreasing price

Increasing price

More reliable

Less reliable

Practically
maintenance free

Continuous
maintenance to brushes

AC induction motors are the most diffused for power


conversion in industrial application. In the batteryfed lift-truck applications DC motors are more used,
because they are easy to control in torque with a
simple chopper drive with a current limitation.

High speed

Low speed

High torque
performance at high
speed

Low torque
performance at high
speed

To reach the traction requirements the AC control


has to be very advanced and the motor parameters
have to be known by the control algorithms.

High braking
performance at high
speed

Poor braking
performance at high
speed

Safer

Less safe

The reason of their recent diffusion are related to


the technological development and to deeper
studies about this matter.

Controller Characteristics

The advantages of using AC motors instead of


DC motors are many:
1. More robust and easy to build
2. Less complex and more reliable
3. Practically maintenance free (no continuous
brush maintenance)
4. Higher speed
5. More performance at high speed especially in
regeneration
6. Absence of contactors for speed inversion
7. Continuous torque control during inversion (no
delay with zero torque)
8. Safer because AC motor is not supplied and it
doesnt work in case of short circuit

AC Motor systems
9

10 No auxiliary contactor

See following tables and relative explanation for a


comparison between AC and DC motor systems.

Complex controller

13

DC Motor system
Simple controller
Presence of auxiliary
contactors

11

4 quadrants
continuous transition

Torque discontinuity and


delay

12

Precise and smooth


regulation

Poor regulation

AC and DC Motors Difference Explanation


DC motor is made with a rotor with power windings
and a stator with excitation windings and brushes.
The AC motor is composed by a rotor and a stator
with windings.
Because of great diffusion of AC motors and the
automatic industrial production process, their prices
continue to decrease.
Because of DC motor more complexity, brush
presence and poor environmental protection, the life
of DC motor is greatly reduced, compared with AC
motor.
The maintenance of DC motor must be continuous
because of consumption of brushes.
The most critical component for AC motor are the
bearings. AC motor reaches higher speed because
of DC sparkling limitation of brushes.
AC motor has higher torque at high speed because
of DC sparkling limitation of brushes. AC motor has
much more regenerative braking torque at high
speed because of DC sparkling limitation of brushes.
AC motor is safer than DC because if a short circuit
happens in armature, DC motor accelerates. The
AC motor needs an AC voltage to accelerate.
The AC controller is much more complex of a DC
one. The reason why is the AC control algorithms
requires the use of a very powerful microprocessor
which performs a fast real time control.
In most of DC controllers are present auxiliary
breakers which operate every drive inversion,
introducing delays and compromising the controller
life.
Most of DC controller systems has zero torque
delays during inversion causing a poor driving
performance. In AC the transition between forward
and reverse and acceleration and braking is
continuous giving an optimum performance even at
very low speed and in sharp ramp.
Because of 4 quadrants continuous transition and
the presence of a sophisticated controller the
regulation of AC system is superior in precision,
stability, smoothness and safety to DC one.

14

Main ITC(Intelligent Torque Control)


features

Software control algorithm is customised in order to


best fit lift truck characteristics; you can set the
value of a wide range of parameters, in order to
optimise system performance and to adjust the
settings of main functions in compliance with users
needs.

Most important features of Intelligent Torque


Control system developed by DHIM the
following:

User can interact with control board making use of a


software application (named EYE) developed by
DHIM, or with COMPACT display. In both cases, its
possible to obtain an exhaustive on line diagnostic
for all lift truck functional parameters and also to
adjust them.

1. Control unit: One panel assembly containing


three power inverters for drive and pump and a
control board; main board, wired directly to the
power modules, could manage up to 4 inverters.
The presence of 2 DSP (Digital Signal
Processors), working in mutual redundant
control, guarantees powerful software
performance: in case of such a system,
managing both drive and pump motors, high
dynamic performance in vectorial torque control
can be obtained (see Appendix A for technical
data)

You can upgrade control board internal software


connecting a PC via serial port (or via USB 1.x or
higher, inserting the appropriate serial port-USB
adapter); in fact, working with RS232
communication standard, EYE application permit to
load and upgrade panel software in any working
conditions, if only control board is correctly fed on .

2. Two asynchronous three-phase drive motors


equipped with magnetic sensors(64 impulses/
rotation) (see Appendix A for technical data)
3. An asynchronous three-phase pump motor for
lifting equipped with magnetic sensor (64
impulses/ rotation) (see Appendix A for technical
data)
4. Compact Display

Instrument Panel

15

Basic ITC

ITC system characteristics

Following basic hardware and software


functions characterize DHIM Company system:

You can obtain high performance for the lift


truck with DHIM system, thanks to following
specific features:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Protection against reverse battery polarity


Anti-roll-back, with adjustable ramp stop time
Anti-roll-down
Regenerative braking
Electrically assisted braking
Management of static return to off function
(SRO)
Drive speed compensation (load/unload)
Drive speed acceleration/deceleration
Drive speed reduction
Redundant control of acceleration pedal
(applying a control switch or a double
potentiometer)
Continuous lift speed control
Pump speed compensation (load/unload)
Lift speed acceleration/deceleration
Continuous control of main contactor applied to
DC power line
Seat switch open check with delay time
Battery discharged indicator with adjustable
reset value
Overtemperature protection for inverters and
motors
Low and high battery voltage limit
Drive/pump speed feedback
Zero speed drive in ramp
Standby for supply
Diagnostics and stored error code
Power line fault detection (fuse/contactor)
Continuous temperature measuring (Controller,
drive/pump motor)

1. DSPs(Digital Signal Processor) high


performance control with custom software: this
is resident in the internal FLASH memory, and
allows to control 3 independent AC motors.
2. One serial asynchronous RS232 interface for
PC communication in order to obtain:
a. Software update
b. Diagnosis of truck functionalities
c. Parameters modification, in order to
custommize the system
3. One accelerator (0 - 5 V) and all on/off
emergency micro-switches interface.
4. One encoder (0 - 5 V) interface for traction and
pump motors.
5. Motor torque control by speed and current loop.
6. Controlled acceleration and deceleration ramps
of drive and pump motors in order to avoid
uncontrolled jolts of the load due to oversights
of the operator.
7. Automatic truck speed limitation depending on
steering angle.
8. Ramp stop of the lift truck.
9. Automatic energy recovery at each truck
braking.
10. LIN (Local Interconnect Network) display
interface.
11. Automatic truck speed limitation, depending on
the height of the load lifted(option).
12. Automatic truck maximum speed limitation, in
function of:
13. Weight present on the forks(option)
a. Fork height
b. Battery voltage level
c. Any thermal alarm
d. Full protection of drives against overcurrent
of the motors, overheating of the power
transistors and both maximum and minimum
battery voltage.
14. Low maintenance costs by using A.C induction
motors

G
G
G
G
G

16

Installation and Wiring


General
1. A metallic container encloses control board (Fig.
1). ( Refer to APPENDIX A for technical data
and other details about control board)
2. There are three power modules (see fig 2 for
single module) assembled to main board as
shown in Fig. 3 and Fig. 4. ( Refer to
APPENDIX A for technical data and other
details about power inverters)

Fig. 1: Logic control board

3. A 68 ways AMP connector (named K1), permits


to interface control board to lift truck
electrical/electronic sub-devices. See Fig. 4 for
a view of K1- 68 ways connector. ( Refer to
APPENDIX B for technical data and other
details about K1 connector and to APPENDIX D
for a generic interconnection schemata)
4. Three 26 ways connectors (named C1 C2 C4)
permit to wire and control 3 power inverters. No
details are given about the pin-out of these
connectors t, because they are not user
accessible for maintenance or diagnostic
operations. Power modules shall be connected
also to battery supply (wire named +B and -B)
and to corresponding motor phases.

Fig. 2: Single power module

Working on electrical systems is potentially


dangerous; you should protect yourself
against :
Uncontrolled operation: some conditions could
cause the motor to run out of control:
disconnect the motor or jack up the vehicle and
get the drive wheels off the ground before
attempting any work on motor control circuitry.
High current arcs: batteries can supply very
high power, and arcs can occur if they are short
circuited. Always open the battery circuit
ground before working on motor control circuit.
Wear safety glasses and use properly insulated
tools to prevent shorts.
Lead acid batteries: charging or discharging
generates hydrogen gas, which can build up
and go around the batteries. Follow the battery
manufacturers safety

Fig. 3: Power modules assembly with main contactor and


fuses

Fig. 4: Power modules assembly with control board mounted

17

Fig. 4: View of accessible terminals on 68 ways connector

18

K1 connector: list of all terminals


Pin
number

Use

Name

K1 1

IN

K1 2

OUT
IN
A

Lift pressure (optional)

K1 3

Proportional voltage signal (0-5V); you can connect a


pressure linear sensor, made by SME cod B00ID160
working correctly in 0250 bar pressure range

K1 4

IN
D

start switch for accelerator


pedal

START signal
N.O. with internal pull-up and Vmax(in)=24V

K1 5

IN
A

accelerator pedal 2
potentiometer

Proportional voltage signal (0-5V) or (0-12V) managed as


accelerator pedal input

K1 6

IN
D

park brake switch

Park brake signal


N.C., with internal pull-up and Vmax(in)=24V

K1 7

IN
D

seat switch

Seat switch signal


N.O., with internal pull-up and Vmax(in)=24V

K1 8

IN
D

reverse drive direction switch

reverse drive direction di selezione signal


N.O., with internal pull-up and Vmax(in)=24V

K1 9

IN
D

forward drive direction switch

forward drive direction signal


N.O., with internal pull-up and Vmax(in)=24V

K1 10

IN
A

accelerator pedal 1
potentiometer

Proportional voltage signal (0-5V) or (0-12V) managed as


accelerator pedal input

+ 12 V supply

+12V supply voltage (self-protected electronic


component) with: Idc (nominal) =500mA; Imax = 1Adc

K1 11

OUT

-Battery

Negative supply voltage of control board

+ 24 V supply

K1 12

IN/OUT
D

K1 13

IN
A/D

not used

- Digital input, for an optional encoder, Vmax(in) =5V


- Analogue input (0-12V)

OUT

+ 5 V encoder supply

+5V supply voltage (self-protected electronic component)


with: Idc (nominal) =500mA; Imax = 1Adc

OUT

GND

Negative supply voltage for data type signals, with self


protection against noises coming from DC power line;
Imax=500mA

K1 14

LIN data line (Display I/0)

K1 15

Function

Data line of LIN interface for COMPACT display

K1 16

IN
D

PHASE B of left drive motor


encoder

PHASE B signal of the sensor bearing mounted into the


left drive motor; internal pull-up; Vin:(0 5V)

K1 17

IN
D

PHASE A of left drive


motor encoder

PHASE A signal of the sensor bearing mounted into the


left drive motor; internal pull-up; Vin:(0 5V)

K1 18

OUT

+ coil main breaker

Positive command of contactor coil; Inom=1A; Imax = 5A

K1 19

OUT

- coil main breaker

Main breaker coil reference signal; Inom=1A; Imax = 5A

OUT
A

not used

K1 20

Self-protected open collector power output, you can


apply it to an ON/OFF or proportional electrovalve coil;
Vmax =Vali; Inom=2A; Imax=6A

19

Pin
number

Use

Name

Function

OUT
D

not used

K1 21

Self-protected open collector power output, you can


apply it to an ON/OFF or proportional electrovalve
coil; Vmax =Vali; Inom=2A; Imax=6A

K1 22

IN

+ battery

Control board supply voltage; V = Vsupply

K1 23

IN

+ battery key input

Supply voltage of key and coils ; Vkey=Vsupply

K1 24

IN
A/D

not used

- Digital input , N.O., internal pull-up, Vmax(in)=24V;


- Analogue input (0-12V)

K1 25

IN
D

not used

Digital input , N.O., internal pull-up, Vmax(in)=24V

K1 26

IN
A

not used

Analogue input (0-12V)

K1 27

IN
A

not used

Analogue input (0-5V)

K1 28

IN
D

PHASE B of pump
motor encoder

PHASE B signal of the sensor bearing mounted into


the pump motor; internal pull-up; Vin:(0 5V)

K1 29

IN
D

PHASE A of pump
motor encoder

PHASE A signal of the sensor bearing mounted into


the pump motor; internal pull-up; Vin:(0 5V)

K1 30

IN
D

Not used;
PHASE A of an optional encoder

Digital input for an optional encoder, motor; internal


pullup; Vmax(in)=5V;

IN/OUT
A/D

Not used;
PHASE B of an optional encoder

- Digital input for an optional encoder, Vmax(in)=5V;


- Open Collector power output, to command an
ON/OFF electrovalve coil; Vmax =Vsupply; Inom=2A;
Imax=6A

K1 31

K1 32

IN
D

Asynchronous RS232
serial RX input

RX input for asynchronous RS232 serial


communication standard

K1 33

IN
D

PHASE A of left drive


motor encoder

TX output for asynchronous RS232 serial


communication standard

OUT

+ coil main breaker

H line input for CAN (Controller Area Network )


component; presence of internal termination
resistance

OUT

- coil main breaker

L line input for CAN component; presence of internal


termination resistance

K1 36

OUT
A

not used

PHASE B signal of the sensor bearing mounted into


the right drive motor; internal pull-up; Vin:(0 5V)

K1 37

OUT
D

not used

PHASE A signal of the sensor bearing mounted into


the right drive motor; internal pull-up; Vin:(0 5V)

IN

AUX 2

Digital input to activate pump motor auxiliary function


AUX2; N.O., internal pull-up, Vmax(in)=24V

IN

FANS Command (optional)

Open Collector power output, to command fans (or


other devices) Inom = 1A, Imax=3A; Vmax=60V;

not used

Open Collector power output, to command an


ON/OFF
electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A

K1 34

K1 35

K1 38
K1 39

K1 40

IN
A/D

20

Pin
number

Use

K1 41

IN
D

not used

Open Collector power output, to command an ON/OFF


electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A

K1 42

IN
A

not used

Open Collector power output, to command an ON/OFF


electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A

K1 43

IN
A

not used

Open Collector power output, to command an ON/OFF


electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A

K1 44

IN
D

not used

Open Collector power output, to command an ON/OFF


electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A

K1 45

IN
D

not used

PWM supply voltage for electrovalve coils (or similar


devices)

K1 46

IN
D

lift high switch(optional)

Voltage signal of lift critical high switch, N.O., internal


pull-up, Vmax(in)=24V

K1 47

IN
A/D

Not used

- Digital input , N.O., internal pull-up, Vmax(in)=24V;


- Analogue input (0-12V)

K1 48

IN
D

Pedal brake switch

Activation signal for park brake, N.O., internal pull-up,


Vmax(in)=24V

K1 49

IN
A/D

Not used

- Digital input , N.O., internal pull-up, Vmax(in)=24V;


- Analogue input (0-12V)

K1 50

IN
A

lift lever potentiometer voltage

Proportional voltage signal (0-12V), input of lift lever


potentiometer

K1 51

IN
A

Not used

Proportional voltage signal (0-12V)

K1 52

IN
A

Not used

Proportional voltage signal (0-12V)

K1 53

OUT
D

buzzer command

Open Collector power output, to command buzzer


activation; Vmax =24V; Inom=30mA; Imax=100mA.

K1 54

IN
D

tilt switch

Request of tilting, N.O., internal pull-up, Vmax(in)=24V

IN
D

Not used;
PHASE B of an optional
encoder

- Digital input - PHASE B signal for an optional encoder;


internal pullup; Vin:(0 5V)

IN
D

digital input for 3 / 4 wheels


choice;
PHASE A of an optional
encoder

- Digital input to select a lift truck with 3 wheels (Closed )


or 4 wheels (Open);
- PHASE A signal for an optional encoder; internal pull
up; Vin:(0 5V)

K1 57

IN
D

AUX1

Digital input to activate pump motor auxiliary function


AUX1; N.O., internal pull-up, Vmax(in)=24V

K1 - 58

IN
A/D

right drive motor thermal


sensor/ switch

Analogue input (or digital as optional) used for right drive


motor thermal sensor (0-5V); internal pull-up;

K1 59

IN
A/D

left drive motor thermal sensor/


switch

Analogue input (or digital as optional) used for left drive


motor thermal sensor (0-5V); internal pull-up;

K1 - 60

IN
A/D

pump motor thermal sensor/


switch

Analogue input (or digital as optional) used for pump


motor thermal sensor (0-5V)

K1 55

K1 56

Name

Function

21

Pin
number

Use

K1 - 61

IN
A/D

K1 62
K1 63

Name

Function

Not in use

- Digital input , N.O., internal pull-up, Vmax(in)=5V;


- Analogue input (0-5V)

IN
A

steering angle sensor voltage

Proportional voltage signal (0-12V) or (0-5V), used as input


to steering sensor circuit

OUT
D

Not used;
Electrovalve (or alike) command

Open Collector power output, to command an ON/OFF


electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A

OUT
D

Not used;
Electrovalve (or alike)
command

Open Collector power output, to command an ON/OFF


electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A

K1 65

OUT
D

Not used;
Electrovalve (or alike)

Open Collector power output, to command an ON/OFF


electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A

K1 66

OUT
D

Not used;
Electrovalve (or alike)

Open Collector power output, to command an ON/OFF


electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A

K1 67

OUT
A

Not used

Power output, to command a proportional electrovalve coil;


Vmax =Vsupply; Inom=2A; Imax=6A

K1 68

OUT
D

Not used;
Electrovalve (or alike)

Open Collector power output, to command an ON/OFF


electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A

K1 64

NOTES:
D

: digital signal, with boolean values (ON/OFF)

: analogue signal, assuming values in


[Vground -Vmax] range

A/D : signal that could be both analogue and digital


NO : normally open
NC : normally close
IN

: signal used as input

OUT : signal used as output

NOTICE
Remember the controller contains ESD(Electro
Static dischange) sensitive components.
Use appropriate precautions in connecting,
disconnecting and handling it.

22

System Circuit
Power Circuit

If divide greatly composition of electric controller


system of this vehicles, is consisted of 1 Logic
control board, Power Unit (Left Drive, Right Drive,
Pump) 3, Line Contactor 1.
Each power unit controls each motor's speed, logic
control board vehicles situation and driver's select
receiving feedback vehicles control.

23

Actuation Circuit

This circuit supplies power to the Logic Control


Board and the Instrument Panel(Display). It must be
activated before power steering, hydraulics or drive
will operate.

When the seat switch is closed, current will flow


from the logic K1-7 through the seat switch to
controller negative. The logics then activates the
line contactor by allowing current to flow from K1-18
through the line contactor coil (+) and K1-19 the line
contactor coil (-).

When the battery is connected and the key switch is


closed, current flows from battery positive through
the key fuse, key switch, wire #23 to the logic
control board (logic) contactor K1-23.
The logic connection to battery negative is at K1-1.
The logic circuits are powered up to accept voltage
inputs and create voltage outputs whenever the
battery is connected and the key is turned to ON.

With the line contactor tips closed the logics


continues its checks for any Run Time faults. If no
faults are detected the display will indicate the
battery charge level, the power steering (IDLE)
system operates, the pump and drive power circuits
receive battery voltage and the logics receives
battery voltage.

24

Hydraulic Pump Motor Circuit


Only one hydraulic pump motor is used for all power
steering, lift, tilt and auxiliary hydraulic functions. To
activate the pump circuit, the seat switch, key switch
and line contactor must be closed first as explained
in the topic, Actuation Circuit.

Power Steering Circuit


The power steering speed of this vehicles operate
by speed (default 500 rpm) that specify in pump
motor calibration.

Location Components

Lift Control Circuit

(2) Lift Sensor. (3) Magnet.

When the operator pulls the lift lever, magnet (3)


moves closer to the lift sensor (2). The sensor
detects the increasing magnetic field and sends an
increasing voltage to the valve control card. The
input to the logics at K1-50. The logics uses these
changing voltages to determine what speed to
operate the pump motor. The logics then controls
the pump power unit.

1
Location Components
(1) Valve control card.

This control panel accept a linear speed lift signals


and tilt/aux lever signals. The lift control system is
controlled by valve control card (1) mounted at the
top of the control valve.
The drive control card uses a hall-effect transducer
(Lift Sensor) and magnet to sense lift lever
movement. The closer the magnet is to the
transducer the greater the hydraulic pump motor
speed.

25

Thermal protection circuit

Accessory Circuits

Control Panel

Horn Circuit

If the Power Units MOSFETs overheat, a thermal


senders mounted in the MOSFET heatsink will give
a voltage signal to logic. If the temperature is over
than preset value(100C), the Instrument Panel will
display a Run Time diagnostic symbol and E1, E2,
E3. The logics will decrease the speed of the drive
motors and the pump motor. The amount of current
allowed to flow through the MOSFETs is decreased
to permit them to cool. When the heatsink cools off
the truck will return to normal operation. But due to
the reduced speed, acceleration performance will
be decreased. Each error code is stored in memory.

The horn will operate when the battery is connected


and the horn button is pushed. Current ows from
battery positive through horn fuse, horn switch and
horn, back to battery negative.

DC-DC Converter Circuit

Drive Motor
If the drive motor overheats a thermal sensor
mounted in the stator coil of drive motor will warn at
a predetermined temperature (155C). If reach in
overheating temperature, the Instrument Panel will
display a Run Time diagnostic symbol and E4, E5.
To decrease the amount of current allowed to flow
through the drive motor, the logics will reduce the
speed. When the drive motor cools off, the truck will
return to normal operation. Drive system
acceleration performance and top travel speed is
affected by an overheated drive motor. MOTOR
TEMPERATURE will be stored for Drive Motor
overheating in memory.
The 12 volt output of the converter is protected
against short circuits and overloading by an internal
15 amp current limit circuit. A fuse on the converter
protects it from reverse connection of the battery
voltage.

Hydraulic Pump Motor


If the drive motor overheats a thermal sensor
mounted in the stator coil of drive motor will warn at
a predetermined temperature (155C). If reach in
overheating temperature, the Instrument Panel will
display a Run Time diagnostic symbol and E6. To
decrease the amount of current allowed to flow
through the pump motor, the logics will reduce the
speed. When the pump motor cools off, the truck
will return to normal operation. MOTOR
TEMPERATURE will be stored for Pump Motor
overheating in memory.

Notice: Do not connect the 12 volt negative output


of the DC-DC converter to battery negative.
Damage to system components could
occur.
The DC-DC converter changes the lift truck battery
voltage to 12 volts. This 12 volts is used to power
accessories such as floodlights, brakes/side lights
and backup alarms.
The positive of the 12 volt output is common to the
positive of the batter y voltage. The negative of the
12 volt output is pulsed to maintain a steady 12 volt
supply.

26

Testing and Adjusting

Cell Voltage Test

Preparation Tests and Check

With the truck powered up and the pump(Idle) motor


running, measure the voltage at each cell. Normal
voltage should be between 1.95V and 2.12V per cell.
If the voltage on each cell is below 1.95V the battery
must be charged or repaired before continuing to
troubleshoot.

Battery Tests
A weak battery can cause or contribute to problems
in the Logic Control Board and power circuits. Verify
the battery is good before investigating other
possibilities.

NOTE: The indication between cells should not


differ more than 0.05 volts. If it does, the
battery must have an equalizing charge or
be repaired.

1. Verify proper polarity at the battery connector


and the control panel. Positive cable should be
at the line fuse and negative at the negative on
control panel.

Hydrometer Test

2. If the lift truck is operational, perform a battery


load test.

Test each cell of the battery with a hydrometer. If the


specific gravity indication is below 1.140, the battery
must be charged. The battery is fully charged if the
indication is 1.265 to 1.285.

3. If the truck is not operational and the battery is


suspected, perform a cell voltage or specific
gravity test.

NOTE: The indication between cells should not


differ more than .020. If it does, the battery
needs an equalizing charge or needs to be
repaired.

Battery Load Test


1. Turn the range switch on the multimeter to read
battery voltage.
2. Connect the battery.

2
1

Battery Voltage Test.


(1) Positive cable connection.
(2) Negative cable connection.

3. Connect the multimeter leads between positive


(+) cable connection (1), and negative (-) cable
connection (2).
4. In a safe area, operate the hydraulic system,
(hold tilt lever to maximum position
momentarily) while reading the voltage indicated
on the multimeter.
5. If the indication is less than 45.0 volts, the
battery needs to be charged or repaired before
continuing to troubleshoot.

27

Battery Maintenance

6. Keep accurate battery records. Regular battery


readings should be taken with a battery tester or
voltmeter and a written record kept. Specific
gravity and voltage of each cell should be
checked and recorded at least once each month.
This inspection should be made after an
equalizing charge. Readings should never be
taken directly after water has been added.
Records of all battery maintenance should be
made and filed so it will be known which
batteries are being abused or wearing out.

NOTE: It is important that all batteries be charged


and maintained according to the battery
manufacturers instructions.
The care and maintenance of batteries is most
important to maximize battery life and efficient truck
operation. Periodic inspection and service will
increase the life of batteries. Special attention
should be given to the rules that follow:
1. Keep batteries clean at all times. Cleaning will
prevent corrosion, current leakage and shorts to
chassis. Tighten all vent plugs, wash the battery
with water and a brush, then dry with an air
hose. It may be necessary to use a baking soda
solution if water alone will not clean the top of
the battery.

Repairs should be made immediately otherwise the


battery may become damaged. Batteries stored in a
discharged condition may be difficult to recharge
due to sulfate formation.

2. Add enough water to cover the plates before


charging. This will ensure the proper chemical
reaction over the entire plate surface. After
charging is complete, add water until it is about
12.7 mm (.50 in) above the plates. Use distilled
water or water that has tested free from
minerals.

1. Verify all components and wires are in their


proper place. Check fuses, components,
contactor tips, wires and connections. Verify that
they are not burned, broken or loose.

3. Charge the battery correctly. A battery should be


discharged to 80% of its capacity then fully
recharged. It should cool four to eight hours to
allow the voltage to stabilize before being put
back in use. The battery should have an
equalizing charge (an extra three or four hour
charge at a low finish rate) once a month to
make sure all cells are in a fully charged
condition. Properly charged batteries should be
identified to prevent low batteries from being
installed in trucks.

3. Visually check the parking brake switch, the


hydraulic switches and accelerator linkage for
adjustment or interference problems.

Visual Checks

2. Verify there is no mechanical binding or


interference in the contactor.

4. Operation with a low battery must be prevented.


Low battery operation may damage the battery
and will cause higher than normal current in the
electrical system. High current draw due to a
low battery will damage contactor tips and
shorten motor brush life.
5. The battery's maximum temperature is critical.
The electrolyte temperature should never
exceed 43C (110F) either while operating or
charging. Overcharging a battery will cause
over heating and warp the batter y plates.
Maximum battery life will result from maintaining
25C (77F) electrolyte temperature. Most of the
charging equipment is fully automatic but should
be checked periodically to assure proper
working order.

28

Resistance to Chassis Checks


Resistance between any point in the truck wiring
and the chassis should be a minimum of 10,000
ohms or more.
Many malfunctions are caused by shorts to chassis.
Usually, two shorts must exist before a malfunction
will occur. But, since batteries can have chassis
leakage, only one short to chassis in the truck wiring
can cause problems. To prevent problems because
of shorts, do the following:
1. Disconnect the battery and discharge the Power
Uint.
2. Randomly measure any component connection
or wiring connection in respect to the lift truck
chassis for a minimum resistance of 10,000
ohms. Any test point with low resistance must
have the short to chassis removed.
3. Always keep batteries clean to minimize current
leakage to the chassis.
4. Routinely clean the brush dust from the motors.
5. Be sure that all attachments, such as horns and
lights are designed for no chassis connection (a
two wire system).

29

Programmable Parameters
Adjustable Parameters Description
The possibility of interfacing by PC with the system
allows to have an exhaustive real time analysis of
the system working and of the condition of its
components; moreover, you can choose among a
wide range of parameters in order to reach the
optimum operating of the system in compliance with
your needs.
Adjustable parameters are listed below, divided by
functional groups, both for a 36 V and a 48 V
system. We briefly explain whats the meaning of
each programmable parameter, and which is the
effect of its changes in lift truck performance.

30

<48V SYSTEM>
Drive Motor
Parameter
No
5

Deceleration
steering ramp 1

Deceleration
steering ramp 2

26
41

Stop on slop
timer
Drive maximum
current

42

Forward
maximum speed

43

Reverse
maximum speed

44
46
47
48
49
50

Parameter

Drive limitation
maximum speed
Critical height
drive maximum
speed (optional)
Steer limitation
maximum speed
Drive
acceleration
ramp
Drive inversion
ramp
Drive release
ramp

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

rpm/s

10

800

5000

10

rpm/s

1000

10

20

100

100

rpm

1,000

4,500

4,500

50

rpm

1,000

4,500

4,500

50

rpm

500

2,000

2,500

50

Maximum lift truck speed when forks high


is more than critical one

rpm

400

2,000

4,500

50

Maximum speed reference in the angle in


which the internal wheel is mechanically still.

rpm

400

1,500

4,500

50

Lift truck acceleration with accelerator pedal


pressed

rpm/s

400

1,150

2,000

10

Lift truck deceleration in inversion

rpm/s

400

1,200

2,000

10

rpm/s

400

900

2,000

10

rpm/s

400

1,000

2,000

10

rpm

100

300

2,000

mm

300

451

600

rpm/s

10

50

500

Parameter Description
as high it is as quickly the truck decreases
its speed if the truck driver is turning the
wheel quickly
as high it is as quickly the truck decreases
its speed in relation to the drive speed of
truck. This parameter increases the
deceleration ramp while the driver is steering
at high speed.
Without stepping on pedal brake, time that is
doing stop in slope
Drive motors maximum current (expressed
in per cent of high energetic mode value)
Maximum forward lift truck speed with no
speed limitation
(no alarms present and turtle not active)
Maximum reverse lift truck speed with no
speed limitation
(no alarms present and turtle not active)
Maximum lift truck speed with speed
limitation (turtle active)

Lift truck deceleration with accelerator pedal


released
Lift truck deceleration with pedal brake
pressed
If the truck speed is greater then this
threshold, the speed reference becomes a
parabolic function of the accelerator
potentiometer voltage.

51

Pedal brake ramp

52

Creep speed

53

Diameter of drive
tyres

Drive tyre's diameter

59

Partial release
ramp

Parameter that softens the drive inversion


ramp if the traction motors are working with
low rpm

93

Power mode
(E-S-H, limitations)

Power mode setting up state

94

Slow speed

95

British unit

96

Display brightness

97

E-S-H enable

98

Time meter /
Odometer on
display

If parameter is set to1, speed limitation is


active; otherwise lift truck speed is managed
as usual.
If parameter is set to 1, values are
expressed in British unit, otherwise in
international ones.
Display's brightness adjustment
If this parameter is set to 1, it is possible to
change the value of the power mode with
the display
If parameter is set to 1, odometer indication
appears on display ; otherwise display
shows the hour meter.

31

10

digit

Accelerator signal 1 = E mode,


2 = S mode,
3 = H mode

digit

Disable = 0, Enable = 1

digit

Normal = 0, British unit = 1

digit

digit

Disable = 0, Enable = 1

digit

Timer meter = 0, Odometer = 1

Sensors and Potentiometers


Parameter
No
23
24
33
34
18
32
19
20

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

mV

200

1,000

4,500

10

mV

3,000

5,000

12,000

10

mV

200

1,000

12,000

10

mV

2,000

7,500

12,000

10

mV

500

1,200

11,500

10

mV

3,000

11,500 12,000

10

mV

500

10,030 11,500

10

Steering voltage with wheels straight ahead

mV

500

6,300

11,500

10

Parameter Description

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

Maximum lift speed

rpm

1,500

3,200

4,500

50

Pump motor speed with lift function active


Pump motor speed with lateral shift function
(1st auxiliary) active
Pump motor speed with 2nd auxiliary
function active
Pump motor speed with 3rd auxiliary
function active

rpm

500

900

2,000

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

Minimum lift speed

rpm

500

700

1,500

50

Pump motor speed when steering


Pump motor speed with direction command
lever not in neutral, acceleration pressed
and no pump command active

rpm

400

500

800

10

rpm

200

300

500

10

rpm/s

1,000

7,000

10,000

10

rpm

1000

7000

10000

10

20

100

100

10

62

100

rpm

500

500

4500

50

Parameter

Parameter Description

Accelerator pedal
minimum value
Accelerator pedal
maximum value
Lift sensor
minimum value

Accelerator sensor voltage with pedal


released
Accelerator sensor voltage with pedal
completely pressed

Lift sensor middle


value
Steering sensor
minimum value
Lift sensor
maximum value
Steering sensor
maximum value
Steering sensor
middle value

Lift sensor voltage with lift lever released


Lift lever potentiometer voltage to which the
lifting becomes proportional to the shift of the
lever
Steering sensor voltage with wheels turned
on left
Lift sensor voltage with lift lever completely
pressed
Steering sensor voltage with wheels turned
on right

Pump Motor
Parameter
No

70

Lift maximum
speed
Tilt speed
Lateral shift (AUX
1 function) speed
AUX 2 function
speed
AUX 3 function
speed
Lift minimum
speed
Hydro speed

71

Hydro idle speed

63
64
65
66
67
68

72
73
61
62
69

Parameter

Pump
acceleration ramp
Pump
deceleration ramp
Lift maximum
current
Auxiliary
maximum current
High lift 1 switch
lift max speed

Lift acceleration
Pump motor deceleration after the end of a
command
Pump motor maximum current with lift
function active
Pump motor maximum current with lift lever
released
Maximum pump motor speed with forks
above the critical height

32

Timers
Parameter
No

Parameter

Parameter Description

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

Time interval between seat switch opening


and drive and pump motors stopping
Time delay between last command given to
a drive or pump motor and chat mode
signalling
Time interval when pump motor works (with
hydro speed) after the end of a command

10

10

20

Parameter Description

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

Minimum battery voltage necessary to reset


battery discharged voltage alarm

V*10

464

470

501

Parameter

Parameter Description

Unit

Maintenance time
Maintenance time
inserting enable

Maintenance period decision

Mini
mum
0

Def
ault
0

11

Seat switch delay

12

Chat time

13

Hydro time

Battery
Parameter
No
9

Parameter
Battery reset
value

Program Service
Parameter
No
99
14

Maintenance time inserting enable

33

h
digit

Maxi Varia
mum tion
10000 100

Disable = 0, Enable = 1

<36V SYSTEM>
Drive Motor
Parameter
No
5

Deceleration
steering ramp 1

Deceleration
steering ramp 2

26

Stop on slop timer

41

Drive maximum
current

42

Forward
maximum speed

43

Reverse
maximum speed

44
46
47
48
49
50

Parameter

Drive limitation
maximum speed
Critical height
drive maximum
speed (optional)
Steer limitation
maximum speed
Drive acceleration
ramp
Drive inversion
ramp
Drive release
ramp

Parameter Description
as high it is as quickly the truck decreases
its speed if the truck driver is turning the
wheel quickly
as high it is as quickly the truck decreases
its speed in relation to the drive speed of
truck. This parameter increases the
deceleration ramp while the driver is steering
at high speed.
Without stepping on pedal brake, time that is
doing stop in slope
Drive motors maximum current (expressed
in per cent of high energetic mode value)
Maximum forward lift truck speed with no
speed limitation
(no alarms present and turtle not active)
Maximum reverse lift truck speed with no
speed limitation
(no alarms present and turtle not active)
Maximum lift truck speed with speed
limitation (turtle active)
Maximum lift truck speed when forks high
is more than critical one
Maximum speed reference in the angle in
which the internal wheel is mechanically still.
Lift truck acceleration with accelerator pedal
pressed
Lift truck deceleration in inversion
Lift truck deceleration with accelerator pedal
released
Lift truck deceleration with pedal brake
pressed
If the truck speed is greater then this
threshold, the speed reference becomes a
parabolic function of the accelerator
potentiometer voltage.

51

Pedal brake ramp

52

Creep speed

53

Diameter of drive
tyres

Drive tyre's diameter

59

Partial release ramp

Parameter that softens the drive inversion


ramp if the traction motors are working with
low rpm

93

Power mode (ES-H, limitations)

Power mode setting up state

94

Slow speed

95

British unit

96

Display
brightness

97

E-S-H enable

98

Time meter /
Odometer on
display

If parameter is set to1, speed limitation is


active; otherwise lift truck speed is managed
as usual.
If parameter is set to 1, values are
expressed in British unit, otherwise in
international ones.
Display's brightness adjustment
If this parameter is set to 1, it is possible to
change the value of the power mode with
the display
If parameter is set to 1, odometer indication
appears on display ; otherwise display
shows the hour meter.

34

Unit

Mini
mum

Def
ault

Maxi
mum

Vari
ation

rpm/s

10

800

5000

10

rpm/s

1000

10

20

100

100

rpm

1,000

3,800

3,800

50

rpm

1,000

3,800

3,800

50

rpm

500

2,000

2,500

50

rpm

400

2,000

3,800

50

rpm

400

1,500

3,800

50

rpm/s

400

1,150

2,000

10

rpm/s

400

1,200

2,000

10

rpm/s

400

900

2,000

10

rpm/s

400

1,000

2,000

10

rpm

100

300

2,000

mm

300

451

600

rpm/s

10

50

500

10

digit

Accelerator signal 1 = E mode,


2 = S mode,
3 = H mode

digit

Disable = 0, Enable = 1

digit

Normal = 0, British unit = 1

digit

digit

Disable = 0, Enable = 1

digit

Timer meter = 0, Odometer = 1

Sensors and Potentiometers


Parameter
No
23
24
33
34
18
32
19
20

Parameter
Accelerator pedal
minimum value
Accelerator pedal
maximum value
Lift sensor
minimum value
Lift sensor middle
value
Steering sensor
minimum value
Lift sensor
maximum value
Steering sensor
maximum value
Steering sensor
middle value

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

mV

200

1,000

4,500

10

mV

3,000

5,000

12,000

10

mV

200

1,000

12,000

10

mV

2,000

7,500

12,000

10

mV

500

1,200

11,500

10

mV

3,000

11,500 12,000

10

mV

500

10,030 11,500

10

Steering voltage with wheels straight ahead

mV

500

6,300

11,500

10

Parameter Description

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

Maximum lift speed

rpm

1,500

3,200

4,500

50

Pump motor speed with lift function active


Pump motor speed with lateral shift function
(1st auxiliary) active
Pump motor speed with 2nd auxiliary
function active
Pump motor speed with 3rd auxiliary
function active

rpm

500

900

2,000

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

Minimum lift speed

rpm

500

700

1,500

50

Pump motor speed when steering


Pump motor speed with direction command
lever not in neutral, acceleration pressed
and no pump command active

rpm

400

500

800

10

rpm

200

300

500

10

rpm/s

1,000

7,000

10,000

10

rpm

1,000

7,000

10,000

10

20

100

100

10

62

100

rpm

500

500

4500

50

Parameter Description
Accelerator sensor voltage with pedal
released
Accelerator sensor voltage with pedal
completely pressed
Lift sensor voltage with lift lever released
Lift lever potentiometer voltage to which the
lifting becomes proportional to the shift of the
lever
Steering sensor voltage with wheels turned
on left
Lift sensor voltage with lift lever completely
pressed
Steering sensor voltage with wheels turned
on right

Pump Motor
Parameter
No

70

Lift maximum
speed
Tilt speed
Lateral shift (AUX
1 function) speed
AUX 2 function
speed
AUX 3 function
speed
Lift minimum
speed
Hydro speed

71

Hydro idle speed

63
64
65
66
67
68

72
73
61
62
69

Parameter

Pump acceleration
ramp
Pump deceleration
ramp
Lift maximum
current
Auxiliary
maximum current
High lift 1 switch
lift max speed

Lift acceleration
Pump motor deceleration after the end of a
command
Pump motor maximum current with lift
function active
Pump motor maximum current with lift lever
released
Maximum pump motor speed with forks
above the critical height

35

Timers
Parameter
No

Parameter

11

Seat switch delay

12

Chat time

13

Hydro time

Parameter Description
Time interval between seat switch opening
and drive and pump motors stopping
Time delay between last command given to
a drive or pump motor and chat mode
signalling
Time interval when pump motor works (with
hydro speed) after the end of a command

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

10

10

20

Battery
Parameter
No
9

Parameter

Parameter Description

Unit

Mini
mum

Def
ault

Maxi
mum

Vari
ation

Battery reset
value

Minimum battery voltage necessary to reset


battery discharged voltage alarm

V*10

344

356

373

Parameter

Parameter Description

Unit

Maintenance time
Maintenance time
inserting enable

Maintenance period decision

Mini
mum
0

Def
ault
0

Program Service
Parameter
No
99
14

Maintenance time inserting enable

36

h
digit

Maxi Vari
mum ation
10000 100

Disable = 0, Enable = 1

E-S-H Energetic Modes Parameters


Some parameters value depend on selected energetic mode: in following tables are listed parameter default
values for each operating mode (Economic, Standard and High)
In case of 48 V system:
PARAMETER

ECONOMIC MODE

STANDARD MODE

HIGH MODE

62

76

100

Maximum forward speed [rpm]

3000

3500

4500

Maximum reverse speed [rpm]

3000

3500

4500

Acceleration proportional to load

20

20

20

Drive acceleration ramp [rpm/s]

700

800

1150

Drive inversion ramp [rpm/s]

600

900

1200

Drive release ramp [rpm/s]

600

850

1000

Lift maximum current

75

80

100

2500

2750

2950

ECONOMIC MODE

STANDARD MODE

HIGH MODE

62

76

100

Maximum forward speed [rpm]

2800

3300

3800

Maximum reverse speed [rpm]

2800

3300

3800

Acceleration proportional to load

20

20

20

Drive acceleration ramp [rpm/s]

700

900

1100

Drive inversion ramp [rpm/s]

700

900

1100

Drive release ramp [rpm/s]

700

900

1200

Lift maximum current

75

80

100

1600

2500

2950

Maximum drive current

Maximum lift speed [rpm]v

In case of 36 V system:
PARAMETER
Maximum drive current

Maximum lift speed [rpm]v

37

Some Functions Management


Static Return to Off

Buzzer Management

To ensure operator safety, when switching on the lift


truck, a number of inputs are analysed; if one of
these signals indicates a wrong start condition or
any likely danger situation, main breaker is not
closed and all system modes are disabled.

The buzzer is activated in the following cases:


1. Alarm condition
2. Switching your device on you find wrong start
conditions:
a. Accelerator pedal pressed or directional
(forward or reverse) switch inserted.
b. One of pump motor command levers not
released.
3. Parhig lever is pot pulling and no one is in the
seat.

If the anomalous input assumes the correct value,


main breaker is closed and its now possible go on
with usual truck management.
The analysed inputs are the followings:
1. Seat switch (the closing is checked)
2. Directional switch (the insertion of a selected
direction is checked)
3. Accelerator (the system controls if the pedal is
pressed)

B.D.I. Measure Management


To measure battery voltage one of the following
conditions must be true :
1. Chat mode
2. Lift with drive and pump motors still
3. Drive motors still and pump motor working to its
minimum speed (idle speed)

Pump Motor Modes


Control of a command lever moving when
starting

If this conditions are fulfilled for at least 2 seconds,


battery voltage begins to be evaluated, using a low
pass filtering. After 15 seconds of voltage
processing, the filter output signal is uses to
evaluate the battery charge level.

G
When switching on the key, in case an hydraulic
command is active, the lift, lateral shift, tilt and
auxiliary functions are disabled.

If the battery is discharged for at least two


consecutive sampling periods, low battery voltage
alarm is signalled and following limitations are
activated:
1. Limitation of drive motor speed and maximum
torque
2. Limitation of maximum pump motor speed
3. Lift, tilt and auxiliary functions are disabled

Only when the activated lever and/or the requested


command assumes the released position, operator
can return to the usual operative condition.
Pump motor commands management Switching on
the key, the motor works at minimum speed (idle
speed, adjustable by PC).
If the operator moves a command lever or the
steering wheel, the speed takes on a value that can
be adjusted, depending on the type of the active
command and on the possible presence of
limitations (caused by thermal or low battery alarms).

If the alarm is observed switching on the key, the


first received pump command is keep active for 3
seconds and then is disabled. Battery voltage must
exceed an adjustable limit value (Battery reset value,
see Chapter4) to return to normal operative
condition after a low battery voltage alarm.

After the active command is switched off, motor


speed assumes idle speed value for an adjustable
time (idle time), relating to the start of hydro guide; if
no command is activated during this period of time, the
speed returns to no operation value (0 rpm)

38

Diagnostic and Troubleshooting


General Description

Alarm List

Diagnostic information about anomalous working


condition is provided by COMPACT display or by
PC (using EYE software utility).
This chapter explains how to manage any detected
fault and how to return to a normal working
situation; suggestions to be applied in case of each
possible alarm are listed in a growing order, i.e.
from the least to the most serious one.

Maximum battery voltage


1.
2.
3.
4.

If an alarm condition is detected by main board,


software control inhibits some lift truck functions, to
guarantee operator safety.
Anomalous working conditions are indicated by
different alarm levels, classified as follows,
depending on their effects on the system:

If the controller detects such a fault, refer to


following troubleshooting procedure:
1. Such an alarm can be caused also by the
presence of regeneration currents; when lift
truck is on release or reverse braking ramp,
motors work as generators, and battery voltage
can exceed overvoltage limit. In a case like that,
the battery condition should be verified ( if the
battery is new it is necessary to do some
charge-discharge cycles before reaching the
rating declared by the constructor) or has a high
internal resistance. If the case is the second
and it is not possible to change the battery, the
solution may be to reduce the release and
reverse braking ramp.
2. Incorrect wiring to battery positive or negative
terminals.
3. Verify if battery is still in good conditions.
4. Replace the logic.

1. Main breaker is opened and both pump and


drive motors are stopped; buzzer and red led on
the upper right corner of COMPACT display,
signal the presence of such an alarm.
2. Pump and drive motors are stopped.
3. Drive motors speed is limited to 2000 rpm.
Moreover, in presence of such an alarm, first
command given to pump motor is inhibited 3
seconds after activation, together with all pump
motor functions (except hydro functions).
4. Drive and pump motors speed is limited to 800
rpm; buzzer signals the presence of such an
alarm.
5. Drive motors speed is limited to 800; over
temperature alarms are signalled by. buzzer
activation.
6. Pump motor speed is limited to 800; buzzer
signals the presence of such an alarm.
7. No effects on system performance.

Minimum battery voltage


1.
2.
3.
4.

NOTICE
If more than one faulty condition is detected,
Compact displays shows alarm code referring to
the most serious one (the one characterized by
lower alarm level).

Eye alarm code: 2


Display alarm code: F1
Alarm level: 1
Alarm cause: battery voltage, measured by an
internal circuit, is lower than following levels :
a. 24 V , in case of systems working at 36 V

b. 24 V , in case of systems working at 48V

Following section gives useful suggestions covering


a wide range of possible faults, listing
corresponding alarm cause identified by its alarm
code.

Eye alarm code: 1


Display alarm code: F0
Alarm level: 1
Alarm cause: battery voltage, measured by a
circuit inside control unit, exceeds following
levels:
a. 63 V, in case of systems working at 36 V
b. 63 V, in case of systems working at 48 V

39

In case of minimum battery voltage alarm, follow


these steps:
1. Incorrect wiring to battery, or corroded positive
or negative terminals;
2. Verify battery conditions: if the electrolyte inside
is partially exhausted, an under voltage alarm
can sometimes be detected from the controller;
even in case of low battery charge (<10%), high
current rates (i.e. both pump and drive motors
working in full load conditions) could cause an
under voltage alarm, in particular in presence of
an exhausted battery.
3. Replace the logic.

Eeprom alarm

Pedal trimmer fault

Pre-charge capacitors low voltage


alarm (Capacitors not charged)

1.
2.
3.
4.

1.
2.
3.
4.

In case of alarm follow this procedure:


1. Load default values for eeprom variables, both
using PC with serial communication software
and Instrument;
2. Replace the logic.

Eye alarm code: 3


Display alarm code: F2
Alarm level: 2
Alarm cause: voltage measured on accelerator
circuit exceeds the value calculated averaging
calibration and reachable voltages; moreover,
start switch seems to be open.

Eye alarm code: 6


Display alarm code: A
Alarm level: 1
Alarm cause: voltage level of pre-charge
capacitors is less then 70 % of nominal battery
level.
It could happen, in example, if the inverter is
working with main breaker open.
Capacitors voltage decreases cause energy spent
to keep motors in motion.
1.
2.
3.
4.

In case of such an alarm, follow these


troubleshooting steps :
1. Verify if the potentiometer initial set-up is
correct; if not, repeat calibration procedure. (You
can use both PC with serial com-munication
software and Instrument).
2. Verify if the following 68 ways connector
terminals are correctly wired to their
correspondent inputs in potentiometer circuit:
a. K1-14 (5 V)
b. K1-15 (ground)
c. K1-10 (pedal input A)
d. K1-5 (pedal input B)
3. In case of correct wiring, replace the
potentiometer itself.
4. Replace logic

Eye alarm code: 5


Display alarm code: F
Alarm level: 1
Alarm cause: eeprom does not work properly, or
one of memorised values is out of correct limits.

In case of alarm follow this procedure:


1. Verify if main breaker coil and power terminals
are in good conditions;
2. Verify if supply lines power fuse is damaged;
3. Verify if main breaker coils are correctly wired to
their correspondent inputs :
a. K1-18 (positive terminal)
b. K1-19 (negative terminal)
4. Replace main breaker;
5. Replace logic.

40

Inverter desaturation or overcurrent


alarm

Pump motor inverter overtemperature


1.
2.
3.
4.

1. Eye alarm code:


8 for right drive motor power module
24 for pump motor power module
25 for left drive motor power module
2. Display alarm code:
F3 for right drive motor power module
F4 for pump motor power module
F5 for left drive motor power module
3. Alarm level: 1
4. Alarm cause: actual current exceeds limits
929A

In case of alarm follow this procedure:


1. Alarm could be caused by ineffective temperature dissipation. Verify thermal coupling
between inverter block and aluminium plate,
and between aluminium plate and truck ballast.
The presence of a correct amount of thermal
grease in the coupling is essential to ensure an
efficient heat exchange;
2. Replace cable connecting the output CN4 of the
logic to the pump inverter;
3. If temperature readings seem too high in
function of total time interval of lift truck using,
replace pump inverter causing the alarm. You
can read temperature measures using
Instrument Panel display or EYE
communication software.
4. Replace logic.

In case of alarm follow this procedure:


1. With such an alarm present when you turn on
lift truck, disconnect the power cable between
the malfunctioning inverter and the
corresponding motor (first, turn off the system,
of course).
If turning lift truck on again, alarm is not active,
then:
1. Replace the cable connecting logic and inverter.
2. Replace the inverter;
3. Replace logic.
If turning lift truck on again, alarm is active,
then :
1. Replace the inverter;
2. Replace the motor.

Inverter capacitors pre-charge too fast


1.
2.
3.
4.

Eye alarm code: 9


Display alarm code: A
Alarm level: 1
Alarm cause: pre-charge capacitors voltage
increases too fast when you turn the system on.

In case of too fast pre-charge alarm, follow this


procedure:
1. Replace main breaker.
2. Replace cable connecting the CN1 output of the
logic with the corresponding
3. Inverter;
4. Replace the inverter connected with the
CN1output of control board replace logic

Eye alarm code: 10


Display alarm code E3:
Alarm level: 6
Alarm cause: the inverter temperature
(measured with a temperature probe), exceeds
100 C

41

Capacitors too charged on start


1.
2.
3.
4.

Drive motor overtemperature

Eye alarm code: 11


Display alarm code: A
Alarm level: 1
Alarm cause: when you turn on the system,
capacitors are not completely discharged by
pump motor. In fact, if you turn suddenly on the
lift truck, after a turning off, capacitors voltage
level is too high. You have to discharge them
before checking the presence of any fault (both
of capacitors and of logic)

1. Eye alarm code:

13 for right drive motor


19 for left drive motor
2. Display alarm code: E4 for right drive motor
E5 for left drive motor
3. Alarm level: 5
4. Alarm cause: The measure of drive motor
temperature exceeds 155 C.
In case of alarm, follow this procedure:
Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
operating mode) you have to measure a
resistance of about 10 kohm between the two
wires of the temperature sensor (execute the
measure at ambient temperature of 25C). If the
measure is not correct it is necessary to replace
the temperature sensor.
2. Disconnect the temperature sensor and check
the wiring insulation between signal wire and
ground wire (towards logic);
3. Replace logic.

In case of alarm follow this procedure:


1. Verify the correctness of wiring from pump
motor and relative inverter;
2. Replace cable connecting the output CN4 of the
logic with the corresponding inverter;
3. Replace the inverter connected to CN4 output
of the logic;
4. Verify if main breaker has stuck closed
terminals: in such a case replace it;
5. Replace the cable connecting the output CN1 of
the logic to the right drive motor inverter: a
defective cable could give a wrong measure for
capacitors voltage;
6. Replace the right drive inverter;
7. Replace logic.

Presence of alarm with hot motors:


1. If temperature value (you can read it from
Instrument or via PC) seems correct, verify if
fans (if present) work properly; fault is caused
by on inefficient motor refreshing, or by
operating out of nominal maximum ranges.

Low battery alarm


1.
2.
3.
4.

Eye alarm code: 12


Display alarm code: EL
Alarm level: 3
Alarm cause: battery voltage level is lower than
minimum charge value expected, referred to
table 2 (for 36V system) and table 3 (for 48V
system) in Instrument user manual.

In case of low battery alarm, follow this


procedure:
1. Measure battery voltage with a tester and, if
different from the value reported on Instrument,
replace logic;
2. Otherwise recharge battery.

42

Pump motor overtemperature


1.
2.
3.
4.

Main breaker fault

Eye alarm code: 14


Display alarm code: E6
Alarm level: 6
Alarm cause: The measure of pump motor
temperature exceeds 155 C.

1.
2.
3.
4.

In case of alarm follow this procedure:


1. Replace main breaker
2. Replace logic.

In case of alarm follow this procedure:


Presence of alarm with cold motors:
1. With a handheld multimeter in resistance
operating mode, you have to measure about
10kohm at ambient temperature of 25C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature sensor.
2. Disconnect the temperature sensor and check
the wiring insulation between signal wire and
ground wire (towards logic);
3. Replace logic.

Watchdog timer alarm


1.
2.
3.
4.

Eye alarm code: 18


Display alarm code: F
Alarm level: 1
Alarm cause: improper communication between
DSPs present on logic, or/and defective logic.

In case of alarm follow this procedure:


1. Using EYE program interface, try to program
control board flash memory;
2. Replace logic.

Presence of alarm with hot motors:


1. If temperature value (you can read it from
Instrument panel or via PC) seems correct,
verify if the motor stator case are clean

Motor current offset alarm


1. Eye alarm code:

15 for right drive motor


16 for left drive motor
36 for pump motor
2. Display alarm code: F6 for right drive motor
F7 for left drive motor
F8 for pump motor
3. Alarm level: 1
4. Alarm cause: non-zero phase currents when
you turn lift truck on.
In case of motor current offset alarm, follow this
procedure:
1. Replace the cable connecting the
malfunctioning inverter to logic.
2. Replace inverter.
3. Replace logic.

Eye alarm code: 17


Display alarm code: 17
Alarm level: 1
Alarm cause: overcurrent on main breaker coil.

43

Drive motor inverter overtemperature

Serial communication alarm

1. Eye alarm code:

20 for right drive motor


22 for left drive motor
2. Display alarm code: E1 for right drive motor
E2 for left drive motor
3. Alarm level: 5
4. Alarm cause: inverter temperature, measured
with a probe, exceed 100 C.

1.
2.
3.
4.

In case of alarm follow this procedure:


1. Alarm could be caused by ineffective temperature dissipation; verify thermal coupling
between inverter block and aluminium plate and
between aluminium plate and truck ballast. The
presence of the correct amount of thermal
grease in the coupling are essential to ensure a
correct heat exchange;
2. Replace cable connecting the output CN1 ( for
right drive motor) or CN2 ( for left drive motor)
of the logic to the corresponding inverter;
3. If temperature readings seem too high in
function of total time interval of lift truck using,
replace inverter unit causing the alarm. You can
read temperature measures using Instrument
Panel display or EYE communication
software.
4. Replace logic.

In case of alarm follow this procedure:


1. Program pump and drive DSP again; maybe
software present in flash memory was corrupted.
2. Replace logic.

Eye alarm code: 21


Display alarm code: F
Alarm level: 1
Alarm cause: error in serial communication
between the two DSP; DSP present on main
board make a mutual software control, to insure
fast diagnosis of such a fault.

Alarm on 5 V encoder voltage


1.
2.
3.
4.

Eye alarm code: 37


Display alarm code: FA
Alarm level: 1
Alarm cause: K1-14 terminal (5 V output)
voltage is lower than 4.3 V.

In case of alarm follow this procedure:


1. Verify if 5 V output is grounded, cause an
incorrect encoder wiring.
2. Verify if 5 V output is grounded, cause any
encoder malfunction. In that case, replace the
defective one.
3. Replace logic.

Alarm on 12 V output voltage


1.
2.
3.
4.

Eye alarm code: 38


Display alarm code: FH
Alarm level: 1
Alarm cause: K1-11 terminal (12 V output)
voltage is lower than 10.5 V.

In case of an alarm on 12 V output voltage,


follow this procedure:
1. Verify if 12 V output is grounded, cause an
incorrect wiring to:
a. Steering sensor
b. Buzzer
c. Display
2. Replace defective device;
3. Replace logic.

44

Pump motor commands active on


start

Wrong start
1. Eye alarm code: 64
2. Eye alarm code: EE
3. Alarm level: warning; main breaker is opened
and pump and drive motors are stopped.
4. Alarm cause: when you start working, you find
accelerator pedal pressed or a forward/ reverse
switch active.

1. Eye alarm code: 50


2. Display alarm code: FL
3. Alarm level: warning; while the fault condition is
active, all pump motor functions (except hydro
functions) are inhibited.
4. Alarm cause: you find a pump motor command
active when you turn your system on.

In case of alarm follow this procedure:


1. Verify if a switch was active or the pedal
pressed, when you turn on the lift truck;
2. Verify if start, forward or reverse switches are
stuck close;
3. Verify if pedal circuit voltage exceeds 1/3 its
maximum range (measured in Volt);
4. Replace logic.

In case of alarm follow this procedure:


1. Before starting to operate, turn off any active
command (both levers and switches);
2. Be sure that lift, tilt and auxiliary command
switches, are not active;
3. Replace logic.

Seat switch open on start

Encoder alarm

1. Eye alarm code: 63


2. Display alarm code: EE (flashing)
3. Alarm level: warning; main breaker is opened
and pump and drive motors are stopped.
4. Alarm cause: when you start working, you find
seat switch open, or, after the main breaker is
closed, the seat switch remains opened for at
least seat switch delay s.

1. Eye alarm code:


74 (for right drive motor encoder)
75 (for left drive motor encoder)
2. Display alarm code:
Fc (for right drive motor encoder)
Fd (for left drive motor encoder)
3. Alarm level: 1
4. Alarm cause: an encoder channel is
disconected, and motor is working.

In case of alarm follow this procedure:


1. Verify if seat switch is defective;
2. Replace logic.

In case of alarm follow this procedure:


1. Verify if the encoder is correctly connected to:
a. Motor itself
b. Ground : K1- 15 terminal
c. + 5 V: K1- 14 terminal
d. A channel:
K1- 37 terminal (for right drive motor
encoder)
K1- 17 terminal (for left drive motor encoder)
e. B channel:
K1- 36 terminal (for right drive motor
encoder)
K1- 16 terminal (for left drive motor
encoder);
2. If correctly wired, replace the encoder;
3. Replace logic.

45

Alarm of motor thermal sensor

CRC(Cyclic Redundancy Check) fault


alarm

1. Eye alarm code:


77 (for right drive motor thermal sensor)
78 (for left drive motor thermal sensor)
79 (for pump motor thermal sensor).
2. Display alarm code:
77 (for right drive motor thermal sensor)
78 (for left drive motor thermal sensor)
79 (for pump motor thermal sensor).
3. Alarm level: 7
4. Alarm cause: Temperature difference between
any two of the 3 motors results greater than
70 C

1.
2.
3.
4.

In case of alarm follow this procedure:


1. Restore eeprom with EYE application software,
using the RESTORE item present in main
page
2. If alarm is still present, replace logic.

In case of alarm, follow this procedure:


1. Verify if the wiring is correct;
2. Replace the sensor;
3. Replace logic.

Bank CRC(Cyclic Redundancy Check)


restored
1.
2.
3.
4.

Alarm of a inverter temperature


thermal sensor
1. Eye alarm code:
80 (for right drive motor power module sensor)
81 (for left drive motor power module thermal
sensor)
82 (for pump motor power module thermal
sensor)
2. Display alarm code:
80 (for right drive motor power module thermal
sensor)
81 (for left drive motor power module thermal
sensor)
82 (for pump motor power module thermal
sensor)
3. Alarm level: 7
4. Alarm cause: Temperature difference between
any two of the 3 inverters is greater than 70C.

Eye alarm code: 84


Display alarm code: 84
Alarm level: warning
Alarm cause: there was an eeprom restore,
caused by a CRC(Cyclic Redundancy Check)
alarm.

In case of alarm follow this procedure:


1. Switch on the system and the turn it on again

Steering sensor alarm


1.
2.
3.
4.

Eye alarm code: 91


Display alarm code: F9
Alarm level: 5
Alarm cause: steer circuit voltage is out of
nominal range.

In case of a steering sensor alarm follow this


procedure:
1. Verify correctness of wiring with :
a. K1-11 (12 V),
b. K1-15 (ground)
c. K1- 62 (steering sensor input);
2. If correctly wired, replace steering sensor;
3. Replace logic.

In case of alarm follow this procedure:


1. Check the wiring connecting logic and inverter;
2. Replace the inverter;
3. If alarm is still present, replace logic.

Eye alarm code: 83


Display alarm code: 83
Alarm level: 1
Alarm cause: Faulty eeprom or mismatching
software release.

46

Capacitors pre-charge too slow


1.
2.
3.
4.

Eye alarm code: 98


Display alarm code: A
Alarm level: 1
Alarm cause: pre-charge capacitor voltage
grows too slowly, when you turn on the system.

In case of alarm follow this procedure:


1. Replace cable connecting the CN1 output of the
logic with the corresponding inverter
2. Replace the inverter connected with CN1 output
of the logic;
3. Replace logic;

Capacitors pre-charge timeout


1.
2.
3.
4.

Eye alarm code: 99


Display alarm code: A
Alarm level: 1
Alarm cause: pre-charge capacitor voltage
grows too slowly, when you turn on the system.

In case of alarm follow this procedure:


1. Replace cable connecting the CN1 output of the
logic with the corresponding inverter
2. Replace the inverter connected with CN1 output
of the logic;
3. Replace logic;

47

Troubleshooting Problem List


Problem #
TROUBLESHOOTING PROBLEM LIST
1
CVMS doesnot work,with no lift truck operation.
2
CVMS doesnot work at all, lift truck operation normal.
Display protion of CVMS seems random or wrong.
3
Lift truck operation normal.
4
Direction switch circuit defect.
5
Lift sensor circuit defect.
6
Tilt switch circuit defect.
7
Auxiliary switch circuit defect.
8
Park brake switch circuit defect.
9
Pedal brake switch circuit defect.
10
Display="E1", The max speed of drive motor is reduced.
11
Display="E2", The max speed of drive motor is reduced.
12
Display="E3", The max speed of pump motor is reduced.
13
Display="E4", The max speed of drive motor is reduced.
14
Display="E5", The max speed of drive motor is reduced.
15
Display="E6", The max speed of pump motor is reduced.
Display="EL", The max speed and max torque of drive &pump motor is reduced
16
to minimum value
17
Display="EE", No left truck operation
18
Display="EE(Flash)", No left truck operation
19
Display="F", No lift truck operation
20
Display="F0", Left truck operation
21
Display="F1", Left truck operation
22
Display="F2", No left truck operation
23
Display="F3", No left truck operation
24
Display="F4", No left truck operation
25
Display="F5", No left truck operation
26
Display="F6", No left truck operation
27
Display="F7", No left truck operation
28
Display="F8", No left truck operation
29
Display="F9",The max speed of pump motor is reduced.
30
Display="FA", No left truck operation
31
Display="Fc", No left truck operation
32
Display="Fd", No left truck operation
33
Display="FH", Left truck operation
34
Display="FL", No left truck operation
35
Display="A", No lift truck operation
36
Display="60", Lift truck operation
37
Display="77", Lift truck operation
38
Display="78", Lift truck operation
39
Display="79", Lift truck operation
40
Display="80", Lift truck operation
41
Display="81", Lift truck operation
42
Display="82", Lift truck operation
43
Display="83", No lift truck operation
44
Display="84", No lift truck operation
45
Display does work normal,Lift truck operation abnormal.

48

EYE Abrm code


20
22
10
13
19
14
12
64
63
5, 18, 21
1
2
3
8
24
25
15
16
36
91
21, 37
74
75
38
50
6, 9, 11, 98, 99
60
77
78
79
80
81
82
83
84
-

PROBLEM 1
Central Vehicle Monitoring System (CVMS) does not work,
with no lift truck operation.

POSSIBLE CAUSE
Battery polarity not correct on control panel;
Key fuse open circuit; Key switch defect; Logics

CHECKS
With battery connected, check control panel battery connections for correct polarity.
Positive battery connected to line fuse and negative battery connected to B - on controller.
If correct
If not correct

Make correction to cables.

Push horn button to close horn switch.


Horn work

Horn does not work

Disconnnect battery and check the horn


fuse for continuity.
Continuity

No continuity

Check for shorts and


replace fuse.

Close key switch. Measure voltage on K1-23


Battery
Voltage

Measure voltage on horn (wire #90) with


depressing the horn switch.
Check continuity the negative wire of horn

Less than
Battery voltage

Battery
Voltage

Less than
Battery voltage

Replace logics.
Replace horn or
check the battery.
Replace key switch or repair broken wire
#23 between key switch and K1-23.

49

Repair or replace
open wire

PROBLEM 2
CVMS does not work at all, lift truck operation normal.
If only part of CVMS works.

POSSIBLE CAUSE
Open circuit from K1-11 to CVMS connector PIN 8;
Open circuit from K1-15 to CVMS connector PIN 7;
CVMS defect.

CHECKS
Make sure CVMS connector is connected to CVMS.
If connected

If not connected

Connect CVMS connector.

Connect multimeter positive lead to K1-11


and negative lead to K1-15.
Measure the voltage.
12 volts

Replace the CVMS module.

0 volts

Repair or replace open circuit between 5 wires


from controller to CVMS.

50

PROBLEM 3
Display portion of the CVMS seems random or wrong.
Lift truck operation normal.

POSSIBLE CAUSE
Connection defect; Wiring defect; Logics defect;
Display defect.

CHECKS
Check continuity from logics to CVMS connector
Continuity

No continuity

Repair or replace open wire.

Check for shorts to battery negative from


PIN 1 to PIN 8 on CVMS connector.
No shorts found

Shorted

Replace logics.

Repair or replace shorted wire.

51

PROBLEM 4
Direction switch circuit defect.

POSSIBLE CAUSE
Direction switch defect; Wiring to direction
switch defect;

CHECKS
Disconnect the battery.
Disconnect K-1 connector.
Check continuity from K1-15 to K1-9 harness connector;
With direction lever in forward should have a closed circuit,
in neutral should be open.
Check OK

Check failed

Check continuity from K1-15 to K1-8.


With direction lever in reverse should have a
closed circuit, in neutral should be open.

Disconnect direction switch connector.


Check continuity between Pin2 and Pin3.
Check OK

Check OK

Replace logics.

Repair or replace direction switch.

Check wiring for open/short circuits


between harness connector K1-15 and K1-8.
Repair any open/short circuit found.

Check wiring for open/short circuits


between harness connector K1-15 and K1-9.
Repair any open/short circuit found.

Replace direction switch.

Check failed

Check failed

52

PROBLEM 5
Lift sensor circuit defect.

POSSIBLE CAUSE
Lift sensor not adjusted properly or defective;
Lift sensor wiring defect; Valve control card (board)
defect; Logics defect.

CHECKS
Retest lift sensor circuit in self diagnostics.
Circuit passes
Diagnostics

Circuit fails
Diagnostics

Perform Problem 11,12 Tilt or


auxiliary circuit defect.

Key switch ON.


Connect multimeter negative lead to Pin5
and the positive lead to Pin2 and Pin7.
Measure the voltage.
Battery Voltage

Repair or replace broken wire


between Pin1 and Pin5(wire #15)
or between Pin5 and battery
negative(-).

Measure voltage from Pin7 to Pin5 battery


negative as the lever is pulled and released.
9.0 to 11.0 and .2v
Measured

Replace logics.

0 Volt

9.0 to 11.0 and .2V


NOT measured

Replace Valve Control Card.

NOTE: Before lift truck is placed into operation, connect tilt and auxliary switches and verify proper adjustment.
Refer to Valve Control Card Adjustments.

53

PROBLEM 6
Tilt switch circuit defect.

POSSIBLE CAUSE
Tilt switch defect; Wiring defect; Logics defect.

CHECKS
Disconnect K1 connector. Pull tilt lever to maximum.
Check continuity from K1-54 to K1-15.
Continuity
No continuity

Replace logics.

Check continuity of wire #54.


Continuity

Check continuity from K1-54 of wire #54 to


Pin5 of valve board connector.
Continuity

Replace tilt switch.

No continuity

Repair or replace wire.

54

No continuity

Repair or replace wire.

PROBLEM 7
Auxiliary switch circuit defect.

POSSIBLE CAUSE
Wiring defect; Auxiliary switch defect; Logics defect.

CHECKS
Disconnect K1 connector. Pull auxiliary lever to maximum.
Check continuity from K1-15 to K1-38 or K1-57.
Continuity

Replace logics.

No continuity

Check continuity of wire #38 or #57.


Continuity

Check continuity from K1-15 of wire #15 to


Pin1 of valve board connector.

Continuity

No continuity

Replace AUX switch.

Repair or replace wire.

55

No continuity

Repair or replace wire.

PROBLEM 8
Park brake switch circuit defect.

POSSIBLE CAUSE
Wiring defect; Park brake switch defect; Logics defect.

CHECKS
Disconnect K1 connector. Release park brake lever.
Check continuity from K1-6 to K1-15.
Continuity

No continuity

Replace logics.

Check continuity of wire #6.


Continuity

Check continuity from K1-6 of wire #6


to terminal of park brake switch.
Continuity

Replace park brake switch.

No continuity

Repair or replace wire.

No continuity

Repair or replace wire.

56

PROBLEM 9
Pedal brake switch circuit defect.

POSSIBLE CAUSE
Wiring defect; Pedal brake switch defect; Logics defect.

CHECKS
Disconnect K1 connector. Push down the brake pedal.
Check continuity from K1-15 to K1-48.
Continuity

No continuity

Replace logics.

Check continuity of wire #48.


Continuity

Check continuity from K1-15 of wire


#15 to Pin2 of pedal brake switch.
Continuity

Replace park brake switch.

No continuity

Repair or replace wire.

No continuity

Repair or replace wire.

57

PROBLEM 10
Display=E1
The max speed of drive motor is reduced.
POSSIBLE CAUSE
Right drive inverter overtemperature.
Control board failed

CHECKS
Let the truck cool for 15 minutes.
Continuity

Normal

Check temperature of right


inverter seem too high

If repeat occur, check right drive


motor current draw or operating
cycle for excessive ramp climbing
or towing

You can read temperature


measures using COMPACT
display or EYE software.
Yes

Replace right inverter

No

Repair logic board

58

PROBLEM 11
Display=E2
The max speed of drive motor is reduced.
POSSIBLE CAUSE
Left drive module overtemperature.
Control board failed

CHECKS
Let the truck cool for 15 minutes.
Continuity

Normal

Check temperature of left


inverter seem too high

If repeat occur, check right drive


motor current draw or operating
cycle for excessive ramp climbing
or towing

You can read temperature


measures using COMPACT
display or EYE software.
Yes

Replace right inverter

No

Repair logic board

59

PROBLEM 12
Display=E3
The max speed of pump motor is reduced.
POSSIBLE CAUSE
Pump module overtemperature.
Control board failed

CHECKS
Let the truck cool for 15 minutes.
Continuity

Normal

Check temperature of pump


inverter seem too high

If repeat occur, check right drive


motor current draw or operating
cycle for excessive ramp climbing
or towing

You can read temperature


measures using COMPACT
display or EYE software.
Yes

Replace pump inverter

No

Repair logic board

60

PROBLEM 13
Display=E4
The max speed of drive motor is reduced.
POSSIBLE CAUSE
Right drive motor overtemperature.; Drive
motor thermal sensor defect;
Control board failed

CHECKS
Let the truck cool for 15 minutes.
Continuity

Normal

You have to measure a


resistance about 10kohm
between two wires of the
thermal sensor of right drive.
Yes

Replace control board.

If repeat occur, check right drive


motor current draw or operating
cycle for excessive ramp climbing
or towing

No

Replace thermal sensor.

61

PROBLEM 14
Display=E5
The max speed of drive motor is reduced.

POSSIBLE CAUSE
Left drive motor overtemperature.; Drive
motor thermal sensor defect;
Control board failed

CHECKS
Let the truck cool for 15 minutes.
Continuity

Normal

You have to measure a


resistance about 10kohm
between two wires of the
thermal sensor of left drive.
Yes

Replace control board.

If repeat occur, check right drive


motor current draw or operating
cycle for excessive ramp climbing
or towing

No

Replace thermal sensor.

62

PROBLEM 15
Display=E6
The max speed of drive motor is reduced.

POSSIBLE CAUSE
Right drive motor overtemperature.; Drive
motor thermal sensor defect;
Control board failed

CHECKS
Let the truck cool for 15 minutes.
Continuity

Normal

You have to measure a


resistance about 10kohm
between two wires of the
thermal sensor of pump motor.
Yes

Replace control board.

If repeat occur, check right drive


motor current draw or operating
cycle for excessive ramp climbing
or towing

No

Replace thermal sensor.

63

PROBLEM 16
Display=EL
The max speed and max torque of drive &
pump motor is reduced to minimum value.

POSSIBLE CAUSE
Battery discharged; Logic defect

CHECKS
Connect battery, turn on the key switch, close seat switch
And measure voltage from B+ to B- on controller.
Voltage must be greater than 34.5V at 36V system.
Voltage must be greater than 45V at 48V system.
Voltage OK

Voltage low

With key on, seat switch and main


contactor closed, measure voltage
at BATT+ on controller.

Check battery
connection ;
Charge or replace battery

Battery voltage

Replace logic

64

PROBLEM 17
Display=EE
No left truck operation

POSSIBLE CAUSE
Static Return to Off(SRO) circuit activated by
Improper operation sequence; Direction switch defect
Accelerator linkage not fully release.
Accelerator control defect; Logic defect.

CHECKS
Check SRO by release of accelerator, release park brake
Move the direction lever to neutral, reselect direction and
Press the accelerator.
No change

Check accelerator,
F/R switch.

Lift truck operation ok

Inform operator of correct start-up


procedure. Also, that the direction lever
must be left in neutral when leaving the
truck.

If no faulty component is
found, replace logics.

65

PROBLEM 18
Display=EE(Flashing)
No left truck operation

POSSIBLE CAUSE
No operator in seat; Seat switch defect;
Open wire.

CHECKS
Disconnect K1 connector Check continuity from wire #7
to wire #15 .Should be closed circuit when seat is
pressed on and open circuit when seat release.
No continuity

Check OK

Disconnect seat switch connector.


Push on the seat and check the
continuity across the seat switch.

Replace logics

Continuity

No continuity

Replace seat switch

Check wiring for open circuits


Between harness #7 and #15.
Repair any open circuit found.

66

PROBLEM 19
Display=F
No lift truck operation

POSSIBLE CAUSE
Improper communication between DSP,
Logic board defect.

CHECKS
Install eye software; pedal, steering, lift resetting.
OK

If not ok

Normal operating.

Replace logic board

67

PROBLEM 20
Display=F0,
Lift truck operation.

POSSIBLE CAUSE
Battery voltage exceeds 63V.
Failed logic

CHECKS
Disconnect battery, measure voltage at battery
connector terminal.
More than 63V

Not

Battery discharge

Replace logic board

68

PROBLEM 21
Display=F1
Lift truck operation.

POSSIBLE CAUSE
Battery voltage is lower than 24V.
Failed logic

CHECKS
Disconnect battery, measure voltage at battery
connector terminal.
Lower than 24V

Not

Battery charge

Replace logic board

69

PROBLEM 22
Display=F2
No lift truck operation.

POSSIBLE CAUSE
Accelerator sensor failure. Accelerator
connector disconnect. Failed logic.

CHECKS
Check Accelerator connector.
Connector

Disconnector

Accelerator resetting; value must be lower


than Min 0.2V and higher than Max 3.0V
(You can read temperature measures
using COMPACT display or EYE
software.)
Continuity

No continuity

Replace logic board

70

Connect Accelerator
connector.

PROBLEM 23
Display=F3
No lift truck operation.

POSSIBLE CAUSE
Right drive inverter overcurrent.
(Actual current exceeds limit 340A)
Failed logic board or inverter.

CHECKS
Key switch off and on again.
Display=F3

Drive operation normal

Measure the resistance between U,V,W terminals and


shell on the right motor
Open

0 ohm

Replace right drive motor

Measure the resistance between U,V,W terminals on


the right inverter.
About 4.4 Mohm

0 ohm or open

Replace logic board

Replace right inverter

71

PROBLEM 24
Display=F4
No lift truck operation.

POSSIBLE CAUSE
Left drive inverter overcurrent.
(Actual current exceeds limit 340A)
Failed logic board or inverter.

CHECKS
Key switch off and on again.
Display=F4

Drive operation normal

Measure the resistance between U,V,W terminals and


shell on the left motor
Open

0 ohm

Replace left drive motor

Measure the resistance between U,V,W terminals on


the left inverter.
About 4.4 Mohm

0 ohm or open

Replace logic board

Replace left inverter

72

PROBLEM 25
Display=F5
No lift truck operation.

POSSIBLE CAUSE
Pump inverter overcurrent.
(Actual current exceeds limit 410A)
Failed logic board or inverter.

CHECKS
Key switch off and on again.
Display=F5

Drive operation normal

Measure the resistance between U,V,W terminals and


shell on the pump motor
Open

0 ohm

Replace pump motor

Measure the resistance between U,V,W terminals on


the pump inverter.
About 4.4 Mohm

0 ohm or open

Replace logic board

Replace pump inverter

73

PROBLEM 26
Display=F6
No lift truck operation.

POSSIBLE CAUSE
Disconnect cable(CN1) from right inverter to
right drive motor; Right inverter defect.
Logic board defect.

CHECKS
Check the cable connecting from right invert to right drive motor.
Connection

Disconnection

Connect cable (CN1)

Check current of right inverter when you turn on the lift truck.
(You can read temperature measures using COMPACT
display or EYE software.)
Zero current

Non zero current

Replace logic board

Replace right inverter

74

PROBLEM 27
Display=F7
No lift truck operation.

POSSIBLE CAUSE
Disconnect cable(CN2) from left inverter to
Left drive motor; Left inverter defect.
Logic board defect.

CHECKS
Check the cable connecting from left inverter to left drive motor.
Connection

Disconnection

Connect cable (CN2)

Check current of left inverter when you turn on the lift truck.
(You can read temperature measures using COMPACT
display or EYE software.)
Zero current

Non zero current

Replace logic board.

Replace left inverter.

75

PROBLEM 28
Display=F8
No lift truck operation.

POSSIBLE CAUSE
Disconnect cable(CN4) from pump inverter to
Pump motor; Pump inverter defect;
Logic board defect.

CHECKS
Check the cable connecting from pump inverter to Pump motor.
Connection

Disconnection

Connect cable (CN4)

Check current of pump inverter when you turn on the lift truck.
(You can read temperature measures using COMPACT
display or EYE software.)
Zero current

Non zero current

Replace logic board.

Replace pump inverter

76

PROBLEM 29
Display=F9
The max speed of pump motor is reduced.

POSSIBLE CAUSE
Steering angle sensor fault.
Wiring defect.

CHECKS
Check continuity from K-11(12V) to pin3.; Check continuity from
K-15(Gnd) to pin1.; Check continuity from K-62(out) to pin2.
Check the housing.

No continuity

Continuity

Repair or replace wire

Replace angle sensor

77

PROBLEM 30
Display=FA
No lift truck operation.

POSSIBLE CAUSE
5V Encoder not ok.
Voltage of K1-14 terminal is lower than 4.3V

CHECKS
Measure voltage from K1-14 terminal of encoder to
K1-15(GND) terminal of encoder.
5 voltage

Lower than 4.3 voltage

Replace logic board

Replace defective one


(Right/left, pump encoder)

78

PROBLEM 31
Display=Fc
No lift truck operation.

POSSIBLE CAUSE
Right drive motor encoder defect.
An encoder channel is disconnected and
motor is working.

CHECKS
Check right drive motor encoder connection.
If correct

If not correct

Check continuity from K1-36 to


encoder (pin 4) and from K1-36
to encoder (pin 3).
If correct

If no correct

Replace logic board

Connect correctly encoder


connector

Repair or replace wire

79

PROBLEM 32
Display=Fd
No lift truck operation.

POSSIBLE CAUSE
Left drive motor encoder fail.
An encoder channel is disconnected and
motor is working.

CHECKS
Check left drive motor encoder connection.
If correct

If not correct

Check continuity from K1-16 to


encoder (pin 4) and from K1-17
to encoder (pin 3).
If correct

If no correct

Replace logic board

Connect correctly encoder


connector

Repair or replace wire

80

PROBLEM 33
Display=FH
Lift truck operation.

POSSIBLE CAUSE
12V output not ok.
Voltage of K1-11 terminal is lower than 10.5V.

CHECKS
Measure voltage from K1-11 to K1-15.
12 voltage

Replace logic board

Lower than 10.5 voltage

Replace defective device one


(Instrument, steering sensor)

81

PROBLEM 34
Display=FL
No lift truck operation.

POSSIBLE CAUSE
Valve control card defect, Lift setting fault.

CHECKS
Key switch on. Seat switch on.
Measure voltage at K1-50
Over minimum setting voltage

Replace logic board

Resetting lift calibration.


Ok

No voltage

If not ok

Adjust valve board


Ok

If not ok

Replace valve board

82

PROBLEM 35
Display=A
No lift truck operation

POSSIBLE CAUSE
Capacitor discharge; Main contactor fail,
Logic board fail

CHECKS
Key switch off and on again. Key switch off and
measure resistance of the main contactor.
About 85~90

Other resistance

Replace main contactor

Check continuity from K-18 to


main contactor terminal.
Check continuity from K-19 to
main contactor terminal.
Continuity

No continuity

Repair or replace wire

Check power fuse

Normal

Open

Replace logic board

Replace logic board

83

PROBLEM 36
Display=60
Lift truck operation

POSSIBLE CAUSE
Battery miss matching;
Logic board fail

CHECKS
Check battery voltage at the each system.
(36V system must use 36V battery, 48V system must
use 48V battery)
OK

If not ok

Replace logic board

Replace battery

84

PROBLEM 37
Display=77
Lift truck operation

POSSIBLE CAUSE
Thermal sensor wire of right drive motor open.
Logic board fail

CHECKS
Check continuity from K1-15 to thermal sensor pin1.
Check continuity from K1-58 to thermal sensor pin2.
Continuity

No continuity

Replace thermal sensor.

Repair or replace wire.

85

PROBLEM 38
Display=78
Lift truck operation

POSSIBLE CAUSE
Thermal sensor wire of right drive motor open.
Logic board fail

CHECKS
Check continuity from K1-15 to thermal sensor pin1.
Check continuity from K1-59 to thermal sensor pin2.
Continuity

No continuity

Replace thermal sensor.

Repair or replace wire.

86

PROBLEM 39
Display=79
Lift truck operation

POSSIBLE CAUSE
Thermal sensor wire of right drive motor open.
Logic board fail

CHECKS
Check continuity from K1-15 to thermal sensor pin1.
Check continuity from K1-60 to thermal sensor pin2.
Continuity

No continuity

Replace thermal sensor.

Repair or replace wire.

87

PROBLEM 40
Display=80
Lift truck operation

POSSIBLE CAUSE
Wrong right drive inverter Thermal sensor.
Logic board fail

CHECKS
Check temperature of right drive power unit.
(You can read temperature measures using COMPACT
display or EYE software)

Normal

Abnormal

Replace logic board.

Replace right drive inverter

88

PROBLEM 41
Display=81
Lift truck operation

POSSIBLE CAUSE
Wrong left drive inverter thermal sensor
Logic board fail

CHECKS
Check temperature of left drive inverter.
(You can read temperature measures using COMPACT
display or EYE software)

Normal

Abnormal

Replace logic board.

Replace left drive inverter

89

PROBLEM 42
Display=82
Lift truck operation

POSSIBLE CAUSE
Wrong pump inverter thermal sensor
Logic board fail

CHECKS
Check temperature of pump inverter.
(You can read temperature measures using COMPACT
display or EYE software)

Normal

Abnormal

Replace logic board.

Replace pump inverter

90

PROBLEM 43
Display=83
No lift truck operation

POSSIBLE CAUSE
Faulty eeprom or mismatching software release
Logic board fail

CHECKS
Restore eeprom with EYE application, Eye software install
Normal

Still problem

Replace logic board.

91

PROBLEM 44
Display=84
No lift truck operation

POSSIBLE CAUSE
CRC alarm
CHECKS
System turn off/on again.
Eye software reinstall.
Normal

Still problem

Replace logic board.

92

PROBLEM 45
Display does work normal
Lift truck operation abnormal.

POSSIBLE CAUSE
Encoder defect;
Logic board defect

CHECKS
RPM of defected motor is reducing and current of defected
motor is increasing.
(You can see diagnostic mode of display panel and eye
software.)

OK

If not ok

Replace encoder

Replace logic board.

93

System Tests and Adjustments

Hydrometer

Test Equipment

Hydrometers are usually available from any battery


supplier. Battery maintenance is a crucial par t of
maintaining the electric vehicle. The ability to
measure specific gravity and adjust the battery
discharge indicator to match battery manufacturers
specifications is an important part in the total
maintenance of the electric vehicle.
There are various pieces of electric truck test
equipment that Daewoo recommends for all service
personnel. This equipment is available from a
number of world wide manufacturers and local
electronic suppliers. Contact your Daewoo dealer or
the factory for further recommendations.

Handheld Multimeter
There are various pieces of electric truck test
equipment that Daewoo recommends for all service
personnel. This equipment is available from a
number of world wide manufactures and local
electronic suppliers. Contact your Daewoo dealer or
the factory for further recommendations.

A digital multimeter that measures DC voltage,


resistance, and has a diode tester, is required. It is
recommended that a high quality meter that is drop
protected, or comes with a drop proof case, be
purchased. Autoranging features, fast becoming an
industry standard, are convenient for the service
personnel, but are not required for servicing the lift
truck. A variety of miniature test leads, alligator clips,
and needle probes are also useful, and some of
these usually come with the multimeter.

Clamp-on Current Probe


The electric lift truck testing and adjusting
procedures require the measurement of average
DC currents. Currents in excess of 600 amps may
be present, so a clamp-on meter that will exceed
this level is required. It is also highly recommeded
that a device that has a voltage output, as well as a
visible display, be used. This makes viewing and
adjusting currents from the operator's seat possible.
The jaws of the current probe should be able to
accept at least a 19mm (.75 inch) cable diameter.

94

Electrical System Adjustment

Lift Sensor

Parking Brake Switch

1. Disconnect the battery and discharge the head


capacitor.

The lift truck can move suddenly. Injury to


personnel or damage to the lift truck is possible.
Safely lift the drive wheels off the floor. Put
blocks of wood under the frame so both drive
wheels are free to turn. Keep away from drive
wheels that turn.

4
2

Lift Sensor Adjustment


(1) Lift Sensor(transducer)

(2) Magnet.

(3) Screw.

(4) Setscrew. (A) 1.0 mm (.039 in) Clearance.

NOTICE
Lift sensor may be damaged. Do not allow the
magnet (2) to make contact with the plastic
bracket when the lift lever is activated.
Parking Brake Switch Adjustment
(1) Switch. (2) Plate. (3) Bolts.

2. Loosen setscrew (4).


1. Close the seat switch and turn the key to ON.
3. Adjust screw (3) to make clearance (A) 1.0mm
(.039 in) between lift sensor (1) and magnet (2)
when the lift lever is activated fully (pulled all the
way back).

2. Release the parking brake and put the truck in


forward.
3. Reposition plate (2) so the switch (1) actuator is
against the bracket. Tighten bolts (3).

4. Tighten setscrew (4). Check lift sensor circuit.


The valve control card may need adjusting.

4. Engage the parking brake and the park brake


symbol will be displayed. Repeat the procedure
until adjustment is correct.

5. Set lift sensor initial setting.


Refer to Sensor Initial Setting.

95

Valve Control Card Adjustment

8. Pull the lift lever all the way back. A flashing


3must be displayed.
9. If a flashing 3is not displayed, adjust P2 (2)
clockwise until it is.

The lift truck can move suddenly. Injury to


personnel or damage to the lift truck is possible.
Safety lift the drive wheels off the floor. Put
blocks of wood under the frame so both drive
wheels are free to turn. Keep away from drive
wheels that turn.

10. Release the lift lever and adjust P1


counterclockwise until a 0 is displayed.
11. Repeat steps 9 and 10 until 0 to 3 speeds
correct.

1. Verify the lift sensor clearance is adjusted


correctly.

12. Put the lift truck back in the run mode so the
actual hydraulics can be tested.

2. Disconnect all tilt and auxiliary switch


connectors.

13. Connect the battery, close the seat switch and


turn the key to ON.

3. Place the lift truck in Quick or Self


diagnostics so that the display is flashing the lift
speed.

14. Pull the lift lever back until the pump motor turns
on. The forks must not move. Adjust P1 so the
motor starts just before the valve opens.
If the valve opens before the motor turns on, adjust
P1 (1) clockwise.
If the motor turns on too far in advance of the valve
opening, adjust P1 (1) counterclockwise.

Valve Control Card Adjustment


(1) P1 Potentiometer. (2) P2 Potentiometer.

4. Turn potentiometer P1 (1) fully counterclockwise


unitl a clicking sound is heard (roughly 20 turns).
5. Turn potentiometer P2 (2) fully counterclockwise
until a clicking sound is heard (roughly 20 turns).
6. Turn potentiometer P2 (1) 15 full turns
clockwise.
7. Position the lift lever just prior to the hydraulic
valve opening. Adjust P1(1) clockwise until a
flashing 1 is obtained on the display.

96

Tilt and Auxiliary Switches


Because each tilt and auxiliary switch can turn on
the pump motor, it is recommended that only one be
connected to start with. After adjusting the first
switch proceed with the next one.
1. Disconnect the battery and discharge the head
capacitor. Disconnect all but one switch
connector.

Tilt and Auxiliary Switch Adjustment


(1) Screw. (2) Screws.

2. With valve spool in neutral position, loosen


screws (2) and adjust screw (1) to center the
switch roller on cam.
3. After adjusting switch in or out to obtain correct
switch point, tighten screws (1) and (2) to lock
switch into position.
4. Connect the battery, close the seat switch and
turn the key to on. Readjust switch if needed, so
that the pump motor turns on before the control
valve opens.
This must be adjusted for each lever direction
(pushed or pulled).
5. Connect the next switch and repeat this
proccdure.

97

Instrument Panel
LCD Instrument panel shows information about
system main analogue and digital parameters,
as follows:
1.
2.
3.
4.
5.
6.
7.
8.

Truck speed
Park brake insertion
Steering angle
Seat switch closure
Maintenance period expiry
Low speed insertion
Battery charge level
Energetic operating mode

To find further technical data and useful information


about Compact display refer its own user manual.
We briefly mention two important functions:
Diagnostic Mode
This operating mode enables you to test main
analogical and digital signals managed by your
system.
Parameter Calibration
This procedure allows to adjust the main operating
parameters of the system.
You can enter calibration mode before working as
usual with your lift truck.
It is also possible to update the parameters with
default values.
(Notice this way you loose calibration values).

98

Relation between battery charge level and


number of visualized bars

Instrument Panel

DISPLAY INDICATION
No segments
1 flashing segment
1 segment
2 segments
3 segments
4 segments
5 segments
6 segments
7 segments
8 segments
9 segments

The display gives the following information about


the operating state of the system:

Table 1 : Case of a generic system

Lift truck speed (expressed in kmh or


mph)

BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery

Handbrake active, indicated by the


warning symbol
Safety contact open, indicated both by
EE blinking message visualized in
timemeter area and by relative symbol
With any directional switch active and safety contact
still open, lift truck cant be moved, even after seat
switch is closed; in such a case, after safety contact
is closed, the symbol disappears.

BATTERY VOLTAGE
[V]
Voltage < 34.5 V
34.5 V ~ 35.1 V
35.1 V ~ 35.5 V
35.5 V ~ 35.9 V
35.9 V ~ 36.2 V
36.2 V ~ 36.5 V
36.5 V ~ 36.8 V
36.8 V ~ 37.1 V
37.1 V ~ 37.4 V
37.4 V ~ 37.6 V
Voltage > 37.6 V

Table 2 : Case of an 36V system

EE code disappears only after active directional


switch is turned off.

BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery

Time meter or, otherwise, odometer


Steering angle
Maintenance time expiry, indicated by
warning symbol
Slow speed operation, indicated by
Lift truck speed level, range from 0
(NO speed) to 9 (MAXIMUM speed)
segment, as in symbol
Battery level, indicated by a 9
segments symbol.

Table 3: Case of a 48V system

In following Table 1, you can read the generic


relation between battery charge level and number of
visualized bars . See Table 2 in case of an 36V
system and Table 3 in case of a 48V system.
Display signals with alarm code EL the fact battery
is completely discharged.

BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery

99

BATTERY VOLTAGE
[V]
Voltage < 45.6 V
45.6 V ~ 46.4 V
46.4 V ~ 47.0 V
47.0 V ~ 47.6 V
47.6 V ~ 48.2 V
48.2 V ~ 48.7 V
48.7 V ~ 49.2 V
49.2 V ~ 49.7 V
49.7 V ~ 50.1 V
50.1 V ~ 50.4 V
Voltage > 50.4 V

Otherwise symbol indicates, as


usual, selected operating mode.

Lift truck operation mode


Pressing E-S-H button, you can set
energetic operating mode for your
system.

Notice:As usual, if lift truck is moving,


symbol indicates speed level.
Notice: If active mode is one of L1, L2 or L3
limitations and you change operating mode
(from PROGRAMMABLE WORKING to ES-H), software automatically sets operating
mode to economic one.

This function is enabled using EYE menu named


Calibration ESH, to select desired operating mode.
In particular you can choose between E-S-H or
PROGRAMMABLE WORKING :
- Pressing E-S-H (economic, standard, high) button,
you change energetic mode and update related
parameters with a value, corresponding to
selected operating mode, that operator cant
modify.
- Pressing PROGRAMMABLE WORKING you can
manage 3 further options (limit 1, limit 2, and limit
3). You can set parameters value, that are
expressed in per cent of high energetic mode;
changing active limitation (among L1, L2 or L3),
related per cent data are used to calculate actual
parameters value.

Alarm message, indicated by an alpha-numerical


code in the display area where usually lift truck
speed appears.
See Table 5 for the meaning of alarm codes.
Over-temperature alarm, indicated by the
warning light In case the temperature of
power transistors exceeds the warning limit,
alarm code and relative light blink.
Moreover, in case temperature exceeds the alarm
limit, (or it stays between the two thresholds for 30 s
or more), the symbols stop blinking and became still.

Notice:Percent values can be modified only with


EYE Calibration E-S-H menu.

Hour meter separation point, usually blinking, stops


in following cases:
- Seat switch open.
- Serial communication between display and control
unit not active
- Main breaker open

Notice:Pressing PROGRAMMABLE WORKING


you can manage economic, standard or
high operating mode too.
COMPACT display shows different symbols in
function of selected energetic mode:

Turning your lift truck on, some alphanumeric codes,


visible for 3 seconds, appear where usually is
visualized speed indicator symbol; those codes help
to identify system in use (see Table 6).
Where usually is visualized hour meter, on left side
appears feed voltage in VDC, and on right side,
maximum weight industrial truck can lift, expressed
in quintals.

- E-S-H management disabled: no symbol


visualised.
- E-S-H management enabled: active
mode is indicated by symbol
- PROGRAMMABLE WORKING management
enabled: in case you have chosen one of L1, L2 or
L3 operating modes, and lift truck is stopped, one
of the segments of speed indicator symbol (see
Table 4 ) blinks to show selected energetic mode
DISPLAY
VISUALISATION
(from symbol left side)
1st segment
5th segment
9th segment

SYSTEM IN USE
4 Wheels (BX)
3 Wheels (BT)
Table 6

OPERATINGMODE
L1 (Limit 1)
L2 (Limit 2)
L3 (Limit 3)

Table 4 : selected energetic mode

100

CODE
C0
C1

ALARM
CODE
F
F0
F1
F2
F3
F4
F5
F6
F7
F8
F9
FA
Fc
Fd
FE
FH
FL
E1
E2
E3
E4
E5
E6
EE
EL
EE (flashing)
A
AL
17
60
77
78
79
80
81
82
83
84

LED Indicators

ALARM DESCRIPTION
Wrong eeprom + watch dog timer
Maximum battery voltage
Minimum battery voltage
Pedal trimmer fault
Drive right module desat/overcurrent
Drive left module desat/overcurrent
Pump module Desat/overcurrent
Drive right motor current offset
Drive left motor current offset
Pump motor current offset
Steer sensor fault
5V encoders not ok
Drive right motor Encoder
Left right motor Encoder
24V out not ok
12V out not ok
Pump inputs on at start
Drive right module Overtemperature
Drive left module Overtemperature
Pump module overtemperature
Drive right motor Overtemperature
Drive left motor Overtemperature
Pump motor Overtemperature
Wrong start
Low battery voltage
Seat switch opened
Alarm on pre-charge circuit of
internal capacitors
Key retention
Main breaker fault
Battery / inverter mismatch
Wrong right traction motor thermal
probe
Wrong left traction motor thermal
probe
Wrong pump motor thermal probe
Wrong right traction module thermal
probe
Wrong left traction module thermal
probe
Wrong pump module thermal probe
CRC fault
Bank CRC restored

On left side, COMPACT display has four LED


indicators which, when switched on, give
information as follows:
Alarm message; red colour LED
Message of lamps; green colour LED
(future)
Indicator lights activated; green colour
LED (future)
Low oil level of the brakes; red colour LED
(future)

Notice:Alarm LED

- Display normally working: LED lights up


briefly switching on /off your system
- Display not communicating with control
board: after 3 seconds from the moment in
which the communication stops, alarm
LED brightens
- Display board microprocessor not working:
alarm LED brightens.

G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G

Table 5 : Meaning of alarm codes

is managed as follows:

101

Display Keys Utilization


As you can see in Fig.1, on right side of display front there are four keys: E-S-H, UP (TURTLE), DOWN and
ENTER.
The function of each of them is described as
follows:

E-S-H key
With this key, you can modify the device operating
condition, in a circular sequence, as described in
Table 7 :

ENTER key
1. When you switch your device on, this key,
pressed for 3 consecutive seconds, allows
entering both to parameter calibration and to
diagnostic mode.
2. During usual operations, this key, pressed for 3
consecutive s, allows you to access merely to
diagnostic mode.

Current Working
Condition

Remember that if the display is operating in


diagnostic mode during typical operations, you can
exit this procedure pressing once ENTER key.
Moreover, ENTER key is used to confirm the new
value of the parameter in calibration procedure.

Economic (E)

Standard (S)

Standard (S)

High (H)

High (H)
Limitation 1 (L1)

Limitation 1 (L1)
Limitation 2 (L2)

Limitation 2 (L2)

Limitation 3 (L3)

Limitation 3 (L3)

Economic (E)

Table 7

Notice: You can modify system operating modes


only after enabling their management with
EYE applicative software.

UP key
1. Pressing of this key, in calibration and
diagnostic mode, you increase the number of
the parameter displayed.
2. In calibration phase, you increase the numeric
value of the parameter displayed.

Notice: Pressing this key when you are in


diagnostic mode you can see a circular list
of 10 latest alarms.

TURTLE key
Remember that pressing this key you can toggle
between slow running and normal working condition
(if the lift truck is already in speed limitation mode).

DOWN key
1. Pressing of this key, in calibration and
diagnostic mode, you decrease the number of
the parameter displayed.
2. In calibration phase, you decrease the numeric
value of the parameter displayed.

Working Condition After


the Key Pressure

102

The parameter number (blinking) appears on the


display area usually reserved to lift truck speed and
alarm codes, and its value is shown in the timemeter area.
Moreover, appear a number of segments
proportional to the parameter value.

Parameter Calibration
This chapter describes the way to adjust the main
operating parameters of the system.
You inhibit the access to this menu with EYE
submenu named Lift truck setup.
To calibrate your parameters, read following
instructions:

If you see that the numeric data have been modified


in the time meter area, it means that the value of the
chosen parameter has really been updated into
control board memory.

To enter calibration mode:


1. Switching on your system, press ENTER key
until a blinking 0 (zero) appears.
2. Press UP key: the entry to the chosen
calibration mode is indicated by C; this symbol
persists until the first parameter will be selected.

Notice: Remember that parameter values can be


modified only by discrete increments.
See Table 8 for the list of all adjustable
parameters and relative minimum available
variations.

Notice: If calibration procedure is not enabled


using EYE Lift truck setup menu, UP key
pressure has no effect.
Notice: You can exit this operating mode only
switching off your system.
To execute the calibration:
1. Select parameter 10 using UP and DOWN keys,
and confirm your choice pressing ENTER key.
2. Use UP and DOWN keys to set at 4 the value of
this parameter, and confirm with ENTER key.
3. Repeat the above operations to fix parameter
17 value at 6 Notice: it doesnt matter if you first
modify parameter 10 and then 17, or vice versa.
Only after this procedure, you allow operator to
change the value of other parameters:
1. Select the parameter to change, using UP or
DOWN key; press ENTER to confirm.
2. Now adjust the value of the selected parameter
with UP and DOWN keys; confirm your choice
typing ENTER key.

103

<48V>

No
5
6
9
10
11
12
13

Parameter
Deceleration steering ramp 1
Deceleration steering ramp 2
Battery reset value
First parameter for calibration enable
Seat switch delay
Chat time
Hydro time

Unit
rpm/s
rpm/s
V*10

Minimum
10
1
464

14

Maintenance time inserting enable

17
18
19
20
23
24
26
32
33
34
41
42
43
44
46
47
48
49
50
51
52
53
59
61
62
63
64
65
66
67
68
69
70
71
72
73

Second parameter for calibration enable


Steering clockwise
Steering anticlockwise
Steering middle
Minimum accelerator
Maximum accelerator
Stop on slop timer
Maximum lift
Minimum lift
Middle lift
Drive maximum current
Forward maximum speed
Reverse maximum speed
Drive limitation maximum speed
High lift 1 switch drive max speed
Steer limitation maximum speed
Acceleration ramp
Inversion ramp
Release ramp
Pedal brake ramp
Creep speed
Diameter of drive tyres
Partial release ramp
Lift maximum current
Auxiliary maximum current
Lift maximum speed
Tilt speed
AUX 1 speed
AUX 2 speed
AUX 3 speed
Lift minimum speed
High lift 1 switch lift max speed
Hydro speed
Hydro idle speed
Pump acceleration ramp
Pump deceleration ramp

s
s
s

1
3
10

3
9
6
9
10
20
Disable = 0 (Default)
Enable = 1

500
500
500
200
3,000
1
3,000
0
1,000
20
1,000
1,000
500
400
400
400
400
400
400
100
300
10
20
10
1,500
500
500
500
500
500
500
400
200
1,000
1000

1,200
11,500
10,300
11,500
6,300
11,500
1,000
4,500
5,000
12,000
5
10
11,500
12,000
1,000
12,000
2,750
12,000
100
100
4,500
4,500
4,500
4,500
2,000
2,500
2,000
4,500
1,000
2,000
1,100
2,000
1,300
2,000
900
2,000
1,200
2,000
300
2,000
451
600
50
500
100
100
65
100
2,950
4,500
900
2,000
900
2,800
900
2,800
900
2,800
700
1,500
500
4500
500
800
300
500
7,000
10,000
7000
10000
Accelerator signal 1 = E mode,
2 = S mode,
3 = H mode
Disable = 0 (Default)
Enable = 1
Normal = 0 (Default)
British unit = 1
5
8
Disable = 0
Enable = 1 (Default)
Timer meter = 0 (Default)
Odometer = 1
0
10000

93

Power mode (E-S-H, limitations)

digit

94

Slow speed

digit

95

British unit

digit

96

Display brightness

digit

97

E-S-H enable

digit

98

Time meter / Odometer on display

digit

99

Maintenance time

digit
mV
mV
mV
mV
mV
s
mV
mV
mV
%
rpm
rpm
rpm
rpm
rpm
rpm/s
rpm/s
rpm/s
rpm/s
rpm
mm
rpm/s
%
%
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm/s
rpm

104

Default
800
6
470

Maximum
5000
10
501

Variation
10
1
1
1
1
1
1

1
10
10
10
10
10
1
10
10
10
1
50
50
50
50
50
10
10
10
10
1
10
1
1
50
50
50
50
50
50
50
10
10
10
10

100

<36V>

No
5
6
9
10
11
12
13

Parameter
Deceleration steering ramp 1
Deceleration steering ramp 2
Battery reset value
First parameter for calibration enable
Seat switch delay
Chat time
Hydro time

Unit
rpm/s
rpm/s
V*10

Minimum
10
1
344

14

Maintenance time inserting enable

17
18
19
20
23
24
26
32
33
34
41
42
43
44
46
47
48
49
50
51
52
53
59
61
62
63
64
65
66
67
68
69
70
71
72
73

Second parameter for calibration enable


Steering clockwise
Steering anticlockwise
Steering middle
Minimum accelerator
Maximum accelerator
Stop on slop timer
Maximum lift
Minimum lift
Middle lift
Drive maximum current
Forward maximum speed
Reverse maximum speed
Drive limitation maximum speed
High lift 1 switch drive max speed
Steer limitation maximum speed
Acceleration ramp
Inversion ramp
Release ramp
Pedal brake ramp
Creep speed
Diameter of drive tyres
Partial release ramp
Lift maximum current
Auxiliary maximum current
Lift maximum speed
Tilt speed
AUX 1 speed
AUX 2 speed
AUX 3 speed
Lift minimum speed
High lift 1 switch lift max speed
Hydro speed
Hydro idle speed
Pump acceleration ramp
Pump deceleration ramp

s
s
s

1
3
10

3
9
6
9
10
20
Disable = 0 (Default)
Enable = 1

500
500
500
200
3,000
1
3,000
0
1,000
20
1,000
1,000
500
400
400
400
400
400
400
100
300
10
20
10
1,500
500
500
500
500
500
500
400
200
1,000
1000

1,200
11,500
10,300
11,500
6,300
11,500
1,000
4,500
5,000
12,000
5
10
11,500
12,000
1,000
12,000
2,750
12,000
100
100
3,800
3,800
3,800
3,800
2,000
2,500
2,000
3,800
1,000
2,000
1,100
2,000
1,300
2,000
900
2,000
1,200
2,000
300
2,000
451
600
50
500
100
100
65
100
2,950
4,500
900
2,000
900
2,800
900
2,800
900
2,800
700
1,500
500
4500
500
800
300
500
7,000
10,000
7000
10000
Accelerator signal 1 = E mode,
2 = S mode,
3 = H mode
Disable = 0 (Default)
Enable = 1
Normal = 0
British unit = 1 (Default)
5
8
Disable = 0
Enable = 1 (Default)
Timer meter = 0 (Default)
Odometer = 1
0
10000

93

Power mode (E-S-H, limitations)

digit

94

Slow speed

digit

95

British unit

digit

96

Display brightness

digit

97

E-S-H enable

digit

98

Time meter / Odometer on display

digit

99

Maintenance time

digit
mV
mV
mV
mV
mV
s
mV
mV
mV
%
rpm
rpm
rpm
rpm
rpm
rpm/s
rpm/s
rpm/s
rpm/s
rpm
mm
rpm/s
%
%
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm/s
rpm

105

Default
800
6
356

Maximum
5000
10
373

Variation
10
1
1
1
1
1
1

1
10
10
10
10
10
1
10
10
10
1
50
50
50
50
50
10
10
10
10
1
10
1
1
50
50
50
50
50
50
50
10
10
10
10

100

Sensor Initial Setting

Default Setting

In case that initial settings of sensors are not


performed accordingly, the machine performance
can be lowered.
So, in the following cases, initial setting for each
sensor should be done to secure the correct
machine performance.

It is also possible to update the parameters with


default values.
As for the procedure explained below, use UP,
DOWN and ENTER keys to set parameter 10 value
to 5 and parameter 17 value to 2. Once more, the
order you adopt to change the two parameters is
not important.
The loading of default data is indicated by the
symbols d S (default set);

- Replacing Logic
- Updating flash memory(Update EEPROM) or
Resetting EEPROM
- Replacing or adjusting Sensor
- Default Setting

Notice: All parameters whose value is related to


selected energetic operating mode
(economic, standard, high, limitation 1,
limitation 2, limitation 3) are updated with
default values corresponding to the active
one.
Pressing E-S-H key on display, and
selecting a different working mode, you
immediately change the value of all
parameters related. Such parameters, as
well as their default values, are listed in
Table 10 (*)

STEERING SENSOR (parameter 13):


Enter diagnostic mode to visualize steering sensor
voltage.
Minimum value calibration: turn wheels completely
on left and read sensor voltage value from display;
enter calibration mode and set parameter 19 to the
value measured.
Maximum value calibration: turn wheels completely
on right and read sensor voltage value from display;
enter calibration mode and set parameter 18 to the
value measured.

Parameter
Central value calibration: put wheels straight and
read sensor voltage value from display; enter
calibration mode and set parameter 20 to the value
measured.

Maximum drive
current
Maximum forward
speed [rpm]
Maximum reverse
speed [rpm]
Acceleration
proportional to load
Drive acceleration
ramp [rpm/s]
Lift maximum
current
Maximum lift speed
[rpm]
Drive inversion ramp
[rpm/s]
Drive release ramp
[rpm/s]

ACCELERATOR SENSOR (parameter 11):


Enter diagnostic mode to visualize speed sensor
voltage.
Minimum value calibration: read from display sensor
voltage corresponding to start switch closure (when
all segments dedicated to speed level visualisation
are active); enter calibration mode and set
parameter 23 to the value measured.
Maximum value calibration: read sensor voltage
value from display, with pedal completely pressed;
enter calibration mode and set parameter 24 to the
value measured.
LIFT LEVER SENSOR (parameter 5):
Enter diagnostic mode to visualize lift lever voltage.
Minimum value calibration: read from display sensor
voltage with lift lever released; enter calibration
mode and set parameter 33 to the value read.

Standar
d Mode

Hige
Mode

62

76

100

3000

3500

4500

3000

3500

4500

20

20

20

700

800

1150

70

80

100

2500

2750

2950

600

900

1200

600

850

1000

Table 10 (*) Its values are actually implemented into the


software of BX20 48 V lift truck

Notice: Once default data have been loaded, if you


further need to modify parameters value,
you have to switch your system off, before
entering calibration mode again.

Maximum value calibration: read from display


sensor voltage with lift lever completely pressed;
enter calibration mode and set parameter 32 to the
value measured.
Central value calibration: enter calibration mode and
modify parameter 34.

Econom
ic Mode

Notice: Parameter 94 is visualized only in case ES-H management procedure is enabled


with relative EYE software calibration menu.

106

Diagnostic Mode
This operating mode enables you to test main
analogical and digital signals managed by your
system.
Enter diagnostic mode if you are switching on
your lift truck:
1. Press ENTER key (for 3 consecutive seconds)
until the symbol 0 lights up.
2. Press DOWN key to enter diagnostic mode; the
symbol d is visualized and it persists until the
first parameter has been selected.
Enter diagnostic mode if you are working as
usual with your lift truck:
1. Press ENTER key (for 3 consecutive seconds)
until symbol d appears; it will persist as long
as the first parameter has been selected.
After diagnostic operation mode has been enabled,
you can choose the parameter you want to analyse
using UP and DOWN keys (parameter number
increases using UP key and decreases with DOWN
key).
Here, in Table 11, you have a list of the parameters
you can analyze with their respective displaying
order :

107

List of diagnostic
Parameter No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46

Description
Right traction motor speed
Right traction motor speed reference
Left traction motor speed
Left traction motor speed reference
Lift voltage
Battery voltage
Right traction motor power module temperature
Pump motor power module temperature
Pump motor speed
Pump motor speed reference
Accelerator potentiometer voltage
Accelerator second potentiometer voltage
Steering sensor voltage
Left traction motor power module temperature
Right traction motor phase current U
Right traction motor phase current V
Right traction motor phase current W
Left traction motor phase current U
Left traction motor phase current V
Left traction motor phase current W
Pump motor phase current U
Pump motor phase current V
Pump motor phase current W
Right traction motor temperature
Left traction motor temperature
Pump motor temperature
Seat switch hour meter
Drive motor hour meter
Pump motor hour meter
Seat switch
Park brake switch
Start switch
Reverse traction direction switch
Forward traction direction switch
Pedal brake switch
3 / 4 wheels selection switch
Side shift switch
Auxiliary 2 function switch
High lift switch
Tilt switch
Main breaker command
5V out
12V out
24V out
Buzzer command
Fans command

108

Unit
[rpm]
[rpm]
[rpm]
[rpm]
[mV]
[V10]
[C / F]
[C / F]
[rpm]
[rpm]
[mV]
[mV]
[mV]
[C / F]
[A rms]
[A rms]
[A rms]
[A rms]
[A rms]
[A rms]
[A rms]
[A rms]
[A rms]
[C / F]
[C / F]
[C / F]
[h]
[h]
[h]
[digit]
[digit]
[digit]
[digit]
[digit]
[digit]
[digit]
[digit]
[digit]
[digit]
[digit]
[digit]
[digit]
[mV]
[digit]
[digit]
[digit]

In diagnostic mode selected parameter is


visualized as follows:
1. In the area dedicated to speed and alarm
signals, appears parameter number ( flashing)
2. Its actual value is displayed in the area reserved
to the time meter.

Accessing Stored Error Codes


The B18X series of remembers the last 10 error
codes. This is case the truck has had an intermittent
problem, but the operator cannot remember which
code appeared on the display. Also by analyzing the
contents of the last 10 error codes, it may be
possible to determine what sort of application the
truck has been working in.

In particular, if the selected parameter is:


Analogue input: Instrument panel shows the
parameter value, expressed in the unit of Table 11

The stored error codes are accessed at diagnostic


mode by using E-S-H button.

Digital input: if the command activated by the


operator corresponds to the parameter selected, the
value of the quantity is visualized.

1. Access the diagnostic mode.

Other way the symbol E (error) appears, except


in following case:
1. Seat switch active, for any selected digital input.

2. Press E-S-H button. And then, the stored error


code will be shown with SMU hours, if any.

To exit diagnostic mode, type ENTER key again.

3. By pressing UP or DOWN key, more error


codes can be shown.

Notice: If an alarm occurs when diagnostic mode is


enabled, and the system is working as
usual, display returns automatically to its
typical visualization mode.
However you can enter diagnostic mode
again, pressing ENTER key (for 3
consecutive s), until the last parameter
displayed before exiting is visualized.

4. Pressing again E-S-H key, you return to


diagnostic mode.

If the selected parameter


is a temperature, also
thermal alarm symbol is visualized.

109

Eye Software Interface


EYE is a diagnostic software environment designed
to communicate with the forklift truck.

It can be run from a PC with serial or USB (1.x o2.x)


port. Connection between PC and Main harnesss
Serial Communication connector is characterized by
a 38,4 kBaud/s Baud-rate.
User can communicate with lift truck during working
operations, and can analyse on line main electrical
variables value/ status.
EYE software interface is user friendly and intuitive:
it guides the operator through the process of
parameter setting and is an effective data analysis
instrument, helping to identify faults and causes of
malfunctioning.
Following functions are in particular very useful:
1. Diagnostic: User can receive relevant control
data from the main board (such as current,
voltage, rpm, temperatures etc ) evaluating lift
truck performance and detecting any faulty
circuit
2. Calibration: User can transmit parameters and
settings to the truck in order to tune its
performance.
3. Flash memory software update

110

To find further technical data and useful information about EYE software, refer its own user manual.

111

PC-Controller Communication

General Information
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Connect serial port of PC and harness with picture


below.

Minimum Requirements
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1. 350MHz Pentium class or higher
microprocessor
2. 128Mb or greater of RAM
3. Serial port or USB port

Serial port

USB port

4. Graphic card 1Mb


5. Windows 98SE/NT/XP/ME/2000
6. 1024x768 resolution video adapter
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Recommanded Requirements
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1.
2.
3.
4.
5.
6.
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1GHz Pentium class or higher microprocessor


512Mb of RAM
Serial port or USB port
Graphic card 2Mb
Windows 98SE/NT/XP/ME/2000
1024x768 resolution video adapter

112

Installation
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To install EYE software, complete following
steps:
1. Check computer requirements
2. Start Setup.exe application
3. Select destination path then press FINISH
4. At the end press OK and then reboot
5. You can create a short-cut of EYE.exe on
desktop
If there is an old release installed, you must uninstall
it.
To uninstall you must execute Setup.exe application
from CD and confirm any step

113

Features
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If EYE software installation is successful, starting the application from Windows Programs Menu, or using shortcut on desktop (Fig.1), you can access main menu (Fig.2).

Fig.1: Short-cut

Date: xx-xx-xx (Software version)


Fig.2: Main menu operator mode

To quit application or exit a submenu, press ESC key or select Exit menu.
In case of any problems, refer to section 4 TROUBLESHOOTING.

WARNING
Some menus, items or calibration parameters described in this manual are optional lift truck functions: so
they could be not implemented.

114

Main Menu
On left side, there are some notes about software release, operating mode and serial communication setting.
Below lift-truck picture, there are actual active alarms (code level and description);
In case of more alarms with the same priority level, the first occurred is visualized.
In operator mode, you can access following menus:
1. Setup
2. Test
3. Data logging
4. Password
5. About
Even before starting of serial communication between lift truck and PC (Fig.3), you can access Setup,
Password and About menus (Fig.4). In such a case some data field are missing.
In case of faults during a serial communication data flow, any submenu is aborted and main menu front panel is
reinitialized.

Fig.3: operator mode serial communication faulty

Fig.4: About menu

115

Password Insertion
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Fig.5: Password insertion

Selecting Password mode from menu-bar, you can access Supervisor mode (Fig.6) inserting the correct password
(Fig.5).
Contact EYE software developer to know correct password.

Fig.6: main menu supervisor mode

In case wrong password insertion (Fig.7), following message becomes visible:

Fig.7: unauthorized user

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116

In Supervisor mode, you can access these further menus:


1. Calibration
2. Flash
Password menu disappears from menu-bar.
In case of faulty serial communication, main menu front panel is reinitialized as follows (Fig.8):

WARNING
PANEL BLANK message is used to distinguish case of not programmed flash memory, so Flash menu is
obviously active.

Fig.8: supervisor mode communication faulty

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You can select active menus directly from main panel menu bar (any greyed menu is not accessible in that
moment); you can also access present sub panels with a further selection by a pop-up menu (Fig.9)

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Fig.9: Submenu selection

117

Not Actual Software / Eeprom Crc Fault


A CRC alarm message is visualized both in case of failed EEPROM memory writing and of using a software
version without the CRC control procedure.
Pressing the visualized button, you can load in EEPROM default values: if you dont execute this procedure,
calibration functions are inhibited. You have now to execute calibration procedure (see inverter manual).
A message signals also the presence of not actual software loaded on inverter panel.
In such a case you can access only basic EYE functions: some menus, for compatibility reasons, will be inhibited.

Submenus
Print function is accessible from many of listed submenus: you can send active front panel image to printer or
save it on file; in that case destination directory is <EYE PATH>\EYE\ images.
BEWARE: if more than one window is in use, only the one relative to the inner submenu is active and all others
work in background.
If you select a non active window, you cant communicate\ interact with inverter panel.

118

Configuration Menu (Setup)

Fig.10: Setup menu

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From setup menu (Fig.10) you can select communication serial port and image file format used by Print function.

119

Test
This pop-up menu includes of following subjects:
1. Drive (Fig.11)
2. Pump (Fig.12)
3. Battery (Fig.13)
4. Timers (Fig.14)

Drive (Traction)

Fig.11: Drive menu

Following items appear in Drive menu front panel:


1. Accelerator pedal voltage
2. Pedal brake pressure (in bar)
3. Drive motors phase currents: you can select current phase from pop-up menu
4. Both modules temperature: you can select measure unit between C and F.
Temperature above 60C is signalled by a red colour; temperature above 90C is signalled by a flashing
display.
5. Steering angle in percent, using following criteria:
6. 0%
steering completely on left
7. 50%
straight wheels
8. 100%
steering completely on right
9. Steering sensor voltage
10. Request RPM and motor speed for both motors, with an arrow signalling direction
11. Both motors temperature: you can select measure unit between C and F.
In case of an overheating alarm, the corresponding green led becomes red.
12. Active output command status
13. Steering switch status
14. Customizable input switch status
15. Start, forward and reverse switches status
16. Drive motors encoder diagnostic leds, both for A and B channel
17. Pedal brake, hand brake and seat switches status

120

Pump

Fig.12: Pump menu

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Following items appear in Pump menu front panel:
1. Voltage on lift command circuit
2. Hydraulic lift circuit pressure
3. Pump motor current : you can select current phase from pop-up menu
4. Module temperature: you can select measure unit between C and F.
Temperature above 60C is signalled by a red colour; temperature above 90C is signalled by a flashing
display.
5. Request RPM and motor speed, with an arrow signalling direction
6. Motor temperature: you can select measure unit between C and F. In case of an overheating alarm, the
green led becomes red
7. Electrovalves output status
8. Customizable input switches status
9. Tilt, lift and high lift digital input status
10. Encoder diagnostic leds, both for A and B

121

Battery

Fig.13: Battery menu

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Following items appear in Battery menu front panel:
1. Battery and inverter voltages
2. Battery charge level
3. Code, description and level of active more serious alarm for both microprocessors; if there is more than one
alarm of same level, the latest is visualized.
4. There is a chronological list of latest 10 alarms, with code, description, time and temperature. First listed alarm
is the first occurred.
Temperature value is obviously referred to faulty module or faulty motor (if there are no faulty modules or
motors, this is a no meaning data field).
With Reset alarms menu, you can reset alarm list.

122

Timers

Fig.14: Timers menu

Following items appear in Timers menu front panel: total inverter working hours, drive motor and pump motor hour
meter.

123

Calibration
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For safety, you can access all calibration menus only in Supervisor mode and with park brake on.
A confirmation is asked to quit a calibration menu without saving changes.
You cant set a value out of fixed limits: the message OUT OF LIMIT signals a case like that.
By a pop-up menu, you can access following calibration functions:
1. Battery: Battery reset voltage calibration (Refer to page 125)
2. Timers: Timers calibration (Refer to page 126)
3. Steering: Steering sensor (Refer to page 127)
4. Pedal: Pedal accelerator calibration (Refer to page 128) (**)
5. Lift: Lift calibration (Refer to page 129)
6. ESH: E/S/H parameters calibration and limits (Refer to page 130)
7. Steering parameters: Steering parameters calibration (Refer to page 132)
8. Program service: Program service interval setting (Refer to page 133)
9. Drive motor: Drive motors parameters calibration (Refer to page 134)
10. Pump motor: Pump motors parameters calibration (Refer to page 135)
11. Critical height switches: Speed limits calibration in case of critical height (Refer to page 136)
12. Weight sensor: Weight sensor calibration (Refer to page 137) (*)
13. Cab lift: Cab lift speed calibration (Refer to page 138) (*)
14. Timer reset: Timers meters reset (Refer to page 139)
15. Truck setup: Some lift truck parameters setup (Refer to page 140) (*)
16. Backing mode: Slow mode calibration (Refer to page 141) (*)
17. Load eeprom default: EEPROM configuration (Refer to page 142)
18. Paramters image: Parameter store or Restore. (Refer to page 143)
(*): Optional menu
(**): Menu present in standard or optional version

124

Battery reset voltage calibration

Fig.15: Battery reset menu

In that menu front panel, you can find following data about battery reset voltage: description, actual value, new
value you want to set, measure unit, default value, minimum and maximum settable values.
You can execute following operations:
Load default value:
1. Press DEFAULT button ; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field too will be updated
Change actual value:
1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.
Discard changes:
1. Press CANCEL button; initial value will be restored in NEW data field
2. Press SAVE button and confirm; OLD data field too is restored with initial value
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125

Timers calibration

Fig.16: Timers calibration menu

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In that menu front panel, you can find following data about timer parameters: description, actual value, new value
you want to set, measure unit, default value, minimum and maximum settable values.
You can execute following operations:
Load default value:
1. Press DEFAULT button ; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields too will be updated
Change actual value:
1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.
Discard changes:
1. Press CANCEL button; initial values will be restored in NEW data fields
2. Press SAVE button and confirm; OLD data fields too are restored with initial values

126

Steering sensor calibration

Fig.17: Steering calibration menu

There are following data about steering parameters: description, actual value, measure unit, default values,
minimum and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with steering sensor actual voltage.
You can execute following operations:
Load default value:
1. Press DEFAULT button; VALUE data fields will be automatically updated with default values
Change parameters value:
1. Select ANTICLOCK parameter
2. Turn steering completely anticlockwise
3. Press SAVE button and confirm
4. Select CLOCK parameter
5. Turn steering completely clockwise
6. Press SAVE button and confirm
7. Select MIDDLE parameter
8. Put wheels straight ahead
9. Press SAVE button and confirm
Discard changes:
1. Press CANCEL button; initial value will be restored in VALUE data fields
If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any
lift truck fault.

127

Accelerator pedal calibration


Standard version

Fig.18: Men di calibrazione del pedale

There are following data about accelerator parameters: description, actual value, measure unit, default values,
minimum and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with pedal sensor actual voltage.
You can execute following operations:
Load default value:
1. Press DEFAULT button; VALUE data field will be automatically updated with default value
Change parameters value:
1. Select MIN ACCELERATOR parameter
2. Slowly press accelerator pedal until START switch turns on
3. Press SAVE button and confirm
4. Select MAX ACCELERATOR parameter
5. Press completely accelerator pedal
6. Press SAVE button and confirm
Discard changes:
1. Press CANCEL button; initial value will be restored in VALUE data fields
If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any
lift truck fault.
In this window front panel there are 3 green leds, expressing actual state of forward, reverse and start switches.

Optional version
There is a second pedal sensor.
Calibration procedure is like standard one, except that START led present (Fig.18) turns ON only after software
verifies that the voltages on both pedal sensors are equal to Vmin + 0,5 V voltage, obtained slowly pressing
accelerator pedal.

128

Lift calibration

Fig.19: Lift sensor calibration menu

There are following data about lift parameters: description, actual value, measure unit, default values, minimum
and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with lift sensor actual voltage.
You can execute following operations:
Load default value:
1. Press DEFAULT button; VALUE data fields will be automatically updated with default values
Change parameters value:
1. Select MIN LIFT parameter
2. Release lift command lever
3. Press SAVE button and confirm
4. Select MAX LIFT parameter
5. Press completely lift command lever
6. Press SAVE button and confirm
7. Select MIDDLE LIFT parameter
8. Press lift command lever to select start acceleration point for pump motor
9. If lift sensor actual value is inside permitted range, press SAVE button and confirm
Discard changes:
1. Press CANCEL button; VALUE data fields will be restored with initial values
If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any
lift truck fault.

129

E/S/H parameters and L1, L2, L3 limits calibration

Fig.20: E/S/H calibration menu

In that menu front panel, you can find following data about E/S/H parameters: description, actual value, new value
you want to set, measure unit, default values for E, S, and H operating mode, settable per cent values for
parameters in L1,L2,L3 operating mode
You can execute following operations:
Select default value:
1. Press DEFAULT button ; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field too will be updated
Change actual value:
1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.
Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields too are restored with initial values
This calibration procedure is optional, and you can enable/disable it with the ESH button.
In any case, you can disable limits calibration section (L1, L2 and L3 parameters) with PROGRAMMABLE
WORKING button.
N.B.: if programmable working section is disabled, and you select one of L1, L2 or L3 operating modes,
a message will advise user and E operating mode will be forced .
With E_S_H, pop-up menu you can select one of lift truck possible energetic operating modes (Economic,
Standard and High); selected operating mode default values are so loaded on characteristic parameters.
The message in Fig. 21 appears if you have selected a different energetic mode using Compact display; pressing
OK button, parameters are updated loading new values from control board.

130

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Fig.21: Parameters externally changed

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If PROGRAMMABLE WORKING section is enabled, pressing MODIFY LIMITS button you enter Fig. 22 window;
you can now modify per cent values for L1, L2 and L3 limits, remembering that every single data change require
to be confirmed.

Fig.22: Percent parameters menu

In that menu front panel, there are data about L1, L2 and L3 parameters: description, measure unit, modifiable
values expressed in per cent, minimum and maximum settable values.
You can execute following operations:
Change actual value:
1. Insert new value
2. Confirm
If actually selected operating mode percent values are now modified, exiting to ESH calibration menu, user can
load new default values. Every parameter per cent value is referred to High mode data.

131

Steering parameters calibration

Fig.23: Steering parameters calibration menu

In that menu front panel, you can find following data about steering parameters: description, actual value, new
value you want to set, measure unit, default values minimum and maximum settable values.
You can execute following operations:
Select default value:
1. Press DEFAULT button ; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields too will be updated
Change actual value:
1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.
Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields too are restored with initial values

132

Program service calibration

Fig. 24: "Program service" menu

G
To modify assistance interval, you have to enable apposite function.
Change actual value:
1. Set button INCREASE properly to select if increase or decrease service interval
2. Change assistance interval value using HOURS INCREASE pop-up menu
3. Press SAVE AND EXIT button and confirm

133

Drive motor parameters calibration

Fig.25: Drive motors calibration

In that menu front panel, you can find following data about drive motor parameters: description, actual value, new
value you want to set, measure unit, default values minimum and maximum settable values, actual value in
percent.
You can execute following operations:
Select default value:
1. Press DEFAULT button; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; both OLD data fields and first 3 parameters will be updated
Change actual value:
1. Insert changed value in NEW data field (or modify one of first 3 parameters)
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field (or one of first 3 parameters) initial value is restored.
Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields and first 3 parameters are restored with initial values
First 3 parameters, for their particular meaning, are visualized and managed in a more user friendly way.

134

Pump motor parameters calibration

Fig.26: Pump motor calibration menu

In that menu front panel, you can find following data about pump motor parameters: description, actual value, new
value you want to set, measure unit, default values minimum and maximum settable values, actual value in
percent.
You can execute following operations:
Select default value:
1. Press DEFAULT button; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields will be updated
Change actual value:
1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.
Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields are restored with initial values

135

Critical height: speed limits calibration(Optional Menu)

Fig.27: Maximum speed calibration menu

You can set maximum speed of pump and drive motors in case of a fork height superior to critical one (that
condition is signalled by two switches present on lift truck forks)
In that menu front panel, you can find following data about critical maximum speeds: description, actual value,
new value you want to set, measure unit, default values minimum and maximum settable values, actual value in
percent.
You can execute following operations:
Select default value:
1. Press DEFAULT button; NEW data fields will be automatically updated with default value
2. Press SAVE button and confirm; OLD data fields will be updated
Change actual value:
1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.
Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial values
2. Press SAVE button and confirm; OLD data fields are restored with initial values

136

Weight sensor calibration (Optional Menu)

Fig.28: Fork weight calibration menu

In that menu front panel, you can find following data about parameters: description, actual value, measure unit,
default values, minimum and maximum settable values. Pressing SAVE button, visualized pressure value is saved
on actually selected parameter.
You can execute following operations:
Select default value:
1. Press DEFAULT button; VALUE data fields will be automatically updated with default value
Calibrate weight sensor:
1. Select NO LOAD parameter
2. Hoist lift truck forks till 50 cm height
3. Wait for 5 s
4. Press SAVE button and confirm to record weight sensor reading in case of no load on forks
5. Put on lift truck forks a known value load
6. Select LOAD parameter
7. Set, in weight data field, lifted load value
8. Hoist lift truck forks till 50 cm height
9. Wait for 5 s
10. Press SAVE button and confirm to record weight sensor reading in case of known load on forks
Discard changes:
1. Press CANCEL button; VALUE data fields will be restored with initial values

137

Cab lift speed calibration (Optional Menu)

Fig.29: Cab lift calibration menu

In that menu front panel, you can find following data about cab lift speed: description, actual value, new value you
want to set, measure unit, default values minimum and maximum settable values.
You can execute following operations:
Select default value:
1. Press DEFAULT button; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field will be updated
Change actual value:
1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.
Discard changes:
1. Press CANCEL button; NEW data field will be restored with initial values
2. Press SAVE button and confirm; OLD data field are restored with initial values

138

Timers reset

Fig.30: Timers reset menu

In that menu you can reset timers signalling lift truck working hours; remember that if you press that button, a
double confirmation is necessary.
This menu is use possibility developer.

139

Lift truck setup (Optional Menu)

Fig.31: Lift truck setup menu

In that menu front panel, you can find following data: parameters description, actual status (ON or OFF), new
status you want to set, and default status.
You can execute following operations:
Select default value:
1. Press DEFAULT button; NEW data fields will be automatically updated with default status
2. Press SAVE button and confirm; OLD data fields will be updated
Change actual value:
1. Insert changed status in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial status is restored.
Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial status
2. Press SAVE button and confirm; OLD data fields are restored with initial status

140

Backing mode parameters calibration (Optional Menu)

Fig.32: Backing mode calibration menu

In that menu front panel, you can find following data about backing mode parameters: description, actual value,
new value you want to set, measure unit, default values minimum and maximum settable values.
You can execute following operations:
Select default value:
1. Press DEFAULT button; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field will be updated
Change actual value:
1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.
Discard changes:
1. Press CANCEL button; NEW data field will be restored with initial values
2. Press SAVE button and confirm; OLD data field are restored with initial values

141

Eeprom reset menu


That menu has two important functions:
1. In case of Eeprom alarm, you have to use complete EEPROM reset procedure.
2. If you have updated flash memory software, and you want to load default Eeprom configuration, you have to
use complete Eeprom reset; to maintain already calibrated values you can use partial EEPROM reset
procedure.
Pay attention that using complete reset procedure you loose already calibrated values.
Both procedures, in any case, dont modify timers value and alarm history.
Partial EEPROM reset:
1. Press PARTIAL LOAD EEPROM button
2. Give a confirmation to load default values

Fig. 33: Eeprom configuration menu

Complete EEPROM reset:


1. Press TOTAL LOAD EEPROM button
2. Give a confirmation to load default values
3. Give a further confirmation (Fig. 34)

Fig. 34: Further confirmation

142

Parameters Image menu

Fig 35: Parameters image menu

In that menu, You can store and restor about calibration parameters except Lift, pedal, steering setting valure.
Parameter Store
1. Press Export button
2. Store calibration parameters
Parameter Restore (other trucks)
1. Press Import button
2. Restore calibration parameters

143

Data Logging
With that menu (Fig. 36) you can save on file the values of a certain number of variables with a certain frequency;
the resulting file is logging.out, saved in <EYE PATH>\EYE\out directory.

Fig. 36: Data logging menu

Data acquisition procedure is following:


1. Select Nmax, the number of variables you want to save
2. Select the variables whose value you want to record, with apposite pop-up menu
3. You can modify sampling period, expressed in seconds.
4. Pressing START button, saving procedure begins; in that phase you cant modify acquisition parameters
During acquisition procedure (Fig. 37), following data are visualized:
1. A led signals saving instant
2. A gauge scans time between 2 saving instants
3. Indication of number of saved frames
4. Flashing message SAVING
To stop saving procedure you can press START button, or simply exiting the menu.

144

Fig. 37: Data logging menu saving mode

Logging.out file format is:


FIRST ROW: name of NMAX variables to be saved followed by saving date and time;
SUCCESSIVE ROWS: NMAX recorded values separated by space.

145

Flash

Fig. 38: Flash programming phase

To upgrade main controller software, with Flash menu (Fig. 36) follow these steps:
1. Disable all commands
2. Verify if C:\SOURCE_FILE directory exists (otherwise create it)
3. Source directory must contain only 2 source files
4. Select FLASH item from menu-bar
5. Give confirmation to start programming phase
6. In case of troubles with source files, (missing files, wrong version,...) there will be an error message and flash
memory will not programmed .
7. After a synchronization phase, flash programming will start; a bar gives the percent indication of already
programmed memory.
8. In case of problems with serial communication, there will be an error message and flash programming phase
will be stopped.
9. After traction micro successful programming, begins pump micro programming phase (step 7 and 8)
10. A message will signal the end of programming phase, and its result; give confirmation to exit the menu.
See troubleshooting section in case of any error.
NOTE: If programming phase fails after synchronization, panel has to be programmed with correct software
before being used.
Enforce necessarily following item after Flash.
1. Click the total load EEPROM of LOAD EEPROM DEFAULT MENU
2. Re-set the lift, pedal, steering sensor

146

Troubleshooting of Eye Program


Generality

Flash Programmation
G
If panel programming phase fails, when you try
to load source files:
1. Verify if c:\source_file directory exists
2. Verify if c:\source_file directory contains only 2
source files
3. Be sure that source files are the ones provided
by DHIMs Homepage.

Often you can solve problems reading error


messages and following suggestions.

Software Installation
In case of failed EYE software installation, follow
these steps:
1. Verify if your PC complies minimal requirements
2. Be sure of having PC administrator rights
3. Close all active applications and disable
antivirus before installation
4. Verify installation, step by step

If you program memory successfully, but


inverter doesnt work correctly:
1. Be sure that source files are the ones provided
by S.M.E

In case of successful installation, if application


has a runtime error:
1. Verify if your PC complies minimal requirements
2. Turn off PC and try again after turning it on
3. Uninstall and install again EYE software

In case of transmission error:


1. Verify system ground connections
2. Control serial connection cable: you must use a
shielded one
3. Verify if serial port works correctly
4. Verify if there are any active commands

Serial Communication

Other Problems

If application doesnt work and message not


connected appears:
1. Verify system ground connections
2. Verify if inverter panel works correctly
3. Control serial connection cable: you must use a
shielded one
4. Verify if serial port works correctly
5. Use Setup menu to verify serial port
configuration
6. Verify no other applications serial port

Application works slowly:


1. Verify if your PC complies minimal requirements
Application doesnt work properly:
1. Verify if your PC complies minimal requirements
Text and objects on main panel are not centred:
1. Verify if your PC complies minimal requirements
2. Dont modify window size
Monitor doesnt display correctly text and
objects
1. Verify if monitor refresh frequency is at least
75Hz
2. Verify if your PC complies minimal requirements

147

Appendix A : 48[V] Parameter List

No

Parameter
No

Parameter

Parameter Description

Deceleration
steering
ramp 1

Deceleration
steering
ramp 2

Battery reset
value

11

Seat switch
delay

12

Chat time

13

Hydro time

as high it is as quickly the truck


decreases its speed if the truck driver is
turning the wheel quickly
as high it is as quickly the truck
decreases its speed in relation to the
drive speed of truck. This parameter
increases the deceleration ramp while
the driver is steering at high speed.
Minimum battery voltage necessary to
reset battery discharged voltage alarm
Time interval between seat switch
opening and drive and pump motors
stopping
Time delay between last command
given to a drive or pump motor and chat
mode signalling
Time interval when pump motor works
(with hydro speed) after the end of a
command

14

18

19

10

20

11

23

12

24

13

26

14

32

Maximum lift

15

33

Minimum lift

16

34

Middle lift

17

41

18

42

19

43

20

44

21

46

Maintenance
time
inserting
enable
Steering
clockwise
Steering
anticlockwise
Steering
middle
Minimum
accelerator
Maximum
accelerator
Stop on slop
timer

Drive
maximum
current
Forward
maximum
speed
Reverse
maximum
speed
Drive
limitation
maximum
speed
High lift 1
switch drive
max speed

Maintenance time inserting enable


Steering sensor voltage with wheels
turned on left
Steering sensor voltage with wheels
turned on right
Steering voltage with wheels straight
ahead
Accelerator sensor voltage with pedal
released
Accelerator sensor voltage with pedal
completely pressed
Without stepping on pedal brake, time
that is doing stop in slope
Lift sensor voltage with lift lever
completely pressed
Lift sensor voltage with lift lever
released
Lift lever potentiometer voltage to which
the lifting becomes proportional to the
shift of the lever
Drive motors maximum current
(expressed in per cent of high energetic
mode value)
Maximum forward lift truck speed with
no speed limitation
(no alarms present and turtle not active)
Maximum reverse lift truck speed with
no speed limitation
(no alarms present and turtle not active)

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

rpm/s

10

800

5000

10

rpm/s

10

V*10

464

470

501

10

10

20

Disable = 0 (Default)
Enable = 1

digit

mV

500

1,200

11,500

10

mV

500

10,300

11,500

10

mV

500

6,300

11,500

10

mV

200

1,000

4,500

10

mV

3,000

5,000

12,000

10

10

mV

3,000

11,500

12,000

10

mV

1,000

12,000

10

mV

1,000

2,750

12,000

10

20

100

100

rpm

1,000

4,500

4,500

50

rpm

1,000

4,500

4,500

50

Maximum lift truck speed with speed


limitation (turtle active)

rpm

500

2,000

2,500

50

Maximum lift truck speed when forks


high is more than critical one

rpm

400

2,000

4,500

50

148

No

Parameter
No

Parameter
Steer
limitation
maximum
speed
Acceleration
ramp
Inversion
ramp
Release
ramp
Pedal brake
ramp

Parameter Description

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

Maximum speed reference in the angle


in which the internal wheel is
mechanically still.

rpm

400

1,000

2,000

50

Lift truck acceleration with accelerator


pedal pressed

rpm/s

400

1,100

2,000

10

Lift truck deceleration in inversion

rpm/s

400

1,300

2,000

10

rpm/s

400

900

2,000

10

rpm/s

400

1,200

2,000

10

rpm

100

300

2,000

mm

300

451

600

rpm/s

10

50

500

10

Pump motor maximum current with lift


function active

20

100

100

Pump motor maximum current with lift


lever released

10

65

100

rpm

1,500

2,950

4,500

50

rpm

500

900

2,000

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

Minimum lift speed

rpm

500

700

1,500

50

Maximum pump motor speed with forks


above the critical height

rpm

500

500

4500

50

rpm

400

500

800

10

rpm

200

300

500

10

rpm/s

1,000

7,000

10,000

10

Pump motor deceleration after the end


of a command

rpm

1000

7000

10000

10

Power mode setting up state

digit

Accelerator signal 1 = E mode,


2 = S mode,
3 = H mode

22

47

23

48

24

49

25

50

26

51

27

52

Creep speed

28

53

Diameter of
drive tyres

Drive tyre's diameter

Partial
release ramp

Parameter that softens the drive


inversion ramp if the traction motors are
working with low rpm

29

59

30

61

31

62

32

63

33

64

Tilt speed

34

65

AUX 1 speed

35

66

AUX 2 speed

36

67

AUX 3 speed

37

68

38

69

39

70

40

71

41

72

42

73

43

93

Lift
maximum
current
Auxiliary
maximum
current
Lift
maximum
speed

Lift minimum
speed
High lift 1
switch lift
max speed
Hydro speed
Hydro idle
speed
Pump
acceleration
ramp
Pump
deceleration
ramp
Power mode
(E-S-H,
limitations)

Lift truck deceleration with accelerator


pedal released
Lift truck deceleration with pedal brake
pressed
If the truck speed is greater then this
threshold, the speed reference becomes
a parabolic function of the accelerator
potentiometer voltage.

Maximum lift speed


Pump motor speed with lift function
active
Pump motor speed with lateral shift
function (1st auxiliary) active
Pump motor speed with 2nd auxiliary
function active
Pump motor speed with 3rd auxiliary
function active

Pump motor speed when steering


Pump motor speed with direction
command lever not in neutral,
acceleration pressed and no pump
command active
Lift acceleration

149

No

Parameter
No

44

94

Slow speed

45

95

British unit

46

96

Display
brightness

47

97

E-S-H
enable

48

98

49

99

Parameter

Time meter /
Odometer on
display
Maintenance
time

Parameter Description
If parameter is set to1, speed limitation
is active; otherwise lift truck speed is
managed as usual.
If parameter is set to 1, values are
expressed in British unit, otherwise in
international ones.
Display's brightness adjustment
If this parameter is set to 1, it is possible
to change the value of the power mode
with the display
If parameter is set to 1, odometer
indication appears on display ;
otherwise display shows the hour meter.
Maintenance period decision

150

Unit

Mini
mum

Def
ault

Maxi
mum

Varia
tion

digit

Disable = 0 (Default)
Enable = 1

digit

Normal = 0 (Default)
British unit = 1

digit

digit

Disable = 0
Enable = 1 (Default)

digit

Timer meter = 0 (Default)


Odometer = 1

10000

100

Appendix B : 36[V] Parameter List

No

Parameter
No

Parameter

Parameter Description

Deceleration
steering
ramp 1

Deceleration
steering
ramp 2

Battery reset
value

11

Seat switch
delay

12

Chat time

13

Hydro time

as high it is as quickly the truck


decreases its speed if the truck driver is
turning the wheel quickly
as high it is as quickly the truck
decreases its speed in relation to the
drive speed of truck. This parameter
increases the deceleration ramp while
the driver is steering at high speed.
Minimum battery voltage necessary to
reset battery discharged voltage alarm
Time interval between seat switch
opening and drive and pump motors
stopping
Time delay between last command
given to a drive or pump motor and chat
mode signalling
Time interval when pump motor works
(with hydro speed) after the end of a
command

14

18

19

10

20

11

23

12

24

13

26

14

32

Maximum lift

15

33

Minimum lift

16

34

Middle lift

17

41

18

42

19

43

20

44

21

46

Maintenance
time
inserting
enable
Steering
clockwise
Steering
anticlockwise
Steering
middle
Minimum
accelerator
Maximum
accelerator
Stop on slop
timer

Drive
maximum
current
Forward
maximum
speed
Reverse
maximum
speed
Drive
limitation
maximum
speed
High lift 1
switch drive
max speed

Maintenance time inserting enable


Steering sensor voltage with wheels
turned on left
Steering sensor voltage with wheels
turned on right
Steering voltage with wheels straight
ahead
Accelerator sensor voltage with pedal
released
Accelerator sensor voltage with pedal
completely pressed
Without stepping on pedal brake, time
that is doing stop in slope
Lift sensor voltage with lift lever
completely pressed
Lift sensor voltage with lift lever released
Lift lever potentiometer voltage to which
the lifting becomes proportional to the
shift of the lever
Drive motors maximum current
(expressed in per cent of high energetic
mode value)
Maximum forward lift truck speed with
no speed limitation
(no alarms present and turtle not active)
Maximum reverse lift truck speed with
no speed limitation
(no alarms present and turtle not active)

Unit

Mini
mum

Def
ault

Maxi
mum

Vari
ation

rpm/s

10

800

5000

10

rpm/s

10

V*10

344

356

373

10

10

20

Disable = 0 (Default)
Enable = 1

digit

mV

500

1,200

11,500

10

mV

500

10,300

11,500

10

mV

500

6,300

11,500

10

mV

200

1,000

4,500

10

mV

3,000

5,000

12,000

10

10

mV

3,000

11,500

12,000

10

mV

1,000

12,000

10

mV

1,000

2,750

12,000

10

20

100

100

rpm

1,000

3,800

3,800

50

rpm

1,000

3,800

3,800

50

Maximum lift truck speed with speed


limitation (turtle active)

rpm

500

2,000

2,500

50

Maximum lift truck speed when forks


high is more than critical one

rpm

400

2,000

3,800

50

151

No

Parameter
No

Parameter
Steer
limitation
maximum
speed
Acceleration
ramp
Inversion
ramp
Release
ramp
Pedal brake
ramp

Parameter Description

Unit

Mini
mum

Def
ault

Maxi
mum

Vari
ation

Maximum speed reference in the angle


in which the internal
wheel is mechanically still.

rpm

400

1,000

2,000

50

Lift truck acceleration with accelerator


pedal pressed

rpm/s

400

1,100

2,000

10

Lift truck deceleration in inversion

rpm/s

400

1,300

2,000

10

rpm/s

400

900

2,000

10

rpm/s

400

1,200

2,000

10

rpm

100

300

2,000

mm

300

451

600

rpm/s

10

50

500

10

Pump motor maximum current with lift


function active

20

100

100

Pump motor maximum current with lift


lever released

10

65

100

rpm

1,500

2,950

4,500

50

rpm

500

900

2,000

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

Minimum lift speed

rpm

500

700

1,500

50

Maximum pump motor speed with forks


above the critical height

rpm

500

500

4500

50

rpm

400

500

800

10

rpm

200

300

500

10

rpm/s

1,000

7,000

10,000

10

Pump motor deceleration after the end


of a command

rpm

1,000

7,000

10,000

10

Power mode setting up state

digit

Accelerator signal 1 = E mode,


2 = S mode,
3 = H mode

22

47

23

48

24

49

25

50

26

51

27

52

Creep speed

28

53

Diameter of
drive tyres

Drive tyre's diameter

Partial
release ramp

Parameter that softens the drive


inversion ramp if the traction motors are
working with low rpm

29

59

30

61

31

62

32

63

33

64

Tilt speed

34

65

AUX 1 speed

35

66

AUX 2 speed

36

67

AUX 3 speed

37

68

38

69

39

70

40

71

41

72

42

73

43

93

Lift
maximum
current
Auxiliary
maximum
current
Lift
maximum
speed

Lift minimum
speed
High lift 1
switch lift
max speed
Hydro speed
Hydro idle
speed
Pump
acceleration
ramp
Pump
deceleration
ramp
Power mode
(E-S-H,
limitations)

Lift truck deceleration with accelerator


pedal released
Lift truck deceleration with pedal brake
pressed
If the truck speed is greater then this
threshold, the speed reference becomes
a parabolic function of the accelerator
potentiometer voltage.

Maximum lift speed


Pump motor speed with lift function
active
Pump motor speed with lateral shift
function (1st auxiliary)
active
Pump motor speed with 2nd auxiliary
function active
Pump motor speed with 3rd auxiliary
function active

Pump motor speed when steering


Pump motor speed with direction
command lever not in neutral,
acceleration pressed and no pump
command active
Lift acceleration

152

No

Parameter
No

Parameter

44

94

Slow speed

45

95

British unit

46

96

Display
brightness

47

97

E-S-H
enable

48

98

49

99

Time meter /
Odometer on
display
Maintenance
time

Parameter Description
If parameter is set to1, speed limitation
is active; otherwise lift truck speed is
managed as usual.
If parameter is set to 1, values are
expressed in British unit, otherwise in
international ones.
Display's brightness adjustment
If this parameter is set to 1, it is possible
to change the value of the power mode
with the display
If parameter is set to 1, odometer
indication appears on display ; otherwise
display shows the hour meter.
Maintenance period decision

153

Unit

Mini
mum

Def
ault

Maxi
mum

Vari
ation

digit

Disable = 0 (Default)
Enable = 1

digit

Normal = 0
British unit = 1 (Default)

digit

digit

Disable = 0
Enable = 1 (Default)

digit

Timer meter = 0 (Default)


Odometer = 1

10000

100

Appendix C : Error Code List


EYE
Code

Error
Code

Description

F0

Maximum
battery
voltage

F1

Minimum
battery
voltage

F2

Pedal
trimmer fault

Eeprom
alarm

Pre -charge
capacitors
low voltage
alarm
(Capacitors
not
charged)

Level

Cause

Trohbleshooting

Battery voltage, measured


by a circuit inside logic,
exceeds following levels:
63 V, in case of systems
working at 36 V
63 V, in case of systems
working at 48 V

Battery voltage, measured


by an internal circuit, is
lower than following
levels : 24 V , in case of
systems working at 36 V

Voltage measured on
accelerator circuit exceeds
the value calculated
averaging calibration and
reachable voltages;
moreover, start switch
seems to be open.

Eeprom does not work


properly, or one of
memorised values is out of
correct limits.
Voltage level of pre charge capacitors is less
then 70 % of nominal
battery level.
It could happen, in
example, if the inverter is
working with main breaker
open.
Capacitors voltage
decreases cause energy
spent to keep motors in
motion.

154

1. Such an alarm can be caused also by the


presence of regeneration currents; when lift
truck is on release or reverse braking ramp,
motors work as generators, and battery voltage
can exceed overvoltage limit. In a case like
that, the battery condition should be verified ( if
the battery is new it is necessary to do some
charge-discharge cycles before reaching the
rating declared by the constructor) or has a
high internal resistance.
If the case is the second and it is not possible
to change the battery, the solution may be to
reduce the release and reverse braking ramp.
2. Incorrect wiring to battery positive or negative
terminals.
3. Verify if battery is still in good conditions.
4. Replace the logic.
1. Incorrect wiring to battery, or corroded positive
or negative terminals;
2. Verify battery conditions: if the electrolyte
inside is partially exhausted, an under voltage
alarm can sometimes be detected from the
controller; even in case of low battery charge
(<10%), high current rates (i.e. both pump and
drive motors working in full load conditions)
could cause an under voltage alarm, in
particular in presence of an exhausted battery.
3. Replace the logic.
1. Verify if the potentiometer initial set-up is
correct; if not, repeat calibration
procedure.(You can use both PC with serial
communication software and Instrument
panel).
2. Verify if the following 68 ways connector
terminals are correctly wired to their
correspondent inputs in potentiometer circuit:
- K1-11 (12 V)
- K1-15 (ground)
- K1-10 (pedal input)
3. In case of correct wiring, replace the
potentiometer itself.
4. Replace logic
1. Load default values for eeprom variables, both
using PC with serial communication software
and Instrument panel;
2. Replace the logic.
1. Verify if main breaker coil and power terminals
are in good conditions;
2. Verify if supply lines power fuse is damaged;
3. Verify if main breaker coils are correctly wired
to their correspondent inputs :
- K1-18 (positive terminal)
- K1-19 (negative terminal)
4. Replace main breaker;
5. Replace logic.

EYE
Code

Error
Code

F3

24

F4

Description
right drive
motor power
module
pump motor
power
module

Level

Cause

Trohbleshooting

1
Actual current exceeds
limits 929 A

25

10

11

F5

left drive
motor power
module

Inverter
capacitors
pre -charge
too fast

E3

Pump motor
inverter
overtemper
ature

Capacitors
too charged
on start

Pre -charge capacitors


voltage increases too fast
when you turn the system
on.

The inverter temperature


(measured with a
temperature connector),
exceeds 100 C, or is
inside [95 C, 100 C]
range at least 30 s.

When you turn on the


system, capacitors are not
completely discharged by
pump motor.
In fact, if you turn
suddenly on the lift truck,
after a turning off,
capacitors voltage level is
too high. You have to
discharge them before
checking the presence of
any fault (both of
capacitors and of logic)

155

1. With such an alarm present when you turn on


lift truck, disconnect the power cable between
the malfunctioning inverter and the
corresponding motor (first, turn off the system,
of course).
If turning lift truck on again, alarm is not active,
then:
1. Replace the cable connecting logic and
inverter.
2. Replace the inverter;
3. Replace logic.
If turning lift truck on again, alarm is active,
then :
1. Replace the inverter;
2. Replace the motor.
1. Replace main breaker.
2. Replace cable connecting the CN1 output of
the logic with the corresponding inverter;
3. Replace the inverter connected with the
CN1output of logic
4. Replace logic
1. Alarm could be caused by ineffective
temperature dissipation.
Verify thermal coupling between inverter block
and aluminium plate, and between aluminium
plate and truck ballast.
The presence of a correct amount of thermal
grease in the coupling is essential to ensure an
efficient heat exchange;
2. Replace cable connecting the output CN4 of
the logic to the pump inverter;
3. If temperature readings seem too high in
function of total time interval of lift truck using,
replace pump inverter causing the alarm.
You can read temperature measures using
Instrument panel or EYE communication
software.
4. Replace logic.
1. Verify the correctness of wiring from pump
motor and relative inverter;
2. Replace wire connecting CN3 with the
corresponding inverter or if not possible
because the pump motor inverter box
integrates the outlet wire, substitute the
inverter box;
3. Verify if main breaker has stuck closed
terminals: in such a case replace it;
4. Replace the wire connecting CN1 in logic to
right drive motor inverter: a defective wire
could give a wrong measure for capacitors
voltage;
5. Replace logic.

EYE
Code

12

13

14

Error
Code

EL

E4

E6

15

F6

16

F7

17

17

18

Description

Low battery
alarm

Drive motor
over
temperature

Pump motor
over
temperature

Motor
current
offset alarm
Motor
current
offset alarm
Main
breaker fault
Watchdog
timer alarm

Level

Cause

Trohbleshooting

Battery voltage level is


lower than minimum
charge value expected,
referred to table 2 (for 36V
system) and table 3(for
48V system) in Instrument
panel technical
documentation.

1. Measure battery voltage with a tester and, if


different from the value reported on Instrument
panel, replace logic;
2. Otherwise recharge battery.

The measure of drive


motor temperature
exceeds 155 C..

The measure of pump


motor temperature
exceeds 155 C .

Non-zero phase currents


when you turn lift truck on.

Non-zero phase currents


when you turn lift truck on.

Overcurrent on main
breaker coil.
Improper communication
between DSPs present on
logic, or/and defective
logic.

156

Presence of alarm with cold motors:


1. With a handheld multimeter (in resistance
operating mode) you have to measure a
resistance of about 10 kohm between the two
wires of the temperature connector ( execute
the measure at ambient temperature of 25C) .
If the measure is not correct it is necessary to
replace the temperature connector;
2. Disconnect the temperature connector and
check the wiring insulation between signal wire
an ground wire ( towards logic);
3. replace logic.
Presence of alarm with hot motors :
1. If temperature value (you can read it from
Instrument panel or via PC) seems correct,
verify if fans (if present) work properly; fault is
caused by an inefficient motor refreshing, or by
operating out of nominal maximum ranges.
Presence of alarm with cold motors:
1. With a handheld multimeter in resistance
operating mode, you have to measure about
10kohm at ambient temperature of 25C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
2. Disconnect the temperature connector and
check the wiring insulation between signal wire
and ground wire ( towards logic);
3. replace logic.
Presence of alarm with hot motors:
1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
1. Replace the wire connecting inverter to logic.
2. Replace inverter.
3. Replace logic.
1. Replace the wire connecting inverter to logic.
2. Replace inverter.
3. Replace logic.
1. Replace main breaker
2. If alarm is still present, replace logic
1. Using EYE program interface, try to program
logic flash memory;
2. Replace logic .

EYE
Code

19

20

21

22

Error
Code

E5

E1

E2

Description

Drive motor
over
temperature

Right drive
motor
inverter
overtemper
ature

Serial
communicat
ion alarm

Left drive
motor
inverter
overtemper
ature

Level

Cause

Trohbleshooting

The measure of drive


motor temperature
exceeds 155 C..

Presence of alarm with cold motors:


1. With a handheld multimeter (in resistance
operating mode) you have to measure a
resistance of about 10 kohm between the two
wires of the temperature connector ( execute
the measure at ambient temperature of 25C) .
If the measure is not correct it is necessary to
replace the temperature connector;
2. Disconnect the temperature connector and
check the wiring insulation between signal wire
an ground wire ( towards logic);
3. replace logic.
Presence of alarm with hot motors :
1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
1. Alarm could be caused by ineffective
temperature dissipation; verify thermal coupling
between inverter block and aluminium plate
and between aluminium plate and truck ballast.
The presence of the correct amount of thermal
grease in the coupling are essential to ensure
a correct heat exchange;
2. Replace cable connecting the output CN1 of
the logic to the corresponding inverter;
3. If temperature readings seem too high in
function of total time interval of lift truck using,
replace inverter unit causing the alarm. You
can read temperature measures using
Instrument panel or EYE communication
software.
4. Replace logic.

Inverter temperature,
measured with a
connector, exceed 100 C,
or is inside [95 C,
100 C] range at least 30
s.

Error in serial
communication between
the two DSP; DSP present
on logic make a mutual
software control, to insure
fast diagnosis of such a
fault.

1. Program pump and drive DSP again; maybe


software present in flash memory was
corrupted.
2. Replace logic.

Inverter temperature,
measured with a connector,
exceed 100 C , or is inside
[95 C, 100 C] range at
least 30 s.

1. Alarm could be caused by ineffective


temperature dissipation; verify thermal coupling
between inverter block and aluminium plate
and between aluminium plate and truck ballast.
The presence of the correct amount of thermal
grease in the coupling are essential to ensure
a correct heat exchange;
2. Replace cable connecting the output CN2 of
the logic to the corresponding inverter;
3. If temperature readings seem too high in
function of total time interval of lift truck using,
replace inverter unit causing the alarm. You
can read temperature measures using
Instrument panel or EYE communication
software.
4. Replace logic.

157

EYE
Code

Error
Code

Description

Level

Cause

36

F8

Motor
current
offset alarm

Non-zero phase currents


when you turn lift truck on.

37

FA

Alarm on 5
V encoder
voltage

logic K1-14 terminal (5 V


output) voltage is lower
than 4.3 V.

38

FH

Alarm on 12
V output
voltage

logic K1-12 terminal (12 V


output) voltage is lower
than 10.5 V.

FL

Pump motor
commands
active on
start

You find a pump motor


command active when you
turn your system on.

When you start working,


you find seat switch open,
or, after the main breaker is
closed, the seat switch
remains opened for at least
seat switch delay s.

50

63

EE
(flash)

Seat switch
open on
start

Trohbleshooting

64

EE

Wrong start

When you start working,


you find accelerator pedal
pressed or a forward/
reverse switch active.

74

Fc

Encoder
alarm

An encoder channel is
disconnected, and motor
is working.

75

Fd

Encoder
alarm

An encoder channel is
disconnected, and motor
is working.

158

1. Replace the wire connecting inverter to logic.


2. Replace inverter.
3. Replace logic.
1. Verify if 5 V output is grounded, cause an
incorrect encoder wiring.
2. Verify if 5 V output is grounded, cause any
encoder malfunction. In that case, replace the
defective one.
3. Replace logic.
1. Verify if 12 V output is grounded, cause an
incorrect wiring to:
- Accelerator potentiometer
- Steering sensor
- Buzzer
- Display
2. Replace defective device;
3. Replace logic.
1. Before starting to operate, turn off any active
command (both levers and switches);
2. Be sure that lift, tilt and auxiliary command
switches, are not active;
3. Replace valve board.

1. Verify if seat switch is defective;


2. Replace logic.

1. verify if a switch was active or the pedal


pressed, when you turn on the lift truck;
2. verify if start, forward or reverse switches are
stuck close;
3. verify if pedal circuit voltage exceeds 1/3 its
maximum range (measured in Volt);
4. replace logic.
1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K1- 15 terminal
- + 5 V: K1- 14 terminal
- A channel: K1- 37 terminal
- B channel: K1- 36 terminal
2. If correctly wired, replace the encoder;
3. Replace logic.
1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K1- 15 terminal
- + 5 V: K1- 14 terminal
- A channel: K1- 17 terminal
- B channel: K1- 16 terminal
2. If correctly wired, replace the encoder;
3. Replace logic.

EYE
Code

77

77

78

78

79

79

80

80

81

81

82

82

Description
Alarm of
right drive
motor
thermal
connector
Alarm of left
drive motor
thermal
connector
Alarm of
pump motor
thermal
connector
Alarm of
right drive
motor
module
connector
Alarm of left
drive motor
module
connector
Alarm of
pump motor
module
connector

Level

Cause

Trohbleshooting

Temperature difference
between any two of the 3
motors results greater
than 70 C.

1. Verify if the wiring is correct;


2. Replace the connector;
3. Replace logic.

Temperature difference
between any two of the 3
inverters results greater
than 70 C.

1. Check the wiring connecting control unit and


inverter;
2. Replace the inverter;
3. If alarm is still present, replace logic.

1. restore eeprom with EYE application software,


using the RESTORE item present in main
page
2. if alarm is still present, replace logic.
CRC : Cyclic Redundancy Checking error.
1. Switch on the system and the turn it on again

83

83

CRC fault
alarm

Faulty eeprom or
mismatching software
release.

84

84

Bank CRC
restored

There was an eeprom


restore, caused by a CRC
alarm.

91

98

99

Error
Code

F9

Steering
sensor
alarm

Capacitors
pre -charge
too slow

Capacitors
pre-charge
too slow

Steer circuit voltage is out


of nominal range.

Pre -charge capacitor


voltage grows too slowly,
when you turn on the
system.

Pre-charge capacitors
voltage does not reach the
rated battery voltage
within a limit time, when
you turn on the system.

159

1. verify correctness of wiring with :


- K1-11 (12 V),
- K1-15 (ground)
- K1-10 (steering sensor input);
2. if correctly wired, replace steering sensor;
3. replace logic.
1. Replace cable connecting the CN1 output of
the logic with the corresponding inverter
2. Replace the inverter connected with CN1
output of the logic;
3. Replace logic;
1. Replace cable connecting the CN1 output of
the logic with the corresponding inverter
2. Replace the inverter connected with CN1
output of the logic;
3. Replace logic;

Appendix D : Contraction for dot matrix display.


1. Alarm Code
[Display Code]
17
60
76
77
78
79
80
81
82
83
84
A
A
A
A
A
E1
E2
E3
E4
E5
E6
EE
EE(FLASING)
EL
F
F
F
F0
F1
F2
F3
F4
F5
F6
F7
F8
F9
FA
Fc
Fd
FE
FH
FL

[Description]
Main breaker fault
Battery/inverter mismatch
Pump motor Encoder
Wrong right traction motor thermal switch
Wrong left traction motor thermal switch
Wrong pump motor thermal probe
Wrong right traction module thermal probe
Wrong left traction module thermal probe
Wrong pump module thermal probe
CRC fault
Bank CRC restored
Capacitors not charged : fast charge
Trans.precharge in short/Cap. too charged
Capacitors not charged : slow charge
Capacitors not charged : time out
Capacitors not charged
Drive right module Overtemperature
Drive left module Overtemperature
Pump module Overtemperature
Drive right motor Overtemperature
Drive left motor Overtemperature
Pump motor Overtemperature
Wrong start
Seat switch
Low battery voltage
Eeprom
WD Timer/Enable micro signals
Serial communication
Maximum battery voltage
Minimum battery voltage
Pedal trimmer fault
Drive right module Desat/overcurrent
Drive left module Desat/overcurrent
Pump module Desat/overcurrent
Drive right motor current Offset
Drive left motor current Offset
Pump motor current Offset
Steer sensor fault
5V encoders not ok
Drive right motor Encoder
Drive left motor Encoder
24V out
12V out not ok
Pump input on at the start

160

[Contraction]
CONTACTOR FAULT
BATT MISMATCH
P-MOTOR ENCODER
R-M TEMP SENSOR
L-M TEMP SENSOR
P-M TEMP SENSOR
R-INV T SENSOR
L-INV T SENSOR
P-INV T SENSOR
CRC FAULT
CRC RESTORED
FAST CHARGE
TOO CHARGED
CAP SLOW CHARGE
TIME OUT CHARGE
CAP NOT CHARGED
R-INV OVERTEMP
L-INV OVERTEMP
P-INV OVERTEMP
R-MOTOR OVERTEMP
L-MOTOR OVERTEMP
P-MOTOR OVERTEMP
WRONG START
SEAT SW OPEN
LOW BATT VOLT
EEPROM FAULT
WD TIMER FAULT
COMM FAULT
MAX BATT VOLT
MIN BATT VOLT
ACCEL FAULT
R-INVERTER FAULT
L-INVERTER FAULT
P-INVERTER FAULT
R-MOTOR I OFFSET
L-MOTOR I OFFSET
P-MOTOR I OFFSET
STEER SENSOR OUT
5V NOT OK
R-MOTOR ENCODER
L-MOTOR ENCODER
24V NOT OK
12V NOT OK
PUMP SIGN ON

2. Calibration Code
[Display Code]
5
6
9
10
11
12
13
14
17
18
19
20
23
24
26
32
33
34
41
42
43
44
45
46
47
48
49
50
51
52
53
59
61
62
63
64
65
66
67
68
69
70
71
72
73
93
94
95
96
97
98
99

[Description]
Deceleration steering ramp 1
Deceleration steering ramp 2
Battery reset value
First parameter for calibration enable
Seat switch delay
Chat time
Hydro time
Maintenance time inserting enable
Second parameter for calibration enable
Steering sensor value : wheels turned on the right
Steering sensor value : wheels turned on the left
Steering sensor value : wheels on straight position
Accelerator pedal minimum value
Accelerator pedal maximum value
Stop on slop timer
Lift sensor maximum value
Lift sensor minimum value
Lift sensor middle value
Drive maximum current
Forward maximum speed
Reverse maximum speed
Drive limitation max speed
Critical weight drive max speed
Critical height drive max speed
Steer limitation drive max speed
Drive acceleration ramp
Drive inversion ramp
Drive release ramp
Pedal brake ramp
Creep speed
Diameter of drive tyres
Partial release ramp
Lift max current
Auxiliary max current
Lift max speed
Tilt speed
Auxiliary 1 function speed
Auxiliary 2 function speed
Auxiliary 3 function speed
Lift min speed
Pump max speed in limiting
Hydro speed
Hydro idle speed
Pump acceleration ramp
Pump deceleration ramp
Power mode (E-S-H, limitations)
Power mode
Slow speed
British unit
Display brightness
Time meter / Odometer on display
Maintenance time

161

[Contraction]
STEERING DECEL1
STEERING DECEL2
BATT RESET VALUE
1ST PASSWARD
SEAT SW DELAY
CHAT TIME
HYDRO TIME
SERVICE TIME ON
2ND PASSWARD
WHEEL TURN RIGHT
WHEEL TURN LEFT
WHEEL STRAIGHT
ACCEL MIN VALUE
ACCEL MAX VALUE
SLOP TIMER
LIFT MAX VALUE
LIFT MIN VALUE
LIFT START VALUE
DRIVE MAX I
FWD MAX SPEED
REV MAX SPEED
D LIMIT MAX SPD
WEIGHT LIMIT SPD
HEIGHT LIMIT SPD
STEER LIMIT SPD
D ACCEL RAMP
D INVERSION RAMP
D RELEASE RAMP
PEDAL BRAKE RAMP
CREEP SPEED
TIRES DIA
PARTIAL RELEASE
LIFT MAX I
AUX MAX I
LIFT MAX SPEED
TILT SPEED
AUX 1 SPEED
AUX 2 SPEED
AUX 3 SPEED
LIFT MIN SPEED
PUMP LIMIT MAX
HYDRO SPEED
IDLE SPEED
PUMP ACCEL RAMP
PUMP DECEL RAMP
USER MODE
E-S-H
CREEP SPEED
BRITISH UNIT
LCD BRIGHTNESS
TIMER-ODOMETER
SERVICE PERIOD

3. Diagnostic Code
[Display Code]
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46

[Description]
Right traction motor speed
Right traction motor speed reference
Left traction motor speed
Left traction motor speed reference
Lift lever voltage
Battery voltage
Right traction motor power module temperature
Pump motor power module temperature
Pump motor speed
Pump motor speed reference
Accelerator potentiometer voltage
Accelerator second Potentiometer voltage
Steering sensor voltage
Left traction motor power module temperature
Right traction motor phase current
Right traction motor phase current
Right traction motor phase current
Left traction motor phase current
Left traction motor phase current
Left traction motor phase current
Pump motor phase current
Pump motor phase current
Pump motor phase current
Right traction motor temperature
Left traction motor temperature
Pump motor temperature
Seat switch hour meter
Drive motor hour meter
Pump motor hour meter
Seat switch
Park brake switch
Start switch
Reverse traction direction switch
Forward traction direction switch
Pedal brake switch
3/4 wheels selection switch
Auxiliary 1 switch
Auxiliary 2 switch
High lift switch
Tilt switch
Main breaker command
5V out
12V out
24V out
Buzzer command
Fans command

162

[Contraction]
RIGHT MOTOR SPD
R-MOTOR REF SPD
LEFT MOTOR SPD
L-MOTOR REF SPD
LIFT SENSOR OUT
BATT VOLTAGE
R-INVERTER TEMP
P-INVERTER TEMP
PUMP MOTOR SPD
P-MOTOR REF SPD
ACCEL 1ST OUT
ACCEL 2ND OUT
STEER SENSOR OUT
L-INVERTER TEMP
R-MOTOR I-U
R-MOTOR I-V
R-MOTOR I-W
L-MOTOR I-U
L-MOTOR I-V
L-MOTOR I-W
P-MOTOR I-U
P-MOTOR I-V
P-MOTOR I-W
R-MOTOR TEMP
L-MOTOR TEMP
P-MOTOR TEMP
SEAT H METER
DRIVE H METER
PUMP H METER
SEAT SWITCH
PARK SWITCH
SRART SWITCH
REV SELECT SW
FWD SELECT SW
PEDAL BRAKE SW
3 OR 4 WHEEL
AUX 1 OUTPUT
AUX 2 OUTPUT
HIGH LIFT SWITCH
TILT SWITCH OUT
CONTACTOR
5V OUT
12V OUT
24V OUT
BUZZER
FAN

SB4185E00
Feb. 2005

Specifications
Systems Operation
Testing & Adjusting
Disassembly & Assembly
Lift Trucks Power Train
B15T-5, B18T-5, B20T-5 (AC 36V)
B15T-5, B18T-5, B20T-5 (AC 48V)
B15T-5, B18T-5, B20T-5 (SE 48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
B16X-5, B18X-5, B20X-5 (SE 48V)

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as
shown below.

WARNING
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most
current information available.

Index
Specifications
Brake ......................................................................12
Drive Motor............................................................... 7
Final Drive ................................................................ 9
General Tightening Torques ..................................... 5
Motor and Transmission ..........................................11
Wheel Mounting ......................................................10

Systems Operation
Drive Motor ..............................................................14
Final Drive ...............................................................16
General Information.................................................13

Testing And Adjusting


Brake ......................................................................36
Connecting The Brake Cable .............................36
Connecting The Hydraulic Brake System ..........36
Replenishing With Transmission Fluid ...............36
Drive Motor ..............................................................25
Armature Terminal Test ......................................33
Armature Tests ...................................................29
Brush Holder Test...............................................33
Brush Life Estimate ............................................34
Commutator Inspection .....................................31
Field Coil and Terminal Tests .............................32
Motor Brushes ....................................................27
Sensor Bearing ..................................................26
Thermal Sensor Tests ........................................25
Thermal Switch Tests .........................................34
Motor and Transmission ..........................................35
Troubleshooting .......................................................17
Checks During Operation...................................17
Drive Motor....................................................17
Transmission .................................................23
Visual Checks.....................................................17

Disassembly and Assembly


Drive Axle ................................................................37
Disassemble Drive Axle .....................................37
Assemble Drive Axle ..........................................43
Special Service Tools ..............................................53

Power Train

Index

Specifications
General Tightening Torques
General tightening torque
for bolts, nuts and taperlock studs
The following charts give the
standard torque values for bolts,
nuts and taperlock studs of SAE
Grade 5 or better quality.
Exceptions are given in other
sections of the Service Manual
where needed.

thread
size
inches
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8

Use these torques for


bolts and nuts with
standard threads
(Conversions are approximate)

1
1-1/8
1-1/4
1-3/8
1-1/2

standard thread

Use these torques for


bolts and nuts on
hydraulic valve
bodies.

Use these torques for


studs with taperlock
threads.

taperlock stud

standard torque
lbIft
9L3
18 L 5
32 L 5
50 L 10
75 L 10
110 L 15
150 L 20
265 L 35
420 L 60
640 L 80
800 L 100
1000 L 120
1200 L 150
1500 L 200

NIm*
12 L 4
25 L 7
45 L 7
70 L 15
100 L 15
150 L 20
200 L 25
360 L 50
570 L 80
875 L 100
1100 L 150
1350 L 175
1600 L 200
2000 L 275

5/16
3/8
7/16
1/2
5/8

13 L 2
24 L 2
39 L 2
60 L 3
118 L 4

20 L 3
35 L 3
50 L 3
80 L 4
160 L 6

1
5
3
7
1
9
5
3
7

5L2
10 L 3
20 L 3
30 L 5
40 L 5
60 L 10
75 L 10
110 L 15
170 L 20
260 L 30
320 L 30
400 L 40
480 L 40
550 L 50

7L3
15 L 5
30 L 5
40 L 10
55 L 10
80 L 15
100 L 15
150 L 20
230 L 30
350 L 40
400 L 40
550 L 50
650 L 50
750 L 70

1
1-1/8
1-1/4
1-3/8
1-1/2
*1 newton meter(NIm) is approximately the same as 0.1 mkg.

Power Train

Specifications

Metric fasteners
metric ISO thread

[Usually, material strength identification on bolt


head is with numbers (i.e., 8.8, 10.9, etc.)]
The chart on the right gives the torque for bolts and
nuts with Grade 8.8.
NOTICE : Caution must be taken to avoid mixing
metric and standard (customary) fasteners.
Mismatched or incorrect fasteners can result in vehicle
damage or malfunction, or possible personal injury.
Original fasteners removed from the vehicle should
be saved for assembly when possible. If new ones
are required, caution must be taken to replace with
one that is of same part no. and grade or better.

thread
size
(mm)

(NIm)*

M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36

12 L4
25 L7
55 L10
95 L15
150 L20
220 L30
325 L50
450 L70
600 L90
775 L100
1150 L150
1610 L200
2000 L275
2700 L400

torque
(lbIft)
9 L3
18 L5
40 L7
70 L10
110 L15
160 L20
240 L35
330 L50
440 L65
570 L75
840 L110
1175 L150
1450 L200
2000 L300

ISO-International Standard Organization

Hose clamps-worm drive band type


intitial assembly
torque on new hose

clamp
width

(NIm)*

15.9 mm (.625 inch)

7.5 L0.5

(lbIft)
65 L5

13.5 mm (.531 inch)

4.5 L0.5
0.9 L0.2

40 L5
8 L2

7.9 mm (.312 inch)

reassembly or
retightening torque
(NIm)*
4.5 L0.5
3.0 L0.5
0.7 L0.2

(lbIft)
40 L5
2 L5
6 L2

*1 newton meter(NIm) is approximately the same as 0.1 mkg.

Power Train

Specifications

Drive Motor
(AC)

Thermal switch
Warning temperature .......... 155 L 4C (311 L 10F)

Power Train

Specifications

(SE)

Drive Motor
1

New Brush
Thickness B Width B Length

Minimum
Brush Length*

12.5 mm B 32 mm B 35 mm
(.49 in. B 1.25 in. B 1.37 in.)

18 mm
(.70 in.)

New Commutator
Diameter

Minimum
Commutator Diameter**

80 mm
(3.14 in.)

78 mm
(3.07 in.)

*As measured on longest side.


**All rough edges (burrs) must be removed after the commutator is machined.

Machine chamfer on the commutator bars


...................................................... 0.40 mm (.016 in.)

Maximum difference between commutator high and


low point (out of round) ......... 0.03 mm (.001 in.) TIR

Torque for the terminal bolts (not shown) that hold


cable connections ............................. 12 NIm (9 lbIft)

Maximum difference between bar to bar


.......................................... 0.005 mm (.0002 in.) TIR

Depth of the insulation below commutator bars


.......................................................... 1.5 mm (.05 in.)

Thermal switch
Opening temperature.......... 155 L 4C (311 L 10F)

Width of the insulation below commutator bars


........................................................ 0.8 mm (.031 in.)

Power Train

Closing temperature ........... 145 L 6C (293 L 11F)

Specifications

Final Drive
5

11

10
E E

(1) Nut. (2) Flat head bolt. (3) Socket head loolt. (4) Socket head bolt. (5) Socket head bolt. (6) Air breather.
(7) Socket head bolt. (8) Plug-oil level. (9) Plug. (10) Drain plug. (11) Socket head bolt.

(1) Apply LOCTITE NO.277 (or 271) Thread Lock to


thread of nut.
Torque for nut that holds drive shaft
............................. 200 L 20 NIm (148 L 15 lbIft)
(2) Apply LOCTITE NO.277 (or 271) Thread Lock to
threads of bolts.
Torque for flat head bolts that hold end plate
....................................8 L 3 NIm (5.9 L 2.2 lbIft)
(3) Apply LOCTITE NO.277 (or 271) Thread Lock to
threads of bolts.
Torque for socket head bolts that hold carrier
cover .............................30 L 7 NIm (22 L 5 lbIft)
(4) Apply LOCTITE NO.277 (or 271) Thread Lock to
threads of bolts.
Torque for socket head bolts that hold ring gear
stopper plate ...............55 L 10 NIm (41 L 7 lbIft)

Power Train

(5) Apply LOCTITE NO.277 (or 271) Thread Lock to


threads of bolts.
Torque for socket head bolts that hold housing
......................................25 L 7 NIm (18 L 5 lbIft)
(6) Torque for air breather 70 L 10 NIm (52 L 7 lbIft)
(7) Apply LOCTITE NO.277 (or 271) Thread Lock to
threads of bolts.
Torque for socket head bolts that hold housing
......................................30 L 7 NIm (22 L 5 lbIft)
(8) Apply LOCTITE NO.572 to thread of oil level plug.
Torque for plug ............70 L 10 NIm (52 L 7 lbIft)
(9) Torque for plug that holds piston rod
....................................70 L 10 NIm (52 L 7 lbIft)
(10) Apply LOCTITE NO.572 to thread of drain plug.
Torque for plug ..........70 L 10 NIm (52 L 7 lbIft)
(11) Apply LOCTITE No.277 (or 271) Thread Lock to
thread of socket head bolt.
Torque for bolt that holds nut
..................................8 L 3 NIm (5.9 L 2.2 lbIft)

Specifications

Wheel Mounting
2
1

IOPS002I
(1) Nut. (2) Bolt.

(1) Torque for drive wheel mounting nut


............... 180 NIm (133 lbIft) for soild soqter tire
............... 140 NIm (103 lbIft) for cushion tire or pneumatic tire
(2) Torque for bolt that hold housing to frame
............................................... 240 NIm (177 lbIft)

Power Train

10

Specifications

Motor and Transmission

IOPS003I
(1) Socket head bolt

(1) Torque for socket head bolts that hold


transmission and drive motor ..... 55 NIm (41 lbIft)

Power Train

11

Specifications

Brake
Actuating stroke for the hand brake cable
a. in the operating condition
b. limit of wear

mm

(1) Bleeder port. (2) Brake line (hydraulic line). (3) Brake cable. (a) In the operating condition. (b) Limit of wear.

(1) Torque for bleeder port ............... 50 NIm (37 lbIft)


(2) Torque for brake line................... 50 NIm (37 lbIft)
(3) Torque for brake cable................ 50 NIm (37 lbIft)
(a) Stroke in the operating condition
........................................3 ~ 5 mm (0.12~0.20 in)
(b) Limit of wear ....................................8 mm (0.31in)

Power Train

12

Specifications

Systems Operation
General Information

IOPS005S
Power Flow
(1) Final drive. (2) Drive motor.

The power train for the BT/BX-5 MODEL Lift Trucks


consist of two main components; drive motors (2)
and final drives (1).
Electric storage batteries are used as a power source
for the drive motors (2). The drive motor turns final
drive (1), which turn the drive wheels.

Power Train

13

Systems Operation

Drive Motor
(AC)

The motor is protected from over temperature by a


thermal sensor.
If motors temperature reaches in 155 L 4C (311 L
10F), controller does overheat warning and operates
by smallest performance.
The drive motor is activated when the parking brake
is released, the key and seat switch are closed, a
direction is selected and the accelerator pedal is
depressed.
The drive motor powers the power transfer group
through input gear.

Power Train

14

Systems Operation

(SE)

1
4

10

Drive Motor
(1) Input gear. (2) Brush cover. (3) Thermal switch (thermostat). (4) Commutator. (5) Armature. (6) Field coils.
(7) Frame. (8) Brush holder. (9) Fan. (10) Bearing.

The drive system is operated by a direct current


(DC)motor. Electric storage batteries are the source
of power for the DC motor.

Drive motor is protected from overheating by a


thermal switch (thermostat) (3). The thermal switch
opens at 154 L 4C (311 L 10F). It closes at 145 L
6C (293 L 11F). When the normally closed thermal
switch is open, the amount of current through the
motor is limited to allow the motor to cool. The motor
has a fan for cooling.

The drive motor is a series wound motor and uses a


high temperature insulation. The field and armature
circuits are in series, which provides a single path for
the current.
Armature (5) is mounted with single row ball bearings
at each end. The ball bearings are permanently
lubricated with a high temperature lubricant.

The drive motor is activated when the parking brake


is released, the key and seat switch are closed, a
direction is selected and the accelerator pedal is
depressed.

The electrical connections to the motor are made at


corrosion resistant terminals on motor frame (7). On
the outside of the motor frame is the brush cover (2)
that can be removed for easy access to the brushes
and the commutator. Field coils (6) are fastened to
the inside of the motor frame.

The drive motor powers the power transfer group


through input gear (1).

The four motor brushes are held in four brush


holders (8). A spring holds each of the brushes
against commutator (4) as the brushes wear.

Power Train

15

Systems Operation

Final Drive

11

12

2
3
10

10

13

15

E E

14

(1) Pinion gear. (2) Helical gear. (3) Friction disc carrier. (4) Steel ball. (5) Lever plate. (6) Ring gear. (7) Planetary gear.
(8) Drive shaft. (9) Planetary carrier. (10) Brake cylinder. (11) Transmission housing. (12) Air breather. (13) Piston rod.
(14) Drain plug. (15) Friction and steel plate.

This transmission is a helical and planetary gear


transmission unit with an integrated, hydraulically and
mechanically actuated wet disk brake.

When motor shaft turns, the helical pinion(1)


connected on the motor shaft turns helical gear(2).
Helical gear(2) is jointed to sun gear of planetary
gear set and the sun gear turns three planetary
gears(7). Three planetary gears turn planetary carrier
which is inserted into inner hole of planetary
gears(7). The planetary carrier is connected to drive
shaft(8) and drive shaft turns rim mounted on drive
shaft flange.

This transmission consists of two assembly groups.


1. Helical gear transmission with connection for
electric motor and helical gear step.
2. Basic transmission with planetary step, gear shaft
and integrated brake.

Power Train

When hydraulic pressure is supplied to the brake


cylinder(10), piston rod(13) rotates lever plate(5). As
the lever plate is contacted to steel ball (4), it is
moved towards friction and steel plates(15) by
rotation. Then wet disc brake is actuated by this
force. The lever plate can be moved by cable
mechanically as same as hydraulically for parking
brake actuation.

16

Systems Operation

Testing And Adjusting

WARNING
If an electrical failure or an overload of the motor is
present, personnel must not breathe the toxic fumes
which are a product of the burnt insulation. All power
must be disconnected from the motor before any
inspection is made to find the failure. The area around
the motor must be well ventilated (air flow) and the
motor is to be cooled before any repair work is done.
Water must not be used on any electrical equipment
because of the danger of electric shock. If a fire is
present, disconnect the electrical power and use a
carbon dioxide extinguisher to put the flame out.

Troubleshooting
Visual Checks
Make a visual inspection of the truck to check for
problems. Operate the truck in each direction.
Make a note of the noises that are not normal and
find their source. If the operation is not correct, make
reference to the Check List During Operation for
"Problems" and "Probable Causes".

Do not operate the drive motors without a load, as too


much speed may cause damage to the motor and
injury to personnel.

Checks During Operation


Drive Motor

<AC>

Before an analysis is made of any electric drive


motor problem, always make reference to the
Troubleshooting section of the MicroController
System Operation module.

Problem 1 : Drive Motor Will Not Operate.


probable Cause :

WARNING

1. Switch not closed (battery connector, key switch,


seat switch, direction switch or parking brake
switch) :
Close the switch. If it still does not operate test
for power to the control panel and power flow
through each switch with a voltmeter.
But the service brake switch should be opened.

The lift truck can move suddenly. Battery voltage and


high amperage is present. Injury to personnel or
damage to the lift truck is possible. Safely lift both
drive wheels off the floor. Put wood blocks or jack
stands of the correct capacity under the frame so the
drive wheels are free to turn. During any test or
operation check, keep away from the drive wheels.
The Power unit will have to be discharged before any
contact with the control panel is made. Disconnect
the battery and discharge the Power unit. Rings,
watches and other metallic objects should be
removed from hands and arms when troubleshooting
the MicroController Control System.
To prevent personal injury, never use air pressure
that is more than 205 kPa (30 psi), and wear protective
clothing and a face shield.

2. Bad connection. Fuse blown :


Check battery connections. Check connections
at battery connector. Check fuses, drive and
logics. Replace fuse if blown.
Check the Drive motor and control panel for
possible reasons for a blown fuse. Some causes
are :
a. Operation under excessive MOSFET load, too
high current limit (C/L).
b. Possible short circuit in power unit.
3. Low battery voltage:
Check battery terminal voltage. If too low, charge
the battery.
Check all the cells for one or more that have
defects.
Check the specific gravity of each cell. The
maximum density difference from the highest to
the lowest cell must not be more than .020 SG
(specific gravity).

NOTICE
To prevent damage to electrical components, make
sure the air line is equipped with a water filter when
they are cleaned with air.

4. Control panel operation not correct :


See the MicroController System Operation
module.

Power Train

17

Testing And Adjusting

5. Static return to off circuit (S.R.O.) actuated:


If the static return to off is activated, the control
will not start again until the accelerator is
released and the directional control lever is
returned to neutral.

Problem 3 : Neither traction or hydraulic will last


through a complete normal work period.
Probable Cause :
1. Too small a battery equipped in the lift truck :
Use a larger battery for the complete work cycle
and normal work period.

6. Speed sensor is breakdown.


Problem 2 : Traction will not operate through a
normal work period, but hydraulic operation is
normal.

2. Battery not being fully charged or equalized during


the battery charging operation :
Check the battery cells for an equalization
charge(a charge to make the specific gravity the
same in all cells). Check the battery charger for
defects.

Probable Cause :
1. Brakes have a defect, cause a resistance(lack of
free movement). Heat increases, which causes the
motor to stall :
Check the brake adjustment according to the
procedures in Testing And Adjusting in the
Vehicle Systems module.

3. Battery change interval is too long or changed


battery cooling time is too short. This decreases
the capacity and the ability of the battery :
Decrease the battery work duration before a
change. Increase the battery cooling time after a
charge before it is put to use.

2. Too much heat in MicroController control panel


because:
a. Extra heavy traction loads.
Decrease the duty cycle load.
b. Faulty thermal sensor.
See the MicroController System Operation
module.

4. Battery has one or more defective cells which


results in less than the rated capacity and ability of
the battery :
Replace the battery.
5. Traction system draws (makes a consumption of)
too much battery power because of traction
system faults. Operation of the duty cycle
(complete working cycle) condition is not correct :
Check the brake adjustment according to the
procedures in Testing And Adjusting in the
Vehicle Systems module. Check the mechanical
components such as wheel bearings, axles, etc.,
for corrections to eliminate the faults. Change to
a tire with less friction.

These can cause MOSFETS to become defective,


control panel failure or drive fuse to go bad.

6. Hydraulic system draws too much battery power


because of lifting and tilting arrangements, or
hydraulic conditions are not correct for the duty
cycle:
Decrease hydraulic relief valve setting to the
capacity that only will be used.
Change to a smaller hydraulic pump.
Check the mast for restriction during operation.
7. Lift truck working more than the capacity of its
design with no available power after one work shift :
Have available an extra (exchange) battery.
Decrease the speed and work load required to
complete the work shift.

Power Train

18

Testing And Adjusting

Problem 4 : Low resistance to ground [battery


polarity either positive (+) or negative () or a
medium voltage is in direct contact with truck
frame (body) or drive motor body].

Problem 6 : Lift truck does not have enough


power to position itself under a load. Lift truck
does not have enough power on ramps or towing
trailers.

Probable Cause :

Probable Cause:

1. Dirty battery, electrolyte on top of cells and is in


contact with the frame. Current flows through
battery box, which places a voltage on the truck
frame :
Clean the battery with baking soda and water
solution.

1. Unpolished or improperly positioned forks :


Install tapered and polished forks. Position forks
correctly for load being lifted.
2. Lift truck equipped with tires that have poor
traction :
Install tires that have good traction per
recommendation from DAEWOO Inc.

2. Battery or control panel wire connections in


contact with truck frame :
Make a continuity test and move the wire from
contact.
Remove wires in sequence until the fault is
cleared.
The fault will be in the wire last disconnected.

3. Lift truck work load is too heavy or the duty cycle


too long :
Decrease the work load and/or duty cycle.
Problem 7 : Lift truck has slow acceleration.
Probable Cause:

3. Dirty motor :
Remove metallic or carbon dust with air
pressure.

1. Drive control overheated and the thermal switch


opens :

4. Wet motor :
To dry the motor, heat it to 90C (194F).

NOTE : The thermal switch will warning if the


temperature is 155 L 4C (311 L 10F).

Problem 5 : Lift truck will not get to top speed.


Probable Cause :
1. Battery not fully charged or battery has bad cells :
Charge the battery. Check for bad cells. Replace
battery if necessary.
2. A fault either in the drive motor, control panel or
drive train :
Check lift truck speed in both directions. If the
MicroController control panel needs to be tuned
up, make adjustments as shown in the
respective MicroController System Operation
module. If the drive motor is at fault, make the
tests of the motor components in Testing And
Adjusting.

Power Train

19

Testing And Adjusting

5. Brushes are worn:


Inspect the drive motor commutator for burnt
marks or scoring (scratches). Make corrections
or make a repair of the armature commutator
and replace the brushes as necessary.
See Armature Commutator Inspection and Brush
Inspection in Testing And Adjusting.
Make reference to Problem: Sparks At The
Commutator And/Or Rapid Brush Wear.

<SE>
Problem 1 : Drive Motor Will Not Operate.
probable Cause :
1. Switch not closed (battery connector, key switch,
seat switch, direction switch or parking brake
switch) :
Close the switch. If it still does not operate test
for power to the control panel and power flow
through each switch with a voltmeter.
But the service brake switch should be opened.

6. Check for open circuits in the field coils :


Test coils according to procedures in Testing And
Adjusting. If there are open circuits, make a
replacement of the field assembly.

2. Bad connection. Fuse blown :


Check battery connections. Check connections
at battery connector. Check fuses, drive and
logics. Replace fuse if blown.
Check the Drive motor and control panel for
possible reasons for a blown fuse. Some causes
are :
a. Operation under excessive transistor load, too
high current limit (C/L).
b. Operation under stall conditions.
c. Possible short circuit in drive motor, see
Probable Causes 5, 6 and 7.

7. Check for a short circuit in the armature windings :


Loose field winding pole ends, make the
necessary repairs.
Failed armature bar insulation.
Repair or rebuild the insulation or make a
replacement of the armature.
8. Static return to off circuit (S.R.O.) actuated:
If the static return to off is activated, the control
will not start again until the accelerator is
released and the directional control lever is
returned to neutral.

3. Low battery voltage:


Check battery terminal voltage. If too low, charge
the battery.
Check all the cells for one or more that have
defects.
Check the specific gravity of each cell. The
maximum density difference from the highest to
the lowest cell must not be more than .020 SG
(specific gravity).

Problem 2 : Traction will not operate through a


normal work period, but hydraulic operation is
normal.
Probable Cause :
1. Brakes have a defect, cause a resistance(lack of
free movement). Heat increases, which causes the
motor to stall :
Check the brake adjustment according to the
procedures in Testing And Adjusting in the
Vehicle Systems module.

4. Control panel operation not correct :


See the MicroController System Operation
module.

2. Too much heat in MicroController control panel


because:
a. Extra heavy traction loads.
Decrease the duty cycle load.
b. Faulty thermal switch.
See the MicroController System Operation
module.
c. Too high current limit (C/L) setting.
Lower the setting on the C/L adjustments.
These can cause transistors to become defective,
control panel failure or drive fuse to go bad.

Power Train

20

Testing And Adjusting

Problem 3 : Neither traction or hydraulic will last


through a complete normal work period.

Problem 4 : Sparks at the commutator and/or


rapid brush wear.

Probable Cause :

Probable Cause :

1. Too small a battery equipped in the lift truck :


Use a larger battery for the complete work cycle
and normal work period.

1. Worn brushes:
Replace the brushes. See New Brush Installation
And Brush Inspection in Testing And Adjusting.

2. Battery not being fully charged or equalized during


the battery charging operation :
Check the battery cells for an equalization
charge(a charge to make the specific gravity the
same in all cells). Check the battery charger for
defects.

2. Overheating (too much heat) of the traction motor :


Check for an overload motor or a motor with
defects. See Armature Commutator Inspection in
Testing And Adjusting.
Decrease the current limit (C/L) adjustmemts if
set too high. See the MicroController System
Operation module.
Test the plugging rate, if set too short it will
cause arcing and wear at the brushes.
The duty cycle is too heavy, change the duty
cycle.

3. Battery change interval is too long or changed


battery cooling time is too short. This decreases
the capacity and the ability of the battery :
Decrease the battery work duration before a
change. Increase the battery cooling time after a
charge before it is put to use.

3. Defective drive motor :


See Armature Commutator Inspection in Testing
And Ajusting.

4. Battery has one or more defective cells which


results in less than the rated capacity and ability of
the battery :
Replace the battery.

a. Commutator bars burnt in two or more positions at


180 apart because:

5. Traction system draws (makes a consumption of)


too much battery power because of traction
system faults. Operation of the duty cycle
(complete working cycle) condition is not correct :
Check the brake adjustment according to the
procedures in Testing And Adjusting in the
Vehicle Systems module. Check the mechanical
components such as wheel bearings, axles, etc.,
for corrections to eliminate the faults. Change to
a tire with less friction.

(1) Armature bars open.


Replace the armature.
(2) Motor was stalled against a heavy load while
power discharged and caused the two bars, in
contact with the brushes, to burn.

NOTICE
Too heavy a load can stall the motor, and result in a
failure to the drive motor.

6. Hydraulic system draws too much battery power


because of lifting and tilting arrangements, or
hydraulic conditions are not correct for the duty
cycle:
Decrease hydraulic relief valve setting to the
capacity that only will be used.
Change to a smaller hydraulic pump.
Check the mast for restriction during operation.

(3) Short circuit in the armature.


See Armature Tests in Testing And Adjusting.
(4) Armature not in balance, out of round, off center
or with high commutator bars. This causes the
brushes to bounce (move up and down).
Make sure the diameter is the same all the
way around and is in center line with the
shaft. See Specifications.

7. Lift truck working more than the capacity of its


design with no available power after one work shift :
Have available an extra (exchange) battery.
Decrease the speed and work load required to
complete the work shift.

b. Dirty motor that has a metallic or carbon dust.


This dust is a conductor which causes electrical
shorts, increase current draw and decrease
drive motor output :
Remove any dirt with air pressure.
c. Brush movement causing arcing and brush
wear:
Check the brush springs for cracks, and

Power Train

21

Testing And Adjusting

Problem 5 : Low resistance to ground [battery


polarity either positive (+) or negative () or a
medium voltage is in direct contact with truck
frame (body) or drive motor body].

overheat signs (blue).


Compare spring force with a new brush spring.
Check the brush holder for oversize (larger
size than for brush).
Replace the brush spring if necessary.

Probable Cause :

d. Loose brush leads or motor bus bar


connections.
Loose cable connections at motor terminals.
Results are :

1. Dirty battery, electrolyte on top of cells and is in


contact with the frame. Current flows through
battery box, which places a voltage on the truck
frame :
Clean the battery with baking soda and water
solution.

(1) High resistance and heating.


(2) Faster brush wear.
Check brushes for tight connections. Replace
the brushes if leads are loose in brush
material. Check all cable and wire
connections for tightness.

2. Battery or control panel wire connections in


contact with truck frame :
Make a continuity test and move the wire from
contact.
Remove wires in sequence until the fault is
cleared.
The fault will be in the wire last disconnected.

e. Wrong grade of brushes installed that are not


adaptable to the motor :
Make sure all the brushes are of DAEWOO
standards. Do not use other brands of brushes.
f. Possibly heavy working condition that causes
too much motor heat and rapid brush wear:
Make a replacement of the brushes and make
sure the brushes are seated. See New Brush
Installation and Brush Inspection in Testing
And Adjusting.
Check the brush springs for the correct
installation and for the correct spring usage.
Too strong a spring rate will increase current
draw and brush wear rate. Prevent operation
in stall condition. Excessive (too much) duty
cycle which increases motor temperatures
and rapid brush wear.

3. Dirty motor :
Remove metallic or carbon dust with air
pressure.
4. Wet motor :
To dry the motor, heat it to 90C (194F).
Problem 6 : Commutator surface has grooves or
abnormal wear.
Probable Cause :
1. Brushes are worn too low, brush wires caused
arcing on the commutator :
Replace the brushes. See Brush Inspection in
Testing And Adjusting and the method to make
the Brush Life Estimate in Testing And Adjusting.

4. Overload of the drive motor such as: towing,


constant ramp operation, chiseling (hydraulic
actions that are not practical) and dragging (pull or
push loads on the ground) :
Operator training for better working practices.
Add an auxiliary cooling to the drive motors.

2. Dirty motor ; and possibly salt water got inside :


Disassemble motor, remove the debris with air
pressure. If necessary, dry the motor with heat to
90C (194F).

5. Current limit (C/L) set too high that causes too


much current consumption through motors in the
transistor range :
Decrease the current limit (C/L) adjustment to
the correct setting, see the MicroController
System Operation module.

3. Grades of brushes mixed :


Make sure all the brushes are of DAEWOO
standards. Do not use other brands of brushes.

6. Drive motor, armature or field windings have a


defect that results in high current draw at low
torque output:
See Armature Tests and Field Coil and Terminal
Tests in Testing And Adjusting.
7. Restriction caused by components :
Correct and make adjustments to wheel brakes
and parking brakes that drag.
Changes to tire with less friction.
Check and correct wheel bearing torques.
Power Train

22

Testing And Adjusting

Problem 7 : Lift truck moves faster in one


direction than the other direction with the same
amount of accelerator pedal movement in Bypass
mode (speed).

5. Lift truck work load is too heavy or the duty cycle


too long :
Decrease the work load and/or duty cycle.
Problem 10 : Lift truck has slow acceleration.

Probable Cause:
Probable Cause:
1. Motor brushes not located in the correct electrical
position (brush neutral settings) :
If the holes in the brush holder are not extended,
make them longer so that brush holder can have
a little rotation. When the holder is in the correct
position, lift truck speed will be the same in both
directions.

1. Drive control overheated and the thermal switch


opens :
NOTE : The lift truck will still go into the bypass
mode, but current limit will be cut back in the
transistor mode if the thermal switch opens.
Allow the MicroController control panel to cool so the
thermal switch will close.

2. One directional contactor worn more than the


other or loose connection on one contactor :
Check contactor for wear and tighten any loose
connections.

NOTE : The thermal switch will open if the


temperature is 150 L 6C (302 L 11F) and close
at 130 L 7C (266 L 13F).

Problem 8 : Lift truck will not get to top speed.

Transmission

Probable Cause :

Problem 1 : Abnormal movement of drive shaft to


axial direction.

1. Battery not fully charged or battery has bad cells :


Charge the battery. Check for bad cells. Replace
battery if necessary.

Probable cause :
1. Lock nut loosening :
Check if lock nut and socket head bolt for
stopping lock nut are loosened. Tighten lock nut
and socket head bolt with Loctite No.277.

2. A fault either in the drive motor, control panel or


drive train :
Check lift truck speed in both directions. If the
MicroController control panel needs to be tuned
up, make adjustments as shown in the
respective MicroController System Operation
module. If the drive motor is at fault, make the
tests of the motor components in Testing And
Adjusting.

Problem 2 : Rattle noise during coasting and


cornering.
Probable cause :
1. Abnormal wear on tire tread :
Change tires with new tires.
Rattle noise could be improved by change tires
left and right each other.

Problem 9 : Lift truck does not have enough


power to position itself under a load. Lift truck
does not have enough power on ramps or towing
trailers.

Problem 3 : Gear noise during driving.


Probable Cause:

Probable cause :

1. Current limit (C/L) set too low :


Set current limit (C/L) to specification in the
MicroController System Operation module.
2. Current limit (C/L) circuit has a defect :
Test the MicroController control panel as stated
in the respective service module. Repair or
replace components as necessary.
3. Unpolished or improperly positioned forks :
Install tapered and polished forks. Position forks
correctly for load being lifted.
4. Lift truck equipped with tires that have poor
traction :
Install tires that have good traction per
recommendation from DAEWOO Inc.
Power Train

1. Damaged tooth or excessive wear of bearing :


Check gears and bearings and change the
damaged gear and bearing of excessive wear.
Keep the oil drain interval and use specified oil.
Problem 4 : Leakage through air breather.
Probable cause :
1. Excessive oil level :
Check the oil level and keep the specified oil level.
2. Failure of air breather :
Change air breather with new one.

23

Testing And Adjusting

Problem 5 : Long brake pedal stroke.

Problem 8 : Poor brake performance.

Probable cause :

Probable cause :

1. Excessive lining wear :


Check the stroke of brake piston rod. Keep the
stroke within 3~5 mm by adding shim.

1. Damaged brake friction disc and steel plate by


excessive heat :
Check if parking cable is released. Change
friction discs and steel plates. Keep the drain
interval of transmission oil.

2. Failure of brake master cylinder :


Change the seals in the brake master cylinder.

Problem 9 : Leakage from drive shaft.


Problem 6 : Decreased oil level in brake oil
reservoir or leakage through brake piston rod.

Probable cause :

Probable cause :

1. Faulty oil seal of drive shaft :


Check oil seal and drive shaft for damages in the
sealing area.

1. Damage on seals of brake piston rod :


Change the quad ring, back up ring and wear
rings on piston rod.

Problem 10 : Transmission overheats.

2. Scratch on brake piston bore :


Replace transmission housing cover with new one.

Probable cause :
1. Transmission oil level is either too high or too low :
Check oil level.

Problem 7 : Noise during brake application.


Probable cause :

2. Wheel bearings with an excessive prestress :


Check rolling torque of drive shaft.

1. Using wrong transmission oil specification :


Check the transmission oil with specified one
and keep the drain interval.
2. Insufficient soaking hour of friction discs. After a
few days, problem will disappear.

Power Train

24

Testing And Adjusting

Drive Motor
<AC>
Thermal Sensor Tests
Tools Needed
Digital Multimeter Or Equivalent

1. With the digital multimter in resistance operating


mode, you have to measure about 10K ohm at
ambient temperature of 25C between the two
wires of the thermal sensor.

Power Train

25

Testing And Adjusting

Sensor Bearing

1. Remove the protective cover of sensor bearing


2. De-mount the ring nut
3. Remove the front endbell
4. Unthread the rotor
5. Remove the sensor bearing from its seat by
forcing the sensor bearing from inside the motor
(that is now open in one side)
6. Install the new sensor bearing in its own seat
7. Repeat the points from 4 to 1 to mount back the
motor.

Power Train

26

Testing And Adjusting

<SE>
Motor Brushes
Brush Inspection
1. Measure the radial length of brush.
1

P0004332
Install Brushes
(1) Brushes.

NOTICE
Installation of the wrong brushes can cause early
motor failure. Always make sure the correct DAEWOO
brushes are installed.

P0004329
Brush Measurement

2. If the brush length is less than 18 mm (.7 in) on


the longest side, replace the brushes.

5. Install new brushes(1). Make sure the brushes


move freely in the brush holders. Use a piece of
plain bond paper to remove brush material if there
is a restriction of brush movement.

New Brush Installation


NOTE : Installation of new brushes is a two person
operation.
2

1. Disconnect the batteries.


2. Lift the truck and put blocks under the chassis it so
that the drive wheels are off the ground.
3. Discharge the head capacitor.
4. Remove the brush covers.
Loosen two screws of the brush and BWI wires.
Pull out the old brushes from the brush holder by
lifting up the brush springs.

P0004331
Install Springs
(2) Spring.

6. Place carefully the brush spring(2) on the top of


brush and make sure they fasten into the brush
holder box.
7. Pull up on the two wires of each brush until the
contact end of the brush moves away from the
commutator. Release the wires to see if the brush
moves smoothly back into contact with the
commutator. If it is too difficult to pull out, or it does
not move smoothly in the brush holder box,
remove the spring and brush. Make an inspection
to find and correct the cause of the problem.
8. Connect the batteries to the battery connector.

Power Train

27

Testing And Adjusting

WARNING

NOTICE
Never use air pressure that is more than 205 kPa (30
psi). Make sure the line is equipped with a water filter.

Wear eye protection when seating, polishing or


cleaning the motor with air pressure. During the
seating and polishing procedure, keep fingers
away from components in rotation. For prevention
of injury to fingers, do not use a commutator
cleaner or brush seater stone that is shorter than
63.5 mm (2.50 in.).

12. After the brushes have the correct seat contact


surface, operate the motor at slow speed. Use
compressed (pressure) air to remove all dust and
abrasive grit.

P0004333
Brush Seating
(3) ZLX 0036 Brush seater stone.

9. Put ZLX0036 Brush Seater Stone (3) on the


commutator and operate the motor at a slow
speed.

NOTICE
Do not let stone(3) stay in contact with the commutator
bar too long. This causes more wear than is necessary
to the brushes and the commutator.

10. Move stone (3) across the commutator at the


backe edge of the brushes for a short time. This
will take the shiny finish off the commutator and
seat the new brushes.
11. Turn the key switch to the OFF position and
disconnect the batteries. Check the contact
surface of each brush. At least 85% of the brush
contact surface of each brush must show wear. If
necessary, do Steps 8 through 11 again until the
correct wear can be seen on the brush contact
surface.

Power Train

28

Testing And Adjusting

Ground Test

Armature Tests
Tools Needed

Digital Multimeter Or Equivalent

Growler Tester

Test For Short Circuit


1

P0004320
Ground Test.

P0004322

A digital multimeter can also be used to test for


grounds. Put the Function/Range Switch on the 2M
resistance (A) scale. When the test probes are put
on the commutator and the shaft, the meter must
give an indication of over load (OL). This means that
the resistance is more than 2 megohms.

Short Circuit Test


(1) Glowler. (2) Armature. (3) Hacksaw blade.
(4) Green light. (5) Red light.

NOTICE
Never use air pressure that is more than 205 kPa (30
psi). Make sure the air line has a water filter.

1. Turn the growler (1) on.


2. Slowly turn the growler on the armature (2) while a
hacksaw blade (3) is held over the windings.

If there is an indication of a ground in the above test,


remove any dirt or debris form the armature with
compressed (pressure) air.
Do the test for grounds again. If there is still an
indication of a ground, make a replacement of the
armature.

3. If the windings are shorted, the green light (4) will


be on. The red light (5) will be on if the windings
do not have a short.
The odor of burned insulation from the drive motor
while it is in operation is an indication of a short in
the armature.

Power Train

29

Testing And Adjusting

Open Circuit Test

P0004321
Open Circuit Test
(1) Armature. (A) Multimeter.

1. Put the digital multimeter Function / Range Switch


on the 200 ohm resistance (A) scale.
2. Put one test lead on one commutator bar. Put the
other test lead on an adjacent (next to) bar and
there must be less than one ohm resistance.
This test can also be done with an instrument,
such as a Kelvin Double Bridge, that can make a
measurement of very low resistance. Do the test
the same as above and make a comparison of the
resistance measurements.
Two burned areas on opposite sides of the
commutator are indications of an open armature
winding. These burned areas can cause very rapid
brush wear.

Power Train

30

Testing And Adjusting

Commutator Inspection
Surfaces of Commutators that need Replacement

IHPS010P
Grooves on the Commutator Surface
IHPS008P

Grooves on the commutators surface are caused by


a cutting material in the brush or atmosphere.

Marks on the Commutator Surface

Marks on the commutator surface are an indication


that metal has moved from the commutator surface
to the carbon brushes. Marks will cause fast brush
wear.

IHPS011P
Copper Drag on the Commutator Surface

Copper drag is an extra amount of commutator


material at the back edge of the commutator bars.

IHPS009P
Threads on the Commutator Surface

Threads (grooves that look like threads) on the


commutator surface, will also cause fast brush wear.

Power Train

31

Testing And Adjusting

Ground Test

P0004328

Ground Test
(1) Field Terminal. (2) Motor housing.

IHPS012P
Pitch BarMarks on the Commutator Surface

1. Put the digital multimeter Function/Range Switch


on the 20M resistance (A) scale.

Pitch barmarks cause low or burnt marks on the


commutator surface.

2. Put one test lead to either outer field terminal (1)


and the other test lead to the motor housing (2).
There must be more than one megohm resistance.

Field Coil and Terminal Tests


Tools Needed
Digital Multimeter Or Equivalent

3. If there is a measurement of less than one


megohm, it can be caused by wet insulation on the
field windings or excessive brush dust in housing.
Heat the motor at 88C (190F) until the resistance
goes above one megohm. If the resistance does
not go above one megohm, the shell and field
assembly must be replaced.

A
1

Open Circuit Test

P0004327
Open Circuit Test

1. Put the digital multimeter Function/Range Switch


on the 200 ohm resistance (A) scale.
2. Put one test probe to each outer field terminal
(S1,S2).
3. The resistance must be less than one ohm. If the
resistance is too high, it is an indication of
corrosion on the terminals or an open field coil.

Power Train

32

Testing And Adjusting

1. Put the digital multimeter Function/Range Switch


on the 20M resistance (A) scale.

Armature Terminal Test


Tools Needed

Digital Multimeter Or Equivalent

2. Put one test lead to an outer Armature terminal (1)


and the other test lead to the motor housing (2).
There must be more than one megohm resistance.

Test for Continuity


3. Do the test again with one test lead on the other
outer brush terminal.
1

Brush Holder Test


Tools Needed
Digital Multimeter Or Equivalent

A
1

EX00005
Brush Test
(1) Test lead.

1. Put the digital multimeter Function/Range Switch


on the 200 ohm resistance (A) scale.
2

2. Put one test lead to an outer Armature terminal (1)


and the other test lead to each brush lead that
connects to that terminal. There must be less than
one ohm resistance.

P0004319
Brush Holder Test
(1) Brush holder. (2) End bell. (A) Multimeter.

3. Do Step 2 again with the other outer Armature


terminal (A1, A2) and brush leads.

1. The brush holders are mounted on the rocker at


the commutator end of the motor. Make a visual
inspection of the brush holders and the rocker.

4. Too much resistance is an indication of corrosion


at the connection to the terminal.

2. Put digital multimeter Function/Range Switch (A)


on the 200 ohm resistance (A) scale. Put one test
lead to a brush holder (1) and the other test lead
to the end bell (2). The meter must show overload
(OL).

Ground Test

3. Check each brush holder. If meter reading is low,


the brush holder is grounded. Replace the rocker.

EX00006
Ground Test
(1) Armature terminal. (2) Motor housing.

Power Train

33

Testing And Adjusting

Thermal Switch Tests


Tools Needed
Digital Multimeter Or Equivalent

Brush Life Estimate


1. Before installation of new brushes, make an
inspection of the armature commutator, see
Armature Commutator Inspection in Testing and
Adjusting.

A
1

2. Do the steps and procedures for New Brush


Installation in Testing and Adjusting.

Open Circuits Test

3. Make the initial (first) inspection of brush wear


between 250 smh and 500 smh. The reason for
this initial inspection is to see if the brush wear
rate is normal and not too fast. The measurement
will help make an estimate of the length of brush
life to be expected.
NOTE : If there is an indication that brush wear is too
fast, see Troubleshooting, Problem: Sparks at the
commutator and/or rapid brush wear; for probable
causes of this problem.

P0004325
Open Circuit Test

4. Inspect all brushes in the motors. Measure and


record each brush length (see Specification for
each new brush length and minimum brush
length).

1. Put the digital multimeter Function/Range Switch


on the 200 ohm resistance (A) scale.
2. Put one test lead to each side of the thermal
switch harness.

5. Estimate expected brush life (hours). Use the


shortest measurement from Step 4 and the
following Sample Procedure:

3. The resistance must be less than one ohm.

Length of new brush...................35 mm (1.387 in.)


Minimum length of brush..............18 mm (.708 in.)
New brush length [35 mm (1.387 in.)] Minimum
brush length [18 mm(.708 in.)] = Total amount of
usable brush wear [17 mm(.67 in.)].

Ground Test

Length of shortest brush at 500 smh is 32.5 mm


(1.279 in.).
New brush length [35 mm (1.378 in.)] Length of
shortest brush at 500 smh [32.5 mm (1.279 in.)] =
Amount of brush wear at 500 smh [2.5 mm (.10 in.)].

1. Put the digital multimeter Function/Range Switch


on the 20M resistance (A) scale.

Amount of brush wear at 500 smh [2.5 mm (.10


in.)] Total amount of usable brush wear [17 mm
(.67 in.)] = Portion of brush used at 500 smh (.1).
Service Meter Hours (smh) at brush wear
measurement (500 smh) Portion of brush used
(.1) = Approximate total brush life of a new brush
(5000 smh).

2. Put one test lead to either of the plug prongs. The


other test lead must be grounded to the motor
housing.
There must be more than one megohm resistance.

Approximate total brush life of a new brush


(5000smh)Amount of smh at brush life estimate
(500 smh) = Remainder of usable brush life (4500
smh).

P0004326
Ground Test

Power Train

34

Testing And Adjusting

6. The smh estimate of brush life can be used if the


machine is to work at the same rate (duty cycle),
the battery is not discharged too much or the
battery cells have not become damaged. If the
machine is made to work harder, the battery is
discharged too much, or the battery cells become
damaged, the motor temperature will get hot very
fast. This will cause rapid wear of the brush.

Motor and Transmission


1

7. It is important to check brush length and brush


condition at a specific time, such as during the
preventive maintenance check. If an inspection
shows that brush life will not extend to the next
preventive maintenance check, install new brushes.

3
2

IOPS003I
(1) Socket head bolt. (2) Drive motor. (3) Transmission

1. Place the drive motor (2) carefully on the


transmission (3) and join the gearings of motor
spline and pinion gear carefully.
NOTE : When joining the splines, turn the motor
shaft carefully until the motor spline engages into the
pinion gear.
2. Turn motor so that bore pattern of transmission
lines up with that of motor.
3. Screw motor and transmission together with three
socket head bolts (1). Tighten the bolts to a torque
of 55 NIm (41 lbIft).

Power Train

35

Testing And Adjusting

Replenishing With Transmission


Fluid

Brake
Actuating stroke for the hand brake cable
a. in the operating condition
b. limit of wear

Approx. 0.5L
1 0.35L
2

3
1

IOPS006I
14mm
a(3~5mm)
b(8mm)

(1) Air breather. (2) Sealing washer. (3) Oil level plug.

Loosen air breather (1).


Use a funnel with a hose for easier filling.
Maximum outside diameter of hose to be 10mm (0.4
in). The correct fluid level and amount of fluid has
been reached when the level can be seen at hole for
oil level plug (3). When filling the fluid in, make sure
that no air bubbles are formed in the transmission.
Turn the wheel shaft to remove them.

(1) Bleeder port. (2) Brake line (hydraulic line).


(3) Brake cable. (4) Shim. (a) In the operating condition.
(b) Limit of wear.

Connecting the hydraulic brake


system

Screw the air breather (1) with the sealing washer


(2). Tighten the air breather to torque of 70 L 10 Nm
(52 L 7 lbIft).

Connect the bleeder tube to the bleeder port (1) and


the brake line (hydraulic line) (2) according to the
assembly position.
Tightening torque of bleeder port (1) and brake line
(2) is 50 NIm (37 lbIft).

Apply LOCTITE No.572 to thread of drain plug (3)


and tighten to a torque of 70 L 10 Nm (52 L 7 lbft).
Bleed the brake system after filling of brake fluid.
Refer to Brake System Air Removal of Lift Trucks
Vehicle System

Connecting the brake cable


Screw the brake cable (3) to a torque of 50 NIm (37
lbIft).
Check and maintain the installation dimensions when
the installation has been finished.
If the measured value is larger than installation
dimension, insert shims (4) in the shown location to
meet installation dimension

Power Train

36

Testing And Adjusting

1. Remove drain plug (1), oil level plug (2), air


breather (3) and washer (4).

Drive Axle
Disassemble Drive Axle
Tools Needed

A B

T126 Nut lnstaller

Bearing Puller

1
6

Start By :
5

a. Remove drive axle.


IOPD004P

2. Remove snap ring (5) from housing cover (6).

IOPD001P

IOPD005P

3. Remove four socket head bolts (7) and ten socket


head bolts (8) from housing (9).

10

2
3

IOPD002P

10

IOPD006P

4. Using two M8 bolts (10), remove housing


assembly from housing cover assembly.

IOPD003P

Power Train

37

Disassembly And Assembly

18

IOPD007P

5. Remove pinion gear assembly (11) from housing


cover (6).

16

IOPD010P

7. Remove helical gear assembly (16) from housing


(9).

17
12

15

18

19
13

IOPD008P

12

13

14

14

15

19

IOPD009P

IOPD012P

20

17

18

8. Remove snap rings (17), (18) and sun gear (19)


from helical gear (20).

6. Remove ball bearing (12), thrust bearing (14) and


race ring (15) from pinion gear (13).

Power Train

20

IOPD011P

38

Disassembly And Assembly

21

22

23

IOPD013P

IOPD017P

23

22

26

26

23

21

IOPD014P

IOPD018P

9. Remove three flat head bolts (21), end plat (22) and
three guide washers (23) from housing cover (6).

24

25

11. Remove three guide washers (23) and steel plate


(26).

26

27

6
6

IOPD015P

IOPD019P

25

24

IOPD016P

26

IOPD020P

10. Remove three springs (24), five friction discs (25)


and four steel plate (26) from housing cover (6).

Power Train

29

28

27

12. Remove plug (27), return spring (28) and piston


rod (29) from housing cover (6).
39

Disassembly And Assembly

41

40

30
31

IOPD021P

IOPD024P

15. Remove five steel balls (40) and ball bearing (41)
from housing cover (6).
30
42

43

31

IOPD022P

13. Remove lever plate (30) and lever hook (31).

IOPD025P

16. Remove six socket head bolts (42) from carrier


assembly (43).

31

32

42

29

38

44

33

34

IOPD023P

35

36

37

39

14. Remove pin (32) and split pin (33) from lever
hook (31). Remove wear rings (34), (39), backup
rings (35), (38) and quad rings (36), (37) from
piston rod (29).

Power Train

IOPD026P

17. Remove carrier cover (44) using three socket


head bolts (42).

40

Disassembly And Assembly

49

44

45

IOPD027P

52

IOPD030P

50

18. Remove ball bearing (45) from carrier cover (44).

46

50

47

51

IOPD031P
IOPD028P

20. Remove socket head bolt (49).


21. Remove nut (50) and shims (51) by using tool
(A). And, remove carrier (52) from housing.

48

47
53

46

52

IOPD029P

19. Remove six race rings (46), three planet gears


(47) and three needle roller bearings (48).

IOPD032P

22. Remove taper roller bearing cone (53) from


carrier (52) by using tool (B).

Power Train

41

Disassembly And Assembly

55

52

53

61

60

54

IOPD059P

IOPD035P

23. Remove pins (54) and spring pins (55) from


carrier (52).

26. Remove twelve socket head bolts (60) from ring


gear (61).

63

62
61

56

IOPD033P

IOPD036P

24. Remove drive shaft assembly (56) from housing


(9).

63

62

59
58

57

IOPD037P

61

27. Remove snap ring (62) and stopper plate (63)


from ring gear (61).
25. If necessary, remove taper roller bearing cone
(58) and eight wheel bolts (59) from drive shaft
(57).

Power Train

42

Disassembly And Assembly

Assemble Drive Axle


9

Tools Needed

T127 Bearing Installer

T130 Needle Bearing Installer


T126 Nut Installer

65

67

68

T129 Gamma Seal Installer

64

T128 Oil Seal Installer

IOPD038P

1
1
1

T131 Bolt Installer

NOTE : Before the assembly, carry out the following


operations :

66

a. Thoroughly clean all parts and remove all residual


Loctite.
b. Check all the parts for wear and damage.
Replace, if necessary.
c. Finish the mating surface of sealing with an oil
stone or a fine finishing file.
d. Lubricate the cleaned antifriction bearings before
installing.
e. Be sure to replace all the sealing elements.
f. Be sure to use mastic sealants (such as Loctite)
only.

IOPD039P

28. Remove taper roller bearing cups (64), (65), gamma


seal (66) and oil seal (67) from housing (9).

WARNING

29. Remove needle roller bearing (68) from housing (9).

Make sure corrosive detergents do not come in


contact with the skin. Do not swallow them or inhale
their vapors. Be sure to wear protective gloves and
goggles. If any detergent has been accidentally
swallowed, seek medical attention immediately.
Scrupulously observe the manufacturers
instructions.

Power Train

43

Disassembly And Assembly

58

65

67

66

59

57

IOPD039P

1. Install taper roller bearing cone (58) by using tool


(A). Apply Total MULTIS EP2 grease to the inner
ring of taper roller bearing and the space between
the rollers.

4. Apply Three Bond No.1102 on outer race of oil


seal (67) and install oil seal into housing (9) by
using tool (B).
Apply grease on the rib of oil seal (67).

2. Install eight wheel bolts (59) into drive shaft (57).

5. Apply Three Bond No.1102 on inner race of


gamma seal (66) and install gamma seal onto
housing (9) by using tool (C). Apply grease on the
rib of gamma seal (66).

54
55

6. Install taper roller bearing cup (65) into housing


(9).

52

53
9

IOPD040P
P0004209

3. Install pins (54) and spring pins (55) into carrier


(52). Install taper roller bearing cone (53) onto
carrier (52) by using tool (A). Apply Total MULTIS
EP2 grease to the inner ring of taper roller bearing
and the space between the rollers.

IOPD038P

64

68

7. Install taper roller bearing cup (64) into housing


(9). Install needle roller bearing (68) into housing
(9) by using tool (D).

Power Train

44

Disassembly And Assembly

50
54

56

IOPD041P

52
51

IOPD043S

8. Assemble drive shaft assembly (56) and housing


(9).

10. To calculate the required thickness of shim pack


(51), the following method is to be used.
Dimension B = Distance between plain surface of
carrier (52) and the plain surface
of drive shaft (54).
Dimension C = Hight of step in nut (50).

IOPD042P

Dimension D = Required thickness of shim


pack(51), calculated by following
formula
D=B-C-(0 ~ 0.05 mm)

52

9. Assemble carrier (52) into housing (9).

Example:
B = 2.58 mm measured at carrier and drive shaft
C = 2.05 mm measured at nut
D = 2.58 - 2.05 - (0 ~ 0.05) = 0.48 0 ~ 0.53 (mm)
Then 0.5 mm thickness of shim pack can be applied.
NOTE: Before determination of the shim pack
thickness, to locate the taper roller bearing of drive
shaft assembly in proper location, tighten the nut (50)
to a torque of 80~110 NIm (59~81 lbIft) with rotating
drive shaft assembly by hand.

Power Train

45

Disassembly And Assembly

50

IOPD044P

50

52

52

IOPD044P

11. Install shim pack with the proper thickness which


was determined in step 10. Tighten nut (50) to a
torque 150~220 NIm (110~162 lbIft) by using tool
(E).

14. Remove nut (50) from carrier (52).

60

12. Check if the slot in nut (50) for stopping socket


head bolt is well aligned with tap in carrier (52). If
not, the carrier should be rotated by one or two
splines in step 17.

61

62

54

IOPD036P

15. Assemble stopper plate (61) and snap ring (60)


into ring gear (62).

IOPD045P

62

13. Measure rolling torque of drive shaft assembly


(54). The specification of rolling torque is 4.5~6.5
NIm (3.3~4.8 lbIft).
If the measured rolling torque value is out of the
specification, increase or decrease the shim pack
thickness and follow the procedure in steps 11
through 13.

58

IOPD033P

16. Install ring gear assembly (62) into housing (9).


Apply LOCTITE No. 277 on threads of twelve
socket head bolts (58) and tighten bolts to a
torque 55 L 10 NIm (40.6~7.4 lbIft).

Power Train

46

Disassembly And Assembly

49

44

45

IOPD030P

52

50

IOPD027P

17. Apply LOCTITE No. 277 on thread of nut (50)


and tighten nut to a torque 150~220 NIm
(110~162 lbIft) by using tool (E).

20. Install ball bearing (45) into carrier cover (44).

42

43

18. Apply LOCTITE No. 277 on thread of stopping


socket head bolt (49) and tighten bolt to a torque
8 L 3 NIm (59 L 2.2 lbIft).

48

IOPD025P
47

21. Apply LOCTITE No. 277 on threads of six socket


head bolts and tighten bolts to a torque of 30 L 7
NIm (22 L 5 lbIft)

46

IOPD029P

46

47

IOPD046P
IOPD028P

NOTE : Carrier cover (44) should be assembled so


that marks on carrier and carrier cover are aligned.

19. Assemble six race rings (46), three needle roller


bearings (48) and three planet gears (47).

Power Train

47

Disassembly And Assembly

31

32

30
29

38

31

33

34

IOPD023P

35

36

37

39

IOPD022P

22. Assemble pin (32) and split pin (33) into lever
hook (31).
Split pin (33) should be bent enough not to be
removed.
23. Assemble quad rings (36), (37), backup rings
(35), (38) and wear rings (34), (39) into piston rod
(29).

33

30

NOTE: Apply brake oil (Total AZOLLA ZS 10) on the


surface of six rings in piston rod.
Check the location of backup rings carefully.

6
31

IOPD021P

41

25. Install lever plate (30) and lever hook assembly


(31) into housing cover (6).
NOTE: The split pin (33) of lever hook assembly
should be located on top side as shown.

40

IOPD024P

29

24. Install ball bearing (41) into housing cover (6).


Install five steel balls (40). Apply Total MULTIS
EP2 grease on the surface of steel balls.
IOPD047P

26. Assemble piston rod assembly (29) to lever hook


(31).

Power Train

48

Disassembly And Assembly

25

24

IOPD020P

28

29

27

26

IOPD016P

24

25

26

27

IOPD019P

IOPD015P

27. Apply total MULTIS EP2 grease onto outer of


piston rod (29).

30. Install five firiction discs (25) and four steel plate
(26) one by one as shown. Install three springs
(24).

28. Install return spring (28) into housing cover and


tighten plug (27) to a torque of 70 L 10 NIm (52
L 7 lbIft).

23

NOTE : Before installation of friction discs, soak


those friction discs in transmission oil as much time
as possible. If possible, over 12 hours are
recommended.

26

23

IOPD017P
IOPD048P

29. Install steel plate (26) and three washers (23)


onto housing cover as shown.

31. Put three guide washers (23) carefully on three


springs as shown.

NOTE: Locate guide washers carefully on the


positions of three taps in housing cover.

Power Train

49

Disassembly And Assembly

19

21

22

IOPD049P

IOPD012P

32. Put end plate (22) carefully on washers. Apply


LOCTITE No.277 on threads of three flat head
bolts (21) and tighten bolts to a torque of 8 L 3
NIm (5.9 L 2.2 lbIft) by using tool (F).

20

18

17

17
18

22

22

19
20

IOPD011P

66

34. Assemble sun gear (19), snap ring (18) and snap
ring (17) into helical gear (20). Make the opening
directions of two snap rings opposite.

IOPD050I

33. Press end plate (22) and measure the distance


(L) between the surface of end plate and the
surface of housing cover (6). Specification for L
is 1.03 ~1.63 mm (0.041~ 0.064 in).
20

IOPD051P

35. Align the teeth of the friction discs and assemble


carefully helical gear assembly (20) into housing
cover (6).

Power Train

50

Disassembly And Assembly

13

IOPD052P

IOPD004P

36. The housing cover areas must be cleaned and


degreased. Apply Three Bond No.1215 to coat on
one side as shown.

39. Install pinion gear assembly (13) into housing


cover and assemble snap ring (5).

2
3

IOPD002P
IOPD005P

40. Apply LOCTITE No. 572 on thread of oil level


plug (2) and tighten plug to a torque of 70 L 10
NIm (52 L 7 lbIft).

37. Put housing assembly (9) on housing cover


assembly. Apply LOCTITE No. 277 on threads of
four socket head bolts (7) and ten socket head
bolts (8). Tighten them to torque of 25 L 7 NIm
(18 L 5 lbIft) for four bolts (7) and 30 L 7 NIm
(22 L 5 lbIft) for ten bolts (8).

12

IOPD008P

41. Install washer (4) and air breather (3) and tighten
air breather to a torque of 70 L 10 NIm (52 L 7
lbIft).

15

13

14

38. Assemble ball earing (12) onto pinion gear (13).


Apply Total MULTIS EP2 grease to thrust bearing
(14) and race ring (15) and assemble them onto
pinion gear (13).

Power Train

51

Disassembly And Assembly

IOPD001P

42. Apply LOCTITE No. 572 on thread of drain plug


(1) and tighten plug to a torque of 70 L 10 NIm
(52 L 7 lbIft).
End By:
a. Install drive Axle.

Power Train

52

Disassembly And Assembly

Special Service Tools


Ref. No

Tool Name

Nut Installer

Illustration

Remark

DAEWOO Tool
No: T126

IOPD053I

DAEWOO Tool
2

No: T127

Bearing Installer

IOPD054I

DAEWOO Tool
3

Oil seal Installer

No: T128

IOPD055I

DAEWOO Tool
4

Gamma Seal Installer

No: T129

IOPD056I

Power Train

53

Disassembly And Assembly

Ref. No

Tool Name

Needle Bearing Installer

Illustration

Remark

DAEWOO Tool
No: T130

IOPD057I

DAEWOO Tool

Flat Head Bolt Installer

No: T131

IOPD058I

Power Train

54

Disassembly And Assembly

SB4186E00
Feb. 2005

Specifications
Systems Operation
Testing & Adjusting
Lift Trucks Vehicle Systems
B15T-5, B18T-5, B20T-5(AC 36V)
B15T-5, B18T-5, B20T-5(AC 48V)
B15T-5, B18T-5, B20T-5(SE 48V)
B16X-5, B18X-5, B20X-5(AC 48V)
B16X-5, B18X-5, B20X-5(SE 48V)

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as
shown below.

WARNING
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most
current information available.

Vehicle Systems

Specifications

Index
Specifications

Testing & Adjusting

Dual Steer Axle And Wheel .....................................12

Priority Valve............................................................10

Brake System ..........................................................48


Brake System Air Removal.................................48
Parking Brake Control Group Adjustment ..........50
Parking Brake Test .............................................49
Pedal Adjustment................................................49
Hydraulic Pump Motor .............................................51
Armature Tests....................................................53
Brush Holder Test ...............................................56
Brush Lift Estimate .............................................57
Commutator Inspection ......................................54
Field Coil And Terminal Tests .............................56
Motor Brushes ....................................................52
Thermal Switch (Themostat)Tests ......................57

Sideshift Cylinder.......................................................6
Steering Gear...........................................................11
Steering Wheel ........................................................10

Hydraulic System.....................................................43
Lift Cylinders Air Removal ..................................44
Relief Valve Pressure Check ..............................43

Tilt Cylinder ................................................................9

Steering System ......................................................45


Steer Wheel Bearing Adjustment .......................45
Steering System Air Removal.............................46
Steering System Pressure Check ......................46

Hydraulic Control Vavel .............................................5


Hydraulic Pump .........................................................6
Hydraulic Pump Motor .............................................13
Lift Cylinders ..............................................................7
Standard ...............................................................7
Full Free Triple Lift And Full Free Lift Primary......7
Full Free Lift Secondary .......................................8
Full Free Triple Lift Secondary .............................8

Systems Operation

Troubleshooting .......................................................31
Brake System .....................................................36
Electric Motors ....................................................37
Hydraulic System And Mast ..............................31
Steering System .................................................35
Visual Checks .....................................................31

Brake System ..........................................................27


Master Cylinder...................................................27
Electric Motor...........................................................29
Hydraulic Pump Motor ........................................29
Hydraulic System.....................................................14
Control Valve ...........................................................17
Lift Position .........................................................18
Lift Lower Posision .............................................19
Lift Valve Neutral Position...................................17
Relif Valve...........................................................23
Tilt Back Position ................................................22
Tilt Forward Position ...........................................21
Tilt Neutral Position.............................................20
Steering System ......................................................24
Hydraulic Operation ............................................24
Steering Unit-Steering Gear ...............................25

Vehicle Systems

Index

Specifications
Hydraulic Control Valve

3
2

IHCS101S

AC Type
36 [V]

48 [V]

SE Type
48 [V]

B16X-5, B15T-5
Min. 400 [A] Min. 350 [A] Min. 330 [A]
B18X-5, B18T-5
Max. 420 [A] Max. 370 [A] Max. 350 [A]
B20X-5, B20T-5

Main Relief Valve Pressure Auxiliary Relief Valve Pressure


L 250 kPa

L 35 psi

19,800

2,880

19,800

2,880

21,550

3,125

L 350 kPa

L 35 psi

14,000

2,025

(1)Torque for nuts that hold control valve


sections together ......26 to 32 N m (19 to 23 lb ft)
(2)Torque for nuts that hold control valve
sections together ......24 to 29 N m (18 to 21 lb ft)
(3)Torque for main and auxiliary relief valve
...................................44 to 49 N m (32 to 36 lb ft)

Vehicle Systems

Specifications

Hydraulic Pump

Sideshift Cylinder

EHCS002B

EHCS003B

Rotation is counterclockwise when seen from drive


end.

(1) Torque for head ..............................270 L 35 Nm


(200 L 25 lbft)

Type of pump : Gear

(2) Torque for piston nut ......................260 L 25 Nm


(190 L 20 lbft)

Displacement : 16 cc/rev

Vehicle Systems

Specifications

Lift Cylinders
Full Free Triple Lift and
Full Free Lift Primary

Standard

1
1

(1) Put Pipe Sealant on the last three threads of


bleed screw and tighten to a torque of
.......................................6 L 1 Nm (53 L 9 lbin)

(1) Put Pipe Sealant on the last three threads of


bearing.
Put Pipe Sealant of the last three threads of bleed
screw(not shown) and tighten to a torque of
.............................................6 L 1 Nm (53 L 9 lbin)

NOTE : All seals to be lubricated with hydraulic oil.

NOTE : All seals to be lubricated with hydraulic oil.

Vehicle Systems

Specifications

Full Free Lift Secondary

Full Free Triple Lift Secondary

1
2

(1) Put Pipe Sealant on the last three threads of


bearing.

(1) Put Pipe Sealant on the last three thread of


bearing.

(2) Put Pipe Sealant on the last three threads of


bleed screw and tighten to a torque of
.......................................6 L 1 Nm (53 L 9 lbin)

(2) Put Pipe Sealant on the last three thread of bleed


screw and tighten to a torque of
.......................................6 L 1 Nm (53 L 9 lbin)

NOTE : All seals to be lubricated with hydraulic oil.

NOTE : All seals to be lubricated with hydraulic oil.

Vehicle Systems

Specifications

Tilt Cylinder

Z
X-closed, Y-open

EHCS008B

Tilt Angle Degrees


Tilt Group

Cyl. Closed X

Cyl. Open Y

Stroke Z

Forward

Backward

mm

in

mm

in

mm

in

A155319

382

15.0

463

18.2

81

3.2

A155008

396

15.6

463

18.2

67

2.6

A155009

409

16.1

463

18.2

54

2.1

(1) Adjust pivot eye to dimension(Y) with cylinder


open(extended)
(2) Torque for bolt
.................................. 95 L 15 Nm (70 L 10 lbft)
(3) With mast at tilt back position shim as required to
permit no gap between eye(1) and spacer.
Torque for head .... 270 L 35 Nm (200 L 25 lbft)
(4) Torque for jam nut
.............................. 260 L 25 Nm (190 L 20 lbft)

Vehicle Systems

Specifications

Steering Wheel

Priority Valve

EHCS017

Flow ................................Load sensing closed center.


EHCS016B

(1) Torque for steering wheel nut


.....................................80 L 6 Nm (60 L 4 lbft)
(2) Torque for bolt..............................15 Nm (11 lbft)

Vehicle Systems

10

Specifications

Steering Gear
2

3
VIEW C-C
TIGHTENING SEQUENCE
FOR BOLTS

VIEW B-B

C
5
B

B
C

EHCS018B

(1) Pin(1) in the body must be aligned with internal


pump gear (gerotor) (2) and drive (3) as shown.
(4) Tighten bolts in sequence shown.
Tighten to a first torque of ............14.1 L 2.8 Nm
(125 L 25 lbin)
Tighten to a final torque of ...........28.2 L 2.8 Nm
(250 L 25 lbin)
(5) Torque for plug ......................11.3 Nm (100 lbin)
Plug to be flush (even) with or below mounting
surface.

Vehicle Systems

11

Specifications

Dual Steer Axle And Wheel

1
2

3
4
5

EHCS015B

(1) Torque for bolts (three) ......................45 L 7 Nm


(35 L 5 lbft)
(2) Use as required to obtain end play of pinion shaft
...................................................0.01 to 0.035 mm
(3) Torque for bolts that hold support group to pinion
shaft .....................270 L 25 Nm (200 L 20 lbft)

Steer Wheel Bearing Adjustment :


a. Tighten nut (5) slowly to 133 Nm (98 lbft) while
the steer wheel is turned.
b. Loosen nut (5) completely and tighten again to
..................................45 to 55 Nm (33 to 41 lbft)
c. Bend a tap of lock (4) into a notch of the nut.

Vehicle Systems

12

Specifications

Hydraulic Pump Motor


(AC)

Thermal switch
Warning temperature ..........155 L 4C (311 L 10F)

Vehicle Systems

13

Specifications

(SE)

2
1
EHCS020B

Hydraulic Pump Motor


1

New Brush

Minimum

Minimum

Thickness B Width B Length

Brush Length *

Commutator Diameter**

12.5 mm B 32 mm B 35 mm

18 mm

78 mm

(.49 in B 1.25 in B 1.37 in)

(.70 in)

(3.07 in)

*As measured on longest side.


** All rough edges(burrs) must be removed after the commutator is machined.

Machine chamfer on the commutator bars


........................................................0.40 mm (.016 in)

Maximum difference between commutator high and


low point(out of round) ............0.03 mm (.001 in) TIR
Maximum difference between bar to bar
.............................................0.005 mm (.0002 in) TIR

Torque for the terminal bolts(not shown) the hold


cable connections .............................14 Nm (10 lbft)
Depth of the insulation below commutator bars.
............................................................1.5 mm (.05 in)
Width of the insulation below commutator bars
..........................................................0.8 mm (.031 in)

Vehicle Systems

14

Specifications

Systems Operation
Hydraulic System

IHCS102I
Basic Hydraulic Schematic With Standard Lift
(1) Lift cylinders. (2) Excess flow protector. (3) Sideshift cylinder(option). (4) Flow regulator.
(5) Hydraulic control valve. (6) Tilt cylinders. (7) Relief valve (lift and tilt). (8) Relief valve (sideshift).
(9) Hydraulic oil filter. (10) Hydraulic oil tank. (11) Priority valve. (12) Oil line.
(13) Hydraulic pump. (14) Oil line to steering unit. (15) Oil line.

The hydraulic system has hydraulic oil tank (10),


which holds the oil for gear type hydraulic pump (13).
Hydraulic pump (13) sends pressure oil to hydraulic
and steering systems.
Pump oil flows from pump (13) to priority valve (11)
where the oil flow divides to the steering unit through
line (14). Oil also flows to hydraulic control valve (5)
and back to hydraulic tank (10).

The return hydraulic oil from the cylinders flows


through hydraulic control valve (5), line (12), into
filter (9) and hydraulic tank (10). Relief valve (7) in
the control valve body will make the flow control
valve release extra pressure to the hydraulic tank
when the pressure in the lift or tilt circuits goes
higher than relief valve pressure shown in the control
valve section of Specifications. Relief valve (8) does
the same thing for the sideshift circuit when it goes
higher than the auxiliary relief valve pressure shown
in the control valve section of Specifications.

The control valve levers move the valve spools in


control valve (5) to let the pump oil in the control
valve go to lift cylinders (1) and/or (18), tilt cylinders
(6) or sideshift cylinder (3).

Vehicle Systems

15

Systems Operation

IHCS103I
Basic Hydraulic Schematic With Full Free Lift Or Full Free Triple Lift
(1) Lift cylinders. (2) Excess flow protector. (3) Sideshift cylinder(option). (4) Flow regulator.
(5) Hydraulic control valve. (6) Tilt cylinders. (7) Relief valve (lift and tilt). (8) Relief valve (sideshift).
(9) Hydraulic oil filter. (10) Hydraulic oil tank. (11) Priority valve. (12) Oil line. (13) Hydraulic pump.
(14) Oil line to steering unit. (15) Oil line. (16) Excess flow protector. (17) Lift cylinder(primary).

The maximum speed when the lift cylinders are


lowered is controlled by flow regulator (4).
Excess flow protectors (2) and (16) will act as flow
regulator if an oil line between them and flow
regulator (4) is broken when the mast is raised or
lowered. This prevents a sudden fall of the mast or
carriage if an oil line is broken.
REFERENCE : For the Hydraulic Systems
Schematics.

Vehicle Systems

16

Systems Operation

Control Valve
Lift Valve Neutral Position

6
7

10
8

ICCS009S
Control Valve for Lift (Shown In NEUTRAL Position)
(1) Spool. (2) Outlet To Head End Of Lift Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring.

Oil from pump enters the valve through a passage in


the inlet section. From there it goes to both chamber
(6) and chamber (9). Since spool (1) is in the
NEUTRAL position, the only path the oil can take is
from chamber (9) into the tilt valve. It would go out
through passage (8).
The mast can be stopped and held in any position
when the lift control valve is in neutral. This is
because the flow to and from the cylinders is
stopped by spool (1). In the NEUTRAL position, oil
can not flow from passage (4) to outlet (2) or back.

Vehicle Systems

17

Systems Operation

Lift Position

6
7

10
8

ICCS010S
Control Valve for Lift (Shown In LIFT Position)
(1) Spool. (2) Outlet To Head End Of Lift Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring.

When the control lever is moved to the LIFT position,


lift spool (1) is moved into the valve. Movement of
spool (1) opens a path for oil to flow from chamber
(6) through load check valve (3) into passage (4).
From passage (4) the oil goes to outlet (2) and then
to the lift cylinders. Pressure oil to the head end of
the lift cylinders moves the rod up and the mast will
raise.

Vehicle Systems

18

Systems Operation

Lift Lower Position

6
7

10
8

ICCS011S
Control Valve For Lift (Shown In LOWER Postion)
(1) Spool. (2) Outlet To H ead End Of Lift Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring.

When the control lever for lift is moved to the


LOWER position, lift spool (1) moves until a path is
opened between outlet (2) and passage for return oil
(7).

Vehicle Systems

19

Systems Operation

Tilt Neutral Position

13
9

10

14

16

15
11

12

ICCS012S
Tilt Spool In Neutral Position
(1) Spool. (2) Outlet To Rod End Of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil. (6) Chamber.
(7) Outlet To Head End of Tilt Cylinders. (8) Passage For Return Oil. (9) Spring. (10) Spool. (11) Passage. (12) Chamber. (13) Spring.
(14) Orifice. (15) Orifice. (16) Passage.

Oil from lift valve goes to both chamber (6) and (12).
Since spool (1) is in the NEUTRAL position, the only
path the oil can take is from chamber (12) to tank
through passage (11).
The mast can be stopped and held in any position
when the tilt control valve is in neutral. This is
because the flow to and from the tilt cylinders is
stopped by spool (1). In the NEUTRAL position, oil
can not flow from passage (4) to outlet (2) or (7).

Vehicle Systems

20

Systems Operation

Tilt Forward Position

13
9

14

10

16

15
11

12

ICCS013S
Tilt Spool In Forward Position
(1) Spool. (2) Outlet to Rod End Of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Outlet To Head End Of Tilt Cylinders. (8) Passage For Return Oil. (9) Spring. (10) Spool. (11) Passage.
(12) Chamber. (13) Spring. (14) Orifice. (15) Orifice. (16) Passage.

As tilt spool (1) is moved to the TILT FORWARD


position, two paths are opened for the flow of oil to
the tilt cylinders. One is from passage (4) to outlet
(7), which allows pressure oil to go to the head end
of the tilt cylinders. The other path is for return oil
from the rod end of the tilt cylinders. As spool (1)
moves, orifice (15) moves into position to send
pressure oil to the chamber behind spool (10). Spool
(10) moves against the force of spring (9) and opens
a path for return oil between passage (16) and
orifice (14). This has the effect of slowing down the
flow of oil from the rod end of the tilt cylinders and
preventing cavitation in the head end. If pump flow
(pressure) is lost, for any reason, spool (10) will
return to the NEUTRAL position and the path for
return oil is closed.

When the control lever for tilt is moved to TILT


FORWARD position, spool (1) is moved until a path
is opened between passage (4) and outlet (7) and oil
flow from chamber (12) to passage (11) is stopped.
This causes the oil pressure to increase and open
load check valve (3). The pressure oil from the pump
can now flow from passage(4) to outlet (7). It then
flows to the head end of the tilt cylinders and the
mast tilts forward. Return oil from the rod end of the
tilt cylinders flows into the valve through outlet (2) in
to passage (8) and then to tank.

Vehicle Systems

21

Systems Operation

Tilt Back Position

13
9

10

14

16

15
11

12

ICCS014S
Tilt Spool In Tilt Back Position
(1) Spool. (2) Outlet To Rod End Of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Outlet To Head End Of Tilt Cylinders. (8) Passage For Return Oil. (9) Spring. (10) Spool. (11) Passage.
(12) Chamber. (13) Spring. (14) Orifice. (15) Orifice. (16) Passage.

When the control lever for tilt is moved to TILT BACK


position, tilt spool (1) is moved until a path is opened
between passage (4) and outlet (2), and oil flow from
chamber (12) to passage (11) is stopped. This
causes the oil pressure to increase and open load
check valve (3). The pressure oil from the pump can
now flow from passage (4) to outlet (2). It then flows
to the rod end of the tilt cylinders and the mast tilts
back.
Return oil from the head end of the tilt cylinders flows
into the valve through outlet (7) into passage (8) and
then to tank.

Vehicle Systems

22

Systems Operation

Relief Valve

If the control lever is held in LIFT or TILT position


after the cylinder rod is fully extended or retracted,
the flow of oil from outlet port to the cylinders is
stopped. The oil under pressure must be released.
The pressure oil flows through piston(11) of the main
relief valve. The pressure oil opens pilot valve (14).
This lets the oil flow go through spring chamber (13)
to passage (7). The oil then returns to tank. When
the pilot valve opened, it caused a decrease in the
pressure in spring chamber (13) that let piston (11)
move against the force of the spring in spring
chamber (13). This stops the flow of oil around the
pilot valve to passage (7) and moves piston (12)
down until a path is open for pump flow to go to the
tank through passage (7). This action will continue
until the control lever is moved to NEUTRAL position.

13

14

12
11

IHCS104S
Relief Valve
(7) Passage for return oil. (11) Piston. (12) Dump valve.
(13) Spring chamber. (14) Pilot valve.

Vehicle Systems

23

Systems Operation

Steering System
Hydraulic Operation (Load Sensing Closed Center Steering System)

5
2

T
P
R

LS

13

10

11

12

IBCS036B
Steering System Schematic
(1) Steering Unit. (2) Hose (to hydraulic tank). (3) Priority Valve. (4) Hose (from hydraulic pump). (5) Hose (to control valve).
(6) Hose. (7) Hose. (8) Steering Axle. (9) Check Valve (in steer gear). (10) Hose (from priority valve). (11) Hydraulic Pump.
(12) Hydraulic Tank. (13) Hose (load sensing).

The steering system is a load sensing closed center


type and uses hydraulic oil for its operation. Oil flow
through the steering system is closed unless the
steering wheel is turned. The flow through the
steering gear is sensed by the priority valve, which
then allows additional oil flow to the steering system.
The priority valve also fills the requirements of the
power brakes (if equipped) and then the mast.

pressure drops in these lines, the priority valve


metering spool will shift to meet the flow demand. As
the metering spool shifts, more oil flow is diverted to
hose (10) than to hose (5). The priority valve
metering spool will shift back and forth to meet the
steering flow demand while maintaining the Load
Sensing Pressure between load sense hose (13) and
the priority valve internal sensing line. At times flow
to hose (5) will be closed completely. The
combination of flow restrictors in the lines and spring
tension on the priority valve metering spool work
together to maintain this balance.

Hydraulic oil is pulled from hydraulic tank (12)


through a strainer to hydraulic pump (11). The pump
sends the oil through hose (4) to priority valve (3).
When the steering gear is in NEUTRAL position,
pressure in hose (10) and the priority valve internal
sensing line rises. When this pressure rises more
than load sensing signal hose (13) the priority valve
metering spool shifts to stop oil flow to the steering
unit. Oil flows hose (5) to the hydraulic control valve.
When the unit (pump) is moved, oil starts to flow to
steer axle (8). The pressure in line (10) and the
priority valve internal sensing line will drop. As
Vehicle Systems

Check valve (9) is in the steering unit (pump) to


prevent oil flow back to priority valve (3), which could
cause a sudden jerk of the steering wheel.
Relief valve in steering unit valve body will open if
the steering pressure goes above 8000 kPa (1143
psi).

24

Systems Operation

Oil Flow

Steering UnitSteering Gear

A
4

PUMP OIL
METERED OIL
RETURN OIL

3 10

11 5
14
15 16

6 7
1

8
9 10 11
IBCS037B

13

9 2

Steering Unit
A. Control valve section. B. Metering section.
(1) Spool. (2) Sleeve. (3) Outlet to tank. (4) Check valve.
(5) Inlet from pump. (6) Rotor. (7) Stator.
(8) Centering springs. (9) Pin. (10) Left turn port.
(11) Right turn port. (12) Body. (13) Drive.

17

IBCS038B
Steering Unit (Shown in RIGHT TURN Position)
(1) Spool. (2) Sleeve. (3) Outlet to tank.
(5) Inlet from pump. (8) Centering springs. (9) Pin.
(10) Left turn port. (11) Right turn port. (13) Drive.
(14) Passage. (15) Passage. (16) Gerotor. (17) Passage.

The steering unit has two main sections ; control


section (A) and pump or metering section (B). These
two sections work together to send oil to the steering
cylinder.

When the steering wheel is turned for a right turn,


pump oil flows into the STEERING UNIT through
inlet (5) and passage (14). From passage (14) it goes
into the gerotor through passage (17). With the
steering wheel turning, gerotor (16) is turning and
pumping oil. The Metered flow comes out through
passage (15), where it is directed out to the steering
cylinder through right turn port (11). When the
steering wheel started to turn ; spool (1), pin (9) and
drive (13) also started to turn. Sleeve (2) did not start
to turn at the same time as the spool because the
diameter of the holes in the sleeve are slightly larger
than the diameter of pin (9). This allows spool (1) to
turn inside of sleeve (2) enough to put the small
holes in sleeve (2) in line with the grooves in spool
(1). The alignment of the small holes in the sleeve
with the grooves in the spool provides the path for oil
flow to gerotor (16) and also to the steering cylinder.
Centering springs (8) are compressed when the
spool moves in relation to the sleeve. When the
steering wheel is no longer turning, the springs will
bring the spool and sleeve back to a NEUTRAL
position. This means that the wheels will stay in the
position they were in when the steering effort
stopped. The steering wheel must be turned in the
opposite direction to bring the wheels back to straight
ahead, or to make a left turn. As the metered oil goes
out to the cylinder through outlet (11) for a right turn,
return oil from the cylinder is coming back into the
STEERING UNIT through outlet (10). This oil is sent
to the tank.

Oil from the priority valve enters the steering unit


through inlet (5) into the control section. When the
steering wheel is turned, the control section sends
the oil to and from the metering section, and also to
and from the steering cylinder.
The metering section is a small hydraulic pump. It
meters the oil that goes to the steering cylinder, As
the steering wheel is turned faster, there is an
increase in the flow of oil to the steering cylinder.
This increased flow causes the steering cylinder to
move farther and faster. As the steering cylinder
moves farther, more oil can flow from the metering
section to the steering cylinder and a faster turn is
made.

Vehicle Systems

4 13

12

25

Systems Operation

PUMP OIL
METERED OIL
RETURN OIL

10 11

5
14

15
16

21

18
2
18

19
20
19
9

17
IBCS040B

LEFT TURN

Spool And Sleeve

IBCS039B

(1) Spool. (2) Sleeve. (18) Slots for spring.


(19) Holes for pin. (20) Small holes for oil flow.
(21) Grooves for oil flow.

Steering Unit (Shown in a LEFT TURN Position)


(1) Spool. (2) Sleeve. (3) Outlet to tank. (5) Inlet from pump.
(9) Pin. (10) Left turn port. (11) Right turn port. (13) Drive.
(14) Passage. (15) Passage. (16) Gerotor. (17) Passage.

The rate of flow the gerotor sections is determined by


how fast the steering wheel is turned. The faster the
steering wheel turns, the greater the flow and the
faster the vehicle will turn.

When the steering wheel is turned to the left, spool


(1), pin (9) and drive (13) turn with it. After spool (1)
has turned a small amount pin (9) will cause sleeve
(2) to move with the spool. They will rotate together
but will be a few degrees apart.
The flow of oil through the STEERING UNIT is in the
opposite direction to that of a right turn. It comes in
through inlet (5) and passage (14) and then goses
into gerotor (16) through passage (15). From the
gerotor, the oil leaves through passage (17), goes
through the sleeve spool combination and then to left
turn port (10). From the left turn port it goes to the
steering cylinder.

Vehicle Systems

26

Systems Operation

TANK OIL (SUPPLY)


METERED OIL
RETURN OIL

7
3 10 11

15 16

17

13
EHCS036B

EMERGENCY

Pump Gears In The Metering Section


(6) Rotor. (7) Stator. (9) Pin. (13) Drive.

EHCS035B
Steering Unit (Shown in Manually Operated Right Turn
Position)
(3) Outlet to tank. (4) Ball check. (10) Left turn port.
(11) Right turn port. (15) Passage. (16) Gerotor.
(17) Passage.

When the steering wheel is turned, in either direction,


pin (9) turns with the sleeve and spool and causes
drive (13) to turn also. The drive cause rotation of
rotor (6) inside of stator (7). This rotation of the rotor
sends a controlled (metered) flow of oil back to the
spool sleeve combination where it is then directed to
either port (10) or (11) and then to the steering
cylinder.

If there is a pump failure or the engine stops and can


not be started again, the STEERING UNIT can be
manually operated. Turning the steering wheel will
take oil from the tank and bring it in through outlet
(3). It will then open check valve (4) and go to the
gerotor (16) through passage (17). It will come out of
(16) through passage (15) and go to the right turn
port (11). This is the flow for a right turn. It would be
reversed for a left turn.

If the unit is taken apart for any reason, it must be


put back together with the relationship between pin
(9) and rotor (6) as shown.

During normal operation, check valve (4) will be held


closed by pressure oil from the pump.

Vehicle Systems

27

Systems Operation

Brake System
1

Master Cylinder

IHCS112P
(1) Master Cylinder Reservoir

Brake fluid from remote reservoir (1) to replenish


master cylinder (2).
The master cylinder has a piston which push brake
liquid into the brake lines. The reservoir, located on
the middle plate, is connected to inlet of master
cylinder. The supply lines keep master cylinder (2)
filled so no air enters the system. Reservoir (1)
supplies brake liquid to the system.

When the brake pedal is first pushed, the piston


moves into the master cylinder and pushes brake
liquid through outlet into the brake lines.
IOCS008I

The liquid pushed through outlet goes through the


brake lines to the brake cylinder (3).

Master Cylinder And Cylinder of Brake Lever


(1) Master Cylinder reservoir. (2) Master Cylinder.
(3) Brake Cylinder.

5
3

IOCS009I
(3) Brake Cylinder. (4) Piston Rod. (5) Lever Plate.

When hydraulic pressure is supplied to the brake


cylinder (3), piston rod (4) rotates lever plate (5).
With rotation, lever plate is moved towards friction
and steel plates. Then wet disc brake is actuated by
this force from lever plate.

Vehicle Systems

28

Systems Operation

Electric Motors
Hydraulic Pump Motor
(AC)

The motor is protected from over temperature by a


thermal sensor. If motors temperature reaches in
155 L 4C (311 L 10F) controller does overheat
warning and operates by smallest performance.
The hydraulic pump motor is activated when the key
and seat switches are closed and lift, tilt or auxiliary
lever is moved. In lift operation, the speed of the
motor is variable. The larger the distance the lever is
moved, the faster the motor will rotate. The speed of
the motor is fixed in tilt or auxiliary operation.
On the instrument Panel or Eye program the speed
of lift or tilt or auxiliary operation could be presettable.

Vehicle Systems

29

Systems Operation

(SE)

EHCS039B
Electric Motor
(1) Brush cover. (2) Thermal switch. (3) Motor frame. (4) Brush. (5) Commutator. (6) Armature. (7) Fleld coil. (8) Fan.

The hydraulic system is operated by a direct current


(DC) motor. Electric storage batteries are the source
of power for the DC motor

The motor is protected from over temperature by a


thermost switch (2). When the normally closed
thermost switch is open, the amount of current
through the motor is limited to allow, the motor to
cool. All motors are fan (8) cooled.

The hydraulic pump motor is a series wound motor


and uses high temperature insulation. Armature (6) is
mounted with single row ball bearings at each end.
The ball bearings are permanently lubricated with
high temperature lubricant.

The hydraulic pump motor is activated when the key


and seat switches are closed and lift, tilt or auxiliary
lever is moved. In lift operation, the speed of the
motor is variable. The larger the distance the lever is
moved, the faster the motor will rotate. The speed of
the motor is fixed in tilt or auxiliary operation.

The electrical connections to the motor are made of


corrosion resistant terminals on motor frame (3). On
the outside of the motor frame is cover (1) that can
be removed for easy access to brushes (4) and
commutator (5). Field coils (7) are fastened to the
inside of the motor frame.

On the Option MicroController Control, the speed of


lift or tilt or auxiliary operation could be pre-settable.

The motor brushes are held in the four brush holders


by springs. The springs hold the brushes against
commutator (5) and compensate for brush wear.
The parts of armature (6) include the shaft, core,
windings and commutator.

Vehicle Systems

30

Systems Operation

Testing & Adjusting

3. Check all oil lines and connections for damage or


leaks.

Troubleshooting

4. Check all the lift chains and the mast and carriage
welds for wear or damage.

Troubleshooting can be difficult. A list of possible


problems and corrections are on the pages that follow.

Hydraulic System and Mast

This list of problems and corrections will only give an


indication of where a problem can be and what
repairs are needed. Normally, more or other repair
work is needed beyond the recommendations on the
list. Remember that a problem is not necessarily
caused only by one part, but by the relation of one
part with other parts. This list can not give all
possible problems and corrections. The serviceman
must find the problem and its source, then make the
necessary repairs.
The pressure Gauge Kit or the Tetragauge Group
can be used to make the pressure tests of the
hydraulic system. Before any test is made, visually
inspect the complete hydraulic system for leakage of
oil and for parts that have damage.

During a diagnosis of the hydraulic system,


remember that correct oil flow and pressure are
necessary for correct operation. The output of the
pump(oil flow) increases with an increase in motor
speed(rpm) and decreases when motor speed(rpm)
is decreased. Oil pressure is caused by resistance to
the flow of oil.
Visual checks and measurements are the first step
when troubleshooting a possible problem. Then do
the Operation Checks and finally, do instrument tests
with pressure gauges.
Use the Pressure Gauge Kit, a stop watch, a magnet,
a thermometer and a mm (inch) ruler for basic test
measurements.

WARNING
1. The pressure of the oil required to open the relief
valve. Relief valve pressures that are too low will
cause a decrease in the lift and the tilt
characteristics of the lift truck. Pressures that are
too high will cause a decrease in the life of hoses
and components.

To prevent personal injury when testing and


adjusting the hydraulic system, move the machine
to a smooth horizontal location and lower the mast
and carriage to the ground. If the mast and
carriage can not be on the ground, make sure they
are blocked correctly to keep them from a fall that
is not expected. Move away from machines and
personnel that are at work. There must be only one
operator. Keep all other personnel away from the
machine or where the oerator can see the other
personnel. Before any hydraulic pressure plug,
line or component is removed, make sure all
hydraulic pressures are released.

2. Drift rates in the cylinders. Cylinder drift is caused by


a leakage past cylinder pistons, O-ring seals in the
control valve, check valves that do not seat correctly
or poor adjustment or fit in the control valve spools.
3. Cycle times in the lift and tilt circuits; Cycle times
that are too long are the result of leakage, pump
wear and/or pump speed(rpm).

Performance Test

Visual Checks

The performance tests can be used to find leakage in


the system. They can also be used to find a bad
valve or pump. The speed of rod movement when
the cylinders move can be used to check the
condition of the cylinders and the pump.

A visual inspection of the hydraulic system and its


components is the first step when a diagnosis of a
problem is made. Lower the carriage to the floor and
follow these inspections;
1. Measure the oil level. Look for air bubbles in the
oil tank.

Lift, lower, tilt forward and tilt back the forks several
times.

2. Remove the filter element and look for particles


removed from the oil by the filter element. A magnet
will separate ferrous particles from nonferrous
particles (piston rings, O-ring seals, etc.).
Vehicle Systems

1. Watch the cylinders as they are extended and


retracted. Movement must be smooth and regular.

31

Testing & Adjusting

2. Listen for noise from the pump.

Mast and Carriage

3. Listen for the sound of the relief valve. It must not


open except when the cylinders are fully extended
or retracted, when the forks are empty.

Problem: The hydraulic system will not lift the


load.
Probale Hydraulic Cause :

Hydraulic Oil Temperature


(Too Hot)

1. There is an air leak, which lets air into the


hydraulic system on the inlet side of the hydraulic
pump.

When the temperature of the hydraulic oil gets over


98.8C (210F), polyurethane seals in the system
start to fail. High oil temperature causes seal failure
to become more rapid. There are many reasons why
the temperature of the oil will get this hot.

2. The relief valve opens at low oil pressure.


3. The hydraulic pump has too much wear.
4. The load is not correct (too heavy).

1. Hydraulic pump is badly worn.


Probable Mechanical Cause:
2. Heavy hydraulic loads that cause the relief valve to
open.

1. The mast is not in alignment with the other lifting


components and does not move freely.

3. The setting on the relief valve is too low.


2. Not enough lubricant on the parts of the mast that
move.

4. Too many restrictions in the system.


5. Hydraulic oil level in the tank is too low.

3. The carriage or mast rollers(bearings) are worn


and do not move(seized).

6. High pressure oil leak in one or more circuits.


Problem : Lift cylinder extends too slowly.
7. Very dirty oil.
Probable Hydraulic Cause :
8. Air in the hydraulic oil.
1. Not enough oil supply to lift cylinder.
NOTE : If the problem is because of air in the oil, it
must be corrected before the system will operate at
normal temperatures. There are two things that
cause air in the oil(aeration). These are :

2. Defective lift cylinder seals.


Probable Mechanical Cause :

a. Return oil to the tank goes in above the level of


the oil in the tank.

1. The mast is not in alignment with the other lifting


components and does not move freely.

b. Air leaks in the oil suction line between the pump


and the tank.

2. Not enough lubricant on the parts of the mast that


move.
3. The carriage or mast rollers (bearings) are worn
and do not move (seized).
Problem : Mast does not move smoothly
Probable Hydraulic Cause :
1. Air in the hydraulic system.
2. Relief valve sticks or defective.

Vehicle Systems

32

Testing & Adjusting

Probable Mechanical Cause :

5. Air in the hydraulic system.

1. Not enough lubricant on the parts of the mast that


move.

Probable Mechanical Cause:


1. The mast is not in alignment with the other lifting
components and does not move freely.

2. Load rollers(bearings) defective or not adjusted


correctly.

2. Carriage chains need an adjustment.


Problem : Mast will not lower completely or will
not lower at all.

3. Not enough lubricant on the part of the mast that


moves.

Probable Mechanical Cause :


4. The carriage or mast rollers(bearings) are worn
and do not move(seized).

1. Lift cylinder damaged or bent.


2. Load rollers(bearings) defective or not adjusted
correctly.

Problem : The lift or tilt cylinders do not hold


their position with the valve control levers in
neutral position.

3. Not enough lubricant on the parts of the mast that


move.

Probable Cause :

Problem: The mast does not tilt correctly or


moves too slowly.

1. The valve spools do not hold their positions


because the springs for the valve spools are weak
or broken.

Probable Hydraulic Cause :


2. Control valve leakage caused by worn valve
spools.

1. There is an air leak, which lets air into the


hydraulic system on the inlet side of the hydraulic
pump.

3. The check valve or flow control valves in the


control valve are bad.

2. The relief valve opens at low oil pressure.


4. Leakage of the cylinder lines or piston seals.
3. The hydraulic pump has too much wear.
5. There is foreign material in the control valve.
4. The internal valve of the tilt spool is stuck.
5. Control valve tilt spool has a restriction.

Hydraulic Pump

Probable Mechanical Cause :

Problem: Noise in the pump.

1. Damage or failure of the piston rods on the tilt


cylinders.

Probable : Cause :
1. The oil level is low.

Problem : The carriage will not lower correctly.


2. The oil is thick(viscosity too high).
Probable Hydraulic Cause:
3. The pump inlet line has a restriction in it.
1. There are restrictions in the lift line.
4. Worn parts in the pump.
2. The lift spool in the control valve has a restriction
caused by foreign material and does not operate
freely.

5. Oil is dirty.
6. Air leaks into the inlet line.

3. The lift cylinder flow control valve has a restriction.


4. Lift cylinders excess flow protectors have a
restriction.

Vehicle Systems

33

Testing & Adjusting

Problem: The oil temperature is too high.


Probable Cause :

7. The bolts of the pump do not have the correct


torque.

1. The oil level is low.


Hydraulic control valve
2. There is a restriction in an oil passage.
Problem:The control spools do not move freely.
3. The relief valve setting is too low.
Probable Cause:
4. The oil is too thin.
1. The temperature of the oil is too high.
5. There is air leakage in the system.
2. There is foreign material in the fluid.
6. The pump has too much wear.
3. The fitting connections in the valve body are too
tight.

7. The system operates at too high a pressure.


a. Relief valve setting too high.
b. Attachment components cause a restriction
during movement.
c. Restrictions in flow control valve, check valve
and in oil lines.

4. The fastening bolts of the valve assembly do not


have the correct torque and have twisted the body.
5. Linkage of the lift and tilt levers does not operate
smoothly.

Problem : Leakage at the pump shaft seal.

6. Bent lift or tilt spools.

Probable Cause :

7. Damage to the return springs of the spools.

1. The shaft seal is worn.

8. The hydraulic oil is not at normal temperature for


operation.

2. The inner parts of the pump body are worn.


Problem : Control valve spools have leakage
around the seals.

3. Operation with too low oil level in tank causes


suction on the seal.

Probable Cause :
4. Seal cut on shoulder of pump or keyway during
installation.

1. There is foreign material under the seal.

5. Seal lips are dry and hardened from heat.

2. The valve spools are worn.

Problem : There is failure of the pump to deliver


fluid.

3. The seal plates are loose.


4. The seals have damage or are badly worn.

Probable Cause :
Problem : The load lowers when the lift spool is
moved from the NEUTRAL position to the RAISE
position.

1. Low level of the oil in the tank.


2. There is a restriction in the pump inlet line.

Probable Cause :
3. There is air leakage in the pump inlet line.
1. There is foreign material in the check valve area.
a. Loose bolts.
b. Defects in suction line.

2. The check valve poppet and seat show wear.

4. The viscosity of the oil is wrong.

3. Sudden loss of pump oil pressure.

5. The pump has too much wear.

4. Damage to the relief valve which causes low oil


pressure.

6. Failure of the pump shaft.


Vehicle Systems

34

Testing & Adjusting

Problem : Foreign material behind the wiper rings


causing scratches on the cylinder rod.

Problem : Spools do not return to neutral.


Probable Cause:

Probable Cause :
1. The springs are broken.
1. The wiper rings show wear and do not remove dirt
and foreign material.

2. The spool is bent.


3. The system or valve has foreign particles in it.
4. The control linkage is not in alignment.

Steering System

5. The fastening bolts of the valve have too much


torque.

Problem : Too much force needed to turn


steering wheel.

Problem : No motion or slow, then a too sudden


action of the hydraulic system.

Probable Cause :
1. Priority valve (if equipped) releases pressure oil at
a low setting

Probable Cause :

2. Pump oil pressure is low, worn pump.

1. The relief valve is not correctly set, or will not


move in base and/or is worn.

3. Steering gear covers are too tight.


2. There is air in the system.
4. Steering column not aligned with steering gear.
3. Dirt or foreign particles between relief valve control
poppet and its seat.

5. Priority valve spool is held in one position.

4. Valve body has a crack inside.

6. Steering gear without lubrication.

5. Spool not moved to a full stroke.

7. Low fluid level in the hydraulic supply tank.

Lift and Tilt Cylinders

Problem : Steering wheel does not return to


center position correctly.

Problem : Leakage around the cylinder rod.

Probable Cause :

Probable Cause :

1. Steering gear covers are too tight.

1. Cylinder head(bearing) seals are worn.

2. Steering column is not in correct alignment.

2. Cylinder rod is worn, scratched or bent.

3. Valve spool in the steering gear has a restriction.

Problem There is leakage of oil inside the


cylinder or loss of lift or tilt power.

4. Priority valve check valve permits lift and tilt


hydraulic oil to affect hydraulic circuit.

Probable Cause :

Problem : Oil leakage at the pump.

1. The piston seals are worn and let oil go through.

Probable Cause :

2. Cylinder has damage.

1. Loose hose connections.

Problem: The tilt cylinder rods show wear.

2. Bad shaft seal.

Probalble Cause :
1. The cylinder are not in correct alignment.
2. Oil is dirty.
Vehicle Systems

35

Testing & Adjusting

Problem: Low oil pressure.

Problem : The temperature of the oil is too hot.

Probable Cause :

Probable Cause :

1. Low oil level.

1. The viscosity of the oil is wrong.

2. Priority valve (if equipped) relief valve spring weak.

2. Air is mixed with the oil.

3. Relief valve(priority valve) will not move from the


open position.

3. The relief valve is set too high(priority valve).


4. There is a restriction in the return line circuit.

4. Oil leakage inside or outside of the system.


5. Bad pump.

Brake System

Problem : Pump makes noise when turning the


steering wheel and does not move smoothly.

Wet Disc Brake

Probable Cause :

Problem : Pedal resistance is not solid(spongy).

1. Air in the steering hydraulic circuit.

Probable Cause :

2. The pump has to much wear.

1. Leakage or low fluid level.

3. Loose connection of the oil line on the inlet side of


the pump.

2. Air in the brake hydraulic system.


3. Master cylinder is loose.

4. The viscosity of the oil is wrong.


Problem : Extra (excessive) pedal pressure
needed for braking action.

5. The oil level in the hydraulic tank is low.

Probable Cause :

Problem : Lift truck does not turn when steering


wheel is slowly turned.

1. Mechanical resistance on the brake pedal.


Probable Cause :
2. Restriction in the brake line.
1. The oil level of the tank is low.
3. Bad master cylinder.
2. There is air in the steering system.
4. Discs look like glass(glazed) or are worn.
3. The pump operation is not correct.
Problem : Pedal gradually goes to the floor.
4. Dirt in the steering system.
Probable Cause :
5. Steering gear operation is not correct.
1. Leakage or low fluid level.
6. Restriction in the steer axle linkage.
2. Bad master cylinder.

Vehicle Systems

36

Testing & Adjusting

Problem : Extra(excessive) pedal travel.

Parking Brakes

Probable Cause :

Problem : Brakes will not hold.

1. Pedal adjustment is not correct.

Probable Cause :

2. Leakage or low fluid level.

1. Parking brake assembly out of adjustment.

3. Air in the brake hydraulic system.

2. Parking brake control cable out of adjustment.

4. Bad master cylinder.

3. Worn brake discs.

5. Discs are worn.


Problem : Brakes will not apply.

Electric Motors

Probable Cause :

Before an analysis is made of any electric motor


problem, always make reference to the
troubleshooting section of MicroController Control
System module.

1. Leakage or low fluid level.


2. Air in the brake hydraulic system.
3. Linkage is not in correct adjustment or is bent.

WARNING

4. Discs look like glass (glazed) or worn.


If an electrical failure or an overload of the motor
is present, personnel must not breathe the toxic
fumes which are a product of the burnt insulation.
All power must be disconnected from the motor
before any inspection is made to find the failure.
The area around the motor must be well
ventilated(air flow) and the motor is to be cooled
before any repair work is done. Water must not be
used on any electrical equipment because of the
danger of electrical shock. If a fire is present,
disconnect the electrical power and use a carbon
dioxide extinguisher to put the flame out.

5. Oil or brake fluid is on the lining.


6. Bad master cylinder.
Problem : Not braking evenly or rough feeling
during braking (chatter).
Probable Cause :
1. Discs look like glass (glazed) or worn.
2. Oil or brake fluid is on the lining.

Do not operate the drive motor without a load as


too much speed may cause damage to the motor
and injury to personnel.

3. Bad contact between the steel discs and friction


discs.
4. Brake discs uneven (out of flat).
5. Loose pressure plate bearing.

NOTICE
Never use air pressure that is more than 30 psi(205
kPa) and make sure the air line is equipped with a
water filter.

6. Bad disc and friction disc assembly.

Vehicle Systems

37

Testing & Adjusting

2. Battery not being fully charged or equalized during


the battery charging operation.
Check the battery cells for an equalization
charge (a charge to make the specific gravity the
same in all cells).
Check the battery charger for defects.

(AC)
Problem 1 : Hydraulic pump motor will not
operate.
Probable Cause :

3. Battery Discharge Indicator (BDI) lift interrupter


circuit which protects the battery, shuts off the
hydraulic motor circuit too soon.
See Battery Discharge Indicator Operation
Adjustment and Troubleshooting in the
MicroController Control System module.

1. Bad connections or fuses.


Check battery connections.
Check the key fuse.
Check the hydraulic pump motor for possible
reasons for a bad fuse.
Some causes are:
a) Operation with too high hydraulic pressures.
b) Operation with too much current draw.
c) Possible short circuit in power(Inverter) unit.

4. Battery charge interval is too long or charged


battery cooling time is too short. This causes
excessive (too much) cell temperatures which
decreases the capacity of the battery to supply the
rated amp hours.
Decrease the battery work duration before a
change.
Increase the battery cooling time after a charge
before it is put to use.

2. Key switch, seat switch or line contactor not


closed.
Close the seat and key switch. Use a
multimeter(VOM) to check power flow thru the
seat switch, key switch, line contactor coil and
line contactor. The key switch, seat switch and
line contacor must be closed for the power
steering function to operate.
The key switch, seat switch, control valve switch
and the line contactor must be closed for the
hydraulic pump motor to operate.

5. Battery has one or more defective cells which can


result in less than the rated capacity and ability of
the battery.
Test and locate the defective cells. Replace the
defective cell (s).
Battery cells are connected in series, one bad
cell causes a high resistance in series with the
other cells. This slows down the speed of the
motor as the cell resistance increases. This can
occur with the other cell almost fully charged.

3. Not enough voltage. High resistance in battery


cells or cables.
Charge the battery or replace the battery.
Check all the cells for one or more that has
defects.
Check the specific gravity of each cell. The
maximum density difference from the highest to
lowest cell must not be more than .020 SG
(specific gravity).
Check cable terminals for tight fit at battery
terminal and control panel connectors.
Check for broken inner wires in cables.

6. Hydraulic system draws too much battery power


because of lifting and tilting arrangements or
hydraulic controls are not correct for the duty
cycle.
Decrease hydraulic relief valve setting to the
capacity needed for the application.
Change to a smaller hydraulic pump (if
available). Check the mast for restriction during
operation.
Remove quick disconnects and install fittings with
lesser resistance to oil flow.
Check for defective hydraulic control valve, the
pilot operated relief valve.
Remove any restrictions in the hydraulic circuit.
Make an inspection of the movable hydraulic
attachments for restrictions. Check for
components that slide, bearing wear, hinges
binding and the correct amount of lubrication on
necessary components.

4. Speed Sensor is breakdown.


5. Lift and drive system operation not correct.
See troubleshooting section of the Micro
Controller Control System module.
Problem 2 : Battery will not last a complete
normal work period.
Probable cause :
1. Too small a battery installed in the lift truck.
Study and question the use of the lift truck in its
complete working conditions, select and
purchase appropriate capacity of battery
regarding work hours.

Vehicle Systems

38

Testing & Adjusting

Problem 4 : Lift truck has slow hydraulic speeds.


Probable Cause :
1. Hydraulic pump motor overheated.
In case motors temperature reaches in 155C
controller does overheat warning and reduce the
performance.
2. Pump motor control circuit overheated.
In case power units tenperature reaches in
100C controller does overheat warning and
reduce the performance.

Vehicle Systems

39

Testing & Adjusting

5. Check for short or open circuit in the armature or


between armature and field.
Loose field winding pole pieces.
Check poles for damaged insulation, repair or
replace damaged insulators.
Failed armature bar insulation or armature bar
connector open. Repair or rebuild the insulation,
replace the armature.

(SE)
Problem 1 : Hydraulic pump motor will not
operate.
Probable Cause :
1. Bad connections or fuses.
Check battery connections.
Check the key fuse and power steering fuse.
Check the hydraulic pump motor for possible
reasons for a bad fuse.
Some causes are:
a) Operation with too high hydraulic pressures.
b) Operation with too much current draw.
c) Possible short circuit in power unit(Module).

NOTE : If armature open circuits cause commutator


bar pitting or burnt areas, armature will need
replacement. Heat from the arcing causes the
hardened copper commutator bars to be annealed
(soft). Just machining (turned to a lesser diameter) of
the commutator will not correct the problem from
occurring again. The armature must be replaced.
Opens in the armature bar connections must be
found and soldered(repaired).

2. Key switch, seat switch or line contactor not


closed.
Close the seat and key switch. Use a
multimeter(VOM) to check power flow thru the
seat switch, key switch, line contactor coil and
line contactor. The key switch, seat switch and
line contacor must be closed for the power
steering function to operate.
The key switch, seat switch, control valve switch
and the line contactor must be closed for the
hydraulic pump motor to operate.

6. Lift and drive system operation not correct.


See troubleshooting section of the Micro
Controller Control System module.
Problem 2 : Battery will not last a complete
normal work period.
Probable cause :
1. Too small a battery installed in the lift truck.
Study and question the use of the lift truck in its
complete working conditions, select and
purchase appropriate capacity of battery
regarding work hours.

3. Not enough voltage. High resistance in battery


cells or cables.
Charge the battery or replace the battery.
Check all the cells for one or more that has
defects.
Check the specific gravity of each cell. The
maximum density difference from the highest to
lowest cell must not be more than .020 SG
(specific gravity).
Check cable terminals for tight fit at battery
terminal and control panel connectors.
Check for broken inner wires in cables.

2. Battery not being fully charged or equalized during


the battery charging operation.
Check the battery cells for an equalization
charge (a charge to make the specific gravity the
same in all cells).
Check the battery charger for defects.
3. Battery Discharge Indicator (BDI) lift interrupter
circuit which protects the battery, shuts off the
hydraulic motor circuit too soon.
See Battery Discharge Indicator Operation
Adjustment and Troubleshooting in the
MicroController Control System module.

4. Brushes are worn.


Disconnect the battery and discharge the
commutating capacitor(HEAD CAP). Inspect the
pump motor commutator for burnt marks or
scoring (scratches).
Make corrections or repair the armature
commutator, replace the brushes as necessary.
See Armature Commutator Inspection and Brush
Inspection in Testing And Adjusting.
Make reference to Problem : Pump Motor
Overheat (Too Much Heat).
Check for open circuits in the field coil.
Test coils according to procedures in Testing And
Adjusting. If there are open circuits, replace the
coils.

Vehicle Systems

4. Battery charge interval is too long or charged


battery cooling time is too short. This causes
excessive (too much) cell temperatures which
decreases the capacity of the battery to supply the
rated amp hours.
Decrease the battery work duration before a
change.
Increase the battery cooling time after a charge
before it is put to use.

40

Testing & Adjusting

5. Battery has one or more defective cells which can


result in less than the rated capacity and ability of
the battery.
Test and locate the defective cells. Replace the
defective cell (s).
Battery cells are connected in series, one bad
cell causes a high resistance in series with the
other cells. This slows down the speed of the
motor as the cell resistance increases. This can
occur with the other cell almost fully charged.

If the motor has EE covers and the duty cycle is


heavy and within the lift truck capacity, remove
the covers if permitted.
4. Commutator bars burnt in two or more positions at
180 apart because :
Armature bars open, replace armature, Short
circuit in the armature, see Armature Tests.
Armature not in balance which causes brush
bounce, see Specifications.
Motor was stalled against a heavy load and
caused the two bars in contact with the brushes
to burn, see Armature Commutator Inspection.

6. Hydraulic system draws too much battery power


because of lifting and tilting arrangements or
hydraulic controls are not correct for the duty
cycle.
Decrease hydraulic relief valve setting to the
capacity needed for the application.
Change to a smaller hydraulic pump (if
available). Check the mast for restriction during
operation.
Remove quick disconnects and install fittings with
lesser resistance to oil flow.
Check for defective hydraulic control valve, the
pilot operated relief valve.
Remove any restrictions in the hydraulic circuit.
Make an inspection of the movable hydraulic
attachments for restrictions. Check for
components that slide, bearing wear, hinges
binding and the correct amount of lubrication on
necessary components.

5. Dirty motor that has metallic or carbon dust. This


dust is a conductor which causes electrical shorts,
increase current draw and decrease pump motor
output.
Remove any dirt with air pressure.
6. Brushes too tight in brush holder. Brush springs
not strong enough to force one or more brushes in
contact with commutator.
a. At installation, pull upon brush leads to make sure
they return to contact with commutator correctly.
See Brush Installation in Testing And Adjusting.
b. If brushes are too tight remove the brush
material with sandpaper until brush movement
in brush box is free.
7. Loose movement of the brushes.
Check the brush springs for cracks and
overheating signs (bluing).
Compare spring force with a new brush spring.
Check the brush holder for oversize (too large for
brush size).
Replace the brush spring if necessary.

Problem 3 : Sparks at the commutator and/or


rapid brush wear.
Probable Cause :
1. Worn brushes.
Replace the brushes and make sure the brushes
are seated. See New Brush installation and
Brush Inspection in Testing And Adjusting.

8. Loose brush leads or motor bus bar connections.


Check the brushes for tight connections. Replace
if leads are loose in brush material.
Check all cables and wire connections for
tightness.

2. Loose cable connections at the motors terminals


cause a high resistance in the circuit. The
resistance increases amperage
draw(consumption), as a result brushes
deteriorate(destroy), there is arcing on the
commutator, insulation on wires burns and causes
a short circuit to lift truck frame.
Tighten the nuts or bolts that hold the cable
connections on the motor terminals.

9. Wrong grade of brushes installed that are not


adaptable to the motor.
Make sure all the brushes are of DAEWOO
standards. Do not use other brand brushes.
10. Replacement brushes are not seated, the current
goes through a small contact area with the
commutator. As a result the brush temperature
increases. Possibly if the contact area is poor the
brushes will be destroyed in a few service meter
hours.
Always seat new brushes when installed, see
New Brush Installation, in Testing And Adjusting.

3. Overheating(too much heat) of the pump motor.


Check for an overload or a motor with defects.
See Armature Commutator Inspection in Testing
And Adjusting.
The duty cycle is too heavy, use the hydraulics
only to the limited capacity of the lift truck.
Vehicle Systems

41

Testing & Adjusting

11. Pump motor armature or field windings have a


defect that results in high current draw at low
torque output.
See Armature Tests and Field Coil and
Terminal Tests in Testing And Adjusting.

4. Wet pump motor.


Dry the motor with heat to 190 (90 ).
Problem 5 : Commutator surface is grooved or
extra wear.

12. Possible heavy working conditions that cause too


much motor heat and rapid brush wear.
Commutator skin is very black which gives an
indication of high temperatures.
Make a replacement of the brushes and make
sure the brushes are seated. See New Brush
Installation and Brush Inspection in Testing And
Adjusting.
Install extra heavy duty brushes when
available. Check the brush springs for the
correct installation and for the correct spring
usage. Too strong a spring force will increase
amperage draw and brush wear rate.
Prevent operation in an overload condition
caused by excessive duty cycle which
increases motor temperature and gives rapid
brush wear.

Probable Cause :
1. Brushes are worn too low, brush wires caused
arcing on commutator.
Inspect the commutator for damage. If the arcing
caused light pitting on commutator, install new
brushes and seat the brushes with the Brush
Seater Stone which will also clean the
commutator surface.
Make another inspection, if there is still pitting,
commutator surface must be machined only to
the minimum diameter as shown is in
Specifications.
2. Dirty motor, and possibly salt water got inside.
Disassemble motor, remove the debris with air
pressure. If necessary, dry the motor with heat to
190C (90F).

13. Restriction caused by system components.


Operate the hydraulic and steering system with
an ammeter and a pressure gauge installed. If
amperage draw and oil pressure are too high,
see Testing And Adjusting and Specifications
for the acceptable amperage draws and oil
pressure, the system must be inspected for
both mechanical and hydraulic restrictions.

3. Grade of brushes mixed.


Make sure all of the brushes are DAEWOO
standards. Do not use other brands of brushes.
4. Overload on brushes.
Check the brush springs for the correct
installation and make sure the lift truck is
operating at a rated capacity.

Problem 4 : Low resistance to ground [ battery


potential either positive (+) or negative (-) or a
medium voltage is in direct contact with truck
frame (body) or drive motor body].

Problem 6 : Lift truck has slow hydraulic speeds.


Probable Cause :

Probable Cause :

1. Hydraulic pump motor overheated and pump


motor thermal switch opens.
Allow the motor to cool so the thermal swithch
will close. See Specifications for thermal switch
opening and closing temperatures.

1. Dirty battery, electrolyte on top of cells and is in


contact with the frame. Current flows through
battery box which places a voltage on the truck
frame.
Clean off the battery with baking soda and water
solution.

2. Pump motor control circuit overheated and thermal


switch opens.
Allow the control panel to cool so the Controller
thermal switch will close. The thermal switch
Opens at 85 L 4C (185 L 7F) and close at
73 L 4C (163 L 7F) for this model.

2. Battery or control panel wire connections in


contact to truck frame.
Make a continuity test to move the wire from
contact. Remove wires in sequence until the fault
is cleared. The fault will be in the wire last
disconnected.
3. Dirty motor.
Remove the metallic or carbon dust with air
pressure.

Vehicle Systems

42

Testing & Adjusting

Hydraulic System
2

Relief Valve Pressure Check


Use the Pressure Gauge Group to check the relief
valve pressure.

WARNING
Hydraulic oil, under pressure can remain in the
hydraulic system after the engine and pump have
been stopped. Personal injury can be caused if
this pressure is not released before any work is
done on the hydraulic system. To prevent possible
injury, lower the carriage to the ground, key
switchoff and move control levers to make sure all
hydraulic pressure is released before any fitting,
plug, hose or component is loosened, tightened,
removed or adjusted.
Always move the lift truck to a clean and level
location away from the travel of other machines.
Be sure that other personnel are not near the
machine when engine is running and tests or
adjustments are made.

IHCS105S
Relief Valve Adjustment
(2) Control valve. (3) Screw. (4) Jam nut. (5) Acorn nut.

1. With the key switch off, remove plug(1) from pump


(6) and install a pressure gauge.
2. Turn the key switch ON and tilt the mast back to
the end of its travel.
3. With the motor at fast rpm, hold the tilt control
lever in the TILT BACK position and watch the
gauge. This indication of the gauge is the pressure
of the oil that opens the relief valve. For the
correct pressure setting, see the topic Control
Valve in SPECIFICATIONS.
4. If an adjustment to the relief valve setting is
necessary, do the steps that follow:

a. Turn the key switch OFF.


b. Remove acorn nut (5) and loosen jam nut(4).
c. Turn Screw (3) either clockwise for an increase
or counterclockwise for a decrease.
d. Hold screw (3) and tighten jam nut (4). Install
acorn nut (5).

IHCS113P
Control Valve Pressure Check
(1) Plug (6) Priority Valve.

Vehicle Systems

5. Check the relief valve pressure setting again.

43

Testing & Adjusting

Lift Cylinders Air Removal


After the lift cylinder has been disassembled and
then assembled again, it may be necessary to
remove the air (bleed) from the cylinder.

24

1. With no load, lift and lower the mast and carriage


through one complete cycle.
2. With the forks on the floor, check the oil level in
the hydraulic tank. Add oil (if necessary)to bring
the oil level to the full mark.

EHCS009C
Lift Cylinder Air Removal (FFTL - Secondary Cylinders)
(24) Bleed Screw.

3. With no load, left and lower the mast and carriage


again through four complete cycles.

5. Open bleed screws (23 and 24) no more than one


turn. The weight of the carriage will force air and
hydraulic oil out of the cylinders through the bleed
screws. Close the bleed screws before all the
pressure is out of the cylinders. This will prevent
air from entering back through the bleed screws.

WARNING
The oil will have high pressure present. To prevent
personal injury, do not remove the bleed screws
completely . Keep hands and feet away from any
parts of the truck that move, because the forks will
lower when the bleed screw is loose.

6. Repeat Steps 4 and 5 until there is no air bubbles


at the bleed screws.
7. After all the air is removed, tighten the bleed screws.
8. Fill the hydraulic tank to the full mark.

4. Lift the forks high enough to put a load on all


stages of the lift cylinders. (The illustrations shown
are of a full free triple lift mast.).

9. Lift and lower the mast and carriage again through


one complete cycle. If the mast does not operate
smoothly, repeat Step 3 through 9.

23

EHCS008C
Lift Cylinder Air Removal (FFTL - Primary Cylinder)
(23) Bleed Screw.

Vehicle Systems

44

Testing & Adjusting

<BT>

Steering System
Steer Wheel Bearing Adjustment
<BX>

2
1

EHCS033C
Bearing Adjustment
(1) Nut. (2) Lock washer.

EHCS033C

Single wheel

Bearing Adjustment
(1) Nut. (2) Lock washer.

1. Tighten nut (1) slowly to 100 Nm (74 lbft) while


the wheel is rotated in both directions to put the
bearings into position.

Dual wheel
2. Loosen nut (1) completely. Tighten nut (1) again to
40 L 3 Nm (30 L 2 lbft).

1. Tighten nut (1) slowly to 133 Nm (98 lbft) while


the wheel is rotated in both directions to put the
bearing into position.

3. Bend lock (2) over nut (1) to hold the nut in


positon.

2. Loosen nut (1) completely. Tighten nut (1) again to


45 ~ 55 (33 ~ 41 lbft).

Dual wheel

3. Bend lock (2) over nut (1) to hold the nut in


position.

1. Tighten nut (1) slowly to 133 Nm (98 lbft) while


the wheel is rotated in both directions to put the
bearing into position.
2. Loosen nut (1) completely. Tighten nut (1) again to
45 ~ 55 (33 ~ 41 lbft).
3. Bend lock (2) over nut (1) to hold the nut in
position.

EHCS034C
Bearing Adjustment

Vehicle Systems

45

Testing and Adjusting

Steering System Air Removal

WARNING

1. Fill the hydraulic tank nearly full. Be ready to add


oil when the pump motor is started.
Do not let the oil level go below the outlet to the
pump.

To prevent personal injury, do not operate vehicle


until air is removed. The steering will not operate
correctly until the air is removed.

NOTICE
To prevent damage to the steering pump, keep the oil
level in the hydraulic tank above the outlet to the
pump.

7. When the oil in the tank is clear(not cloudy), the


system is free of air.

2. Close the seat switch and turn the key switch on.
Add oil immediately to the tank as needed.

Steering System Pressure Check

8. Fill the tank to the recommended level.

3. Lift a capacity load to take the weight off of the


steer axle. Turn the steering wheel as rapidly as
possible to remove the air in the steer axle and
lines.
4. Add oil immediately when the valve spool of the
steering gear is activated to replace oil that flows
through the circuit.

NOTICE
Do not hold the steer wheel against its stops for an
extended period of time. This will cause the oil to get
hot and damage the components.

IHCS114P
Hydraulic Steering Gear
(1) "P" port of steering unit.

If the steering system does not work correctly, check


the hydraulic tank for the correct oil level and the
hoses and connections for leakage. If all these items
are correct, use the pressure gauge to check the
steering hydraulic system and its relief pressure
setting.

5. Turn the steer wheel until it has reached the stop


in one direction, then quickly turn the steering
wheel in the opposite direction to the opposite
stop.
6. This procedure must go on approximately 15 to 20
times, to remove the air from the system. Add oil
as required.
NOTE : The oil in the lines to the steer axle stops at
the piston assemblies of the rack. The oil in the steer
axle does not flow in a circuit. As the piston moves
backward and forward, the oil moves backward and
forward in the lines. Air in these lines, and in the
steer axle may move slowly into the steering gear
and then to the tank.

Vehicle Systems

46

Testing and Adjusting

WARNING
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
components are disconnected, make sure all
hydraulic pressure is released in the steering
system. Move the steer wheels to the left and right
and then to the straight forward direction.

1. Turn the motor off. Disconnect off.


2. Connect the 28000 kPa (4000 psi) gauge to the
port(1) after removing plug.
3. Turn the key switch to the ON position and
activate the hydraulic controls until the oil is at a
temperature for normal operation.
4. Turn the steer wheels to the left or right against
the stops and make a note of the indication on the
pressure gauge.
5. The indication on the pressure gauge must be the
priority valve relief setting. The priority relief setting
should be 10,340~10,840 kPa(1,500~1,570 psi). If
the indication is correct and a problem exists, then
there is possibly a mechanical failure in the
steering system.
6. If the indication is not correct, then there is
steering hydraulic failure in the components. Do
these procedures to find the failure as follws.
a. With the motor running and read the indication on
pressure gauge.
b. If the indication is approximately the pressure
shown in Step 5, then the steering gear has a
hydraulic failure.
c. If the indication is too low or too high, then the
priority valve on its components must be replaced.
7. If the steering gear and the priority valve are
working properly, the steering cylinder is defective
and must be repaired.
8. Correct the problem and check steering relief
valve pressure again.

Vehicle Systems

47

Testing and Adjusting

Brake System
2

Brake System Air Removal


When the brake pedal resistance is spongy(not solid)
it is usually an indication that there is air in the brake
hydraulic system. The cause may be low fluid or oil
level, leakage in the system, a broken brake line or a
brake line that is not connected.

IHCS116P

To remove air from the brake system. do the


procedure that follows :

Bleed Screw Location


(2) Bleed screw.

2. Put pressure on the brake pedal and open bleed


screw (2) to let air out of the system. Close bleed
screw (2), while pressure is still on the brake
pedal, then let the pedal return to the original
position.

3. Do step 2 again as many times as necessary until


the brake fluid is free of air.
4. (If equipped) : Use the procedure in Steps 2 and 3
again, except this time use the other bleed screw
(not shown).

IHCS115P
Reservoir Location
(1) Reservoir.

5. Fill the reservoir again, with the correct fluid, to the


level explained in Step 1.

1. Fill reservoir (1) with the correct fluid to 12.7 mm


(.50 in) from the filler cap. See the Operation And
Maintenance Manual for the correct brake fluid.

Vehicle Systems

48

Testing and Adjusting

Pedal Adjustment

Parking Brake Test

The brake pedal must have enough free play to let


the master cylinder piston return to the release
positon and open the relief outlet.

1. Drive the lift truck with a rated load up a 15%


incline.

Hydraulic pressure in the brake lines goes back


through the relief opening and releases the brakes. If
there is no pedal free play, the pressure can not go
back through the relief opening, and the brakes will
tighten and not release.

WARNING
To prevent personal injury, the operator must be
ready to use the service brake if the parking brake
is not adjusted correctly and the lift truck starts to
move.

If there is too much free play, the brake pedal will be


low even with the correct brake adjustment.

2. Half way up the incline, stop the lift truck with the
service brakes. Apply the parking brake.

The master cylinder push rod must be adjusted so


the brake pedal has 3.0 to 8.0 mm(.118 L .315 in) of
free play from the pedals stop to the push rod
contact point with the master cylinder piston.

3. If the parking brake has the correct adjustment,


the lift truck will be held in this position.

If the pedal free play adjustment is not correct, do the


procedure that follows :

IHCS117P

4. If the parking brake does not hold, do the steps in


Parking Brake Adjustment.

Location of Master Cylinder


(1) Boot. (2) Rod. (3) Nut.

NOTE : On some trucks the rubber boot may have to


be moved to expose the adjustment nuts.
1. Loosen nut (3).
2. Adjust rod (2) until there is the correct amount of
free play.
3. Hold rod (2) and tighten nut (3).

Vehicle Systems

49

Testing and Adjusting

Parking Brake Control Group


Adjustment

EHCS048B

Parking Brake Control Group


(1) Switch assembly. (2) Cam.

1. Put the parking brake in the OFF position.


2. Adjust the switch assembly (1) which is depressed
by cam (2) when parking brake put in the ON
position.

Vehicle Systems

50

Testing and Adjusting

Hydraulic Pump Motor


(AC)
Instruction about sensor bearings
exchange
Explain the instructions to change the sensor
bearing.
PUMP MOTOR : Look at exploded view of A244952
and related components
1. Remove the protective cover of sensor bearing
2. Demount the ring nut
3. Remove the rear endbell
4. At now the sensor bearing is easy to seize and
you have to extract it from its seat
5. Install the rear endbell again
6. Mount the sensor bearing in its seat
7. Mount the the ring nut
8. Mount the cover fo sensor bearing

Vehicle Systems

51

Testing and Adjusting

(SE)
Motor Brushes
Brush Inspection

1. Measure the radial length of the brush.

EHCS040C
Install Brushes
(1) Brushes.

NOTICE
Installation of the wrong brushes can cause early
motor failure. Always make sure the correct DAEWOO
brushes are installed.

EHCS039C
Brush Measurement

2. Brush measurement :

4. Install new brushes(1). Make sure the brushes


move freely in the brush holders. Use a piece of
plain bond paper to remove brush material if there
is a restriction of brush movement.

a. If the brush length is less than 18 mm (.7 in) on


the radial side, replace the brushes.

New Brush Installation


NOTE : Installation of new brushes is a two person
operation.

1. Disconnect the batteries and remove them from


the lift truck. Put the batteries close enough to the
truck that the battery connector can be plugged in.
2. Discharge the head capacitor.
EHCS041C

3. Remove the brush covers.


Loosen the two screws of the brush and BWI
Wires.
Pull out the old brushes from the brush holder
while lifting up the brush spring.

Install Springs
(2) Spring.

5. Place carefully the brush spring (2) on the top of


brush and make sure they fasten into the brush
holder box.
6. Pull up on the two wires of each brush until the
contact end of the brush moves away from the
commutator. Release the wires to see if the brush
moves smoothly back into contact with the
commutator. If it is too difficult to pull out, or it does
not move smoothly in the brush holder box,
remove the spring and brush. Make an inspection
to find and correct the cause of the problem.

Vehicle Systems

52

Testing and Adjusting

7. Connect the batteries to the battery connector.


NOTICE
Never use air pressure that is more than 205 kPa (30
psi). Make sure the line is equipped with a water filter.

WARNING
Wear eye protection when seating, polishing or
cleaning the motor with air pressure. During the
seating and polishing procedure, keep fingers
away from components in rotation. For prevention
of injury to fingers, do not use a commutator
cleaner or brush seater stone that is shorter than
63.5 mm (2.50 in).

11. After the brushes have the correct seat contact


surface, operate the motor at slow speed. Use
compressed (pressure) air to remove all dust and
abrasive grit.

Armature Tests
Tools Needed
Digital Multimeter Or Equivalent

Growler Tester

Short Circuit Test

EHCS042C
Brush Seating
(3) Brush seater stone.

8. Put ZLX-0036 Brush Seater Stone (3) on the


commutator and operate the motor at a slow
speed.
3

EHCS043C

Short Circuit Test


(1) Glowler. (2) Armature. (3) Hacksaw blade.
(4) Green light. (5) Red light.

NOTICE
Do not let stone (3) stay in contact with the
commutator bar too long time. This causes more wear
than is necessary to the brushes and the commutator.

The odor of burned insulation from the pump motor


while it is in operation is an indication of a short in
the armature.

9. Move stone (3) across the commutator at the back


edge of the brushes for a short time. This will take
the shiny finish off the commutator and seat the
new brushes.

1. Turn the growler (1) on.


2. Slowly turn the growler on the armature (2) while a
hacksaw blade (3) is held over the windings.

10. Turn the key switch to the OFF position and


disconnect the batteries. Check the contact
surface of each brush. At least 85% of the brush
contact surface of each brush must show wear. If
necessary, do Steps 8 through 11 again until the
correct wear can be seen on the brush contact
surface.

Vehicle Systems

3. If the windings are shorted, the green light (4) will


be on.
The red light (5) will be on if the windings do not
have a short.

53

Testing and Adjusting

1. Put the digital multimeter Function/Range Switch


on the 200 ohm resistance ( ) scale.

Ground Test

2. Put one test lead on one commutator bar, Put the


other test lead on an adjacent (next to) bar and
there must be less than one ohm resistance.

This test can also be done with an instrument, such


as a Kelvin Double Bridge, that can make a
measurement of very low resistance. Do the test the
same as above and make a comparison of the
resistance measurements.
Two burned areas on opposite sides of the
commutator are indications of an open armature
winding. These burned areas can cause very rapid
brush wear.
EHCS044C
Ground Test
(A) Multimeter.

Commutator Inspection
Surfaces of Commutators that need Replacement

Digital multimeter (A) can be used to test for


grounds. Put the Function / Range Switch on the 2M
resistance ( ) scale. When the test leads are put on
the commutator and the shaft, the meter must give
an resistance is more than 2 megohms.

NOTICE
Never use air pressure that is more than 205 kPa
(30psi). Make sure the air line has a water filter.

If there is an indication of a ground in the above test,


remove any dirt or debris from the armature with
compressed (pressure) air.
EHCS049B

Do the ground test again, If there is still an indication


of a ground, replace the armature.

Marks on the Commutator Surface

Marks on the commutator surface are an indication


that metal has moved from the commutator surface
to the carbon brushes. Marks will cause fast brush
wear.

Open Circuit test

EHCS045C
Open Circuit Test
(1) Armature.

Vehicle Systems

54

Testing and Adjusting

EHCS050B

EHCS052B

Threads on the Commutator Surface

Copper Drag on the Commutator Surface

Threads (grooves that look like threads) on the


commutator surface, will also cause fast brush wear.

Copper drag is an extra amount of commutator


material at the back edge of the commutator bars.

EHCS053B
EHCS051B
Pitch Bar-Marks on the Commutator Surface.
Grooves on the Commutator Surface

Pitch bar-marks cause low or burnt marks on the


commutator surface.

Grooves on the commutators surface are caused by


a cutting material in the brush or atmosphere.

Vehicle Systems

55

Testing and Adjusting

Ground Test

Field Coil And Terminal Tests


Tools Needed
Digital Multimeter Or Equivalent

Open Circuit Test

EHCS048C
Ground Test
(1) Field terminal. (2) Motor housing.

1. Put the digital multimeter Function / Range Switch


on the 20M resistance ( ) scale.

EHCS046C
Open Circuit Test

2. Put one test lead to either outer field terminal (1)


and the other test lead to motor housing (2). There
must be more than one megohm resistance.

1. Put the digital multimeter Function / Range Switch


on the 200 ohm resistance ( ) scale.

3. If there is measurement of less than one megohm,


it can be caused by wet insulation on the field
windings or excessive brush dust in housing. Heat
the motor at 88 C(190 F)until the resistance
goes above one megohm. If the resistance does
not go above one megohm, the shell and field
assembly must be replaced.

2. Put one test lead to each outer field terminal (P1,


P2).
3. The resistance must be less than one ohm. If the
resistance is too high, it is an indication of
corrosion on the terminals or an open field coil.

Brush Holder Test


Tools Needed

Digital Multimeter Or Equivalent

1
A

EHCS047C
Brush Test
(1) Field terminal. (2) Brush leads. (A) Multimeter.

4. Put one test lead to one of outer field terminals (1).


Put the other test lead to each of brush leads (2)
that connect to the brush holders. There must be
continuity to two of the leads with a resistance of
less than 1 ohm.

EHCS049C
Brush Holder Test
(1) Brush holder. (2) End bell. (A) Multimeter.

5. Put one test lead to the other outer field terminal.


There must be continuity from this field terminal to
the other two brush holder leads.
Vehicle Systems

56

Testing and Adjusting

Ground Test

1. The brush holders are mounted in the cover at the


commutator end of the motor. Make a visual
inspection of the brush holders and the cover.
2. Put digital multimeter (A) Function / Range Swich
on the 200 ohm resistance ( ) scale. Put one test
lead to brush holder (1) and the other test lead to
the end bell (2). The meter must show
overload(OL).
3. Check each brush holder. If meter reading is low,
the brush holder is grounded. Replace the cover.

EHCS051C

Thermal Switch(Thermostat) Tests

Ground Test

Tools Needed
Digital Multimeter Or Equivalent

1. Put the digital multimeter Function / Range Switch


on the 20M resistance ( ) scale.

2. Put one test lead to either of the plug prongs. The


other test lead must be grounded to the motor
housing. There must be more than one megohm
resistance.

Open Circuit Test

Brush Life Estimate


1. Before installation of new brushes, inspect the
armature commutator. See Armature commutator
Inspection in Testing and Adjusting.
2. Do the steps and procedures for New Brush
Installation in Testing and Adjusting.

EHCS050C
Open Circuit Test

3. Make the initial (first) inspection of brush wear


between 250 smh and 500 smh. The reason for
this initial inspection is to see if the brush wear
rate is normal and not too fast. The measurement
will help make an estimate of the length of brush
life to be expected.

1. Put the digital multimeter Function / Range Switch


on the 200 ohm resistance ( ) scale.
2. Put one test lead to each side of the thermal
switch harness.

NOTE : If there is an indication that brush wear is too


fast, see Troubleshooting, Problem: Sparks at the
commutator and/or rapid brush wear.

3. The resistance must be less than one ohm.

4. Inspect all brushes in the motors. Measure and


record each brush length. See Hydraulic Pump or
Steering Pump Motor in Specifications for new and
minimum brush length.

Vehicle Systems

57

Testing and Adjusting

5. Estimate expected brush life (hours). Use the


shortest measurement from Step 4 and the
following Sample Procedure :
Length of new brush ................ 35mm (1.387 in)
Minimum length of brush ............18mm (.708 in)
New brush length [35mm (1.387 in)] - Minimum
Brush length [18mm (.708 in)] = Total amount of
Usable brush wear [17mm (.67in)]
Length of shortest brush at 500 smh is 32.5
mm(1.279 in)
New brush length [35mm (1.378 in)] - Length of
shortest brush at 500 smh [32.5mm (1.279)
in)]=Amount of brush wear at 500 smh [2.5
mm(.10in)].
Amount of brush wear at 500 smh [2.5mm(.10 in)]
Total amount of usable brush wear [17mm (.67
in)]=Portion of brush used at 500 smh (.1).
Service Meter Hours (smh) at brush wear
measurement (500 smh) - Portion of brush used
(.1)=Approximate total brush life of a new brush
(5000 smh).
Approximate total brush life of a new brush
(5000smh) - Amount of smh at brush life estimate
(500smh)=Remainder of usable brush life(4500
smh).
6. The smh estimate of brush life can be used if the
machine is to work at the same rate(duty cycle),
the battery is not discharged too much or the
battery cells have not become damaged. If the
machine is made to work harder, the battery is
discharged too much, or the battery cells become
damaged, the motor temperature will get hot very
fast. This will cause rapid wear of the brushes.
7. It is important to check brush length and brush
condition at a specific time, such as during the
preventive maintenance check. If an inspection
shows that brush life will not extend to the next
preventive maintenance check, install new
brushes.

Vehicle Systems

58

Testing and Adjusting

SB4187E00
Feb. 2005

Disassembly &
Assembly
Lift Trucks Vehicle Systems
B15T-5, B18T-5, B20T-5(AC 36V)
B15T-5, B18T-5, B20T-5(AC 48V)
B15T-5, B18T-5, B20T-5(SE 48V)
B16X-5, B18X-5, B20X-5(AC 48V)
B16X-5, B18X-5, B20X-5(SE 48V)

Important Safety Information


Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result in
injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as
shown below.

WARNING

The meaning of this safety alert symbol is as follows :


Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current
information available.

Index
Accelerator Control Switch .......................................19
Assemble Hydraulic Control Valve ...........................11
Brake Master Cylinder..............................................41
Control Panel
AC .........................................................................62
SE .........................................................................63
Counterwieght ..........................................................68
Disassemble & Assemble Brake ..............................42
Disassemble Hydraulic Control Valve.........................8
Drive Motor & Drive Axle ..........................................65
Hood(with seat) Assembly..........................................5
Hydraulic Control Valve ..............................................7
Hydraulic Pump ........................................................17
Hydraulic Pump Motor
AC .........................................................................13
SE .........................................................................15
Link Assemblies........................................................50
Overhead Guard.........................................................6
Primary Lift Cylinder .................................................25
Priority Valve.............................................................40
Secondary Lift Cylinder ............................................22
Spindle-Steer Axle ....................................................57
Standard Lift Cylinder ...............................................20
Steer Axle .................................................................43
Steer Axle .................................................................52
Steer Sensor Group..................................................32
Steer Wheels & Hub.................................................48
Steering Column.......................................................33
Steering Cylinder ......................................................45
Steering Gear ...........................................................35
Steering Knuckles, Kingpins & Bearings ..................50
Steering Wheel .........................................................33
Tilt Cylinder...............................................................28

WARNING
Disconnect batteries before performance of any
service work.

Vehicle Systems

Index

Hood(with seat) Assembly


Remove & Install Hood(with seat)
Assembly

EHCD003C

4. Remove two bolts (3) and washers.

EHCD001C

1. Raise the hood. Support the hood with a hoist.


2. Disconnect harness connector (1) for seat brake.

EHCD004C

5. Use the hoist to remove hood and seat assembly


(4).
6. Install the hood and seat assembly in the reverse
order of removal.
EHCD002C

WARNING
The hood and seat assembly can fall when nut (2)
is removed from the support cylinder rod.
To avoid personal injury, support the seat and
hood assembly before removing nut (2).

3. Remove nut (2) from the support cylinder.


Remove the cylinder rod from the bracket.

Vehicle Systems

Disassembly And Assembly

Overhead Guard
Remove & Install Overhead Guard

IHCD101P

4. Remove nuts, bolts (4) and washers from the front


leg (each side).

1. Remove cowl platic right cover (1).

5. Remove caps (5) from the rear leg (each side).


EHCD005C

2. Disconnect harness connector (2) from inside of


the cowl.

6
3

IHCD102P

6. Remove bolts and washer (6) from the rear leg


(each side).
EHCD006C

7. Remove overhead guard (3).

3. Support overhead guard (3) with lifting straps and


a hoist as shown.

Vehicle Systems

8. Install overhead guard (3) in the reverse order of


removal.

Disassembly And Assembly

3. Support control valve (1). Remove four bolts (3)


from frame. And remove three bolts (4), nuts and
control value (1) from plate.

Hydraulic Control Valve


Remove & Install Hydraulic Control
Valves

4. Install the control valve (1) in the reverse order of


removal.

WARNING
5. Fill the hydraulic tank to the correct level with fluid.
Refer to the Operation And Maintenance Manual
for further information.

Hydraulic oil under pressure can remain in the


hydraulic system after the pump motor have been
stopped. Personal injury can result if the pressure
is not released before any work is done to the
hydraulic system. To prevent possible personal
injury, turn the key switch off and move the
control levers to make sure the hydraulic pressure
is released before any fitting, plug, hose or
component is loosened, tightened, removed or
adjusted. Always move the lift truck to a clean and
level location away from the travel of other
machines.

End By :
a. Install the hydraulic control valve switch group.

Start By :
a. Remove hydraulic control valve switch group.
1. Drain the hydraulic tank.

IHCD103P

NOTE: For purposes of reassembly, put


identification marks on all lines, tubes and hoses
before any disconnections are made.
2. Disconnect lines (2) from control valve (1).
NOTE: Plug and cap all openings to avoid
contamination and debris from entering the system
after removing any tubes or lines.

Vehicle Systems

Disassembly And Assembly

Disassemble Hydraulic Control


Valve
Start By :
a. Remove hydraulic control valve.
6

IHCD107P

5. Remove lift section assembly (6) from the valve


body.
1
7
8

10

IHCD105P

NOTE: For purpose of assembly, put identification


marks on all valve sections.
11

1. Remove three nuts (1) to separate the valve


sections.

IHCD108P

2. Remove inlet section assembly (2) from the valve


body.

6. Remove plug (7) and O-ring (8) from the lift


section assembly (6).
7. Remove O-ring (9), poppet (10) and spring (11)
from lift section assembly (6).

5
2

12
13

IHCD106P

3. Remove O-ring (3) from inlet section assembly (2).


4. Remove relief valve (4) and O-ring (5).

IHCD109P

8. Remove two screws (12) and cap (13) from lift


section assembly.

Vehicle Systems

Disassembly And Assembly

16

17
18
26

IHCD110P

IHCD112P

9. Remove two screws (16) and seal plate (17).

13. Remove tilt section assembly (26) from the valve


body.

10. Remove lift spool (18).

28

26
19

24

29

23

27

20
21

25
22

IHCD113P
IHCD111P

14. Remove O-ring (27), poppet (28) and spring (29)


from tilt section assembly (26).

11. Remove the wiper seals (19) and O-rings (20)


from the spool. Check the condition of O-rings and
wiper seals and replace with new ones if needed.
NOTE: Remove the spool end (21) from the spool.
The centering spring (22) has a slight preload and will
extend to its free length when the spool end is
removed.

30
31

12. Remove the spring seats (23 and 24), centering


spring (22) and seal plate (25).

IHCD114P

15. Remove two screws (30) and cap (31) from tilt
section assembly.

Vehicle Systems

Disassembly And Assembly

15

45
44

14
33

32
34

43

IHCD115P

IHCD118P

16. Remove two screws (32), seal plate (33) and tilt
spool (34).

20. Remove side shift section assembly (43) and


fourth section (44) from the valve body.

17. Remove valve (14) and O-ring (15).

NOTE: Do step 7 through 12 to disassemble valve


spools of side shift and fourth section assembly.
21. Remove section assembly (45).

35
47

45

46

36
37

38

IHCD116P

18. Remove the wiper seals (35) and O-rings (36).


Check the condition of wiper seals and O-rings
and replace with new ones if needed.

IHCD119P

22. Remove relief valve (46) and O-ring (47) from the
section assembly (45).

NOTE: Remove the spool end (37) from the spool.


The centering spring (38) has a slight preload and will
extend to its free length when the spool end is
removed.
39

38

40

37

42

41

IHCD117P

19. Remove spring seats (39 and 40), spring (38 and
42) and piston (41).

Vehicle Systems

10

Disassembly And Assembly

Assemble Hydraulic Control Valve


19

24

NOTICE
Do not use caustic (corrosive) materials to clean any
parts in this valve group. Caustic materials will cause
corrosion and damage to parts.

23

20
21

25
22

1. Make sure all valve parts are clean and free of dirt.
IHCD111P

4. Install the spring seats (23 and 24), centering


spring (22) and seal plate (25) on the lift spool.

5
2

5. Compress the spring with spool end (21) and


tighten spool end. Torque the spool end to 8 ~ 11
Nm (70 ~ 97 lbin).

6. Install the wiper seals (19) and O-ring (20) to the


spool (18).
IHCD106P

2. Install O-ring (3) to inlet section assembly (2).


3. Install relief valve (4) with O-ring (5) to inlet
section assembly (2). The torque for the relief
valve is 44 ~ 49 Nm (32 ~ 36 lbft).
16

17
18

IHCD110P

7. Install the spool (18), seal plate (17) and the


screws (16).

Vehicle Systems

11

Disassembly And Assembly

45

47
46

12
13

IHCD119P

IHCD109P

8. Install cap (13) and two screws (12).

13. Install O-ring (47) and relief valve (46) to the


section assembly (45).

7
8

10

11

1
9

IHCD108P
IHCD105P

9. Install O-ring (9), poppet (10) and spring (11) to lift


section assembly (6).

14. Assemble all the sections on the studs.

10. Install O-ring (8) and plug (7) to the lift section
assembly.
39

38

15. Install the nuts (1) that hold the valve sections
together. Tighten the single top nut to torque of 26
~ 32 Nm (19 ~ 23 lbft) and two bottom nuts to
torque of 24 ~ 29 Nm (18 ~ 21 lbft).

40

37

End By :
42

a. Install hydraulic control valve.

41

IHCD117P

11. Install piston (41), spring (42), spring seats (39


and 40) and spring (38) on the tilt spool assembly.
12. Compress the spring with spool end (37). Torque
the spool end to 8 ~ 11 Nm (70 ~ 97 lbin).
NOTE: Do step 6, 7, 8 and 9 to assemble the tilt
spool to the tilt section assembly.
NOTE: Do same steps to assemble the side shift
section and fourth section assembly.
Vehicle Systems

12

Disassembly And Assembly

Hydraulic Pump Motor


(AC)
Remove & Install Hydraulic Pump Motor
Start By :

a. Raise the hood.


b. Disconnect the battery.
NOTE: For purpose of assembly, put identification
marks on the wires and cables for proper installation.

3. Disassemble brake pedal assy (2).

1. Prevent brake oil being drained from reservoir by


using tie wrap or equivalent material.

4. Disconnect cables from UVW terminal.


5. Disconnect encoder cable & thermal sensor cable
from main harness.

2. Disconnect brake oil hose from master cylinder (1).

Vehicle Systems

13

Disassembly And Assembly

8. Disconnect tube assy (4).

6. Disconnect suction hose (3) from priority valve to


control valve.

9. Disconnect suction hose(5) from hydraulic pump


to priority valve.

7. Disconnect bulk hose from hydraulic pump.

Vehicle Systems

14

Disassembly And Assembly

(SE)
Start By :
a. Raise the hood.
b. Disconnect the battery.
NOTE: For purpose of assembly, put identification
marks on the wires and cables for proper installation.

10. Support pump motor with straps and move out


motor and pump assembly.
11. Remove two bolts, washers, hydraulic pump from
hydraulic motor.
For the reassembly purpose, the torque for bolt is
55 10 Nm (40 7 lbft).

12. Install the hydraulic pump motor and hydraulic


pump in reverse order of removal.

EHCD045C

[Caution! When assembling & disassembling]

1. Remove side panel (1) from lift truck.

1. Do not apply any impact on the motor.


4
3

2. Ensure encoder (sensor bearing) cable not to be


damaged.
3. Ensure U.V.W. marks on motor cables to be
matched with
U.V.W. marks on terminal board of pump motor.

End By :
a. Connect the battery.
EHCD046C

b. Close the hood.


2. Disconnect two cables (2), harness connector (3)
and BWI Cable (4) from hydraulic pump motor (5).

Vehicle Systems

15

Disassembly And Assembly

11
5

EHCD047C

ILCD021P

3. Loosen clamp (6) and remove hose (7).

6. Remove two bolts (11), washers, hydraulic motor


and pump assembly.

3
5

ILCD018P
ILCD020P

4. Loosen two bolts (8) and pull the motor (5)


outward.

7. Support pump motor (5) with straps and move out


motor and pump assembly.
8. Remove two bolts, washers, hydraulic pump from
hydraulic motor. For the reassembly purpose, the
torque for bolt is 55 10 Nm (40 7 lbft).

10
9

9. Install the hydraulic pump motor and hydraulic


pump in reverse order of removal.
End By :
a. Connect the battery.
EHCD048C

b. Close the hood.


5. Remove elbow (9) from the hydraulic pump (10).
NOTE: Plug and cap all openings to avoid
contamination and debris from entering the system
after removing any tubes or lines.

Vehicle Systems

16

Disassembly And Assembly

Hydraulic Pump
Disassemble Hydraulic Pump
Start By :

a. Remove hydraulic pump.

EHCD053C

4. Remove two gears (8) from the pump body.


Separate the pump sections.
1

3
11

EHCD050C

12

NOTE: Identify and mark all sections of the hydraulic


pump for purposes of reassembly.

10

1. Remove four bolts (1) and washers (2) to remove


pump cover (3).

EHCD054C

5. Remove O-ring (9), seal (10), back up-ring (11)


and bush (12) from the pump body.
Replace seals, back up-ring, O-ring with new ones
if needed.

14

13

EHCD051C

2. Remove O-ring seal (4) from the pump body.

EHCD055C

6. Remove seal (13) from the flange (14).


7
6

EHCD052C

3. Remove seal (5), back up-ring (6) and bushes (7)


from the pump gears.

Vehicle Systems

17

Disassembly And Assembly

Assemble Hydraulic Pump


4

14

13
7
6

EHCD052C

4. Install back-up ring (6) and seal (5) in the bushes


(7).

EHCD055C

NOTE: When installing seal (13), make sure the lip


of the seal is positioned toward the inside of the pump
housing.

5. Install bushes (7) in the pump body.

1. Install seal (13) in the pump body.

11
12

10

EHCD051C
9

6. Install seal (4) on the pump body.


EHCD054C

2. Install bush (12), back-up ring (11), seal (10) and


O-ring (9) in the pump body.

EHCD050C

7. Install the bolts (1), washers (2) and pump cover


(3) onto the pump body. Tighten the bolts for cover
(3) to a torque of 39 to 40 Nm (28 to 30 lbft).

EHCD053C

End By :

3. Install two gears (8) in the pump body.

a. Install the hydraulic pump.

Vehicle Systems

18

Disassembly And Assembly

Accelerator Control Switch


Remove And Install Accelerator Control
Switch

IOCD014P

4. Disconnect accelerator connector (4) from main


harness.

IOCD011P

1. Remove the floormat (1).

5. Remove three screws (5).


6. Install the accelerator assembly in the reverse
order of removal.

IOCD0012P

2. Remove rear floor plate (2).

IOCD013P

3. Remove front floor plate (3).

Vehicle Systems

19

Disassembly And Assembly

Standard Lift Cylinder


3

Disassemble Standard Lift Cylinder


Start By :
a. Remove standard lift cylinders.

EHCD101C
1

3. Remove rod (3) from the cylinder body.

EHCD099C

1. Put standard lift cylinder (1) in position as shown.

EHCD102C
2

4. Remove retaining ring (4) from the cylinder rod.

EHCD100C

2. Remove rod-cover assembly (2) with tool.


5
6

EHCD103C

5. Remove screw bleeders (5) and steel ball (6) from


the rod-cover.

Vehicle Systems

20

Disassembly And Assembly

Assemble Standard Lift Cylinder


7

12
9

8
10

EHCD104C
11

6. Remove O-ring seal (7) and back up ring (8) from


the rod-cover.

EHCD105C

1. Install slide ring (12), back up ring (11) U-packing


(10) and wiper seal (9) on the inside of the
rodcover.

12
9

10

11
8

EHCD105C

7. Remove wiper seal (9), U-packing (10), back up


ring (11) and slide ring (12) from the rod-cover.

EHCD104C

2. Install back up ring (8) and O-ring seal (7) onto the
rod-cover.

5
6

EHCD103C

3. Install the steel ball (6) and screw-bleeder (5) onto


the rod cover.

Vehicle Systems

21

Disassembly And Assembly

Secondary Lift Cylinder


3

Disassemble Secondary Lift Cylinder


Start By :
a. Remove secondary lift cylinders.

EHCD101C
1

4. Install rod (3) with a retaining ring into the cylinder


body.

EHCD099C
2

1. Put secondary lift cylinder (1) in position as shown.

EHCD100C
2

5. Install rod-cover assembly (2) on the cylinder rod


and tighten using tool.
End By :
a. Install standard lift cylinder.*
EHCD100C

* Refer to the topic "Assemble Mast" in this module.

Vehicle Systems

2. Remove rod-cover assembly (2) with tool.

22

Disassembly And Assembly

3
10

11

EHCD101C

EHCD104C

3. Remove rod (3) from the cylinder body.

6. Remove O-ring seal (10) and back up ring (11)


from the rod-cover.

15

12

13

14

EHCD105C

7. Remove wiper seal (12), U-packing (13), back up


ring (14) and slide ring (15) from the rod-cover.

IOCD015I

4. Remove wear rings (5), snap ring (7) and cushion


ring (6) from piston (4).

8
9

EHCD103C

5. Remove screw bleeders (8) and steel ball (9) from


the rod-cover.

Vehicle Systems

23

Disassembly And Assembly

Assemble Secondary Lift Cylinder


5

15
12

13

14

EHCD105C
IOCD015I

1. Install slide ring (15), back up ring (14) U-packing


(13) and wiper seal (12) on the inside of the
rodcover

4. Install cushion ring (6), snap ring (7) and wear


rings (5) onto the piston (4).

10

11

EHCD104C
EHCD101C

2. Install back up ring (11) and O-ring seal (10) onto


the rod-cover.

5. Install rod (3) with a retaining ring into the cylinder


body.

8
9

EHCD103C
EHCD100C

3. Install the steel ball (9) and screw-bleeder (8) onto


the rod cover.

6. Install rod-cover assembly (2) on the cylinder rod


and tighten using tool.
End By :
a. Install secondary lift cylinder.*
* Refer to the topic "Assemble Mast" in this module.

Vehicle Systems

24

Disassembly And Assembly

NOTE: The following steps are for the installation of


the primary lift cylinder.

Primary Lift Cylinder


Remove And Install Primary Lift
Cylinder
Start By :

a. remove carriage.

WARNING
Be sure all the pressure in the hydraulic system
has been released before any lines or hoses are
disconnected.

EHCD106C

4. Put primary lift cylinder (5) in position on the mast.


5. Connect hydraulic hose.
2

6. Install U-bracket (2) and bolts (1).


End By :
a. Install carriage.

Disassemble Primary Lift Cylinder


EHCD106C

Start By :

1. Fasten nylon straps and a hoist to the primary lift


cylinder.

a. Remove primary lift cylinder.

2. Remove bolts (1) and U-bracket (2).


1
2

4
5

EHCD108C

1. Remove head assembly (1).


EHCD107C

2. Remove rod (2) from the cylinder body.

3. Pull the cylinder out enough to disconnect


hydraulic hose (4). Remove primary lift cylinder (5).

Vehicle Systems

25

Disassembly And Assembly

Assemble Primary Lift Cylinder


3

6
7

EHCD109C
9

3. Remove rings (3) from the cylinder rod.

EHCD111C

1. Install back-up ring (7) and U-packing (8) in the


head assembly. Install the seal with the lip toward
the inside.

2. Install wiper seal (6). Install the seal with the lip
toward the outside.

3. Install slide rings (9) in the head assembly.

EHCD110C

4. Remove O-ring seal (4) and back-up ring (5) from


the head assembly.

EHCD110C

NOTE: Install the back-up ring with the curved side


contacting the O-ring seal.
8

4. Install the back-up ring (5) and O-ring seal (4) on


the head assembly.

EHCD111C

5. Remove wiper seal (6), back-up ring (7), Upacking (8) and slide rings (9) from the head
assembly.

Vehicle Systems

26

Disassembly And Assembly

EHCD109C

5. Install split rings (3) on the cylinder.

1
2

EHCD108C

6. Install cylinder rod (2) in the cylinder body.


7. Install head assembly (1) on the cylinder body.
Tighten the head assembly.
End By :
a. Install primary lift cylinder.

Vehicle Systems

27

Disassembly And Assembly

Tilt Cylinder
Remove & Install Tilt Cylinder
NOTE: The procedure for removing and installing
the tilt cylinders is the same for both cylinders.

WARNING

If both tilt cylinders are removed at the same time


the mast can fall. To avoid possible personal injury,
make sure the mast is securely held in place or
supported by a hoist before removing the tilt
cylinders.

IOCD016P

WARNING
To prevent personal injury, move the control
levers backward and forward to release any
pressure in hydraulic system. Slowly loosen the
cap of the hydraulic tank to release any pressure
in the tank. Be cautious of hot hydraulic oil when
any lines are disconnected in the hydraulic
system.

2. Disconnect hoses (5) and (6). Remove retainer


bolt (7) and pin (4).

NOTE: Plug and cap all openings to avoid


contamination and debris from entering the system
after removing any hoses or lines.
IOCD011P

11

10

EHCD212C

IOCD012P

3. Remove retainer bolt (9) from pin (8). Remove pin (8).

1. Remove floor mat (1) and floor plates (2), (3).

4. Remove tilt cylinder (10).


5. Install the tilt cylinder in the reverse order of
removal.
6. Adjust tilt cylinders as follows:
a. Loosen nut (11).
b. Slide spacer down so rod can be turned into or
out of pivot eye to obtain the correct length.
c. Tighten nut (11) and the nut to a torque of 95
15 Nm (70 10 lbft).
d. With mast at tilt back position, install shims as
required to permit no gap between pivot eye
and spacer. Shim so mast does not twist at full
tilt back.

Vehicle Systems

28

Disassembly And Assembly

Disassemble & Assemble Tilt Cylinders


7

Start By :
a. Remove tilt cyliner.

EHCD115C

6. Remove spacer (6) with a O-ring seal and shims


from the cylinder rod (7) if they are installed.
7. Loosen the nut and bolt on the rod eye. Remove
cylinder rod (7).

EHCD113C

1. Remove cover-rod (1) from the cylinder body.


9

NOTICE
Use extra care not to damage the highly finished
surface of the cylinder rod and the bore of the
cylinder body during disassembly and assembly
of the tilt cylinder.

10

2. Remove rod assembly (2) from the cylinder body.


EHCD116C

8. Remove slipper seal (9) and O-ring seal (10) from


the piston.

5
3

NOTICE
Check the condition of all seals. If any parts are
worn or damaged use new parts for replacement.

EHCD114C

3. Remove nut (3) from the cylinder rod.


4. Remove piston and seal assembly (4) from the
cylinder rod.
5. Remove cover-rod assembly (5).

Vehicle Systems

29

Disassembly And Assembly

11

15
13

12

14

EHCD117C

EHCD118C

9. Remove O-ring seal (11) and back up-ring (12)


from the cover-rod.

NOTE: U-packing (15) should be installed with the


lip of the seal toward the outside of the cover-rod.
12. Install wiper seal (13) in the cover-rod. Position
the lip of the seal toward the outside of the
coverrod as shown.

15
13

13. Install back-up ring (14).


14. Install U-packing (15) in the cylinder head.

14
11

EHCD118C

12

10. Remove wiper seal (13), back-up ring (14) and


Upacking (15) from the cover-rod.

EHCD117C
16

15. Install O-ring seal (11) and back up-ring (12) on


the cover-rod.

EHCD119C

11. Inspect the bushing (16) in the cover-rod. If the


bushing has a large amount of wear, Replace the
bushing and cover-rod as a unit. The parts can not
be ordered separately.
NOTE: Use the following steps to assemble the tilt
cylinder.

Vehicle Systems

30

Disassembly And Assembly

5
3

10

EHCD116C

EHCD114C

16. Install slipper seal (9) and O-ring seal (10) on the
piston.

19. Position the cylinder rod eye in a vise as shown.


20. Install cover-rod assembly (5) on the cylinder rod.
21. Install piston assembly (4) onto the cylinder rod.
The torque for the nut (3) is 260 25 Nm (190
20 lbft).

EHCD115C

17. Install cylinder rod (7) and shims. Tighten the nut
and bolt on the rod eye to a torque of 95 15 Nm
(70 10 lbft).

EHCD113C

18. Install the spacer (6) with O-ring seal onto the
cylinder rod if needed.

22. Install the rod assembly (2) in the cylinder body.


23. Tighten cover-rod (1). The torque for cover-rod (1)
is 270 35 Nm (200 25 lbft).
End By :
a. Install tilt cylinder.

Vehicle Systems

31

Disassembly And Assembly

(BX)

Steer Sensor Group


Remove And Install Steer Sensor Group

(BT)
Start By :

a. Raise the hood.

1. Disconnect harness connector (1).


3

2. Remove two screws (2) and washers.


3. Remove steer sensor from steer axle.
2

NOTE: Use the following steps to install the steer


sensor.
1. Disconnect harness connector (1).

4. Turn steering wheel to make the steer tire be


straight forward.

2. Remove two blots (2) and washers.

5. Measure the resistance between P1 and P2 or P2


and P3 of steer sensor connector.

3. Remove two screws (3) and washers.


4. Remove steer sensor from steer axle.

6. Make this resistance be 2.6 0.1 k by turning


the pole of steer sensor.

NOTE: Use the following steps to install the steer


sensor.

7. Install steer sensor on steer axle.

5. Turn steering wheel to make the steer tire be


straight forward.

End By :
a. Set Sensor Initial setting.

6. Measure the resistance between P1 and P2 or P2


and P3 of steer sensor connector.
7. Make this resistance be 2.6 0.1 k by turning
the pole of steer sensor.
8. Install steer sensor on steer axle.
End By :
a. Close the hood.
b. Set Sensor Initial setting.

Vehicle Systems

32

Disassembly And Assembly

Steering Wheel

Steering Column

Remove And Install Steering Wheel

Remove Steering Column


Start By :
a. Remove steering wheel.

2
1
3

IOCD020P
2

1. Remove 10 screws (1), washer, covers (2) and


key switch (3).

5
4

1. Remove cap (1) from the steering wheel.


2. Remove nut (3) and washers (2) from the steering
wheel.
IOCD021P

3. Use a suitable puller to remove the steering wheel.


2. Remove two screws (4) and cover (5).
NOTE: The following steps are for installation of the
steering wheel.
6

4. Put the steering wheel in position on the shaft.


Install WASHER (2) and nut (3). Tighten the nut to
a torque 80 7 Nm (60 5 lbft).
5. Install cap (1) on the steering wheel.

EHCD127C

3. Remove horn switch (6) from the steering column.

Vehicle Systems

33

Disassembly And Assembly

8
7
15

9
18
14

17

EHCD128C

4. Remove two bolts (7), washers and bracket with a


directional switch (8) from the support assembly.

7. Remove screw (14) and handle (15).


Loosen nut (17) and remove gas cylinder (18).

5. Disconnect four hoses (9) from the steering gear.

8. Install the steering column in the reverse order of


removal.

NOTE: Put identification marks on all hoses for


profer installation. Plug and cap all openings to avoid
contamination and debris from entering the system
after removing any hoses or lines.

Install Steering Column

12

11

24
25
23

10

13

EHCD133C

EHCD129C

1. Install the bushings if they were removed. Put the


support assembly (25) in position on the cowl.
Install bolts (24), washers and nuts (23).

6. Remove four bolts (11) and separate steering gear


(10) from steering column (12). Remove cotter pin
(13). Remove steering column (12).

NOTICE
Steering gear (10) and column (12) can separate
after bolts (11) have all been removed, causing
gear (10) to fall. To avoid damaging components,
support the steering gear while removing bolts
(11).

Vehicle Systems

34

Disassembly And Assembly

Steering Gear
6

Disassemble & Assemble Steering


Gear(Pump)

10

Start By :
a. Remove steering gear (pump).

4
8

Refer to the Remove Steering Column in this module


for further information.

EHCD136C

4. Remove the components from housing (3) as


follows:
a. Remove plate (6) from housing (3) and cap (4).
b. Remove shaft (7) from gerotor (9).
c. Remove gerotor (9) from housing (3).
d. Separate cap (4) from housing (3).
e. Remove O-rings seal (8) from housing (3).
f. Remove O-ring seal (10) from cap (4).

EHCD134C
Typical Example
12

1. Remove the elbows (1) from pump body (2).

11

5
4

14

13

EHCD137C
3

5. Remove suction valve balls (12) and pins (11).


2

6. Remove screw (13) and check valve ball (14).

EHCD135C

2. Remove seven bolts (5) from gerotor housing (3)


and cap (4).

NOTICE
Make a note of the position of special bolt with a
pin. It is locatedmat a mark in line with check
valve.

16

EHCD138C

3. Separate housing (3) and cap (4) from pump body

15

7. Remove O-ring seal (15) from pump body (2).


8. Remove sleeve (16) from pump body (2).

Vehicle Systems

35

Disassembly And Assembly

16

17

28

27

23

EHCD139C

EHCD142C

12. Remove plugs (27) and washer (28) from pump


body (2).
22

21
19

32

2
35

23

33

20

18

34

EHCD140C

9. Remove the components from sleeve (16) as


follows :
a. Remove pin (18) from spool (17) and sleeve
(16).
b. Remove spool (17) from sleeve (16).
c. Remove two bearing races (19), (20) and
bearing (21) from spool (17).
d. Remove six springs (23) and ring (22) from
spool (17).

EHCD003B

13. Remove plug (31) and spring (32) from the pump
body (2).
14. Remove poppet (34) and relief valve housing (35)
from the pump body.

25
37

36

26

24

EHCD143C

15. Remove plug (36) and washer (37) from the pump
body.

EHCD141C

10. Remove O-ring seal (24) and king-ring (25) from


body (2).

NOTE: The following steps are for assembling the


steering pump.

11. Check the condition of dust seal ring (26).


Replace seals with new if worn or damaged.

Vehicle Systems

36

Disassembly And Assembly

25

26

36

37

24

EHCD143C

EHCD141C

16. Install washer (37) and plug (36) into the pump
body.

32

20. Install dust seal ring (26). Install O-ring seal (24)
with king-ring (25) into pump body (2).

22

21

19

35

33
34

23
20

EHCD003B

18

EHCD140C

17. Install housing (35) and poppet (34) into the pump
body.

NOTICE
For purposes of installation, note that springs (23)
are installed in two stacks of three. Make sure the
curves of the two stacks are in contact and
positioned in the center of spool (17). The notched
side of springs (23) must be positioned toward
sleeve (16).

18. Install spring (32) and plug (31) into pump body
(2). Tighten plug (31) to a torque 11.3 Nm (100
lbin).

17
28

16

27

EHCD142C
23

19. Install washer (28) and plug (27) into pump body
(2) Tighten plugs to a torque 30 Nm (22 lbft).

EHCD139C

21. Install springs (23) into spool (17).


22. Install spool (17) into sleeve (16).
23. Install pin (18), ring (22), two bearing races (19),
(20) and bearing (21) in their original positions on
spool (17).
Vehicle Systems

37

Disassembly And Assembly

16

EHCD138C

15

EHCD004B

24. Install sleeve (16) into pump body (2).


25. Install O-ring seal (15) into pump body (2).
6

12

10

11

4
8

EHCD136C
14

28. Install plate (6) onto pump body (2).

13

EHCD137C

NOTICE
Make sure the notch of shaft (7) properly seats on
pin (18) when installed into body (2) and spool (17).

26. Install check valve ball (14) and screw


(13).Tighten the screw (13).
27. Install suction valve balls (12) and pins (11) in their
original positions into the pump body.

29. Install shaft (7) into body (2) and spool (17).

NOTICE
Gerotor (9) must be aligned with shaft (7) and pin
(18) as shown in the illustration.

30. Install O-ring seal (8) and housing (3).


31. Install O-ring seal (10) and cap (4).

Vehicle Systems

38

Disassembly And Assembly

EHCD005B

NOTICE
To assure proper operation of the pump, make
sure bolts (5) are clean and dry before installing.
Tighten bolts (5) in the sequence shown in the
illustration.

5
4

3
2

EHCD135C

32. Install bolts (5) into cap (4). Tighten bolts (5)
asfollows:
a. Tighten bolts (5) in correct sequence to a first
torque of 14.1 2.8 Nm (125 25 lbin).
b. Tighten bolts (5) in correct sequence to a
second torque of 28.2 2.8 Nm (250 25
lbin).
End By :
a. Install steering pump.

Vehicle Systems

39

Disassembly And Assembly

5. Fill the hydraulic tank with fluid to the correct level.


Fefer to the Operation and Maintenance Manual
for further information.

Priority Valve
Remove & Install Priority Valve

End By :

Start By :

a. Install the floorplate.

a. Remove floorplate.

WARNING

Disassemble & Assemble Priority Valve

Hydraulic oil under pressure can remain in the


hydraulic system after the pump motor have been
stopped. Personal injury can result if the pressure
is not released before any work is done to the
hydraulic system. To prevent possible personal
injury, turn the key switch off and move the
control levers to make sure the hydraulic pressure
is released before any fitting, plug, hose or
component is loosened, tightened, removed or
adjusted. Always move the lift truck to a clean and
level location away from the travel of other
machines.

Start By :
a. Remove priority valve
NOTE: Mark the positions of all components for
purposes of reassembly.

1. Drain the hydraulic tank.

4
3

EHCD145C

1. Remove the spool assembly from valve body as


follows :
a. Remove plug (1). Check the condition of the
bush (2). Replace with new bush if worn or
damaged.
b. Remove spool (3).
c. Remove spring (4).

EHCD144C

NOTE: For purposes of reassembly, put


identification marks on all lines, tubes and hoses
before any disconnections are made.
2. Disconnect four hydraulic lines (1) from priority
valve (2). Plug and cap all openings to prevent
contamination and debris from entering the
system.
3. Support valve (2). Remove the two bolts (3) and
priority valve and mount assembly (2).
4. Install priority valve (2) in the reverse order of
removal.

Vehicle Systems

40

Disassembly And Assembly

Brake Master Cylinder


Remove And Install Brake Master
Cylinder

EHCD146C
1

2. Remove check valve (5) from the valve body.


NOTE: Check the condition of all components.
Replace any worn or damaged components with new
parts. Make sure all components are clean before
reassembling.

IHCD120P

3. Assemble the priority valve in the reverse order of


disassembly.
End By :
2

a. Install the priority valve.

IHCD121P

1. Remove floor mat (1) and floor plates (2), (3).

Vehicle Systems

41

Disassembly And Assembly

Disassemble & Assemble Brake


7

Master Cylinder

8
4

Start By :

a. Remove master cylinder.

2. Disconnect hose (4) and tube (5) from the master


cylinder.
3. Remove the cotter pin and pin (6) from the clevis
and brake pedal assembly.
4. Remove two bolts (7) and master cylinder (8) from
the bracket.
1. Remove head (1) and boot(2).

5. Install the brake master cylinder in the reverse


order of removal.

2. Remove snap ring (3) from master cylinder.

6. Fill the brake reservoir and master cylinder with


brake fluid. See the Operation And Maintenance
Manual.
7 15 9
4

7. Bleed the brake system, and if necessary, adjust


the pedal free level. See Brake System Air
Removal And Pedal Adjustment in Testing And
Adjusting.

13 3

14
6

12

11 10

3. Remove large spring (4) and small spring (5).


4. Remove retaining ring (6) from small piston (12).
5. Remove spring seat (7), primary cup1 (8) and
small spacer (9) from small piston(12).
6. Remove secondary cup (10) from large piston (13).
7. Remove spring pin (11).
8. Remove small piston (12) from large piston (13).
9. Remove primary cup2 (14) and large spacer (15)
from large piston (13).
10. Assemble the master cylinder in the reverse order
of disassembly.
End By :
a. Install master cylinder.
Vehicle Systems

42

Disassembly And Assembly

(BX)
G

Steer Axle
Remove & Install Steer Axle
WARNING
Be sure the pressure in the hydraulic system is
released before any lines or hoses have been
disconnected.

IBCD062C

3. Support the steer axle with a floor jack.

4. Loosen rear mounting bolt (3) until approximately


two bolt threads are left in the mounting boxes.

5. Lower the steer axle onto the bolt heads with the
floor jack.

IBCD061C

1. Raise the rear of the lift truck and support with


wooden block.
2. Disconnect hose (1) and tube (2). Plug and cap all
openings to prevent contamination and debris
from entering the system.

5
6

IBCD061C

6. Remove front mounting bolts (5) and mounting


caps (6) from the steer axle.

Vehicle Systems

43

Disassembly And Assembly

IBCD177C

IBCD062C

7. Remove steer axle (4).


NOTE:
axle.

NOTE: Use bolts (3) and cap to align steer axle (4)
with the mounting bosses while raising steer axle (4)
into position with the floor jack.

Use the following steps to install the steer

9. Seat steer axle (4) as follows:


a. Install bolts (5) through cap (6) and into the
mounting bosses approximately two bolt
threads.
b. Use the floor jack to raise steer axle (4) into the
mounting boss.
c. Tighten bolts (5) to a torque of 270 40 Nm
(200 30 lbft).

IBCD177C

8. Use a floor jack to position steer axle (4).


1

IBCD063C

10. Connect hose (1) and tube (2).

Vehicle Systems

44

Disassembly And Assembly

Steering Cylinder
3

Disassemble Steering Cylinder


Start By:
a. Remove steer cylinder.

IBCD162C

4. Remove retaining rings (3) from the cylinder rod.

IBCD064C

1. Put location marks on rod cover (1) as to their


position on the steering cylinder tube (2).
2. Remove rod covers (1) from the steering cylinder.
IBCD163C

5. Remove piston (4) from the cylinder rod.


2

IBCD161C

3. Remove cylinder tube (2) from the rod assembly.


IBCD164C

6. Remove and inspect O-ring seal (5).

Vehicle Systems

45

Disassembly And Assembly

Assemble Steering Cylinder

9
8

IBCD165C
7

IBCD166C

G
G
G
G
G
G
G
G
G
G
G
G
G IBCD165C

IBCD166C

7. Disassemble each rod cover as follows:


a. Remove O-ring seal (6).

1. Assemble each rod cover as follows:

b. Remove wiper seal (7).

a. Install du-bush (9).

c. Remove U-packing (8).

b. Install U-packing (8).

d. Remove du-bush (9).

c. Install wiper seal (7).


d. Install O-ring seal (6).

IBCD164C

2. Install O-ring seal (5) on the cylinder rod.

Vehicle Systems

46

Disassembly And Assembly

4
1

IBCD163C

IBCD064C

3. Install piston (4) on the cylinder rod.

6. Install rod cover (1) on cylinder tube (2).


End By:

a. Install the steering cylinder.

IBCD162C

4. Install rings (3) on each side of piston.

IBCD161C

5. Install cylinder tube (2) on the rod assembly.

Vehicle Systems

47

Disassembly And Assembly

Steer Wheels & Hub


Remove Steer Wheels & Hub
3

NOTE: The procedure to remove the steer wheels is


the same for the right and left steer wheel.

IBCD049C

4. Remove wheel cap (3).


5. Eliminate grease in the hub.

IBCD047C
4

1. Raise the rear of the machine and support with


wooden block as shown.
2. Remove six nuts (1).
5

NOTE: Tighten the nuts (1) to a torque of 113 9


Nm (83 61 lbft) when installing.
IBCD050C

6. Bend the tap in locking washer (4) clear slot in nut.


7. Use tool (A) to remove nut (5). Remove locking
washer (4).
2

IBCD048C

3. Remove steer wheel (2).


6
7

IBCD051C

8. Remove washer and bearing cone (6) from hub


(7).

Vehicle Systems

48

Disassembly And Assembly

12

IBCD052C

IBCD055C

9. Remove hub (7) from steering knuckle (8).

12. Remove bearing cone (12) from knuckle.


NOTE: Check the condition of all seals, bearings
and components. If any parts are worn or damaged
use new parts for replacement. For purposes of
assembly, lower the temperature of the bearing cups
and before installing into steer wheel (2). Install
bearing cups and seals.

10

13. Pack bearing cones (6) and (12), and lubricate the
contact surfaces of the bearing cups with
Multipurpose Grease
14. Reverse the procedures and steps 1 through 12 to
install the steer wheels and bearings.

IBCD053C

10. Remove seal (9) and bearing cup (10) from hub
(7).

15. Adjust the steer wheel bearings as follows by


proper tool:
a. Tighten nut (5) to a torque of 135 14 Nm
(100 10 lbft) while slowly rotating steer
wheel (2).
b. Loosen nut (5) completely.
c. Tighten nut (5) again to a torque of 50 5 Nm
(37 4 lbft).
d. Grease fully inside hub.

11

16. Install wheel cap (3).


17. Install steer wheel (2).
IBCD054C

18. Raise the rear of the machine and remove the


wooden bolck.

11. Remove bearing cup (11) from the hub.

Vehicle Systems

49

Disassembly And Assembly

Link Assemblies

Steering Knuckles, Kingpins &


Bearings

Remove & Install Link Assemblies

Remove & Install Steering Knuckles,


King Pins & Bearings

NOTE: The procedure to remove and install the link


assembly is the same for each steer wheel.

Start By:
a. Remove steer wheels
3

b. Remove hub assembly.

c. Remove link assembly.


NOTE: The procedure to remove and install the
steering knuckles, kingpins, and bearings is the same
for both sides of the lift truck.

2
1

IBCD056C
1

1. Position the wheel to gain access to the tie rods.

2. Remove two split pin (1). Remove two nuts (2)


and washer. Remove pin assembly (3) and link (4).

7
3

IBCD058C
6

1. Remove snap ring (1), and plug (2) from axle


beam(each sides).

IBCD057C

3. Remove conical bearing (5) and washer (6) from


link assembly (7).
4. Install the link assembly in the reverse order of
removal.

Vehicle Systems

50

Disassembly And Assembly

NOTICE
Check the condition of all seals, bearings and
components. If any parts are worn or damaged use
new parts for replacement.

1
2

6. Lubricate the kingpins and bearings with Lubricant.

7. Install the steering knuckle, kingpins and bearings


in the reverse order of removal.

IBCD058C

End By:

2. Remove bolt (3) and nut (4).

a. Install steer wheels.


b. Install link assembly.

c. Install hub assembly.

IBCD059C

3. Remove king-pin (5) ball bearing (6), shims (7),


and knuckle (8).

IBCD060C

4. Remove needle bearing (9) from the beam.


5. Repeat steps 3 and 4 for the remaining seal,
bearing and spacer in the other side of knuckle (8).

Vehicle Systems

51

Disassembly And Assembly

(BT)
Steer Axle
Remove & Install Steer Axle

Start By :
a. Remove overhead guard.
b. Remove counterweight.
c. Remove steer sensor group.

IBCD158C

3. Disconnect hose-steer (2) and (3) from the


housing-steer axle.

WARNING
Be sure the pressure in the hydraulic system is
released before any lines or hoses have been
disconnected.

1. Raise the rear of the lift truck and support with


wooden block.

NOTE: For purposes of reassembly, put


identification marks on hoses and lines before any
disconnections are made. Plug and cap all openings
to prevent contamination and debris from entering the
system.

IBCD159C

4. Support the axle beam with a floor jack.


5. Remove six bolts (4) and washers. For the
reassembly purpose, the torque for bolt (4) is 270
25 Nm (200 18 lbft). Apply the Loctite NO.
262 on the bolt thread.
6. Remove axle beam assembly (5) from the housing
assembly.
1

IBCD157C

2. Disconnect overflow hose (1) from the housing


steer axle.

Vehicle Systems

52

Disassembly And Assembly

Disassemble & Assemble Housing


Group-SteerAxle
Start By :
6

a. Remove housing group-steeraxle


1. Drain hydraulic oil.
2
7

IBCD160C

7. Remove three bolts (6) and washers (7) then,


remove axle-housing assembly (8) from the frame.
For the reassembly purpose, the torque for bolt (6)
is 460 60 Nm (340 45 lbft). Apply the Loctite
NO. 262 on the bolt thread.
8. Install the steer axle assembly in the reverse order
of removal.

IBCD161C

End By :

2. Remove three bolts (1) and top plate (2).

a. Install counterweight.
b. Install overhead guard.

c. Install steer sensor group.

IBCD162C

3. Remove shim pack (3) from the pinion gear.

Vehicle Systems

53

Disassembly And Assembly

10

IBCD166C

IBCD163C

4. From the top of the pinion gear assembly, tap the


pinion gear assembly (4) and remove pinion gear
assembly (4) from the housing.

7. Remove piston and rack gear assembly (10) from


the housing.

11

13

12
14

IBCD167C
IBCD164C

8. Disassemble piston and rack gear assembly as


follows :
a. Remove wear ring (11) from the piston.
b. Remove bolt (12) and washer.
c. Remove piston (13) from the rack gear.
d. Remove win seal (14) and O-ring from the piston.

5. Remove cone bearing (5) from the pinion gear


assembly (4).

NOTE: Check the condition of ring and seals and


replace with new ones if needed.

16

15

IBCD165C

6. Remove four bolts (8), washers and cap (9) with


O-ring from the housing (7). Check the condition
of O-ring and replace with new one if needed.
IBCD168C

9. Remove Lip seal (15), cone bearing (16) and cup


bearing from the housing. Replace with a new
seal if needed.

Vehicle Systems

54

Disassembly And Assembly

18

15

16

17

IBCD169C

IBCD168C

10. Remove Lip seal (17) from the housing. Replace


with a new seal if needed.

14. Install cup bearing in the housing. Install cone


bearing (16) in the housing.

11. Remove cup bearing (18) from the housing.

15. Install Lip-seal (15) in the housing.

NOTE: Use the following steps to install the housing


group-steer axle.

11
13

18
17

12
14

IBCD167C

16. Install and assemble the piston and rack gear


assembly as follows :

IBCD169C

12. Install the cup bearing (18) in the housing.

a. Install O-ring, win seal (14) to the piston (13).

13. Install Lip seal (17) in the housing.

NOTE:
Apply light coat of Loctite NO.592
sealant to outer of seal case.

NOTE: Lubricate sealing lip lightly with the lubricant


being sealed.

b. Install the piston (13), bolt (12) and washer to


the rack gear. The torque for the bolt (12) is 55
10 Nm (40 7 lbft).
NOTE:
Prepack rack gear with NLGI NO. 2
(GREASE) lubricant.
c. Install wear-ring (11) on the piston. Install the
piston and rack gear assembly in the housing.

Vehicle Systems

55

Disassembly And Assembly

7
3

IBCD167C

IBCD162C

17. Install the cap (9), washers and four bolts (8) to
housing (7). The torque for the bolt (8) is 55 10
Nm (40 7 lbft).

20. Adjust the shim (3) on the pinion gear assembly


as follows :
a. Install top plate and bolts on the housing Torgue
for the bolt is 55 10 Nm (40 7 lbft).
b. Remove bolts and top plate again.
c. Measure the distance (Y) from the surface of
housing to the top of pinion gear. Record this
measurement.
d. Measure the distance (X) from the surface of
housing to the top of cone bearing Record this
measurement.
e. Calculate the required shim thickness.

Required Shim=XY
Following is the content of the shim pack.

IBCD164C

18. Install cone bearing (5) to pinion gear assembly


(4).

SHIM NO
THICKNESS

1
0.05

2
0.13

3
0.80

f. Combine the above shims to obtain end play of


0.01 to 0.035.

IBCD161C
IBCD006B

21. Install the top plate (2) and bolt (1). The torque for
the bolt (1) is 45 7 Nm (33 5 lbft).

19. Put the pinion gear assembly (4) in position as


follows :
a. Put the rack gear assembly in center of housing.
b. Put the pinion assembly in top position as
shown.

Vehicle Systems

End By :
a. Install the housing group-steer axle.

56

Disassembly And Assembly

Spindle-Steer Axle
Remove And Install Spindle-Steer Axle

2
6

IBCD051C

7. Remove washer and bearing cone (6) from hub


(7).
IBCD170C

1. Loosen six nuts (1) and put wooden block under


the lift truck, and lower it onto the wooden block
as shown.

2. Remove six nuts (1) and tire (2).


8

IBCD052C
3

8. Remove hub (7) from steering knuckle (8).

10

IBCD049C
7

3. Remove wheel cap (3).


4. Eliminate grease in the hub.

IBCD053C
4

9. Remove seal (9) and bearing cup (10) from hub


(7).

IBCD050C

5. Bend the tap in locking washer (4) clear slot in nut.


6. Use tool (A) to remove nut (5). Remove locking
washer (4).

Vehicle Systems

57

Disassembly And Assembly

11
1

IBCD170C

IBCD054C

10. Remove bearing cup (11) from the hub.

16. Install the steer tire (2) and nuts (1). Torque for the
nut (1) is 113 Nm (83 lbft) for unfuion Tire for
solid sokter Tire.
17. Remove the wooden block.

12

IBCD055C

11. Remove bearing cone (12) from knuckle.


NOTE: Check the condition of all seals, bearings
and components. If any parts are worn or damaged
use new parts for replacement. For purposes of
assembly, lower the temperature of the bearing cups
and before installing into steer wheel (2). Install
bearing cups and seals.
12. Pack bearing cones (6) and (12), and lubricate the
contact surfaces of the bearing cups with
Multipurpose Grease
13. Reverse the procedures and steps 1 through 12 to
install the steer wheels and bearings.
14. Adjust the steer wheel bearings as follows by
proper tool:
a. Tighten nut (5) to a torque of 135 14 Nm
(100 10 lbft) while slowly rotating steer
wheel (2).
b. Loosen nut (5) completely.
c. Tighten nut (5) again to a torque of 50 5 Nm
(37 4 lbft).
d. Grease fully inside hub.
15. Install wheel cap (3).

Vehicle Systems

58

Disassembly And Assembly

IBCD172C

IBCD175C

18. Bend the locking tab of washer (5) back.

22. Remove cup bearing (9) from the beam-axle.

19. Remove the nut (6) lock washer (5) and washer
(4) from the spindle.

NOTE: Put identification on cup bearings to use at


assembly.
23. Remove dust-seal (10) from the beam-axle.
Replace with a new seal if needed.

10

IBCD173C

20. From the front of beam-axle, tap the spindle and


remove cone bearing (7) from the spindle.

11

IBCD176C

24. Remove cone bearing (11) from the beam-axle.


25. Remove cup bearing from the beam-axle.
NOTE: Use the following steps to install and
assemble the spindle-steer axle assembly.

IBCD174C

21. Remove spindle assembly (8) from the beam-axle.

Vehicle Systems

59

Disassembly And Assembly

NOTICE
Prepack wheel, actuator bearing and hub with
NLGI NO. 2(GREASE) lubricant.

IBCD174C

10

30. Install the spindle assembly (8) into the beam axle.
11

IBCD176C

26. Install cup bearing into the beam-axle.


7

27. Install cone bearing (11) into the beam-axle.


28. Install dust-seal (10) into the beam-axle.
NOTE: Lubricate sealing lip lightly with the lubricant
being sealed.

IBCD173C

31. Install cone bearing (7) onto the spindle assembly


(8).
32. Install washer, lock washer (5) and nut (4) on the
spindle assembly.
NOTE1: Single Wheel
While rotating the wheel or hub to seat bearings,
tighten locknut (6) to 100 Nm (74 lbft) then loosen
nut (6) completely. Retighten to 40 3 Nm (30 2
lbft).

IBCD175C

NOTE2: Dual Wheel


While rotating the wheel or hub to seat bearing,
tighten lock nut (6) to 133 Nm (98 lbft) the loosen
nut (6) completely. Retighten to 45 to 55 Nm (33 to
41 lbft).

29. Install cup bearing (9) into the beam-axle

33. Bend the lock washer (5) to groove of nut (6) and
tighten the nut (6).

Vehicle Systems

60

Disassembly And Assembly

NOTE: Before installing cover (3) apply grease


(NLGI NO. 2) to fitting until it comes out at cover end,
fill cap with grease and install in place.

IBCD171C

34. Install the cover (3) into the beam-axle.

2
1

IBCD170C

35. Install the steer tire (2) and nuts (1). Torque for the
nut (1) is 140 Nm (103 lbft).
36. Remove the wooden block.

Vehicle Systems

61

Disassembly And Assembly

Control Panel
Remove And Install Control Panel
(AC)
WARNING
Battery voltage and high ampere are present.
Injury to personnel is possible. The power unit
must be discharged before any contact with the
control panel is made. Disconnect the battery and
discharge the power unit.

3. Loosen four bolts and remove the logic control


board.

1. Raise the hood. Remove the side panels.

4. Remove the motors cables and battery cables.


2. Disconnect the main connector and the
communication cables.

5. Loosen two bolts at the bottom of the control panel


and remove three bolts at the top of the control
panel.
6. Remove control panel assembly from the lift truck.
7. Install the control panel in the reverse order of
removal.

Vehicle Systems

62

Disassembly And Assembly

(SE)
WARNING
Battery voltage and high ampere are present.
Injury to personnel is possible.
The power unit must be discharged before any
contact with the control panel is made.
Disconnect the battery and discharge the power
unit.
Remove and Install Control Panel

1. Open up the hood and remove R.H. side cover.


Remove the Logic cover by using screw driver.

4. Disconnect P2, LA2, RA2 Cables.


Disconnect B+, B- Cables
2. Remove the main harness from Logic Board.
Remove the Logic Board assy.
3. Disconnect P1, LA1, RA1 Cables.
Disconnect LS2, LS1, RS1, RS2 Cables

5. Remove controller mounting bolts.

Vehicle Systems

63

Disassembly And Assembly

6. Remove control panel assembly from the lift truck.

7. Install the control panel in the reverse order of


removal.

Vehicle Systems

64

Disassembly And Assembly

Drive Motor & Drive Axle


5

Remove & Install Drive Motor And Drive


Axle

NOTE: The procedure for removing and installing


the drive motor and drive axle is the same for both
sides.

IOCD029P
2

5. Loosen nuts (5) from parking cable and remove


parking cable (6) from the drive axle.
6. Remove brake bleeder tube (7) from the drive axle.

IOCD027P

1. Loosen 8 nuts (1) and put a jack or wooden block


under the lift truck.
2. Remove five nuts (1) and drive tire (2).

IOCD030P

7. Remove brake inlet tube (8) from the drive axle.


3
9

IOCD028P

3. Disconnect wiring harness (3) and connector (4)


from the drive motor.
4. Disconnect four cables from the drive motor.

EHCD189C

NOTE: Put identification marks on all cables and


wiring harness for installation purposes.

Vehicle Systems

8. Remove screw and band (9) from the drive motor.

65

Testing and Adjusting

12
11

13

10

IOCD032P

IOCD031P

9. Support the drive motor and drive axle assembly


(10).
10. Remove six bolts (11) and drive motor and drive
axle assembly (10) from the frame.
11. Lower the drive motor and drive axle assembly
(10).
13
14
IOCD033P

12
13

13. Put the drive motor (13) on the drive axle (14) and
install the bolt (12). The torque for the bolt (12) is
55 Nm (41 lbft).
NOTE:
thread.

Apply Loctite NO. 262 sealant on bolt (12)

IOCD032P

11

10

IOCD031P

13
14
IOCD033P

14. Check the frame surface for damage.

12. Remove three bolts (12). Remove drive motor (13)


from the drive axle (14).

15. Put the drive motor and drive axle assembly (10)
on the frame and install the bolt (11). The torque
for the bolt (11) is 200 Nm (147 lbft). Apply
Loctite NO. 262 on bolt thread.

NOTE: The following steps are for installation of the


drive motor and drive axle assembly.
NOTE: Before mounting, clean the mating surfaces
on the drive axle and electric motor carefully (such as
Loctite NO. 706) and check for damage.

Vehicle Systems

66

Testing and Adjusting

EHCD189C

IOCD028P

16. Install the band (9) and screw on the drive motor.

18. Connect the wiring harness (3), connector (4) and


four cables on the drive motor.

IOCD030P
IOCD027P

19. Clean mating surface on wheel shaft and wheel


thoroughly (such as Loctite NO. 706) and check
for damage.

5
1

20. The bore pattern in the rim should be in line with


the bolts of the wheel shaft, then push the wheel
on.
21. Install the drive tire (2). The torque for the nut (1)
is 140 Nm (103 lbft) for cushion Tire or
Pneumatic Tire. 180 Nm (133 lbft) for solid
soqter Tire.

IOCD029P

17. Install the brake tubes (8), (7) and parking cable
(6) on the drive axle. The torque for the fitting is
50 Nm (37 lbft). Tighten the nut (5).

Vehicle Systems

67

Testing and Adjusting

Counterwieght

(BX)

Remove And Install Counterweight

Start By:

(BT)

a. Open hood.

Start By:
2

a. Open hood.
1
2

1. Install two forged eyebolts at the top of the


counterweight. Attach a hoist.

2. Remove two bolts (1) and washers from the


counterweight (2).

1. Install two forged eyebolts at the top of the


counterweight. Attach a hoist.

3. Remove counterweight (2). The approximate


weight of the counterweight is as follows:

2. Remove four bolts (1) and washers from the


counterweight (2).

B16X : 450kg (992 lb)


B18X : 620kg (1367 lb)
B20X : 770kg (1698 lb)

3. Remove counterweight (2). The approximate


weight of the counterweight is as follows:

NOTE: The following steps are for installation of the


counterweight.

B15T-2, B18T-2, B20T-2..............715 kg (1576 lb)


NOTE: The following steps are for installation of the
counterweight.

4. Put the counterweight in position on the lift truck


and install four bolts (1) and washers. The torque
for the bolt (1) is 460 16 Nm (340 45 lbft).
Apply the Loctite NO.262 on the bolt thread.

4. Put the counterweight in position on the lift truck


and install four bolts (1) and washers. The torque
for the bolt (1) is 460 16 Nm (340 45 lbft).
Apply the Loctite NO.262 on the bolt thread.

End By :
a. Close hood.

End By :
a. Close hood.
Vehicle Systems

68

Testing and Adjusting

SB4182E00
Feb. 2005

Schematic
Lift Trucks Hydraulic Systems
B15T-5, B18T-5, B20T-5 (AC 36V)
B15T-5, B18T-5, B20T-5 (AC 48V)
B15T-5, B18T-5, B20T-5 (SE 48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
B16X-5, B18X-5, B20X-5 (SE 48V)

10

1
11

13

12

Components

Tilt Cylinder
Hydraulic Filter
Steer Axle
Control Valve

12
13

D500037

Lift Cylinder-Secondary, Standard

11

Lift Cylinder-Primary

10

Flow Protector-Primary

Flow Regulator

Flow Protector-Secondary, Standard

Pressure Switch

Steering Unit

Priority Valve
3

Hydraulic Pump
2

Item

MODEL : B15T-5, B18T-5, B20T-5

14

10

13

11

12

D500038

MODEL : B16X-5, B18X-5, B20X-5

SB4181E00
Feb. 2005

Schematic
Lift Truck Electric System
B15T-5, B18T-5, B20T-5 (AC 36V/48V)
B16X-5, B18X-5, B20X-5 (AC 48V)

A244902

WIRING SCHEMATIC - ELECTRIC


MODEL : B15T-5, B18T-5, B20T-5 (AC 36/48V)
B16X-5, B18X-5, B20X-5 (AC 48V)

SB2143E03
Feb.2 0 0 5

Disassembly & Assembly


Testing & Adjusting
Lift Trucks Mast Systems
G15S-2,

G18S-2,

G20SC-2

GC15S-2, GC18S-2, GC20SC-2


D15S-2,

D18S-2,

D20SC-2

B16X,

B18X,

B20X

B16X-5,

B18X-5,

B20X-5 (AC/SE)

B13T-2,

B15T-2,

B18T-2, B20T-2

B13T-5,

B15T-5,

B18T-5 (AC/SE)

B15S,

B18S

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.

WARNING
IImproper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product will not be damaged or made unsafe by the operation,
lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.

Index
Disassembly & Assembly
Forks.........................................................................5
Backrest....................................................................5
Carriage....................................................................6
Mast..........................................................................9

Testing & Adjusting


Carriage Adjustment...............................................22
Chain Adjustments .................................................23
Chain Wear Test.....................................................23
Carriage and Mast Height Adjustment ........................24
Forks Parallel Check ..............................................24
Tilt Cylinder Alignment............................................25
Drift Test .................................................................25
Tilt Cylinder Adjustment..........................................26
Lift & Tilt Mounting Group Adjustment....................27
Mast mounting Group Adjustment..........................28

Lift Trucks Mast System

Index

Backrest

Disassembly & Assembly

Remove & Install Backrest

Forks
Remove & Install Forks

IBCD501P
2

1. Fasten a hoist to the backrest. Remove bolts(2)


that fasten the backrest to the carriage.

IDCD001P

2. Remove backrest (1).


Backrest weighs 32 kg (71 lb).
3. Install backrest(1) in the reverse order of removal.

IDCD002P

1. Remove stopper bolt and washer (3).


2. Lift fork pin (1).
3. Use a suitable C-clamp, strap and hoist to support
the fork as shown.
4. Slide the fork to slot (2) in the middle of the carriage.
5. Remove the fork. The weight of the fork is 35 kg
(77 lb).
6. Repeat steps 1 through 4 for the remaining fork.
7. Install the forks in the reverse order of removal.
8. Put the forks in position. Lower both fork pins(1) to
lock the forks in position.
9. Install stopper bolt and washer (3).
Lift Trucks Mast System

Disassembly & Assembly

Carriage
Remove & Install Carriage
Start By:
a. Remove forks.
b. Remove backrest.

IBCD504P

4. Remove two nuts (6).


Remove carriage stop bolt (7).

1
3

1. Remove two bolts (1) from the cross head (2).


2. Remove cross head (2) from the cylinder rod (3).
8

IBCD510P

5. Raise the inner mast to pull out carriage as


shown.
5

6. Remove carriage from bottom of inner mast (9).


Carriage weighs 64kg (141 lb).

IBCD503P

3. Remove hoses (5).


NOTE: Use the following steps to install the carriage.
7. Raise the inner mast (9) to put in the carriage (8)
onto the mast, and lower the inner mast to cover
carriage bearing fully.

Lift Trucks Mast System

Disassembly & Assembly

End By:
a. Install backrest.
b. Install forks.

Disassemble Carriage
IBCD504P

Start By:

a. Remove carriage.
8. Install stop bolt (7).
Shim stop bolt as required to obtain a 4 to 6 mm
(.157 to .242 in) lap with top carriage stop on the
inner upright.

9. Put the chains in position over cross head. Install


nuts(6) onto the chain anchors to a torque of 300
L 30 NIIm (220 L 22 lbIIft).

IBCD571P

1. Remove the roll pins and pins(2) to disconnect


chains(1).

IBCD503P
3

10. Install hoses (5).

IBCD572P

2. Remove lower roller bearings(3) and the shims


from the carriage.

2
1
3

11. Install cross head (2) to cylinder rod (3).


12. Install hose guard (2) and bolts (1) to a torque of
8 L 2 NIIm (6 L 1.5 lbIIft).
Lift Trucks Mast System

Disassembly & Assembly

1. Select bearings from the chart to obtain minimum


clearance (C) between bearings and channel leg
for full channel length. Use same bearing at all
four locations.

7
4
8

CARRIAGE BEARING CHART


9
5

IBCD573P

Part No.

Bearing Size

Bearing O.D.*

D580006

Undersize

98.5 mm (3.878 in)

D580007

Standard

99.0 mm (3.898 in)

D580008

Oversize

99.5 mm (3.917 in)

* Permissible tolerance of L 0.08 mm (.003in)

3. Remove screw(5) and washer(4).


Remove two top roller bearings(6) and the shims.

Refer to carriage Adjustment in Testing & Adjusting.


4. Remove bolt (7), washer, pin-adjust (8) and sideroller bearing (9) from the carriage.

Assemble Carriage
NOTE : The standard, Full Free Lift and Full Free
Triple Lift carriage load bearings are all adjusted the
same way. The Full Free Triple Lift carriage is shown
in the following illustrations.
To make the carriage clearance adjustments,
carriage must be removed from the mast.

IBCD543P

Use the procedure that follows to adjust carriage


load bearings.

A
B

2. Find narrowest point by ruler on the inner mast in


the area where the bearings make contact.

5(STD)
3
A

C
5 (FF, FFT)

6
VIEW A-A
C

10

IBCD574P

A
VIEW C-C
IBCD581I

VIEW B-B

3. Install enough shims (1) that have been divided


into two equal groups behind bearings (2). At
installation, there is to be contact [zero clearance
(A)] between the bearings and the narrowest point
of inner mast.

Carriage Adjustment
(3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Side-roller bearings. (8) Lower bearings. (9) Pin-adjust.
(10) Bolt. (A) Zero clearance.
(B) 4.0 to 6.0 mm. (.157 to .242 in) clearance.
(C) Minimum clearance. (D) 4.5 L 0.5 mm

Lift Trucks Mast System

4. Do step 2 through 3 for other sets of bearings.

Disassembly & Assembly

Mast
4

Remove & Install Mast


Start By:
a. Remove forks.
Move the truck to the place where pit is set up.
3

IDCD016P

5. Tighten screw (3) that holds the top and middle


bearings (4) to the carriage to a torque of 34 L 7 NIm
(25 L 5 lbIft).

1
2

IBCD511P

1. Support mast assembly(2) with a hoist and strap


(1) as shown.

IBCD571P

6. Position chains (6) on the carriage. Install pins (5)


and the roll pins.
3

End By:
a. Install carriage, raise the inner mast and insert the
carriage from the bottom of inner mast.
IBCD512P

NOTICE
Place identification marks on all hydraulic connectors
and hoses to assure proper installation. Plug and cap
all hydraulic connectors and hoses to avoid debris and
contamination from entering the system.

2. Disconnect hose(3).
NOTE : For B15/18/20T-2(36V), see article 6 prior to
disconnecting hose (3).

Lift Trucks Mast System

Disassembly & Assembly

9
6

IBCD513P

WARNING

IBCD502S

Tilt cylinders (4) can drop when pin(6) is removed.


To avoid component damage or personal injury,
support tilt cylinder (4) while removing pin(6).

6. B15/18/20T-2(36V)
Raise the carriage and mast to open outer lower
part. Remove bolt (9) from the front of mast each
side. Remove bolt (8) from the pit each side.
Disconnect hose (3) of article 2.

3. Remove bolt (5) from each side of mast assembly (2).


4. Remove pin (6) from the tilt cylinders on each side
of the mast assembly.

103

IBCD582I
IBCD514P

7. B16/18/20X, B13/15/18/20T-2(48V)
Tilt forward mast assembly with the hoist. Remove
bolts (8) from each side.

5. D,G15/18/20S(C)-2, GC15/18/20S(C)-2, B15/18S


Tilt forward mast assembly about 8 with the hoist.
Remove four bolts (7) from pit each side of the
base of mast assembly.

WARNING
Loosen the tension of straps to be connected with
hoist when mast assembly is tilted forward.
If straps are too tight, mast assembly could slide
off when bolts (7), (8), (10) are removed.

8. Use the hoist to remove mast assembly from the truck.


9. Install the mast in the reverse order of removal.
End By:
a. Install forks.
Lift Trucks Mast System

10

Disassembly & Assembly

Disassemble Mast
Start By:
a. Remove lift chain to be connected primary lift
cylinder.
b. Remove primary lift cylinder.

NOTE: The following disassembly and assembly


procedure is for a full free triple lift mast.
IBCD520P

4. Disconnect and remove chains(5) from the bottom


of the mast.

IBCD518P

1. Remove hoses (1) along with the hose support


clamps (2).

5. Remove tube assy (9) and bolt (10) from stationary


mast and disconnect regulator (8) from secondary
cylinder.

3
2
4

IBCD519P

2. Remove hose sheave (3).


3. Remove chain nut(4) from the top of the mast
(each side).

Lift Trucks Mast System

11

Disassembly & Assembly

15
11

16
6. Remove top cylinder retainer bolts (11) from each
side of the mast.

17

D,G15/18/20S(C)-2, GC15/18/20S(C)-2, B15/18S

12

16

IBCD524P

7. Remove cylinder retainer brackets(12) from each


cylinder.

15
17

B15/18/20T-2(36V)

IBCD527P

13

8. Remove secondary cylinders(13). Each cylinder


weighs 38 kg (84 lb).

17

14

B16/18/20X, B13/15/18/20T-2(48V)
IBCD584I

10. Remove bearing mounting pins(15) and screw


(16) from the mast lower hinge mounting part.

IBCD526P

11. Check the condition of the bearings(17) located in


each of the mast mounting bracket.
Replace the bearings (17) with new if worn or
damaged.

9. Check the condition of bearings(14) located in


each of the tilt cylinder pin bores. Replace
bearings(14) with new if worn or damaged.

Lift Trucks Mast System

12

Disassembly & Assembly

24

21

24

22

18

23
19

IBCD528P

IBCD534P

13. Move inner mast channel (21) downward.

18. Move intermediate mast channel (24) downward.

14. Remove bearings (18) and shims from the


intermediate mast channel (24).

19. Remove bearings (22) and the shims from the


stationary mast channel.

15. Remove nylon pads (19) and shims.

20. Remove nylon pads (23) and the shims.

20

24
25

IBCD533P

IBCD529P

16. Remove bearings (20) and shims from the inner


mast channel (21).

21. Remove bearings (25) and the shims from the


intermediate mast channel (24).

21

24

IBCD535P

IBCD530P

17. Fasten nylon straps and hoist to inner channel


(21). Remove inner channel. The weight of the
inner channel is 110 kg (243 lb).

Lift Trucks Mast System

22. Fasten nylon straps and a hoist to the intermediate


mast channel (24). Remove intermediate mast
channel. The intermediate mast channel weighs
112kg (247 lb).

13

Disassembly & Assembly

Assemble Mast
NOTE: The standard, Full Free Lift and Full Free
Triple Lift mast load bearings are all adjusted the
same way. The mast shown in the following
illustrations is the Full Free Triple Lift mast.
1. Make sure all parts are clean and free of dirt and
foreign material.
2. Check all parts for damage, use new parts for
replacement.

IBCD541P

A. Lower Bearing Adjustment of


Intermediate Mast

4. Find narrowest point by ruler on the stationary


mast in the area where the bearings make contact
at 420 mm (16.5 in) channel lap.

NOTICE
When the correct amount of shim has been installed
behind bearings (1) there will be contact (zero clearance)
between the bearings and the inner mast at most narrow
point of mast.

IBCD505S
Mast Adjustment Lower Bearings
(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.

IBCD535P

5. Lifting by crane, insert intermediate mast into


stationary mast from the upper side.

3. Select lower bearings (3) and (4) from the chart to


obtain minimum clearance (B) between bearing
and channel leg for full channel length. Use same
bearing on left and right side.

Mast And Carriage Bearings


Part No.

Bearingsize

Bearing O.D.*

D580006

Undersize

98.5 mm (3.878 in)

D580007

Standard

99.0 mm (3.898 in)

D580008

Oversize

99.5 mm (3.917 in)

* Permissible tolerance L 0.08 mm (.003 in)

Lift Trucks Mast System

14

Disassembly & Assembly

1
4
3

IBCD534P

IBCD533P

6. Install 1mm shim and bearing (1) of stationary


upper basically.

9. Install 1mm shim and bearing (4) of intermediate


lower basically.

IBCD538P

NOTE: When installing shims (2) behind bearings


(1), make sure the amount of shim is divided equally
when positioned behind each bearing.

7. Install the correct amount of shim (2) behind


rollers until contact (zero clearance) is made
between the bearings.

IBCD505S

8. Install pads (3) to each side.


Refer to Upper Pad Adjustment of Disassebly &
Assembly.

Mast Adjustment Lower Bearings


(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.

NOTE: When installing shims (5) behind bearings


(4), make sure the amount of shim is divided equally
when positioned behind each bearing (4).

Lift Trucks Mast System

15

Disassembly & Assembly

IBCD531P

IBCD534P

10. Make sure intermediate mast lower bearings are


properly shimmed in the stationary mast by
rolling up and down and moving intermediate
mast to right and left. If clearance between both
masts can be detected, pull out the intermediate
mast from the stationary mast with crane and
add shim 0.5 mm or 1 mm to both intermediate
lower bearings.

13. Install 1 mm shim to each bearing of stationary


mast upper basically. Bearing should be selected
D580006 undersize bearing.

11. In case of standard and full free mast, inner


lower bearings can be easily extruded by pulling
down the inner mast from the bottom of
stationary mast. If intermediate mast is stuck and
cannot move by rolling up and down, there might
be excessive shim. Pull out the intermediate
mast from the stationary mast and remove shim
0.5 mm to both intermediate lower bearings.
Repeat same procedure of above until properly
shimmed. There is to be contact zero clearance
(C) between intermediate lower bearings and
stationary channel at approximately 420 mm
(16.5 in) channel lap.

IBCD533P

14. Install 1mm shim and bearing (4) of intermediate


lower basically.

B. Upper Bearing Adjustment of Stationary


Mast

IBCD535P

12. Lift by crane, insert intermediate mast into


stationary mast from the upper side.

Lift Trucks Mast System

16

Disassembly & Assembly

Repeat same procedure of above until properly


shimmed. There is to be contact zero clearance
(F) between stationary upper bearings and the
widest point of intermediate mast to be checked
before.

D
E
7

C. Upper Pad Adjustment

E
F

10

F
7

IBCD506S

Mast Adjustment Upper Bearings


(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.

8
10

IBCD506S
Mast Adjustment Upper Bearings
(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.

17. Install shims (8) behind each pad (7) until there
is 0.80 mm (.031 in) maximum clearance (E)
between the pads and the inner and intermediate
masts with the masts at full extension. Lift by
crane, and pull out intermediate mast from
stationary mast and insert the shims behind each
pad. In case of standard and full free mast, the
pads of stationary upper can be easily extruded
by pulling down the inner mast from the bottom
of stationary mast.

IBCD532P

15. Make sure stationary mast upper bearings are


properly shimmed by rolling up and down and
moving intermediate mast to right and left. If
clearance between both masts can be detected,
pull out the intermediate mast from the stationary
mast with crane and add shim 0.5 mm or 1 mm
to both stationary upper bearings.
16. In case of standard and full free mast, stationary
upper bearings can be easily extruded by pulling
down the inner mast from the bottom of
stationary mast. If intermediate mast is stuck and
cannot move by rolling up and down, there might
be excessive shim. Pull out the intermediate
mast from the stationary mast and remove shim
0.5 mm to both stationary upper bearings.

Lift Trucks Mast System

17

Disassembly & Assembly

D. Lower Bearing Adjustment of Inner


Mast

3
IBCD542P

19. Find narrowest point by ruler on the intermediate


mast in the area where the inner lower bearings
make contact full length of intermediate mast
excluding minimum channel lap 420 mm (16.5 in).

12

11

IBCD505S
Mast Adjustment Lower Bearings
(A) Zero clearance. (B)Minimum clearance. (C)Zero clearance.
(3)Bearing. (4)Bearing. (5)Shims. (6)Shims.

IBCD530P

18. Select lower bearings (3) and (4) from the chart
to obtain minimum clearance (B) between
bearing and channel leg for full channel length.
Use same bearing on left and right side.

20. Lifting by crane, insert inner mast (11) into


intermediate mast (12) from the upper side.

Mast And Carriage Bearings


Part No.

Bearing Size

Bearing O.D.*

D580006

Undersize

98.5 mm (3.878 in)

D580007

Standard

99.0 mm (3.898 in)

D580008

Oversize

99.5 mm (3.917 in)

13

* Permissible tolerance L 0.08mm (.003in)

IBCD528P

21. Install 1 mm shim and bearing (13) of intermediate


upper basically.

Lift Trucks Mast System

18

Disassembly & Assembly

E. Upper Bearing Adjustment of


intermediate Mast

14

Follow same procedure with above B.


F. Upper Pad Adjustment of Intermediate
Mast
Follow same procedure with above C.
24. If the bearings were removed from the mast
mounting brackets, install new ones.

IBCD529P

25. Put a small amount of clean grease on mounting


bearing. Install mounting pins and screw into
mast mounting brackets.
Refer to Mast Mounting Group Adjustment of
Testing & Adjusting.

22. Install 1mm shim and bearing (14) of inner lower


basically.

15

IBCD526P

26. If the bearings were removed from the tilt


cylinder pin bores (15), install new ones.
IBCD505S
Mast Adjustment Lower Bearings
(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.

23. Make sure inner mast lower bearings are


properly shimmed in the intermediate mast by
rolling up and down and moving inner mast to
right and left. If clearance between both masts can
be detected, pull down the inner mast from the
bottom of intermediate mast. Inner lower bearings
can be easily extruded. Add shim 0.5 mm or 1 mm
to both inner lower bearings. If inner mast is stuck
and cannot move by rolling up and down, there
might be excessive shim. Pull out the inner mast
from the intermediate mast and remove shim 0.5
mm to both inner lower bearings. Repeat same
procedure of above until properly shimmed. There
is to be contact zero clearance (C) between inner
lower bearings and intermediate channel at
narrowest point.
Lift Trucks Mast System

16

IBCD527P

27. Install secondary cylinders (16) into the


stationary mast.

19

Disassembly & Assembly

25
17

IBCD524P

IBCD520P

31. Connect chains (25) at the bottom of the mast.

28. Install secondary cylinder mounting brackets (17)


over the secondary cylinders.

27

18

26

IBCD519P

32. Connect chains (26) at the chain bracket of


stationary mast upper.

29. Install top cylinder retainer bolts (18) for the


secondary cylinders.

33. Install sheave (27) of lift hose.

30. Install regulator (22) to secondary cylinder and


tube assy (23) and bolts (24) to stationary mast.

Lift Trucks Mast System

20

Disassembly & Assembly

28

IBCD518P

35. Install hoses (28) along with the hose support


clamps.
End by :
a. Install primary lift cylinder.
b. Install lift chain to be connected primary lift
cylinder.

Lift Trucks Mast System

21

Disassembly & Assembly

Testing & Adjusting

Mast And Carriage Bearings

Carriage Adjustment
NOTE: The standard, Full Free Lift and Full Free
Triple Lift carriage load bearings are all adjusted the
same way. The Full Free Triple Lift carriage is shown
in the following illustrations.

D580006

Undersize

98.5 mm (3.878 in)

D580007

Standard

99.0 mm (3.898 in)

D580008

Oversize

99.5 mm (3.917 in)

4. Shim bolt as needed to obtain a 4.0 to 6.0 mm


(.157 to .242 in) overlap (B) between bolt (3) and
the carriage stop on the inner upright.
(See Carriage Adjustment in Testing & Adjusting).

5(STD)

Bearing O.D.*

3. Equally shim both sides until contact (A) is made


(zero clearance) between bearings and inner mast
at narrowest point

Use the procedure that follows to adjust carriage


load bearings.

Bearing Size

* Permissible tolerance of L 0.08mm (.003in)

To make the carriage clearance adjustments,


carriage must be removed from the mast.

Part No.

5. Torque for screw.............34 L 7 NIm (25 L 5 lbIft)

6. Refer to Carriage Assembly of Disassembly &


Assembly.

C
B

5 (FF, FFT)

VIEW A-A
C

10

A
VIEW C-C

VIEW B-B

IBCD581I
Carriage Adjustment
(3) Upper Bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Side-roller Bearings. (8) Lower Bearings. (9) Pin-adjust.
(10) Bolt. (A) Zero Clearance.
(B) 4.0 to 6.0 mm. (.157 to .242 in) Clearance.
(C) Minimum Clearance. (D) 4.5 L 0.5 mm

1. Select lower bearings from the chart to obtain


minimum clearance (C) between bearings and
channel leg for full channel length. Use same
bearing in all two locations.
2. Select upper bearing from the chart to obtain
minimum clearance (C) between bearings and
channel leg for full channel length. Use same
bearing at all two locations. (For G20SC-2,
GC20SC-2, B20T, D20SC-2, and B20X, bearings
are same with upper, middle 4 locations.)

Lift Trucks Mast Systems

22

Testing & Adjusting

2. Make adjustments to chain anchor nuts (1) or


bolts (2) for equal tension of the mast and carriage
chains.

Chain Adjustments
Chain Adjustment Check

3. Put LOCTITE NO.242 Thread Lock on the threads


of the locknuts after the adjustment is completed.

IBCD505P
2

IBCD508P

Lift the carriage and mast high enough to put their


full weight on the carriage and mast chains. Check
the chains, and make sure the tension is the same.

Outer Lift Chains


(2) Chain Anchor Bolts.

Chain Adjustment

Chain Wear Test

If the tension is not the same on both chains, do the


procedure that follows:

Chain wear test is a measurement of wear of the


chain links and pins. Do the steps that follow to
check chain wear.

WARNING

1. Lift the mast and carriage enough to put tension


on the lift chains.

Personal injury can be caused by sudden


movement of the mast and carriage. Blocks must
be used to prevent the mast and carriage from any
movement while the adjustments are made. Keep
hands and feet clear of any parts that can move.

2. Measure precisely ten links of chain distance at


the center of pins in millimeter.
A chain wear gauge can also be used.
3. Calculate chain wear rate.
New one pitch = 15.88 mm
Chain wear rate (%)
Actual measurement - 158.8
=
158.8

x 100

WARNING
Do not put a lift truck into service if the chain wear
indication is 2% or more. A reading of 2% or more
could cause damage or injury to persons.

IBCD506P
Inner Lift Chains
(1) Chain Anchor Nuts.

4. If the chain wear indication is 2% or more, replace


the lift chain.
1. Lift the mast and carriage and put blocks under
the mast and carriage to release the tension from
the lift chains.

Lift Trucks Mast Systems

23

Testing & Adjusting

Carriage and Mast Height Adjustment

Forks Parallel Check

1. Move the mast either forward or backward so it is


in the vertical position.

1. Lift the mast and operate the tilt control lever, until
the top surface of the forks is parallel with the
floor. Place two straight bars, that are the same
width as the carriage, across the forks as shown.
Measure the distance from the bottom of each end
of the two bars to the floor. The forks must be
parallel within 3 mm (.12 in) for Full Tapered and
Polished (FTP) forks, all other forks 6.4 mm (.25
in), for their complete length.

2. Lower the carriage completely.

2. If not parallel, determine which one is defective


and replace it.

IDCS130S
Forks Parallel Check
(Typical Example)

IBCD585I

3. On Full Free Lift and Full Free Triple Lift models,


the bottom of the inner mast must be even with
the bottom of the stationary mast.
4. Measure the distance from the bottom of the inner
upright to the bottom of carriage bearing end.
5. The measurement (A) must be as follows:
<STD>
D,G15/18/20S(C)-2.......................22 mm(0.866 in)
B15/18S .........................................7 mm (0.276 in)
B16/18/20X, GC15/18/20S(C)-2,
B13/15/18/20T-2 ..........................- 6 mm(-0.236 in)
<FFL & FFTL>
D, G15/18/20S(C)-2......................36 mm (1.417in)
B15/18S .......................................21 mm (0.827 in)
GC15/18/20S(C)-2 .......................11 mm (0.433 in)
B16/18/20X, B13/15/18/20T-2
NOTE : If the above measurements are not correct,
make adjustments to the chains to get the correct
measurement. See Chain Adjustments in TESTING
AND ADJUSTING.

Lift Trucks Mast Systems

24

Testing & Adjusting

Tilt Cylinder Length Check

Tilt Cylinder Alignment


If the tilt cylinders are out of alignment, extra
stresses in the mast assembly and the mast hinge
area will result. To prevent damage, the tilt cylinders
must stop evenly at the end of the tilt back and tilt
forward strokes.
Tilt Angle Check

IDCD009P

1. Tilt the mast to full forward position. Measure the


extended length of the cylinder rods from the
cylinder housing to the mast. The difference of
length between the two cylinder rods must be
within 3.18 mm (.125 in) of each other.
IDCD008P
Tilt Angle Check (Typical Example)

Drift Test
The tilt angle of the mast must be checked in the full
tilt back and full tilt forward positions. A tilt indicator
or a protractor can be used to measure the angle.
Both sides of the mast must be checked to make
sure that the mast is not twisted.

Drift is movement of the mast or carriage that is the


result of hydraulic leakage in the cylinders or control
valve. Before testing the drift:

The tilt angle is determined by the tilt cylinders used.


See tilt cylinders in specifications to determine the tilt
angle from the cylinder being used.

WARNING
Personal injury can be caused by sudden movement
of the mast or carriage. Use wood blocks and
clamps to hold the mast in this position. Keep hands
and feet clear of any parts that can move.

1. Check the chain adjustment and tilt cylinder


alignment and make necessary adjustments.
2. Lift the mast approximately 762 mm (30 in). Use
wood blocks and clamps to hold the mast in this
position.
3. Check the mast hinge bolts to make sure they are
tight.
4. Remove the blocks and clamps and lower the
mast.

Lift Trucks Mast Systems

25

Testing & Adjusting

Drift Test For Lift System


1. Secure a rated capacity load on the forks of the lift
truck. Operate the lift truck through a complete lift
and tilt cycle until the oil is at normal temperature of
operation, 45 to 55 C (113 to 131 F).

2. Put the mast in a vertical position.


Raise a rated capacity load to a sufficient height to
test the lift cylinders.
3

3. Measure any drift of the carriage for a ten minute


period. Drift for all models shall not exceed 100.0
mm (4.00 in).

IBCD513P
Tilt Cylinder Adjustment
(1) Pivot eye. (2) Bolt. (3) Rod.

1. Loosen bolt (2) at pivot eye (1).

Tilt Cylinder Adjustment

2. Turn rod (3) into or out of pivot eye (1) to obtain


the correct length. The minimum length from the
end of rod to the rear face of eye is 16 mm.

WARNING
Tilt cylinder pivot eyes can loosen if the torque on
the pivot eye clamping bolt is not tight enough.
This will let the tilt cylinder rod turn in the tilt
cylinder eye. The cylinder rod may twist out of the
pivot eye and the tilt cylinder will be out of
alignment or may let the mast fall and cause
personal injury or damage. When the rod lengths
are made even, the tilt angle differences or the
mast alignment will no longer be a problem.

16mm

To correct the tilt angle or tilt cylinder length, an


adjustment must be made to the tilt cylinder as
follows :

EHCS046S

3. Tighten bolt (2) and the nut to a torque of 95 L 15


Nm (70 L 10 lbft).

Lift Trucks Mast Systems

26

Testing & Adjusting

(1) With chains adjusted for equal tension, run mast


to full lift. If mast does not kick (move) to one
side, no shims are needed. If mast does kick
(move) to one side, disconnect cylinder from the
bar on that side. Add shim, connect cylinder,
adjust chains and run mast to full lift to check for
kick. Repeat process if necessary. The total shim
pack must not be more than three shims
maximum.

Lift & Tilt Mounting Group


Adjustment

(2) Install bearing outer race to a depth of (F)


............................4.5 L 0.8 mm (.177 L .031 in).

(3) Tilt cylinder installation shown.


(4) (Full Free Lift Mast Only):
Tighten nuts until U-bolt is firm against cylinder,
do not apply standard torque.

3
VIEW A-A
B

B
2

(F)
VIEW B-B

IBCD508S

Lift Trucks Mast Systems

27

Testing & Adjusting

Mast mounting Group


Adjustment

1
IBCD502S

For B15/18/20T-2(36V)

IBCD509S

For D,G15/18/20S(C)-2, GC15/18/20S(C)-2

2
IBCD582I

For B16/18/20X, B13/15/18/20T-2(48V)

1
3

1. Tighten screw (1) that holds bearing (3) to hinge


bracket of stationary mast to a torque of 34 L7 NIm
(25 L 5 lbIft).

IBCD510S

2. Install roll pin (2) to a depth 2 ~ 3 mm (0.079 ~


0.118 in) from surface of bearing.

For B15/18S
3. Apply the crean grease to a surface of bearing.
4. Apply Loctite No242 to bolts and tighten with a
torque 180 L 20 NIm (130 L 15 lbIft).
Lift Trucks Mast Systems

28

Testing & Adjusting

SB2340E01

Operation &
Maintenance Manual
LIFT TRUCKS
B15T-5, B18T-5, B20T-5 (AC 36V, 48V)

WARNING
Do not start, operate or service this machine unless you have read and understood
these instructions and received proper training.
Unsafe or improper use of the machine may cause serious injury or death.
Operators and maintenance personnel must read this manual and receive training
before operating or maintaining the machine.
This manual should be kept with the machine for reference and periodically
reviewed by the machine operator and by all personnel who will come into contact
with it.

The following warning is provided pursuant to California Health & Safety Code Sections
25247.5 et, seq,

WARNING
California Proposition 65
Engine Exhaust, some of its constituents, and certain vehicle components contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
WASH HANDS AFTER HANDLING.

Table of Contents

Table of Contents
Information Section

Maintenance Section

Foreword ............................................................... 2

Inspection, Maintenance and Repair of Lift Truck


Forks ................................................................... 65
Tire Inflation Information...................................... 69
Torque Specifications .......................................... 70
Lubricant Specifications....................................... 72
Battery Discharge Indicator ................................. 74
Battery................................................................. 75
Cold Storage Applications.................................... 77
Lubricant Viscosities and Refill Capacities .......... 79
Maintenance Intervals ......................................... 80
When Required ................................................... 81
Every 10 Service Hours or Daily.......................... 89
First 50 - 100 Service Hours or a Week............... 95
First 250 Service Hours or a Month ..................... 96
Every 250 Service Hours or Monthly ................... 97
Every 500 Service Hours or 3 Months ............... 101
Every 1000 Service Hours or 6 Months ............. 106
Every 2000 Service Hours or Yearly ................... 111
Every 2500 Service Hours or 15 Months ............116

Safety Section
Important Safety Information.................................. 4
Safety .................................................................... 5
Warning Signs and Labels .............................. 5
General Hazard Information.......................... 10
Lift Chains..................................................... 11
Operation Information ................................... 11
Maintenance Information .............................. 13
Operator Restraint System (If Equipped) ...... 16
Avoiding Lift Truck Tipover............................ 20
Safety Rules ................................................. 22
How to Survive in a Tipover .......................... 27
G

General Section
Specifications....................................................... 28
Noise and Vibration.............................................. 31
Noise ................................................................... 31
Capacity Chart ..................................................... 32
Capacity Chart With Side Shifter....................... 33
Serial Number...................................................... 34
Serial Numbers Locations.................................... 34
Operators Warning and Identification Plate......... 35

Environment Section
Environment Protection ......................................117
G

Index Section
Index ..................................................................118

WORLDWIDE NETWORK

Operation Section
Operators Station and Monitoring Systems ......... 37
Lift Truck Controls ................................................ 45
Before Operating the Lift Truck ............................ 49
Lift Truck Operation.............................................. 52
Operating Techniques .......................................... 55
Parking the Lift Truck ........................................... 59
Lift Fork Adjustment ............................................. 61
Storage Information ............................................. 62
Transportation Hints............................................. 63
Towing Information............................................... 64

Information Section

Foreword

Safety

Literature Information

The Safety Section lists basic safety precautions. In


addition, this section identifies the text and locations
of warning signs and labels used on the lift truck.
Read and understand the basic precautions listed in
the Safety Section before operating or performing
lubrication, maintenance and repair on this lift truck.

This manual should be stored in the operator's


compartment in the literature holder or seat back
literature storage area.
This
manual
transportation,
information.

contains
lubrication

safety,
operation,
and
maintenance

Operator Restraint System (If Equipped)


This manual contains safety, operation and
maintenance information for the DAEWOO operator
restraint system. Read, study and keep it handy.

Some photographs or illustrations in this publication


show details or attachments that can be different
from your lift truck. Guards and covers might have
been removed for illustrative purposes.

WARNING
Your DAEWOO truck comes equipped with an
operator restraint system. Should it become
necessary to replace the seat for any reason, it
should only be replaced with another DAEWOO
operator restraint system.

Continuing improvement and advancement of


product design might have caused changes to your
lift truck which are not included in this publication.
Read, study and keep this manual with the lift truck.
Whenever a question arises regarding your lift truck,
or this publication, please consult your DAEWOO
dealer for the latest available information.

Photographs or illustrations guide the operator


through correct procedures of checking, operation
and maintenance of the DAEWOO operator restraint
system.
SAFE and EFFICIENT OPERATION of a lift truck
depends to a great extent on the skill and alertness
on the part of the operator. To develop this skill the
operator should read and understand the Safe
Driving Practices contained in this manual.
Forklift trucks seldom tipover, but in the rare event
they do, the operator may be pinned to the ground
by the lift truck or the overhead guard. This could
result in serious injury or death.
Operator training and safety awareness is an
effective way to prevent accidents, but accidents can
still happen. The DAEWOO operator restraint
system can minimize injuries. The DAEWOO
operator restraint system keeps the operator
substantially within the confines of the operator's
compartment and the overhead guard.
This manual contains information necessary for Safe
Operation. Before operating a lift truck make sure
that the necessary instructions are available and
understood.

Information Section

Operation

Environment Management

The Operation Section is a reference for the new


operator and a refresher for the experienced one.
This section includes a discussion of gauges,
switches, lift truck controls, attachment controls,
transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the lift truck.

Note that DAEWOO INDUSTRIAL VEHICLE


DIVISION is ISO 14001 certified which is
harmonized
with
ISO
9001.
Periodic
ENVIRONMENTAL AUDITS & ENVIRONMENTAL
PERFORMANCE EVALUATIONS have been made
by internal and external inspection entities.
LIFECYCLE ANALYSIS has also been made
through out the total product life.
ENVIRONMENT MANAGEMENT SYSTEM includes
DESIGN FOR ENVIRONMENT from the initial stage
of the design. ENVIRONMENT MANAGEMENT
SYSTEM considers environmental laws &
regulations, reduction or elimination of resource
consumption as well as environmental emission or
pollution from industrial activities, energy saving,
environment friendly product design(lower noise,
vibration, emission, smoke, heavy metal free, ozone
depleting substance free, etc.), recycling, material
cost reduction, and even environmentally oriented
education for the employee.

Operating techniques outlined in this publication are


basic. Skill and techniques develop as the operator
gains knowledge of the lift truck and its capabilities.

Maintenance
The Maintenance Section is a guide to equipment
care. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items without specific
intervals are listed under "When Required" topics.
Items in the "Maintenance Intervals" chart are
referenced to detailed instructions that follow.

Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at "Every 500 Service
Hours or 3 Months", also service those items listed
under "Every 250 Service Hours or Monthly" and
"Every 10 Service Hours or Daily".

Safety Section

Important Safety Information


Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards, and use common sense. Persons
must also have the necessary training, skills and tools before attempting to perform these functions.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING"
as shown below.

WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure, work method or operating technique not specifically recommended by DAEWOO
is used, you must be sure that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DAEWOO dealers have the most current
information available.

Safety Section

Safety

Warning Signs and Labels

The safety rules and regulations in this section are


representative of some, but not all rules and
regulations noted under the Occupational Safety
and Health Act (OSHA) and are paraphrased without
representation that the OSHA rules and regulations
have been reproduced verbatim.

There are several specific safety signs on your lift


truck. Their exact location and description of the
hazard are reviewed in this section. Please take the
time to familiarize yourself with these safety signs.
Make sure that you can read all warning and
instruction labels. Clean or replace these labels if
you cannot read the words or see the pictures.
When cleaning the labels use a cloth, water and
soap. Do not use solvent, gasoline, etc.

Please refer to 1910. 178 in Federal Register Vol. 37,


No. 202, the National Fire Protection Association No.
505 (NFPA), American National Standard, ANSI B56.
1 Safety Standard for Low lift and High Lift Trucks
and subsequent revisions for a complete list of
OSHA rules and regulations as to the safe operation
of powered industrial lift trucks. Since regulations
vary from country to country outside in U.S.A.,
operate this lift truck in accordance with local
regulations.

You must replace a label if it is damaged, missing or


cannot be read. If a label is on a part that is replaced,
make sure a new label is installed on the replaced
part. See your dealer for new labels.

Training Required To Operate or Service


Warning

DAEWOO lift trucks are manufactured according to


the regulations and standards laid down in EU
Machinery Directive 98/37/EC and EMC directive
89/336/EC. Please refer to the Directives 89/655/
EC and 89/391/EC and its amendments for the safe
use of DAEWOO lift trucks.
The most effective method of preventing serious
injury or death to the lift truck operator or others is
for the lift truck operator to be familiar with the
proper operation of the lift truck, to be alert and to
avoid actions or conditions which can result in an
accident.
Do not operate a lift truck if in need of repair,
defective or in any way unsafe. Report all defects
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and
authorized to do so.

Located on the right side of the steering wheel.

WARNING
Improper operation or maintenance could result
in injury or death. Do not operate or work on the
lift truck unless you are properly trained. Read
and understand the Operation and Maintenance
Manual. Additional manuals are available from
DAEWOO Lift Truck dealers.

This label also provides allowable lift truck capacity


information.

Safety Section

17. Parking-Lower lifting mechanism to floor. Put


directional control or shift lever in neutral. Set
parking/secondary brake. Turn "ON - OFF"
switch off. Chock wheels if machine is on incline.
Disconnect battery when storing electric
machines.

General Warnings to Operator


WARNING
Only trained and authorized personnel may
operate this machine. For safe operation, read
and follow the operation and maintenance
Manual furnished with this lift truck and observe
the following warnings :

18. Observe safety rules when handling fuel for


engine powered machine and when changing
batteries for electric machines.
19. The emergency switch uses in emergency really.
When you use often emergency switch by key
switch, you can cause fatal mistake to your
machine.

1. Before starting machine. Check all controls and


warning devices for proper operation.
2. Refer to machine identification plate for
allowable machine capacity. Do not overload.
Operate machines equipped with attachments
as partially loaded machines when not handling
a load.

20. If user operates continuously pushing work or


both brake pedal and accelerator pedal were
depressed at the same time, main electric parts
were able to damage.

3. Put directional control or shift lever in neutral


before "ON-OFF" switch is turned on.
4. Start, turn and brake smoothly. Slow down for
turns, slippery or uneven surfaces. Extremely
poor surfaces should be repaired. Avoid running
over loose objects or holes in the roadway
surfaces. Use extreme caution when turning on
inclines.
5. Travel with load as low as possible and tilted
back. If load interferes with visibility, travel with
load trailing.
6. On grade operations travel with load up grade.
7. Watch out for pedestrians and obstructions.
Check overhead clearances.
8. Do not permit riders on forks or machine at any
time.
9. Do not allow anyone to stand or pass under the
elevated portion of any machine.
10. Be sure operating surface can safely support
machine.
11. Operate machine and attachments only from
operator's position.
12. Do not handle unstable or loosely stacked loads.
13. Use minimum tilt when picking up or depositing
a load.
14. Use extreme care when handling long, high, or
wide loads.
15. Forks should be completely under load and
spread apart as far as load permits.
16. Machine should be
guard or equivalent
requires it, use load
extreme caution if
devices.

equipped with overhead


protection. Where load
backrest extension. Use
operating without these

Safety Section

Hand Placement Warning

Load Backrest Must Be In Place


Warning

WARNING
WARNING
Operation without this device in place may be
hazardous.
No hands. Do not place hands in this area. Do
not touch, lean on, or reach through the mast or
permit others to do so.

Located on the load backrest.


Located on the mast.

Overhead Guard Must Be In Place


Warning

No Standing On Forks Warning, No


Standing Under Forks Warning

WARNING

WARNING

Operation without this device in place may be


hazardous.
This
guard
conforms
to
A.N.S.I.B56.1 and F.E.M. Section IV. This design
has been tested with an impact of appropriate
value.

Do not stand or ride on the forks. Do not stand


or ride on a load or pallet on the forks. Do not
stand or walk under the forks.

IB9O004P

Located on the Overhead Guard.

Located on the lift cylinder.

Safety Section

No Riders Warning

Battery Restraint Warning

WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.

Located on front of battery cover.

WARNING
Before operating truck, ensure that hood is
securely locked by hood latch, and turn stopper
to locking position. Otherwise, a battery may
come out of a truck in case of tipover. It could
cause the risk of serious injury or death.
Located beside the operator's station.

Packing brake Warning


WARNING
When leaving machine apply parking brake!
Parking brake is not automatically applied.

Located on the top left side of the cowl.

Safety Section

Battery Disconnect Before Servicing


Warning
G

AC
WARNING
Disconect battery from truck and also discharge
high voltages from capacitor banks with a 150
ohm, 25 watt Resistor before attempting to
service this truck.(B+, B-)

Seat Switch Warning


WARNING
Install any seat to this seat frame. Switch must
shut off all power when operator is not seated.

Safety Section

Do not raise loads any higher than necessary and


never raise a load higher than 1830 mm (72 in) with
the overhead guard removed.

General Hazard Information

Always use load backrest extension when the


carriage or attachment does not fully support the
load. The load backrest extension is intended to
prevent the load or any part of the load from falling
backwards into the operator's station.
When operating the lift truck, do not depend only on
flashing lights or back-up alarm (if equipped) to
warn pedestrians.
Always be aware of pedestrians and do not
proceed until the pedestrians are aware of your
presence and intended actions and have moved
clear of the lift truck and/or load.

Attach a "Do Not Operate" or similar warning tag to


start switch or controls before servicing or repairing
the lift truck.

Do not drive lift truck up to anyone standing in front


of an object.

Do not start or service the lift truck when a "DO


NOT OPERATE" or similar warning tag is attached
to the start switch or controls.

Obey all traffic rules and warning signs.

Wear a hard hat, protective glasses and other


protective equipment as required by job conditions.

Keep hands, feet and head inside the operator


station. Do not hold onto the overhead guard while
operating the lift truck. Do not climb on any part of
the mast or overhead guard or permit others to do
so.

Know the width of your attachments so proper


clearance can be maintained when operating near
fences, boundary obstacles, etc.

Do not allow unauthorized personnel to ride on the


forks or any other part of the lift truck, at any time.

Do not wear loose clothing or jewelry that can catch


on controls or other parts of the lift truck.

When working in a building or dock, observe floor


load limits and overhead clearances.

Keep the lift truck, especially the deck and steps,


free of foreign material such as debris, oil tools and
other items which are not part of the lift truck.

Inhaling Freon gas through a lit cigarette or other


smoking method or inhaling fumes released from a
flame contacting Freon can cause bodily harm or
death. Do not smoke when servicing air
conditioners or wherever Freon gas may be present.

Secure all loose items such as lunch boxes, tools


and other items which are not part of the lift truck.
Know the appropriate work-site hand signals and
who gives them. Accept signals from one person
only.

Never put maintenance fluids into glass containers.


Use all cleaning solutions with care.

Always use the overhead guard. The overhead


guard is intended to protect the lift truck operator
from overhead obstructions and from falling objects.

Do not use steam, solvent, or high pressure to


clean electrical components.
Report all needed repairs.

A truck that is used for handing small objects or


uneven loads must be fitted with a load backrest.
If the lift truck must be operated without the
overhead guard in place due to low overhead
clearance, use extreme care. Make sure there is no
possibility of falling objects from any adjacent
storage or work area. Make sure the load is stable
and fully supported by the carriage and the load
backrest extension (if equipped).

10

Safety Section

Lift Chains

Operation Information
Mounting and Dismounting
Mount and dismount the lift truck carefully.
Clean your shoes and wipe your hands before
mounting.
Use both hands face the lift truck when mounting
and dismounting.
Use the handgrips for mounting and dismounting.
Do not try to climb on or off the lift truck when
carrying tools or supplies.

Inspect the part of the chain that is normally


operated over the crosshead roller. When the chain
bends over the roller, the movement of the parts
against each other causes wear.

Do not use any controls as handholds when


entering or leaving the operator's station.

Inspect to be sure that chain link pins do not extend


outside of the bore hole.

Never get on or off a moving lift truck. Never jump


off the lift truck.

If any single link pin is extended beyond its


connecting corresponding link, it should be
suspected of being broken inside of its bore hole.

Keep hands and steering wheel free of slippery


material.

Inspect the chain anchor and the anchor links for


wear.

Before Starting the Lift Truck


Perform a walk-around inspection daily and at the
start of each shift. Refer to the topic "Walk-around
Inspection" in "Every 10 Service Hours or Daily"
section of this manual.

Do not change any factory set adjustment values


(including engine rpm setting) unless you have both
authorization and training. Especially Safety
equipment and switches may not be removed or
adjusted incorrectly. Repairs, adjustments and
maintenances that are not correct can make a
dangerous operating condition.

Adjust the seat so that full brake pedal travel can be


obtained with the operator's back against the seat
back.

For any checkup, repair, adjustments, maintenance


and all other work concerning your forklift truck,
please contact your DAEWOO dealer. We would
like to draw your attention to the fact that any
secondary damages due to improper handling,
insufficient maintenance, wrong repairs or the use
of other than original DAEWOO spare parts waive
any liability by DAEWOO.

Make sure the lift truck is equipped with a lighting


system as required by conditions.
Make sure all hydraulic controls are in the HOLD
position.
Make sure the direction control lever is in the
NEUTRAL position.
Make sure the parking brake is engaged.
Make sure no one is standing and/or working on,
underneath or close to the lift truck before operating
the lift truck.
Operate the lift truck and controls only from the
operator's station.

Make sure the lift truck horn, lights, backup alarm (if

11

Safety Section

equipped) and all other devices are working


properly.

Operating the Lift Truck


Always keep the lift truck under control.

Check for proper operation of mast and


attachments. Pay particular attention to unusual
noises or erratic movement which might indicate a
problem.

Obey all traffic rules and warning signs.


Never leave the lift truck with the engine operating,
or with the parking brake disengaged.

Make sure service and parking brakes, steering,


and directional controls are operational.

Operate the engine only in a well ventilated area.

Make sure all personnel are clear of lift truck and


travel path.

Lower the mast, with or without load, before turning


or traveling. Tip over could result. Watch out for
overhead obstructions.

Refer to the topic "Lift Truck Operation" in the


"Operation Section" of this manual for specific
starting instructions.

Always observe floor load limits and overhead


clearance.
Start, turn, and brake smoothly. Slow down for turns,
grades, slippery or uneven surfaces.

Starting the Lift Truck

Use special care when operating on grades. Do not


angle across or turn on grades. Do not use a lift
truck on slippery grades. Travel with forks
downgrade when unloaded. Travel with load
upgrade.
Do not overload, or handle offset, unstable, or
loosely stacked loads. Refer to load capacity plate
on the lift truck. Use extreme caution when handling
suspended, long, high or wide load.
Tilt an elevated load forward only when directly
over unloading area and with load as low as
possible.

Do not start the engine or move any of the controls


if there is a "DO NOT OPERATE" or similar warning
tag attached to the start switch or controls.

Do not stunt ride or indulge in horseplay.


Always look and keep a clear view of the path of
travel.

Before Operating the Lift Truck


Test brakes, steering controls, horn and other
devices for proper operation. Report any faulty
performance. Do not operate lift truck until repaired.

Travel in reverse if load or attachment obstructs


visibility. Use extreme caution if visibility is
obstructed.

Learn how your lift truck operates. Know its safety


devices. Know how the attachments work. Before
moving the lift truck, look around. Start, turn and
brake smoothly.

Stay in designated travel path, clear of dock edges,


ditches, other dropoffs and surfaces which cannot safely support the
lift truck.

An operator must constantly observe his lift truck


for proper operation.

Slow down and use extra care through doorways,


intersections and other location where visibility is
reduced.
Slow down for cross aisles, turns, ramps, dips,
uneven or slippery surfaces and in congested areas
and avoid pedestrians, other vehicles, obstruction,
pot holes and other hazards or objects in the path
of travel.

12

Safety Section

Maintenance Information

Always use overhead guards except where


operation conditions do not permit. Do not operate
lift truck in high stacking areas without overhead
guards.

Perform all maintenance unless otherwise specified


as follows :

When stacking, watch for falling objects. Use load


backrest extension and overhead guard.

Park the lift truck in authorized areas only.

Park the lift truck level, with the forks lowered


and the mast tilted forward until the fork tips
touch the floor.

Place the controls lever in neutral.

Engage the parking brake.

Remove the start switch key and turn the


disconnect switch OFF (if equipped).

Block the drive wheels when parking on an


incline.

Refer to the topic "Operation Techniques" in the


"Operation Section" of this manual.

Loading or Unloading Trucks/Trailers


Do not operate lift trucks on trucks or trailers which
are not designed or intended for that purpose. Be
certain truck or trailer brakes are applied and wheel
chocks in place (or be certain unit is locked to the
loading dock) before entering onto trucks or trailers.
If trailer is not coupled to tractor, make sure the
trailer landing gear is properly secured in place. On
some trailers, extra supports may be needed to
prevent upending or corner dipping.

Pressure Air
Pressure air can cause personal injury. When using
pressure air for cleaning, wear a protective face
shield, protective clothing and protective shoes.

Be certain dock plates are in good condition and


properly placed and secured. Do not exceed the
rated capacity of dock boards or bridge plates.

The maximum air pressure must be below 205 kPa


(30 psi) for cleaning purposes.

Lift Truck Parking


When leaving the operator station, park the lift truck
in authorized areas only. Do not block traffic.
z

Park the lift truck level, with the forks lowered


and the mast tilted forward until the fork tips
touch the floor.

Move the direction control lever to NEUTRAL.

Engage the parking brake.

Turn the key switch off and remove the key.

Turn the disconnect switch to OFF (If equipped).

Block the drive wheels when parking on an


incline.

Fluid Penetration
Always use a board or cardboard when checking
for a leak. Escaping fluid under pressure, even a
pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid is
injected into your skin, it must be treated by a
doctor familiar with this type of injury immediately.

Crushing or Cutting Prevention


Support equipment and attachments properly when
working beneath them. Do not depend on hydraulic
cylinders to hold it up. Any attachment can fall if a
control is moved, or if a hydraulic line breaks.
Never attempt adjustments while the lift truck is
moving or the engine is running unless otherwise
specified.
Where there are attachment linkages, the clearance
in the linkage area will increase or decrease with
movement of the attachment.
Stay clear of all rotating and moving parts.

13

Safety Section

Keep objects away from moving fan blades. They


will throw or cut any object or tool that falls or is
pushed into them.

Burn Prevention

Do not use a kinked or frayed wire rope cable.


Wear gloves when handling the wire rope cable.

Hot oil and components can cause personal injury.


Do not allow hot oil or components to contact the
skin.
At operation temperature, the hydraulic tank is hot
and can be under pressure.

Oils

Retainer pins, when struck with force, can fly out


and injure nearby persons. Make sure the area is
clear of people when driving retainer pins.

Remove the hydraulic tank filter cap only after the


engine has been stopped and the filter cap is cool
enough to remove with your bare hand.

Wear protective glasses when striking a retainer pin


to avoid injury to your eyes.

Remove the hydraulic tank filter cap slowly to


relieve pressure.

Chips or other debris can fly off objects when struck.


Make sure no one can be injured by flying debris
before striking any object.

Falling Objects Protective Structure (FOPS)

Relieve all pressure in air, oil fuel or cooling


systems before any lines, fittings or related items
are disconnected or removed.

This is an attached guard located above the


operator's compartment and secured to the lift truck.

Batteries
Only trained and designated personnel should
inspect, recharge or exchange batteries.

To avoid possible weakening of the Falling Objects


Protective Structure (FOPS), consult a DAEWOO
dealer before altering, by adding weight to, welding
on, or cutting or drilling holes into the structure.

Always wear protective glasses when working with


batteries.

The overhead guard is not intended to protect


against every possible impact. The overhead guard
may not protect against some objects penetrating
into the operator's station from the sides or ends of
the lift truck.

Service, exchange and handle batteries only in


authorized areas when proper safety and ventilation
facilities are provided.
Do not smoke, or expose battery to sparks or flame
when checking, charging or servicing battery. Keep
chains and metallic tools away from top of battery.

The lift truck is equipped with an overhead guard


and FOPS as standard. If there is a possibility of
overhead objects falling through the guard, the
guard must be equipped with smaller holes or a
Plexiglas cover.

Betteries give off flammable fumes which can


explode.

Any altering done that is not specifically authorized


by DAEWOO invalidates Daewoos FOPS
certification. The protection offered by this FOPS
will be impaired if it has been subjected to structural
damage. Structural damage can be caused by an
overturn accident, by falling objects, etc.

Highly explosive gases are especially hazardous


toward the end of the charging period as the battery
approaches a full charge condition.

Do not mount any item such as fire extinguishers,


first aid kits and lights by welding brackets to or
drilling holes in any FOPS structure. See your
DAEWOO dealer for mounting guidelines.

Service batteries in accordance


manufacture instructions.

Electrolyte is an acid and can cause personal injury


if it contacts skin or eyes.
with battery

Refer to the topic "Batteries" in the "Maintenance


Section" of this manual.

14

Safety Section

Fire or Explosion Prevention

Outer covering chafed or cut and wire


reinforcing exposed.

All fuels, most lubricants and some coolant


mixtures are flammable.

Outer covering ballooning locally.

Evidence of kinking or crushing of the flexible


part of hose.

Armoring embedded in the outer cover.

End fittings displaced.

Do not smoke in areas where batteries are charged,


or where flammable materials are stored.
Clean and tighten all electrical connections. Check
daily for loose or frayed electrical wires. Have all
loose or frayed electrical wires tightened, repaired
or replaced before operating the lift truck.
Keep all fuels and lubricants stored in properly
marked containers and away from all unauthorized
persons.

Make sure that all clamps, guards and heat shields


are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat during
operation.

Store all oily rags or other flammable material in a


protective container, in a safe place.

Tire Information

Do not weld or flame cut on pipes or tubes that


contain flammable fluids. Clean them thoroughly
with nonflammable solvent before welding or flame
cutting on them.

Explosions of air-inflated tires have resulted from


heat-induced gas combustion inside the tires. The
heat, generated by welding or heating rim
components, external fire, or excessive use of
brakes can cause gaseous combustion.

Remove all flammable materials such as fuel, oil


and other debris before they accumulate on the lift
truck.

A tire explosion is much more violent than a


blowout. The explosion can propel the tire, rim and
axle components as far as 500 m (1500 ft) or more
from the lift truck. Both the force of the explosion
and the flying debris can cause personal injury or
death, and property damage.

Do not expose the lift truck to flames, burning brush,


etc., if at all possible.
Do not operate in areas where explosive gases
exist or are suspected.
Fire Extinguisher
Have a fire extinguisher-type BC and 1.5KG
minimum capacity-on rear overhead guard leg with
latch and know how to use it. Inspect and have it
serviced as recommended on its instruction plate.
Lines, Tubes and Hoses
Do not bend or strike high pressure lines. Do not
install bent or damaged lines, tubes or hoses.

Do not approach a warm tire closer than the outside


of the area represented by the shaded area in the
above drawing.

Repair any loose or damaged fuel and oil lines,


tubes and hoses. Leaks can cause fires. Contact
your DAEWOO dealer for repair or replacement.

Dry nitrogen (N2) gas is recommended for inflation


of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure.
Nitrogen mixes properly with air.

Check lines, tubes and hoses carefully. Do not use


your bare hand to check for leaks. Use a board or
cardboard to check for leaks. See Fluid Penetration
in the Safety Section for more details. Tighten all
connections to the recommended torque. Replace if
any of the following conditions are found.
z

Nitrogen inflated tires reduce the potential of a tire


explosion, because nitrogen does not support
combustion. Also, nitrogen helps prevent oxidation
and the resulting deterioration of rubber and

End fittings damaged or leaking.

15

Safety Section

corrosion of rim components.

Operator Restraint System (If


Equipped)

Proper nitrogen inflation equipment and training in


its use are necessary to avoid over inflation. A tire
blowout or rim failure can result from improper or
misused equipment.

Warning Signs and Labels


Your DAEWOO lift truck has the following tipover
warning decals.

Stand behind the tread and use a self-attaching


chuck when inflation a tire.

Make sure that you can read all safety signs. Clean
or replace these if you cannot read the words or
see the pictures. When cleaning the labels use a
cloth, water and soap. Do not use solvent, gasoline,
etc. You must replace a label if it is damaged,
missing or cannot be read. If a label is on a part
that is replaced, make sure a new label is installed
on the replaced part. See you DAEWOO Lift Truck
dealer for new labels.

Servicing, changing tires and rims can be


dangerous and should be done only by trained
personnel using proper tools and procedures. If
correct procedures are not followed while servicing
tires and rims, the assemblies could burst with
explosive force and cause serious personal injury
or death. Follow carefully the specific information
provided by your tire or rim servicing personnel or
dealer.

The most effective method of preventing serious


injury or death to yourself or others is to familiarize
yourself with the proper operation of the lift truck, to
be alert, and to avoid actions or conditions which
can result in an accident.

WARNING
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
could result.

16

Safety Section

WARNING
Do NOT place your hand or fingers under the
seat. Injury may occur as the seat suspension
mechanism moves up and down.

NOTICE
Before getting on the truck, adjust the level of the
suspension using the grip in the rear of the seat.
The "Survive in tipover" warning is located on the
overhead guard. It shows the proper use of the
operator restraint system.
Seat Adjustment

WARNING
When raising and lowering the seat backrest,
avoid placing hand or fingers in the hinge area
indicated by the circle. Injury may occur.

Move the lever, slide the seat to the desired


position, and release the lever.
Adjust the seat before operating the lift truck. After
adjusting, set the seat to make sure it is properly
locked. DO NOT adjust the seat while the truck is in
motion.

17

Safety Section

Seat Belt

If Optional Suspension Seat Equipped

The Operator Restraint System, Prevents the


operator from jumping from the operator's
compartment in the event of forward or side tipover.
The system is designed to keep the operator on the
seat and in the operator's compartment in the event
of tipover.
Inspection

1. If the seat belt is torn, if pulling motion is


interrupted during extension of the belt, or if the
belt cannot be inserted into the buckle properly,
replace the seat belt assembly.

2. Belt Maintenance Every 500 service hours.


Check that the belt fastening works properly
and that winding device is free from run lock
when jerked. Check that the belt is suitably
fastened to the seat. Check that the seat is
correctly secured to the hood and the chassis.
On visual inspection, fastenings must be intact,
otherwise, contact the safety manager.

WARNING
Your DAEWOO truck comes equipped with a
DAEWOO operator restraint system. Should it
become necessary to replace the seat for any
reason, it should only be replaced with another
DAEWOO operator restraint system.

18

Safety Section

WARNING
If you fasten the belt across your abdomen, the
belt may injure your abdomen in an accident.

3. In the event of tipover, the seat and restraint


system should be inspected for damage and
replaced, if necessary.
NOTE: Operator restraints shall be examined at
the regular truck service intervals. It is
recommended that they be replaced if any
of the following conditions are found:
z
z
z
z

3. Be sure to fasten the belt across your hips, not


across your abdomen.

Cut or frayed strap


Worn or damaged hardware including anchor
points
Buckle or retractor malfunction
Loosen stitching

NOTE: The belt is designed to automatically adjust


to your size and movement. A quick pull on
the belt will confirm that the automatic
adjuster will hold the belt position in the
event of an accident.

WARNING
Release the Seat Belt

The seat belt may cause the operator to bend at


the waist. If you are pregnant or have suffered
from some abdominal disease, consult a doctor
before you use the seat belt.

Fasten the Seat Belt

Push the button of the buckle to release the belt.


The belt will automatically retract when released.
Hold the plate of the belt and allow the belt to
slowly retract.

1. Grip the plate (connector) of the belt and pull


the belt from the retractor. Then insert the plate
into the slot of the buckle until a snap is heard.
Pull on the belt to confirm it is latched.
2. Make sure the belt is not twisted.
G

19

Safety Section

Stability and Center of Gravity

Avoiding Lift Truck Tipover


Lift Truck Stability

The stability of the lift truck is determined by the


location of its CG; or, if the truck is loaded, the
combined CG of the truck and load. The lift truck
has moving parts and, therefore, has a CG that
moves. The CG moves forward or backward as the
mast is tilted forward or backward. The CG moves
up or down as the mast moves up or down. The CG
and, therefore, the stability of the loaded lift truck,
are affected by a number of factors such as:
z
the size, weight, shape and position of the load

Counterbalanced lift truck design is based on the


balance of two weights on opposite sides of a
fulcrum (the front axle). The load on the forks must
be balanced by the weight of the lift truck.
The location of the center of gravity of both the
truck and the load is also a factor. This basic
principle is used for picking up a load. The ability of
the lift truck to handle a load is discussed in terms
of center of gravity and both forward and sideways
stability.

Center of Gravity (CG)

The point within an object, at which the whole


weight of the object may be regarded as being
concentrated, is called the center of gravity or CG. If
the object is uniform, its geometric center will
coincide with its CG. If it is not uniform, the CG
could be at a point outside of the object. When the
lift truck picks up a load, the truck and load have a
new combined CG.

the height to which the load is lifted

the amount of forward or backward tilt

tire pressure

dynamic forces created when the lift truck is


accelerated, braked or turned

condition and grade of surfaces on which the lift


truck is operated

These same factors are also important for unloaded


lift trucks. They tip over sideways easier than a
loaded lift truck carrying its load in the lowered
position.

20

Safety Section

standard lift truck with standard backrest, forks and


mast, and having no special-purpose attachment. In
addition, the capacity load assumes that the load
center is no further from the top of the forks than it
is from the face of the backrest. If these conditions
do not exist, the operator may have to reduce the
safe operating load because the truck stability may
be reduced. The lift truck should not be operated if
its capacity/nameplate does not indicate capacity
load.

Lift Truck Stability Base

NOTE: If the load is not uniform, the heaviest


portion should be placed closer to the
backrest and centered on the forks.
For the lift truck to be stable (not tip over forward or
to the side), the CG must stay within the area of the
lift truck stability base a triangular area between
the front wheels and the pivot of the steer wheels. If
the CG moves forward of the front axle, the lift truck
will tip forward. If the CG moves outside of the line
on either side of the stability base, the lift truck will
tip to the side.

NOTICE
1. Capacity/Nameplates originally attached to
forklifts sold by DAEWOO shall not be removed,
altered or replaced without Daewoos approval.
2. DAEWOO assumes no responsibility for lift
trucks placed in service without a valid
DAEWOO Nameplate.
3. If necessary to change your specification,
contact your DAEWOO lift truck dealer.

WARNING
Dynamic forces (braking, acceleration, turning)
also affect stability and can produce tipover
even when the CG is within the stability triangle.

Capacity Load (Weight and Load Center)

The capacity load of the lift truck is shown on the


capacity/nameplate riveted to the truck. It is
determined by the weight and load center. The load
center is determined by the location of the CG of
the load.
The load center shown on the nameplate is the
horizontal distance from the front face of the forks,
or the load face of an attachment, to the CG of the
load. The location of the CG in the vertical direction
is the same as the horizontal dimension.
Remember that, unless otherwise indicated, the
capacity load shown on the nameplate is for a

21

Safety Section

Safety Rules

Do not operate a lift truck unless you are in the


operator's seat.
Keep arms, legs and head inside the confines of
the operator's area. Keep hands and feet out of the
mast assembly.

Only properly trained and authorized personnel


should operate forklift trucks. Wear a hard hat and
safety shoes when operating a lift truck. Do not
wear loose clothing.

Inspect and check the condition of your forklift truck


using the operator's check list before starting work.
Immediately report to your supervisor any obvious
defects or required repairs.

Do not start, stop, turn or change direction suddenly


or at high speed. Sudden movement can cause the
lift truck to tip over. Slow the speed of your truck
and use the horn near corners, exits, entrances,
and near people.

Do not operate your truck in unauthorized areas.


Know your forklift truck and think safety.
Do not compromise safety.
Follow all safety rules and read all warning signs.

Never operate a lift truck with wet hands or shoes.


Never hold any controls with grease on your hands.
Your hands or feet will slide off of the controls and
cause an accident.

22

Safety Section

Do not raise anyone on the forks of your lift truck


unless using an approved safety cage. Do not let
other people ride on the truck. Lift trucks are
designed to carry loads, not people.

Do not overload. Always handle loads within the


rated capacity shown on the capacity plate.
Do not add extra counterweight to the truck. An
overload can cause the truck to roll over and cause
injury to personnel and damage to the lift truck.

Do not operate your truck without the load backrest


extension and overhead guard. Keep the load
against the backrest with the mast tilted backward.

Do not drive on soft ground.


Observe all signs, especially those on maximum
permitted floor loadings, elevator capacities and
clearance heights.
Handle loads carefully and check them closely for
stability and balance.

Do not lift or move loads that are not safe. Do not


pick up an off center load. Such a load increases
the possibility of a tipover to the side. Make sure
loads are correctly stacked and positioned across
both forks. Always use the proper size pallet.
Position the forks as wide as possible under the
load. Position loads evenly on the forks for proper
balance. Do not lift a load with one fork.

Do not drive on slippery surfaces.


Sand, gravel, ice or mud can cause a tipover.
If unavoidable, slow down.

23

Safety Section

Do not permit anyone to stand or walk under the


load or lifting mechanism. The load can fall and
cause injury or death to anyone standing below.

Do not elevate the load with the mast tilted forward.


Do not tilt the elevated loads forwards.
This will cause the lift truck to tip over forward.

Look out for overhead obstructions when raising or


stacking loads. Do not travel with a raised load. Do
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.

Do not jump off if your truck starts to tip over.


Stay in your seat to survive.

Go up ramps in forward direction and down ramps


in reverse direction when moving loads.
Never elevate a load with the forklift truck on an
incline.
Go straight off and straight down. Use an assistant
when going up or down a ramp with a bulky load.

Do not move loose loads that are higher than the


load backrest.
Be alert for falling loads when stacking.
Travel with the load tilted back and the forks as low
as possible.
This will increase stability to the truck and load and
permit better visibility for you.

24

Safety Section

Do not stack or turn on ramps.


Do not attempt to pick-up or deposit a load unless
the lift truck is level. Do not turn on or drive across
an incline.

Do not drive in forward direction when loads restrict


your visibility. Operate your lift truck in reverse to
improve visibility except when moving up a ramp.

Be careful when operating a lift truck near the edge


of a loading dock or ramp. Maintain a safe distance
from the edge of docks, ramps and platforms.
Always watch tail swing.
The truck can fall over the edge and cause injury or
death.

Do not go over rough terrain. If unavoidable, slow


down.
Cross railroad tracks slowly and diagonally
whenever possible. A railroad crossing can give a
loaded forklift truck a real jolt. For smoother
crossing, cross the railroad diagonally so one wheel
crosses at a time.

Do not operate on bridge plates unless they can


support the weight of the truck and load. Make sure
that they are correctly positioned. Put blocks on the
vehicle you enter to keep it from moving.

Avoid running over loose objects. Look in the


direction of travel. Look out for other persons or
obstructions in your path of travel. An operator must
be in full control of his lift truck at all times.

25

Safety Section

Do not operate your truck close to another truck.


Always keep a safe distance from other trucks and
make sure there is enough distance to stop safely.
Never overtake other vehicles.

Park your lift truck in authorized areas only. Fully


lower the forks to the floor, put direction lever in
NEUTRAL position, engage the parking brake, and
turn the key to the OFF position. Remove the key
and put blocks behind the wheels to prevent the
truck from rolling. Shut off your forklift truck when
leaving it unattended.
Check the condition of your forklift truck after the
day's work.

Do not use your lift truck to push or tow another


truck.
Do not let another push or tow your truck.
If a truck will not move, call a service technician.

Forklift trucks may only be refueled at specially


reserved locations. Switch off the engine when
refueling.
Smoking and handling of naked flames during
refueling are strictly prohibited. This prohibition also
applies during the changing of the LPG (liquefied
propane gas) tank.
Mop up spilt fuel and do not forget to close the fuel
tank before restarting the engine.

26

Safety Section

How to Survive in a Tipover


(If Operator Restraint System
Equipped)
WARNING
In the event of a tipover, the risk of serious
injury or death will be reduced if the operator is
using the operator restraint system and follows
the instructions provided.
Brace your feet and keep them within the operator's
compartment.

Always use operator restraint system.


Lean away from the direction of fall.

Dont jump.
Lean forward.

Hold on tight.

27

General Section

Specifications
G
1
2
3
4
5
6
7
8
G
9
10
12
13
14
15
16
17
18
19
20
21
22
23
23a
G

CHARACTERISTICS
G
G
G
G
G
at rated load center
G
distance
G
eletric,diesel,gas,Lp-gas
G
stand-on, rider seated
G
P=pneumatic,E=elastic,C=cushion
number of front/rear
DIMENSIONS
maximum fork height with rated
Lift with STD
load
two-stage mast
free lift
Fork carriage
ISO Class
G
thickiness X width X length
Fork
Spacing (Min. X Max.)
G
Tilt of mast
foreward/backward
G
G
length to fork face
G
G
width
G
Overall
mast lowered height
G
dimensions
mast extended height
G
G
overhead guard height
G
G
seat height to SR (daewon sus.)
Outside turning radius
G
Load moment constant (from front wheel to fork face)
Aisle width with pallets 1000X1200 crosswise,
w/clearance
Aisle width with pallets 800X1200 lengthwise,
w/clearance
G
PERFORMANCE
G

24

25

Speeds

lift,loaded/unloaded

26

lowering,loaded/unloaded

30
G
32
33
34
G
35
36
37
38
39
40
41
42
43
G

Max. gradeability loaded/unloaded, @1.6 km/h


G
WEIGHT
Total weight (with minimum weight of battery)
Axle load
with load : front/rear
G
without load : front/rear
G
CHASSIS
G
number of front/rear
Tires
size, front
G
size, rear
Wheelbase
G
Tread
front/rear
Ground
loaded,at mast lowest point
clearance
loaded,at center of wheel base
Brake
Service brake
Parking brake
Parking brake
G
DRIVE
Volt/Capacity-Max.
Battery
Weight (Minimun)
Drive motor (1 HR Rating)
Electric Motors
Hydraulic motor (20% Duty)
Control type
G
Axle
Brake type
Lift
System pressure
Attachment

45
47
54
55
57

G
Manufacturer
Model
Capacity
Load center
Power type
Operator type
Tire
Wheels(x=driven)
G

travel,loaded/unloaded

G
G
G
G
G
G
G
G
G

G
G
G
G
G
G
G
G
G
G

28

G
G
G
lb(kg)
in(mm)
G
G
G
G
G

DAEWOO
B15T-5
3000(1500)
24(500)
electric
rider seated
E,C
2x/2
G

DAEWOO
B18T-5
3500(1750)
24(500)
electric
rider seated
E,C
2x/2
G

mm

3000

3000

mm
G
mm
mm
deg
mm
mm
mm
mm
mm
mm
mm
mm

130
II
35x100x1050
240x905
5/7
1868
1090
2000
4045
2120
919
1492
376

130
II
35x100x1050
240x905
5/7
2001
1090
2000
4045
2120
919
1625
376

36V AC

mm

3194

3327

mm

3318

3451

G
Mph
(km/h)
Fpm
(mm/s)
Fpm
(mm/s)
%
lb(kg)
lb(kg)
lb(kg)

8.7/8.7(14.0/14.0)

8.7/8.7(14.0/14.0)

61/108(310/550)

61/108(310/550)

98/89(500/450)

98/89(500/450)

24/
G G
7024(3186)

23/
G
7297(3310)

9021/1310(4092/594)
3450/3574(1565/1621)

9844/1312(4465/595)
3596/3702(1631/1679)

G G
G
G
G
mm
mm
mm
mm
G
G
G
V/AH
kg
hp(kw)
hp(kw)
Type
Type
psi(kpa)
psi(kpa)

2/2
18X7X12.12
15X6X11.25
1264
902/198
86
100
foot/hyd
hand/mech
G
36/880
700
6.7(5.0)X2
16.1(12.0)
TR Inverter
ODB
2880(19800)
2025(14000)

G
2/2
18X7X12.12
15X6X11.25
1397
902/198
86
100
foot/hyd
hand/mech
G
36/1100
800
6.7(5.0)X2
16.1(12.0)
TR Inverter
ODB
2880(19800)
2025(14000)

General Section

DAEWOO
B20T-5
4000(2000)
24(500)
electric
rider seated
E,C
2x/2

DAEWOO
B15T-5
(1500)
(500)
electric
rider seated
E,C
2x/2

48V AC
DAEWOO
B18T-5
(1750)
(500)
electric
rider seated
E,C
2x/2

DAEWOO
B20T-5
(2000)
(500)
electric
rider seated
E,C
2x/2

1
2
3
4
5
6
7
8

3000
135
II
40x100x1050
240x905
5/7
2006
1090
2000
4050
2120
919
1625
381
3332
3456

3300
130
II
35x100x900
240x905
5/7
1868
1090
2150
4345
1985
919
1492
376
3194
3318

3300
130
II
35x100x900
240x905
5/7
2001
1090
2150
4345
1985
919
1625
376
3327
3451

3300
135
II
40x100x900
240x905
5/7
2006
1119
2150
4350
1985
919
1625
381
3332
3456

9
10
12
14
15
16
17
18
19
20
21
22
23
23a

8.7/8.7(14.0/14.0)
61/108(310/550)
98/89(500/450)
22/

(17.0/17.0)
(400/600)
(500/450)
26/

(17.0/17.0)
(400/600)
(500/450)
25/

(17.0/17.0)
(400/600)
(500/450)
24/

24
25
26
30

8084(3667)
11027/1466(5002/665)
3869/4215(1755/1912)

(3111)
(4054/557)
(1526/1585)

(3236)
(4427/559)
(1592/1644)

(3598)
(4969/629)
(1722/1876)

32
33
34

2/2
18X7X12.12
15X6X11.25
1397
902/198
86
100
foot/hyd
hand/mech

2/2
18x7-8
15x4.5-8
1264
902/167
86
100
foot/hyd
hand/mech

2/2
18x7-8
15x4.5-8
1397
902/167
86
100
foot/hyd
hand/mech

2/2
200x50-10
16x6-8
1397
912/201
86
100
foot/hydaulic
hand/mech

35
36
37
38
39
40
41
42
43

36/1100
1050
6.7(5.0)X2
16.1(12.0)
TR Inverter
ODB
3125(21550)
2025(14000)

48/550
700
(5.0x2)
(12)
TR Inverter
ODB
(19800)
(14000)

48/770
800
(5.0x2)
(12)
TR Inverter
ODB
(19800)
(14000)

48/770
1050
(5.0x2)
(12)
TR Inverter
ODB
(21550)
(14000)

29

13

45
47
54
55
57

General Section

30

General Section

Noise and Vibration


Noise
unit:dB(A)
Noise Level [ Unit : dB(A) ]
Model

Sound Pressure Level at Operator's Ear (Leq.)


prEN 12053

B15T-5
B18T-5
B20T-5

70

* Test Model : B20T-5

31

General Section

Capacity Chart
SOLID SOFTER TIRE

MODEL

STD, FFL

B15T-5 (48V)

kg

1600
1400
1200
1000
800
600
400

kg

A B

C
D E

1600
1400
1200
1000
800
600
400

A B C

D E
F

500 600 700 800 900 1000 1100 1200

500 600 700 800 900 1000 1100 1200

mm
A. 2000 ~ 4000 mm MAST
B. 4500 mm MAST
C. 5000 mm MAST
D. 5500 mm MAST

kg

B18T-5 (48V)

FFT

1800
1600
1400
1200
1000
800
600
400

mm
A. 3700 ~ 4000 mm MAST
B. 4500 mm MAST
C. 4800 mm MAST
D. 5000 mm MAST

E. 6000 mm MAST

kg

A B C

D
E
F

1800
1600
1400
1200
1000
800
600
400

E. 5500 mm MAST
F. 6000 mm MAST

A B

C D
E

500 600 700 800 900 1000 1100 1200

500 600 700 800 900 1000 1100 1200

mm
A. 2000 ~ 3700 mm MAST
B. 4000 mm MAST
C. 4500 mm MAST
D. 5000 mm MAST

mm

E. 5500 mm MAST
F. 6000 mm MAST

A. 3700 ~ 4000 mm MAST


B. 4500 mm MAST
C. 4800 ~ 5000 mm MAST
D. 5500 mm MAST

E. 6000 mm MAST

ID5O0004

B20T-5 (48V)

kg 2000

kg 2000

1800
1600
1400
1200
1000
800

1800
1600
1400
1200
1000
800
500 600 700 800 900 1000 1100 1200

A
B

C
D

E
F

500 600 700 800 900 1000 1100 1200

mm

mm
A. 4000 mm MAST
B. 4500 mm MAST
C. 4750 mm MAST
D. 5000 mm MAST

A. 2700 ~ 4000 mm MAST


B. 4500 mm MAST

E. 5500 mm MAST
F. 6000 mm MAST

ID5O0007

32

General Section

Capacity Chart With Side Shifter


SOLID SOFTER TIRE

MODEL

STD, FFL

kg 1600

B15T-5 (48V)

1400
1200
1000
800
600
400

1400
1200
1000
800
600
400

D
E
F

A B C

D
F

500 600 700 800 900 1000 1100 1200

500 600 700 800 900 1000 1100 1200

mm

kg

B18T-5 (48V)

kg 1600

A B C

A. 2000 ~ 3300 mm MAST


B. 3500 ~ 4000 mm MAST
C. 4500 mm MAST
D. 5000 mm MAST

1800
1600
1400
1200
1000
800
600
400

mm
A. 3700 ~ 4000 mm MAST
B. 4500 mm MAST
C. 4800 mm MAST
D. 5000 mm MAST

E. 5500 mm MAST
F. 6000 mm MAST

kg

A B C
D

E
F
G

1800
1600
1400
1200
1000
800
600
400

E. 5500 mm MAST
F. 6000 mm MAST

A B C

E
F

500 600 700 800 900 1000 1100 1200

500 600 700 800 900 1000 1100 1200

mm
A. 2000 ~ 3300 mm MAST
B. 3500 ~ 3700 mm MAST
C. 4000 mm MAST
D. 4500 mm MAS

kg 2000

B20T-5 (48V)

FFT

mm

E. 5000 mm MAST
F. 5500 mm MAST
G. 6000 mm MAST

A. 3700 ~ 4000 mm MAST


B. 4500 mm MAST
C. 4800 mm MAST
D. 5000 mm MAST

kg 2000

1800
1600
1400
1200
1000
800

1800
1600
1400
1200
1000
800
500 600 700 800 900 1000 1100 1200

A
B

E. 5500 mm MAST
F. 6000 mm MAST
ID5O0006

C
D

E
F

500 600 700 800 900 1000 1100 1200

mm

mm
A. 4000 mm MAST
B. 4500 mm MAST
C. 4750 mm MAST
D. 5000 mm MAST

A. 2700 ~ 4000 mm MAST


B. 4500 mm MAST

E. 5500 mm MAST
F. 6000 mm MAST

ID5O0007

33

General Section

Serial Number
Serial Numbers Locations
Both the lift truck and its motors have serial
numbers. You can record them in this manual for
quick reference.
Use the spaces provided below the illustrations.

Lift Truck Serial Number


z

34

General Section

Operators Warning and Identification Plate


Familiarize yourself with the information on the ldentification, Lift Capacity and Attachment Plates. Do not
exceed allowable lift truck working capacity load ratings.

Operators Warning Plate

Identification, Lift Capacity and


Attachment Plate

G
G
G
G
G
G
G
G
G
G
G
G
G
Located on the right side of the operators seat on
the battery cover.

Lift Truck Capacity Rating


DO NOT exceed allowable lift truck working
capacity load ratings.
The capacity of the lift truck is given by weight and
distance to the load center. For example: a capacity
of 1200kg(2540 lb) at 600mm (24in) means that the
lift truck can lift 1200kg (2640lb) if the load center is
600 mm (24in) from both the vertical and horizontal
faces of the forks.
Before attempting to lift any load, ensure that the
weight and load center combination is within the
capacity of the lift truck as shown on the capacity
rating plate. To determine the load center, measure
the distance from the face of the carriage to the
gravitational center of the load.
The rated capacity on the plate refers to the
capacity of the lift truck as it left the factory.
Subsequent changes of any form to the equipment
or battery can alter the lift trucks rating.
The rated capacity of the lift truck applies to
operating conditions where the lift truck is on level
ground. The capacity of the lift truck is reduced on
inclines.
Below are abbreviations that may appear on the
Identification, Lift Capacity and Attachment Plate
and their meanings.

35

General Section

Mast Abbreviations

TH

- Tire Handler.

The identification plate indicates the type of mast


installed on the lift truck when it left the factory. The
type of mast is indicated by an abbreviation.

CTH

- Container Top Handler.

CSH

- Container Side Handler

STD

- Standard Mast(single inner member, low


free lift).

LP

- Load Push Device, Non Sideshift.

LPP

- Load Push-Pull Device, Non Sideshift.

FF

- Full Free Lift Mast (single inner member,


with high free duplex or multiple cylinder).

- General Clamp (other than Bale, Carton


or Roll).

- Triple Lift Mast (two inner members) with


either low or full free lift.

BC

- Bale Clamp.

CC

- Carton Clamp.

RC

- Roll Clamp.

LS

- Load Stabilizer.

LH

- Log Handler.

PWH

- Pulp Wood Handler.

SS-ST

- Sideshift-Side Tilt Carriage.

FFT

QUAD

- Quadruple (Quad) Mast (three inner


members).

SPEC

- Special Mast, such as non-telescopic or


double mast, not within the other
classifications.

NOTE: When only a mast-type is listed on the


identification plate, a standard carriage and
forks are used.

Attachment Abbreviations (Includes


Special Forks)
SC

- Special Carriage-increased width, height


or outreach.

SSS

- Shaft-type Sideshift Carriage.

HSS

- Hook-type Sideshift Carriage(ITA).

ISS

- Integral Sideshift Carriage(ITA).

CW

- Special Counterweight.

SF

- Special Forks.

NOTE: Numbers following this abbreviation indicate


number and/or length of forks.
SS-SWS - Sideshift-Swing Shift.
RAM

- Ram or Boom

ROTC

- Rotating Carriage.

DBCBH - Double Cube Block Handler


HFP

- Hydraulic Fork Positioner, Non Sideshift.

CR

- Crane Arm or Crane Boom.

36

Operation Section

Operators Station and Monitoring Systems


Read and understand the Safety, Operation and Maintenance sections before operating the lift truck.

Key Switch

Seat Switch

The key switch is located on the right side of the


steering column.

The seat switch is located under the operators seat.


OPEN - When the operators seat is in
the up position the electrical circuits are
disconnected.

OFF - Turn the key switch to OFF (1) to


disconnect the electrical circuits.
ON - Turn the key switch the ON (2) to
con nect the electrical circuits. If the key
switch is left in the ON position when the
operator leaves the lift truck, the LCD display will
show a flashing EE.

CLOSE - When the operators seat is in


the down position(operator seated) the
electrical circuits are connected.
The power steering pump motor is activated when
the key switch is turned to ON and the seat switch
is closed.

The power steering pump motor is activated when


the key switch is turned to ON and the seat switch
is closed.
NOTE: The power steering pump motor will shut off
if the directional lever is left in NEUTRAL
and no control levers are actuated for
approximately six seconds. The motor will
be turned on when any control lever is used.

37

Operation Section

Monitoring Systems Indicator

Display Segments

Type1

The display gives the following information about the


operating state of the system:

Lift truck speed (expressed in kmh or


mph)

Handbrake active, indicated by the


warning symbol
Safety contact open, indicated both by
EE blinking message visualized in
timemeter area and by relative symbol
Type2

With any directional switch active and safety


contact still open, lift truck cant be moved, even
after seat switch is closed; in such a case, after
safety contact is closed, the symbol disappears.
EE code disappears only after active directional
switch is turned off.
Time meter or, otherwise, milometer
Steering angle
Maintenance time expiry, indicated by
warning symbol

Located on the middle of the console cover panel.


The symbols shown on the instrument panel
identify different features of the lift truck. The
symbol for each feature is identified and an
explanation of the function and location is described
on the following page.

Slow speed operation, indicated by

Low oil level of the brakes.

(Type1)

Lift truck speed level, range from 0


(NO speed) to 9 (MAXIMUM speed)
segment, as in symbol

(Type2)

Battery level, indicated


segments symbol.

by

(Type1)

(Type2)

In following Table 1, you can read the generic


relation between battery charge level and number

38

Operation Section

of visualized bars . See Table 2 in case of an36V


system and Table 3 in case of a 48V system.
Display signals with alarm code EL the fact battery
is completely discharged .

For type2
The display gives the following contraction on the dot
matrix display about the operating state of the system.
See table 4

Relation between battery charge level and


number of visualized bars

Table 4 : Contraction for dot matrix display.


Alarm Code

DISPLAY INDICATION
No segments
1 flashing segment
1 segment
2 segments
3 segments
4 segments
5 segments
6 segments
7 segments
8 segments
9 segments

Display
Code

BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery

BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery

17

Main breaker fault

60

Battery/inverter
mismatch

BATT MISMATCH

76

Pump motor Encoder

78
79
80

BATTERY VOLTAGE
[V]
Voltage < 34.5 V
34.5 V 35.1 V
35.1 V 35.5 V
35.5 V 35.9 V
35.9 V 36.2 V
36.2 V 36.5 V
36.5 V 36.8 V
36.8 V 37.1 V
37.1 V 37.4 V
37.4 V 37.6 V
Voltage > 37.6 V

81
82
83
84
A
A

A
A

Table 2 : Case of an 36V system

BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery

BATTERY VOLTAGE
[V]
Voltage < 45.6 V
45.6 V 46.4 V
46.4 V 47 V
47 V 47.6 V
47.6 V 48.2 V
48.2 V 48.7 V
48.7 V 49.2 V
49.2 V 49.7 V
49.7 V 50.1 V
50.1 V 50.4 V
Voltage > 50.4 V

E1
E2
E3
E4
E5
E6
EE
EE
(FLASI
NG)

Table 3: Case of a 48V system

39

Contraction
CONTACTOR
FAULT

77

Table 1 : Case of a generic system

Description

P-MOTOR
ENCODER
R-M TEMP
SENSOR
L-M TEMP
SENSOR
P-M TEMP
SENSOR

Wrong right traction


motor thermal switch
Wrong left traction
motor thermal switch
Wrong pump motor
thermal probe
Wrong right traction
module thermal
probe
Wrong left traction
module thermal
probe
Wrong pump module
thermal probe
CRC fault
Bank CRC restored
Capacitors not
charged : fast charge
Trans.precharge in
short/Cap. too
charged
Capacitors not
charged : slow
charge
Capacitors not
charged : time out
Capacitors not
charged
Drive right module
Overtemperature
Drive left module
Overtemperature
Pump module
Overtemperature
Drive right motor
Overtemperature
Drive left motor
Overtemperature
Pump motor
Overtemperature
Wrong start

TIME OUT
CHARGE
CAP NOT
CHARGED
R-INV
OVERTEMP
L-INV
OVERTEMP
P-INV
OVERTEMP
R-MOTOR
OVERTEMP
L-MOTOR
OVERTEMP
P-MOTOR
OVERTEMP
WRONG START

Seat switch

SEAT SW OPEN

R-INV T SENSOR

L-INV T SENSOR
P-INV T SENSOR
CRC FAULT
CRC RESTORED
FAST CHARGE
TOO CHARGED
CAP SLOW
CHARGE

Operation Section

EL
F
F
F
F0
F1
F2
F3
F4
F5
F6
F7
F8

Low battery voltage


Eeprom
WD Timer/Enable
micro signals
Serial communication
Maximum battery
voltage
Minimum battery
voltage
Pedal trimmer fault
Drive right module
Desat/overcurrent
Drive left module
Desat/overcurrent
Pump module
Desat/overcurrent
Drive right motor
current Offset
Drive left motor
current Offset
Pump motor current
Offset

F9

Steer sensor fault

FA

5V encoders not ok
Drive right motor
Encoder
Drive left motor
Encoder
24V out
12V out not ok
Pump input on at the
start

Fc
Fd
FE
FH
FL

expressed in per cent of high energetic mode;


changing active limitation (among L1, L2 or L3),
related per cent data are used to calculate actual
parameters value.

LOW BATT VOLT


EEPROM FAULT
WD TIMER
FAULT
COMM FAULT

NOTE: Percent values can be modified only with


EYE Calibration E-S-H menu.

MAX BATT VOLT


MIN BATT VOLT

NOTE: Pressing PROGRAMMABLE WORKING


you can manage economic, standard or
high operating mode too.

ACCEL FAULT
R-INVERTER
FAULT
L-INVERTER
FAULT
P-INVERTER
FAULT
R-MOTOR I
OFFSET
L-MOTOR I
OFFSET
P-MOTOR I
OFFSET
STEER SENSOR
OUT
5V NOT OK
R-MOTOR
ENCODER
L-MOTOR
ENCODER
24V NOT OK
12V NOT OK

COMPACT display shows different symbols in


function of selected energetic mode:
- E-S-H management disabled: no symbol
visualised.
- E-S-H management enabled: active
mode is indicated by symbol
(Type1)

(Type2)

- PROGRAMMABLE WORKING management


enabled: in case you have chosen one of L1, L2
or L3 operating modes, and lift truck is stopped,
one of the segments of speed indicator symbol
(see Table 5 ) blinks to show selected energetic
mode

PUMP SIGN ON

DISPLAY
VISUALISATION
(from symbol left side)
1st segment
5th segment
9th segment

Lift truck operation mode

(Type1)

Pressing E-S-H button, you can set


energetic operating mode for your
system.

OPERATINGMODE
L1 (Limit 1)
L2 (Limit 2)
L3 (Limit 3)

Table 5 : selected energetic mode


Otherwise symbol indicates, as usual,
selected operating mode.

(Type2)

This function is enabled using EYE menu named


Calibration ESH, to select desired operating
mode. In particular you can choose between E-S-H
or PROGRAMMABLE WORKING :

(Type1)

(Type2)

- Pressing E-S-H (economic, standard, high) button,


you change energetic mode and update related
parameters with a value, corresponding to
selected operating mode, that operator cant
modify.
- Pressing PROGRAMMABLE WORKING you can
manage 3 further options (limit 1, limit 2, and limit
3). You can set parameters value, that are

NOTE: as usual, if lift truck is moving,


symbol indicates speed level.
(Type1)

(Type2)

40

Operation Section

NOTE: if active mode is one of L1, L2 or L3


limitations and you change operating mode
(from PROGRAMMABLE WORKING to ES-H), software automatically sets operating
mode to economic one.

82
83
84

Over-temperature alarm, indicated by the


warning light In case the temperature of
power transistors exceeds the warning limit,
alarm code and relative light blink.
Moreover, in case temperature exceeds the alarm
limit, (or it stays between the two thresholds for 30
s or more), the symbols stop blinking and became
still.

Alarm message, indicated by an alpha-numerical


code in the display area where usually lift truck
speed appears.
See Table 6 for the meaning of alarm codes.
Table 6 : Meaning of alarm codes.
ALARM
ALARM DESCRIPTION
CODE
F
Wrong eeprom + watch dog timer
F0
Maximum battery voltage
F1
Minimum battery voltage
F2
Pedal trimmer fault
F3
Drive right module desat/overcurrent
F4
Drive left module desat/overcurrent
F5
Pump module Desat/overcurrent
F6
Drive right motor current offset
F7
Drive left motor current offset
F8
Pump motor current offset
F9
Steer sensor fault
FA
5V encoders not ok
Fc
Drive right motor Encoder
Fd
Left right motor Encoder
FE
24V out not ok
FH
12V out not ok
FL
Pump inputs on at start
E1
Drive right module Overtemperature
E2
Drive left module Overtemperature
E3
Pump module overtemperature
E4
Drive right motor Overtemperature
E5
Drive left motor Overtemperature
E6
Pump motor Overtemperature
EE
Wrong start
EL
Low battery voltage
EE
Seat switch opened
(flashing)
Alarm on pre - charge circuit of
A
internal capacitors
AL
Key retention
17
Main breaker fault
60
Battery / inverter mismatch
Wrong right traction motor thermal
77
probe
Wrong left traction motor thermal
78
probe
79
Wrong pump motor thermal probe
Wrong right traction module thermal
80
probe
Wrong left traction module thermal
81
probe

Wrong pump module thermal probe


CRC fault
Bank CRC restored

Hour meter separation point, usually blinking, stops


in following cases:
- Seat switch open.
- Serial communication between display and control
unit not active
- Main breaker open
Turning your lift truck on, some alphanumeric codes,
visible for 3 seconds, appear where usually is
visualized speed indicator symbol; those codes
help to identify system in use (see Table 7).
Where usually is visualized hour meter, on left side
appears feed voltage in VDC, and on right side,
maximum weight industrial truck can lift, expressed
in quintals.
SYSTEM IN USE

CODE

BT (3WHEEL)

C1

Table 7

LED Indicators
On left side, COMPACT display has four LED
indicators which, when switched on, give
information as follows:
Alarm message; red color LED
Message of lamps; green color LED
(OPTION)
Indicator lights activated; green color LED
(OPTION)
Low oil level of the brakes; red color LED
(Type1)

(Type2)

41

Operation Section

Seat Belt warning (Option) : red color


LED for 10 seconds.
NOTE: Alarm LED

is managed as follows:

- Display normally working: LED lights up


briefly switching on /off your system
- Display not communicating with control
board: after 3 seconds from the moment in
which the communication stops, alarm
LED brightens
- Display board microprocessor not working:
alarm LED brightens.

No Alarm, No Movement (OPTION)


When select the direction lever for forward or
reverse direction, in case the drive motor does not
move even if press on accelerator, it is that service
brake operates. Confirm whether service brake
switch is acted.

42

Operation Section

Front and Rear Floodlights Switch

Tilt Steering Column

Located on the right side of the instrument panel,


below the display panel.

Located on the lower front of the steering column.


To adjust the steering column, raise the handle(1)
and move the steering column to the desired
position. Release the handle and the steering
column will remain in the desired position.

OFF - Push down on the left side of the


switch to turn both front and rear flood
lights off.
Front Floodlights - Push down on the
right side of the switch, to the first position,
to turn the front floodlights on.

Seat Adjustment
Adjust the seat at the beginning of each shift or
when changing operators.

Front and Rear Floodlights - Push down


on the right side of the switch, to the
second position, to turn both the front and
rear floodlights on. The rear floodlights are
optional.

Adjust the seat to allow full travel of all pedals with


the operator seated against the seat back.
The seat must be adjusted with the operator seated.

Horn Button

Move the lever to adjust the seat forward or


backward. Release the lever. Move the seat slightly
to lock it.

Located in the center of the steering


wheel.
Push in on the horn button to sound the
horn.

43

Operation Section

Emergency Switch (If Equipped)

OFF - Push the emergency switch button


to disconnect the electrical circuits. (It
must be done after the key switch is
turned off)
ON - Pull the emergency switch button to
connect the electrical circuit.

44

Operation Section

Lift Truck Controls

Service Brake Pedal

Parking Brake Lever


NOTICE
Do not engage the parking brake while the lift truck
is moving unless an emergency arises. The use of
the parking brake as a service brake in regular
operation will cause severe damage to the parking
brake system.

Service Brake - The service brake pedal is located


on the floor of the operators compartment.
Depress the service brake pedal to slow
or stop the lift truck. Drive circuit will be
interrupted while the pedal is depressed.
Release the service brake pedal to allow
the lift truck to move.

Parking Brake - The parking brake lever


is located on the left side of the cowl.
Parking Brake Engaged - Pull the
parking brake lever up, which will engage
the interlock switch that shuts off power to
the drive motor.
Parking Brake Disengaged - Push the
parking brake lever down to release the
parking brake.

45

Operation Section

Accelerator Pedal

Directional Control Lever

NOTICE
The service brake and accelerator pedals should
not be used at the same time, except for
emergency situations. Use of both the brake and
accelerator pedals at the same time may cause the
drive motor to overheat.

Forward - Push the lever forward. The


lift truck will move forward.
Neutral - Move the lever to center
position. The lift truck should not move
when lever is in neutral.
If the operator leaves the seat, or turns the key
switch off, the lever must be returned to NEUTRAL.
The lift truck will not move until accelerator pedal is
released and lever is returned to NEUTRAL.

Accelerator Pedal - The accelerator pedal is located


on the floor of the operators compartment.

NOTE: Wait Mode of Operation - This condition will


go into effect when the following occurs.
The seat switch is closed, key switch is on
and the directional control lever is left in
NEUTRAL for more than five seconds, with
no operator input to any control.

Push down the pedal to increase travel speed.


If the accelerator pedal is depressed before the key
switch is turned to the ON position, the lift truck will
not move until the pedal is released and depressed
again.

The line contactor will open and the power steering


motor will turn off to conserve energy. The lift truck
will remain in this mode until the operator moves
the directional control lever, pushes on the
accelerator pedal and/or moves any control valve
lever.

Release the pedal to decrease travel speed.

Film for Function of Pedals


(If Equipped)

Reverse - Pull the lever toward the


operator. The lift truck will move in
reverse.
NOTE: The directional control lever can be used for
electrical braking(plugging). To slow or stop
the lift truck when traveling in either
direction, move the directional control lever
to the opposite direction of travel while
keeping the accelerator depressed. The lift
truck will slow to a complete stop and then
accelerate in the opposite direction.
When the operator raises off the seat (seat switch
opens) while the lift truck is in motion, the drive

This film shows the function of the brake and


accelerator pedals.

46

Operation Section

motor will lose power. When this occurs, release


the accelerator, close the seat switch(operator
seated), move the directional control lever to
NEUTRAL and then to desired direction of travel.
Push down on the accelerator.

Tilt Control Lever

Lift Control Lever

The forks tilt control is located at the operators


right side front. The tilt control lever is the lever at
the center.
Tilt Forward - Push the lever forward
smoothly to tilt the forks forward.
Hold - Release the tilt lever. The lever
will return to the center(hold) position
and the forks will remain in the position
they are in.

The forks lift control is located at the operators


right side front. The lift control lever is the lever at
the left.
Lower - Push the lever forward smoothly
to lower the lift forks.

Tilt Back- Pull the lever back smoothly to


tilt the forks back.

Hold - Release the lift lever. The lever


will return to the center(hold) position and
the forks will remain in the position they
are in.

NOTE: To prevent a sudden change of position of


the load, operate all lift, tilt and attachment
controls smoothly. Never tilt an elevated
load forward past vertical.

Raise - Pull the lever back smoothly to


raise the lift forks.

NOTE: To prevent a sudden change of position of


the load, operate all lift, tilt and attachment
controls smoothly.

47

Operation Section

Sideshift Attachment Control


(If Equipped)

The sideshift attachment control is located at the


operators right side front. The sideshift attachment
control lever is the lever at the right.
Sideshift Left - Push the lever forward
smoothly to shift the carriage to the left.
Sideshift Hold - Release the sideshif
attachment lever. The lever will return to
the center(hold) position and sideshifting
action will stop.
Sideshift Right - Pull the lever back
smoothly to shift the carriage to the right.

NOTE: To prevent a sudden change of position of


the load, operate all lift, tilt and attachment
controls smoothly.

48

Operation Section

Before Operating the Lift Truck


Walk-Around Inspection
For your own safety and maximum service life of
the lift truck, make a thorough walk-around
inspection before mounting the lift truck or starting
to move it.
Look for such items as loose bolts, trash build-up,
oil leaks, condition of tires, mast, carriage, forks or
attachments.

6
9

6. Inspect the tires and wheels for proper inflation,


cuts, gouges, foreign objects and loose or
missing nuts.

7. Inspect the overhead guard for damage, loose


or missing mounting bolts.

1
8. Inspect the hydraulic system for leaks, worn
hoses or damaged lines.
9. Inspect the drive axle housing and the ground
for oil leaks.

1. Inspect the operators compartment for


looseitems and clean any mud or debris from
the floor plates for safe footing.
2. Inspect the instrument panel for damage to the
indicator display.
3. Test the horn and other safety devices for
proper operation.

10
4

10. Disconnect the battery. Raise the lever bracket


assembly to the full upright position. Tilt the
steering column to the full upright position.

Batteries give off flammable fumes that can


explode.
Do not smoke when observing the battery
electrolyte levels.
Electrolyte is an acid and can cause personal
injury if it contacts skin or eyes.
Always wear protective glasses when working
with batteries.

4. Inspect the mast and lift chains for wear, broken


links, pins and loose rollers.
5. Inspect the carriage, forks or attachments for
wear, damage and loose or missing bolts.

49

Operation Section

15. Adjust the steering wheel to comfortable


position. Grasp the steering wheel and raise the
handle to release the steering column. PULL
the steering column BACK or PUSH
FORWARD to obtain the most comfortable
position. RELEASE the knob and make sure
the steering column is locked in this position.

11. Release the battery restraint lever in front of


battery cover. Raise the seat and cover
assembly.
12. Inspect the battery compartment for loose
connections and frayed cables.
13. Observe the battery electrolyte level for proper
level. Lower the seat and cover assembly and
the lever bracket assembly and connect the
battery to the lift truck. Secure the battery
restraint properly.

Personal injury may occur from accidents


caused by improper seat adjustment. Always
adjust the operators seat before operating the
lift truck.
Seat adjustment must be done at the beginning
of each shift and when operators change.

16. With the seat switch closed and the directional


lever in NEUTRAL, turn the key switch ON.
Observe the battery discharge indicator.
Type1

14. Position the seat by operating the lever and


moving the seat forward or backward to a
comfortable position.

50

Operation Section

Type2

17. Make sure the battery is charged before


operating the lift truck. A fully charged battery
will cause 9 Segments to be displayed on the
BDI display.

Better Battery Performance


NOTICE
The lift truck operator must not start his shift with a
battery that has been taken off a charger too soon.
A battery should never be disconnected from a
charge until the charge cycle has been completed.
The batteries that have been fully charged should
have a tag attached for identification.
In Operation, a battery should be discharged then
recharged in 8 to 12 hours, depending on the
charger type. Then, they should be allowed to cool
and stabilize 4 to 8 hours. Repeated undercharging
must be prevented. It can damage the battery.
If there is an indication of low battery operation, the
lift truck operator should return the lift truck to the
battery charging area.

NOTE: Refer to the Maintenance Section of this


guide for additional battery exchanging and
charging information.

51

Operation Section

Lift Truck Operation


Be sure no one is working on or near the lift truck.
Keep the lift truck under control at all times.
Reduce speed when maneuvering in tight quarters
or when braking over a rise.
Do not allow the lift truck to overspeed downhill.
Use the service brake pedal to reduce speed when
traveling down hill.

NOTICE
4. Push down on the service brake pedal and
release the parking brake.

Do not move directional control lever from one


direction to the other(plug) when the drive wheels
are off the ground and rotating at full speed.
Damage can occur to the control panel.

1. Adjust the operators seat.


2. Fasten the seat belt (if equipped).

5. Turn the key switch ON. Raise the attachments


to the travel position.

3. Move the directional control lever into the


NEUTRAL position, if it is not already in this
position.

6. Move the directional control lever to the desired


direction of travel.

52

Operation Section

11. Hold the accelerator pedal down until the lift


truck nearly comes to a complete stop. Release
the accelerator pedal.

7. Release the service brake pedal.

12. Push down on the service brake pedal to bring


the lift truck to a complete stop and hold it.
13. To change direction, continue to push down on
the accelerator pedal until the desired travel
speed in the opposite direction is obtained.
14. Do not use electrical braking (plugging) to stop
the lift truck where the stopping distance is too
short.
Instead, release the accelerator pedal, push
down on the service brake pedal, and bring the
lift truck to a smooth stop.

8. Push down on the accelerator pedal to reach


the travel speed. Release the pedal to decrease
travel speed.
9. Electrical braking (plugging) can be used to
slow or stop the lift truck or to change the lift
truck direction of travel.
See the section below, Eletrical Braking
(Plugging) for an explanation of electrical
braking.

10. Move the directional control lever to the


opposite direction of lift truck travel.

53

Operation Section

Electrical Braking (Plugging)

Electrical braking uses the drive motors own power


to slow, stop or change direction when traveling in
either direction. It is a more gradual type of stop,
compared to using the service brakes. Electrical
braking can be used for normal operation where
there is adequate time and distance to stop safely.
Electrical braking should NOT be used for sudden
or emergency stops.
To start electrical braking, move the directional
control lever to the opposite direction while keeping
the accelerator pedal depressed.
The lift truck dirve control senses that the motors
are turning opposite to the vehicle direction of travel
and immediately goes into the plugging mode.
Motor rotation is retarded at a predetermined rate
by electrical braking (plugging).
If the accelerator pedal is kept depressed, the drive
control will slow the lift truck to a complete stop and
then accelerate in the opposite direction.

54

Operation Section

Operating Techniques
NOTE: The illustrations used here are typical examples and may not look exactly like to your particular lift
truck.

Inching into Loads

Lifting the Load

1. Move the lift truck slowly forward into position


and engage the load. Lift truck should be
square with load. The forks should be spaced
evenly between pallet stringers and as far apart
as the load will permit.

1. Lift the load carefully and tilt the mast back a


short distance.
2. Tilt the mast further back to cradle the load.

2. Move the lift truck forward until the load touches


the carriage.

3. Operate the lift truck in reverse until the load is


clear of the other loads.
4. Lower the load to the travel position before
turning or traveling.
The forklift truck must not be used to push
loads or other vehicles.
Only the moving equipment supplied or the rear
hook for towing must be used.

55

Operation Section

Traveling

Turning

Whether you are traveling with or without a load,


keep the fork as low as possible, while still
maintaining good clearance above the floor.

1. When turning sharp corners, keep close to the


inside corner. Begin the turn when the inside
drive wheel meets the corner.
1. Carry the load as low as possible, but maintain
clearance.

2. In narrow aisles, keep as far from the stockpile


as possible when making a turn into the aisle.
Allow for counterweight swing.
2. On grades, alway travel with the load on the
uphill side, as shown above.

NOTE: The MicroCommand control uses the steer


wheel angle signals to adjust drive motor
speeds to match the steering cramp angle.
With steer wheel cramp angles of 20 or
more, the MicroCommand control limits
drive motor speed to both drive motors.
Limiting motor speed when turning reduces
lift truck rotational speed while maintaining
traction and power to both drive wheels.

3. Travel in reverse with bulky loads. This gives


you better vision.

56

Operation Section

Unloading

3. As the steer wheel angle increases, the inside


drive motor speed is progressively slowed down
with respect to the outside drive motor speed. It
is essentially switched OFF when the steer
wheel cramp angle is 45.

1. Move the lift truck into the unloading position.


2. Do not tilt the mast forward until it is directly
over the unloading area.

Do not tilt the mast forward with the load unless


directly over the unloading area, even if the
power is off.

4. At a steer wheel cramp angle of 75, the inside


drive motor rotation is reversed and its speed
will progressively increase as the cramp angle
increases.
5. At a steer wheel cramp angle of 90, the inside
drive motor rotation, in reverse, is as fast as the
outside drive motor rotation in forward.
This causes the lift truck to turn about a point
midway between the two drive tires.

3. Deposit the load and back away carefully to


free the forks.
4. Lower the carriage and forks to either travel
position or park position.

57

Operation Section

Lifting Drums or Round Objects

1. Block the drums or round objects. Tilt the mast


forward and slide the fork tips along the floor to
get under the load.

2. Tilt the mast back slightly until the load is


cradled on the forks before lifting.
3. Lift the load to the travel position.

58

Operation Section

Parking the Lift Truck


NOTICE
Parking or storage of electric lift trucks outdoor can
cause lift truck system damage or failure.
Park or store all electric lift trucks inside a building
to protect electrical system from moisture damage.

3. Engage the parking brake.

When leaving the operators station, park the lift


truck in authorized areas only. Do not block traffic.
Park the lift truck level, with the forks lowered and
the mast tilted forward until the fork tips touch the
floor. Block the drive wheels when parking on an
incline.

4. Tilt the mast forward and lower forks to the


ground.

1. Apply the service brake to stop the lift truck.

5. Turn key switch to OFF and remove the key.

2. Move the directional control lever into


NEUTRAL.

59

Operation Section

6. Disconnect the battery.


7. Block the wheels if parking on an incline.

Parking Alarm Warning (If


Equipped)
G
When leaving the operators station without
engaging the parking brake, warning buzzer is
acted.

60

Operation Section

Lift Fork Adjustment


When adjusting the fork spread, be careful not
to pinch your hand between forks and the
carriage slot.

Hook-on type Fork

1. Move up the hook pin to the free position in


each fork to side the fork on the carriage bar.
2. Adjust the forks in the position most appropriate
for the load and as wide as possible for load
stability.
3. When adjusting the forks, make sure that the
weight of the load is centered on the truck.
4. After adjustment, set the fork locks to keep the
forks in place.

Make sure the forks are locked before carrying


a load.

61

Operation Section

Storage Information
Before Storage
When storing the lift truck for an extended period of
time, take the following measures to ensure that it
can be returned to operation with minimal service.
1. After every part is washed and dried, the
machine should be housed in a dry building.
Never leave it outdoors. In case it has to be left
outdoors, lay wooden boards on the ground,
park the machine on the boards and cover it
with canvas, etc.
2. Lubricate, grease and replace oil before storage.
3. Apply a thin coat of grease to exposed
hydraulic cylinder piston rods.
4. Cover the battery after removing terminals, or
remove it from the machine and store it
separately.

During Storage
Drive the truck for a short at least once a month.
This coats moving part surfaces with a new film of
oil. Charge the battery at this same time.

After Storage
After storage(when it is kept without cover or
rustpreventive operation once a month is not made),
you should apply the following treatment before
operation.
1. Remove the drain plug on hydraulic tank and
drain any accumulated water.
2. Wipe off grease from hydraulic cylinder piston
rod.
3. Measure specific gravity and check that the
battery is charged.
4. Drive at low speed to make sure moving parts
in drive gear boxes are well oiled.

62

Operation Section

Transportation Hints
6. Disconnect the battery.

Shipping

7. Block the tires and secure the lift truck with


tiedowns.

Check travel route for overpass clearances. Make


sure there is adequate clearance if the lift truck
being transported is equipped with a high mast,
overhead guard or cab.

Machine Lifting and Tiedown


Information

To prevent the lift truck from slipping while loading,


or shifting in transit, remove ice, snow or other
slippery material from the loading dock and the
truck bed before loading.

NOTICE

NOTICE

Improper lifting or tiedowns can allow load to shift


and cause injury and/or damage.

Obey all state and local laws governing the weight,


width and length of a load.
Observe all regulations governing wide loads.

1. Weight and instructions given herein apply to lift


trucks as manufactured by DAEWOO.
2. Use properly rated cables and slings for lifting.
Position the crane for level lift truck lift.

NOTICE
3. Spreader bar widths should be sufficient to
prevent contact with the lift truck.

Remove ice, snow or other slippery material from


the shipping vehicle and the loading dock.

4. Use the tiedown locations provided for lift truck


tiedown.
Check the state and local laws governing weight,
width and length of a load.
Contact your DAEWOO Lift Truck dealer for
shipping instructions for your lift truck.

1. Always block the trailer or the rail car wheels


before loading the lift truck.
2. Position the lift truck on the trailer or the rail car.
3. Apply the parking brake and place the
transmission control in NEUTRAL.
4. Tilt the mast forward and lower forks to the floor.
5. Turn key switch OFF and remove the key.

63

Operation Section

Towing Information
Consult your DAEWOO Lift Truck dealer for
towing a disabled lift truck.
Personal injury or death could result when
towing a disabled lift truck incorrectly.
Block the lift truck wheels to prevent movement
before releasing the brakes. The lift truck can
roll free if it is not blocked.
Follow the recommendations below to properly
perform the towing procedure.
The towing instructions given here are for moving a
disabled lift truck only a short distance at low speed
[no faster than 1.2 mph (2 km/h)] to a convenient
location for repair. These instructions are for
emergencies only. If long-distance moving is
required, always haul the lift truck.
1. Release the parking brake.

You must provide shielding on the towing lift truck to


protect the operator if the tow line or bar should
break.

NOTICE
Release the parking brake to prevent excessive
wear and damage to the parking brake system.

Do not allow an operator to sit on the lift truck being


towed unless the steering and braking can be
controlled.
The operator on the towed lift truck must always
steer in the direction of the tow line pull.

2. Release the service brake pedal.

Inspect the tow line or bar and make sure it is in


good condition and has enough strength for the
towing situation involved. For a disabled lift truck
stuck in mud or when towing on a grade, use a
towing line or bar with a strength of at least 1.5
times the gross weight of the towing lift truck.

3. Turn the key switch OFF.

Keep the tow line angle to a minimum. Do not


exceed a 30 angle from the straight-ahead position.
Connect the tow line as low as possible on the lift
truck being towed.

6. Remove any wheel blocks. Tow the lift truck


slowly. Do not tow any faster than 2 km/h (1.2
mph).

4. Disconnect the battery.


5. Fasten the tow bar to the lift truck.

Use gradual and smooth lift truck movement.


Moving the lift truck quickly could overload the tow
line or bar and cause it to break.

Be sure all necessary repairs and adjustments


have been made before a lift truck that has been
towed to a service area is put back into
operation. Personal injury or death could result.

Normally, the towing lift truck should be at least as


large as the disabled lift truck. It should have
enough brake capacity, weight, and power to
control both lift trucks for the grade and distance
involved.
A larger towing lift truck or additional lift trucks
connected to the rear could be required to provide
sufficient control and braking when moving a
disabled lift truck downhill. This will prevent it from
rolling uncontrolled.
The requirements of each towing situation will be
affected by many conditions. Minimum towing lift
truck capacity is required on smooth, level surfaces,
while maximum capacity is needed on inclines or
on poor surface conditions.

64

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks


The following section gives practical guidelines for
inspection, maintenance and repair of lift truck forks.
It also provides general information on the design
and application of forks and the common cause of
fork failures.

Users may also refer to the International


Organization For Standardization-ISO Technical
Report 5057-Inspection and Repair of Fork Arms
and ISO Standard 2330-Fork Arms-Technical
Characteristics and Testing.

Lift truck forks can be dangerously weakened by


improper repair or modification. They can also be
damaged by the cumulative effects of age, abrasion,
corrosion, overloading and misuse.

While there are no specific standards or regulations


in the United States, users should be familiar with
the requirements for inspection and maintenance of
lift trucks as provided by the 29 Code Federal
Register 1910.178 Powerd Industrial Truck, and
ANSI/ASME Safety Standard(s) B56.1, B56.5 or
B56.6 as applicable to the type of machine(s) in use.

A fork failure during use can cause damage to the


equipment and the load. A fork failure can also
cause serious injury.
A good fork inspection and maintenance program
along with the proper application can be very
effective in preventing sudden on the job failures.
Repairs and modifications should be done only by
the fork manufacturer or a qualified technician who
knows the material used and the required welding
and heat treatment process.
Users should evaluate the economics of returning
the forks to the manufacturer for repairs or
purchasing new forks. This will vary depending on
many factors including the size and type of fork.
Forks should be properly sized to the weight and
length of the loads, and to the size of the machine
on which they are used. The general practice is to
use a fork size such that the combined rated
capacity of the number of forks used is equal to or
greater than the Standard(or rated) Capacity of
the lift truck.
The individual load rating, in most cases, will be
stamped on the fork in a readily visible area. This is
generally on the top or side of the fork shank.
z

A fork rated at 1500 pounds at 24 inch load


center will be stamped 1500 X 24.

A fork rated at 2000 kg at 600 mm load center will


be stamped 2000 X 600.

The manufacturer identification and year and date


of manufacture is also usually shown.
Some countries have standards or regulations
which apply specifically to the inspection and repair
of forks.

65

Maintenance Section

Causes of Fork Failure

Repetitive cycling of loads which exceeds the


fatigue strength of the material can lead to fatigue
failure. The overload could be caused by loads in
excess of the rated fork capacity and by use of
the forks tips as pry bars. Also, by handling loads
in a manner which causes the fork tips to spread
and the forks to twist laterally about their
mountings.

Improper Modification or Repair


Fork failure can occur as a result of a field
modification involving welding, flame cutting or
other similar processes which affect the heat
treatment and reduces the strength of the fork.
In most cases, specific processes and techniques
are also required to achieve proper welding of the
particular alloy steels involved. Critical areas most
likely to be affected by improper processing are the
heel section, the mounting components and the fork
tip.

Wear
Forks are constantly subjected to abrasion as
they slide on floors and loads. The thickness of
the fork blade is gradually reduced to the point
where it may not be capable of handling the load
for which it was designed.

Bent or Twisted Forks


Forks can be bent out of shape by extreme
overloading, glancing blows against walls or other
solid objects or using the fork tip as a pry bar.

Stress Risers
Scratches, nicks and corrosion are points of high
stress concentration where cracks can develop.
These cracks can progress under repetitive
loading in a typical mode of fatigue failure.

Bent or twisted forks are much more likely to break


and cause damage or injury. They should be
removed from service immediately.

Overloading

Fatigue

Extreme overloading can cause permanent bending


or immediate failure of the forks. Using forks of less
capacity than the load or lift truck when lifting loads
and using forks in a manner for which they were not
designed are some common causes of overloading.

Parts which are subjected to repeated or fluctuating


loads can fail after a large number of loading cycles
even though the maximum stress was below the
static strength of the part.
The first sign of a fatigue failure is usually a crack
which starts in an area of high stress concentration
This is usually in the heel section or on the fork
mounting.
As the crack progresses under repetitive load
cycling, the load bearing cross section of the
remaining metal is decreased in size until it
becomes insufficient to support the load and
complete failure occurs.
Fatigue failure is the most common mode of fork
failure. It is also one which can be anticipated and
prevented by recognizing the conditions which lead
up to the failure and by removing the fork service
prior to failing.

Repetitive Overloading

66

Maintenance Section

Fork Inspection

First Installation
1. Inspect forks to ensure they are the correct size
for the truck on which they will be used. Make
sure they are the correct length and type for the
loads to be handled.
If the forks have been previously used, perform
the 12 Month Inspection.
If the forks are rusted, see Maintenance and
Repair.
2. Make sure fork blades are level to each other
within acceptable tolerances. See Forks, Step
4, in the 2000 Service Hours or Yearly in
Maintenance Intervals

Establish a daily and 12 month inspection routine


by keeping a record for the forks on each lift truck.
Initial information should include the machine serial
number on each the forks are used, the fork
manufacturer, type, original section size, original
length and capacity. Also list any special
characteristics specified in the fork design.

3. Make sure positioning lock is in place and


working Lock forks in position before using
truck. See Forks, Step 7, in the 2000 Service
Hours or Yearly in Maintenance Intervals.

Record the date and results of each inspection,


making sure the following information is included.

Daily Inspection

Actual wear conditions, such as percent of


original blade thickness remaining.

Any damage, failure or deformation which might


impair the use of the truck.

1. Visually inspect forks for cracks, especially in


the heel section, around the mounting brackets,
and all weld areas. Inspect for broken or jagged
fork tips, bent or twisted blades and shanks.
2. Make sure positioning lock is in place and
working. Lock the forks in position before using
the truck. See 2000 Service Hours or Yearly in
Maintenance Intervals.

Note any repairs or maintenance.

An ongoing record of this information will help in


identifying proper inspection intervals for each
operation, in identifying and solving problem areas
and in anticipating time for replacement of the forks.

3. Remove all defective forks from service.

67

Maintenance Section

With the fork restrained in the same manner as its


mounting on the lift truck, apply the test load twice,
gradually and without shock. Maintain the test for
30 seconds each time.

12 Months Inspection
Forks should be inspected, at a minimum, every 12
months. If the truck is being used in a multi-shift or
heavy duty operation, they should be checked
every six months. See Forks in the 2000 Service
Hours or Yearly in Maintenance Intervals.

Check the fork arm before and after the second


application of the test load. It shall not show any
permanent deformation.
Consult the fork manufacturer for further
information as may be applicable to the specific fork
involved.
Testing is not required for repairs to the positioning
lock or the markings.

Maintenance and Repair


1. Repair forks only in accordance with the
manufacturers recomendations.
Most repairs or modifications should be done
only by the original manufacturer of the forks or
an expert knowledgeable of the materials,
design, welding and heat treatment process.
2. The following repairs or modifications SHOULD
NOT be attempted.
z Flame cutting holes or cutouts in fork blades.
z

z
z

Welding on brackets or new mounting


hangers.
Repairing cracks or other damage by welding.
Bending or resetting.

3. The following repairs MAY be performed.


z

Forks may be sanded or lightly ground, to


remove rust, corrosion or minor defects from
the surfaces.
Heel sections may be ground with a carbon
stone to remove minor surface cracks or
defects. Polish the inside radius of the heel
section to increase the fatigue life of the fork.
Always grind or polish in the direction of the
blade and shank length.
Repair or replace the positioning locks on
hook type forks.
Repair or replace most fork retention devices
used with other fork types.

4. A fork should be load tested before being


returned to service on completion of repairs
authorized and done in accordance with the
manufacturers recommendations.
Most manufacturers and standards require the
repaired fork to be tested with a load 2.5 times
the specified capacity and at the load center
marked on the fork arm.

68

Maintenance Section

Tire Inflation Information


Tire Inflation

Tire Shipping Pressure


Size

18 X 7-8

Ply Rating
or
Strength Index
B15/18T-5
16

Shipping
Pressure
kPa
psi
1000

145

The inflation pressures shown in the following chart


are cold inflation shipping pressures for tires on
DAEWOO lift trucks.
The operating inflation pressure is based on the
weight of a ready-to-work lift truck without
attachments, at rated payload, and in average
operating conditions. Pressures for each application
may vary and should always be obtained youre
your tire supplier.

Personal injury or death could result when tires


are inflated incorrectly.
Use a self-attaching inflation chuck and stand
behind the tread when inflating a tire.

Tire Inflation Pressures


Adjustment

Proper inflation equipment, and training in


using the equipment, are necessary to avoid
overinflation. A tire blowout or rim failure can
result from improper or misused equipment.

A tire inflation in a warm shop area, 18C to 21C


(65F to 70F), will be underinflated if the lift truck
works in freezing temperatures. Low pressure
shortens the life of a tire.

NOTICE
Set the tire inflation equipment regulator at no more
than 140 kPa(20 psi) over the recommended tire
pressure.

69

Maintenance Section

Torque Specifications
Metric Hardware - This lift truck is almost totally
metric design. Specifications are given in metric
and U.S. Customary measurement. Metric
hardware must be replaced with metric hardware.
Check parts books for proper replacement.

Torque for Standard Bolts, Nuts


and Taperlock Studs
NOTICE

NOTE: Use only metric tools on most hardware for


proper fit. Other tools could slip and
possibly cause injury.

The following charts give general torques for bolts,


nuts and taperlock studs of SAE Grade 5 or better
quality.

Torque for Standard Hose Clamps


- Worm Drive Band Type

Torques for Bolts and Nuts With


Standard Threads
Thread Size
Inch
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2

NOTICE
The following chart gives the torques for initial
installation of hose clamps on new hoses and for
reassembly or retightening of hose clamps on
existing hose.

Clamp Width
16 mm (.625 inch)
13.5 mm (.531
inch)
8 mm (.312 inch)

Clamp Width

16 mm (.625 inch)
13.5 mm (.531
inch)
8 mm (.321 inch)

Initial Installation
Troque on New Hose
Nm1
lbin
7.5 0.5
65 5
4.5 0.5

40 5

0.9 0.2
82
Reassembly or
Retightening Troque on
existing hose
Nm1
lbin
4.5 0.5
40 5
3.0 0.5

25 5

0.7 0.2

62

11 Newton meter (Nm) is approximately the same


as 0.1 kgm.

11 Newton meter (Nm) is approximately the same


as 0.1 kgm.

Standard Bolt & Nut Troque


Nm1
lbft
124
93
257
185
457
335
7015
7511
10015
7511
15020
11015
20025
15018
36050
27037
57080
42060
875100
64075
1100150
820110
1350175
1000130
1600200
1180150
2000275
1480200

70

Maintenance Section

Torques for Taperlock Studs


Thread Size
Inch
1/4
5/16
3/8
7/16
1/2
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2

Torque for Metric Fasteners

Standard Taperlock Stud


Torque
Nm1
Ibft
83
62
175
134
35 + 5
264
45 10
33 7
65 10
48 7
11020
80 15
17030
125 22
260 40
190 30
400 60
300 45
500 70
370 50
650 80
480 60
750 90
550 65
870 100
640 75

NOTICE
Be very careful never to mix metric with U.S.
customary (standard) fasteners. Mismatched or
incorrect fasteners will cause lift truck damage or
malfunction and may even result in personal injury.
Original fasteners removed from the lift truck should
be saved for reassembly whenever possible. If new
fasteners are needed, they must be of the same
size and grade as the ones that are being replaced.
The material strength identification is usually shown
on the bolt head by numbers.(8.8, 10.9, etc.) The
following chart gives standard torques for bolts and
nuts with Grade 8.8.

NOTE: Metric hardware must be replaced with


metric hardware. Check parts book for
proper replacement.

11 Newton meter (Nm) is approximately the same


as0.1 kgm.

METREC ISO2 THREAD


Thread Size
Standard Torque
Metric
Nm1
Ibft
M6
124
93
M8
257
185
M10
5510
41 7
M12
95 15
70 11
M14
15020
110 + 15
M16
220 30
16022
M20
450 70
330 50
M24
775 100
570 75
M30
1600 200
1180150
M36
2700 400
2000 300
11 Newton meter (Nm) is approximately the same
as 0.1 kgm.
2ISO-International Standard Organization.

71

Maintenance Section

Lubricant Specifications
Lubricant Information

Hydraulic Oil

Some classifications and abbreviations we use in


this section follow S.A.E. (Society of automotive
Engineers) J754 nomenclature and others follow
S.A.E. J183.
All MIL specifications are U.S.A. Military.
Recommended oil viscosities are given in
theLubricant Viscosities chart later in this section
of the manual.
Greases are classified according to the National
Lubricating Grease Institute (NLGI) based on ASTM
D217-68 worked Penetration characteristics which
give a defined consistency numbel.

The following commercial classifications can be


used in the hydraulic system.
ISO 6743/4 HM
AFNOR NFE 48-603 HM
DIN 51524 TEIL 2 H-LP
HAGGLUNDS DENISON HFO-HF2
CINCINNATI P68, 69, 70

Chain and Linkage Oils (DEO or


EO)

Viscosity : ISO VG 32
These oils should have antiwear, antifoam, antirust
and antioxidation additives for heavy duty use as
stated by the oil supplier. ISO viscosity grade of 32
would normally be selected.

NOTICE
Correct Hydraulic Oil should be used to achieve
maximum life and performance from hydraulic
system components. The following hydraulic Oil is
recommended in most hydraulic and hydrostatic
systems.

Use following engine oils are recommended for use


on chains and linkages.
European oil specification CCMC D3.

Make-up oil added to the hydraulic tanks must mix


with the oil already in the systems. Use only
petroleum products unless the systems are
equipped for use with special products.

API Specification CD, CD/SF, CE


Military specifications MIL-L-2104D or E

If the hydraulic oil becomes cloudy, water or air is


entering the system. Water or air in the system will
cause pump failure. Drain the fluid, retighten all
hydraulic suction line clamps, purge and refill the
system.Consult your DAEWOO Lift Truck dealer for
purging instructions.

72

Maintenance Section

Drive Axle Lubricant

Lubricating Grease (MPGM)

Select an oil that meets below specifications

Use Multipurpose Molybdenum Grease (MPGM) for


all lubrication points. If MPGM grease can not be
used, a multipurpose type grease which contains
3% to 5% molybdenum disulfide can be used.

Universal Transmission Tractor Oil (UTTO) The


following UTTO products are authorized for use.
TOTAL

TRANSMISSION MP

MOBIL

MOBIL FLUID, 422 MOBIL FLUID 425

MOTUL

TRM 97

OPAL

NLGI No.2 grade is suitable for most temperatures.


Use NLGI No.1 or No.0 grade for extremely low
temperature.

Brake Fluid

OPAL FLUID TA/HIS

Located on the left side of the cowl.


Use heavy duty hydraulic brake fluid certified by the
oil supplier to meet ISO 6743/4 HM, ISO VG 10
latest revision.
TOTAL

Azolla ZS 10

AGIP

Acer 10

BP

Spindurn 10

ELF

Spinelf 10

ESSO

Nuto H 10 Spinesso 10

FINA

Hydran 10

SHELL

73

HLP 10

CALTEX

MOBIL

Energol HP 10

Velocite oil No. 5


Velocite oil E
Tllvs oil C10
Morlina 10

Maintenance Section

Battery Discharge Indicator


Type2

The battery discharge indicator should be observed


frequently before and during operation.
Type1

If the warning is ignored, lift interrupt will


prevent the hydraulic pump motor from
operating and an EL will be displayed
on the LCD display.

Type2

To prevent over-discharge, the lift interrupt should


not be reset by disconnecting and reconnecting the
battery.
If the batteries are weak, have them charged or
replaced.
The batteries should not be discharged below 80%
of the full charge as indicated by their specific
gravity. This specification varies with different
battery manufacturers. See the manufacturers
specifications for specific gravity at 80% discharge.
If information is not available from the battery
supplier, use 1.140 specific gravity level.

A fully charged battery will cause a 9 segments to


be displayed on the LCD display. As the battery is
discharged, the LCD display will count down, 9, 8, 7,
and etc., until EL is displayed. When the battery
reaches 80% discharge level, the Micro-Controller
will cause the LCD display to continuously index
through the entire range (1 through 9 segments ) to
signal that the battery is discharged and lift interrupt
is imminent.
Type1

74

Maintenance Section

Battery

When using pressure air for cleaning purposes,


wear a protective face shield and protective
clothing. Maximum air pressure must be below
207 kPa (30 psi).

Low battery operation must be prevented.


Operation with a low battery may cause damage to
the battery. Low battery operation will cause higher
than normal current in the electrical system. This
can damage contactor tips or shorten motor brush
life.

Do not smoke near batteries that are being


stored or when checking the electrolyte level.

Batteries that have been fully charged should have


a tag attached for identification.

Electrolyte is an acid solution and can cause


personal injury. Avoid contact with skin and
eyes.

A battery should be recharged in 8 to 12 hours after


being discharged, depending on the charger type,
then allowed to cool and stabilize 4 to 8 hours.
Repeated undercharging must be prevented
because it can damage the battery.

Maximum life and performance of lift truck batteries


is dependent on the operator, battery charging,
maintenance and service.

A battery requires an equalizing charge at least


once every 20 normal charge/discharge cycles.
This helps correct and prevent unequal cell specific
gravity (SG) readings. An equalizing charge is a
cycle charge with modification, given usually at an
interval to bring all cells up to a state of equal
charge. An equalizing charge usually adds three to
four more hours to the cycle charge, at a low finish
rate. It is usually given when the specific gravity
(SG) of electrolyte has a variation of more than 20
points (.020) from cell to cell, after a regular cycle
charge.

Most dirt and dust picked up by the battery can


usually be blown off with low pressure compressed
air.
However, if cells are overfilled and electrolyte
collects on the covers, the top of the battery will
stay wet.
If necessary, clean the top of the battery with a
solution of baking soda and hot water.

A cycle charge will completely recharge the


battery. The typical cycle charge for a fully
discharged battery usually is an eight-hour charge.
The battery must be recharged before it has been
discharged over 80% of the rated capacity of the
battery. The work shift of the lift truck can be
planned so the battery will not be discharged more
than 80%.

NOTICE
Vent caps must be tight to prevent soda solution
from entering battery cells.

To make the solution, add 0.5 kg (1 lb) of baking


soda to 4 liters (1 gallon) of water. Use a brush
having flexible bristles. Apply the soda solution to
the top of the battery until the cleaning action of the
soda stops.

A battery should never be left in a discharged state


because of sulfate formation. This reduces battery
life drastically. To extend life always recharge the
battery without delay after it has been discharged.
Repeated over discharging of the battery will
damage the cells, which will shorten battery life and
increase operating cost. Battery life(number of
cycles) decreases as the depth of discharge
increases. The estimated life of the battery
discharged to 80% will be approximately twice as
long as if it were discharged 100%.

After cleaning action has stopped, rinse batteries


thoroughly with water. Dry the batteries with low air
pressure.
The lift truck operator must not start his shift with a
battery that has been taken off a charger too soon.
Batteries are designed to be charged and allowed
to cool and stabilize. A battery should never be
disconnected from a charger until the charge cycle
has been completed.

75

Maintenance Section

The batterys maximum temperature is critical. The


electrolyte temperature should never exceed 43C
(110F) either while operating or charging. If higher
temperatures are maintained through use or abuse,
reduced battery service life can be expected.

NOTICE
DISPOSAL OF OLD BATTERY
Careless disposal of a battery can harm the
environment and can be dangerous to persons.
Always dispose of a battery to an authorized
personnel only.
Do not attempt to open or dismantle a battery or a
cell.

Battery condition is important for a long life. The


elecrolyte level should be maintained at the
recommended levels and the battery should be kept
clean and dry. Washing down batteries at different
time periods will reduce the chance of grounds
caused by electrolyte spills and corrosion. If done
often enough, just washing with water alone will
eliminate the need for using baking soda. If not, a
solution of baking soda and water must be used to
wash battery at different time periods.
Add water at regular intervals. Enough water should
be added to bring the electrolyte approximately
13.0 mm (.50 inch) above the plates. This is a
simple matter with the use of an automatic cell filler,
which shows a light when the correct level has
been reached. Water should always be added
before charging to be sure thorough mixing with
acid when gassing occurs near the end of charging
period. Use distilled water or have the water supply
analyzed.
Charge batteries correctly. It is important that all
batteries should be charged according to the
manufacturers instructions. Most of the charging
equipment is fully automatic and should be checked
periodically. Never operate the lift truck with a fully
discharged battery because this will damage the
battery.
When charging, proper provision must be made for
venting of the charging gases. Battery container lids
and the covers of battery compartments must be
opened or removed. The vent plugs should stay on
the cells and remain closed.
When a battery charger operates correctly and
brings a good battery up to full charge, the current
readings will level to the finish rate. The charging
voltage will stabilize, the specific gravity will stop
rising and normal gassing can be seen.

76

Maintenance Section

Cold Storage Applications


Type2

When an electric lift truck is operated in cold


storage applications, at temperatures as low as 20C (-4F), the battery capacity is decreased.
Operation at cold temperatures can also cause
mechanical failures, short circuits and too much
wear due to the formation of ice crystals.
The direct cause of these problems is the extreme
changes in temperature in combination with
humidity in the air which can result in condensation.
To protect the electric lift trucks components and
decrease the effects of the cold temperature,
perform the following items before you put the lift
truck to work in cold storage applications.

Observe the battery discharge indicator frequently.

Battery

Hydraulic System

There is a reduction in battery capacity in cold


storage applications. For this reason, it is important
to :
1. Be sure the battery is completely charged at the
start of each work cycle.
2. If possible, keep the lift truck in a warm storage
area when it is not in use.
3. Do not store a discharged battery at below
freezing temperature.
Type1

Drain the hydraulic system and fill it with SAE 5.


MIL-H-5606A hydraulic oil

Lift Chains
1. Remove the chains Clean them in a
nonflammable cleaning solvent.
2. Put the chains in molybdenum disulfide
(MPGM) grease for one hour. Then, before
installation, hang the chains, where they will not
move, for three hours.

77

Maintenance Section

3. Put MPGM grease on the chains at one-week


intervals.
4. Check chains very carefully for wear on the link
plate edges, caused when they run over the
sheaves. Check the chains regularly for
cracked links, loss of shape in the holes, and
corrosion.

78

Maintenance Section

Lubricant Viscosities and Refill Capacities


Lubricant Viscosities

Refill Capacities
REFILL CAPACITIES-(APPROXIMATE)
Compartment or
Liter
U.S.
Imperi
System
s
Gal
al Gal
Hydraulic & Power
18
5
4.5
Steering System
Drive Axle Housing
1.1
0.29
0.23
Brake Reservoir
0.6
0.16
0.13

LUBRICANT VISCOSITIES FOR AMBIENT


(OUTSIDE) TEMPERATURES
Compartme
Oil
C
nt
Viscositie
Min Max
or System
s
ISO VG
-30 +20
22
Hydraulic
and Power
ISO VG
-20 +30
Steering
32
System
ISO VG
-10 +40
ISO 6743/4
46
HM
ISO VG
0
+50
68
SA
E
API 10 -20 +22
*Drive Axle
CD/ W
Housing
TO-2 SA
E +10 +50
30
*Brake
Reservoir

ISO VG
10

-30

+50

F
Min

Max

-22

+68

-4

+86

+14 +104
+32 +122
-4

+72

+50 +122
-22

+122

* For the detailed information about the lubricant


specifications, see Lubricant Specifications
section.
The SAE grade number indicates the viscosity of oil
A proper SAE grade number should be selected
according to ambient temperature.

79

Maintenance Section

Maintenance Intervals
Every 500 Service Hours or 3 Months
NOTICE
All maintenance and repair, except every 10 service
hours or daily, on the lift truck must be performed
by qualified and authorized personnel only.

Tilt Cylinders - Check, Adjust, Lubricate ............ 101


Crosshead Rollers - Inspect............................... 102
Mast Hinge Pins - Lubricate ............................... 103
Steering Mechanism - Lubricate......................... 103
Drive Axle Oil - Change...................................... 103
Overhead Guard - Inspect.................................. 103
Control Panel - Clean, Inspect ........................... 104
Directional Lever Check .................................. 105

NOTICE
Careless disposal of waste oil can harm the
environment and can be dangerous to persons.
Always dispose of waste oil to an authorized
personnel only.

Every 1000 Service Hours or 6 Months


Drive Axle Oil - Change...................................... 106
Drive and Pump Motor - Clean, Inspect ............. 106
Tires and Wheels - Inspect, Check .................... 108
Lift Chains - Test, Check, Adjust......................... 109

When Required
Self Diagnostics - Test .......................................... 81
Compact Display Keys.......................................... 81
Carriage Roller Extrusion Adjust........................ 86
Power Modules Discharge................................. 87
Fuses - Replace.................................................... 88
Seat - Lubricate .................................................... 88

Every 10 Service Hours or Daily

Every 2500 Service Hours or 15 Months

Walk-Around Inspection - Inspect......................... 89


Mast Channels - Lubricate.................................... 91
Battery - Check, Exchange, Charge ..................... 91
Indicator - Check................................................... 93
Tires and Wheels - Inspect ................................... 94
Back-up Alarm (If Equipped) - Test....................... 94

Hydraulic Oil - Check, Change............................116

Every 2000 Service Hours or Yearly


Steer Wheel Bearings - Reassemble .................. 111
Fork - Inspect ......................................................113
Air Breather - Change .........................................115

First 50 - 100 Service Hours or a Week


Drive Axle Oil Change........................................ 95
G

First 250 Service Hours or a Month


Hydraulic Return Filter - Change .......................... 96

Every 250 Service Hours or Monthly


Brake Oil Level - Check ........................................ 97
Drive Axle Oil Level - Check ................................. 97
Parking Brake - Test ............................................. 98
Hydraulic Oil Level - Check .................................. 98
Wheel Bolts - Check ............................................. 99
Mast, Carriage, Lift Chains & Attachmemts - Inspect,
Lubricate ............................................................... 99

80

Maintenance Section

When Required
You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Self Diagnostics - Test

Compact Display Keys


Type1

Prepare for the Self Diagnostic - Test


The Micro-Controller has a built-in diagnostic
system to provide aid in rapid troubleshooting of lift
truck problems.
NOTE: Make sure the battery is fully charged
before any of the following tests are made.
After the self-diagnostics tests have been started,
the procedure does not have to be completed. At
any point the procedure can be interrupted, and the
lift truck made ready for operation.
Type2

1. Park the lift truck level, with the forks lowered


and the mast tilted forward until the fork tips
touch the floor.

As you can see in Fig. on right side of display for


type1 or type2 there are four keys: E-S-H, UP
(TURTLE), DOWN and ENTER.

2. Block the drive wheels.

The function of each of them is described as


follows:

3. Release the parking brake.

ENTER key
1. When you switch your device on, this key,
pressed for 3 consecutive seconds, allows
entering both to parameter calibration and to
diagnostic mode.
2. During usual operations, this key, pressed for 3
consecutive s, allows you to access merely to
diagnostic mode.
Remember that if the display is operating in
diagnostic mode during typical operations, you can
exit this procedure pressing once ENTER key.

4. Move the directional control lever to NEUTRAL.


5. Move the key switch to OFF.

81

Maintenance Section

Moreover, ENTER key is used to confirm the new


value of the parameter in calibration
procedure.

Run Time Diagnostic


Type1

UP key
1. Pressing of this key, in calibration and
diagnostic mode, you increase the number of
the parameter displayed.
2. In calibration phase, you increase the numeric
value of the parameter displayed.

TURTLE key
Remember that pressing this key you can toggle
between slow running and normal working condition
(if the lift truck is already in speed limitation mode).

Type2

DOWN key
1. Pressing of this key, in calibration and
diagnostic mode, you decrease the number of
the parameter displayed.
2. In calibration phase, you decrease the numeric
value of the parameter displayed.
3. "3. way of shifting from the visualization of "time
meter" and "odometer": you can do it by
pressing the "DOWN ARROW" button of
Compact display for 1 second in succession
during normal working of the display. "

This operating mode enables you to test main


analogical and digital signals managed by your
system.

E-S-H key

Enter diagnostic mode if you are switching on your


lift truck:

With this key, you can modify the device operating


condition, in a circular sequence, as described in
Table 7 :
CURRENT WORKING
CONDITION
Economic (E)
Standard (S)
High (H)
Limitation 1 (L1)
Limitation 2 (L2)
Limitation 3 (L3)

1. Press ENTER key (for 3 consecutive s) until the


symbol 0 lights up.
2. Press DOWN key to enter diagnostic mode; the
symbol d is visualized and it persists until the
first parameter has been selected.

WORKING
CONDITION AFTER
THE KEY PRESSURE
Standard (S)
High (H)
Limitation 1 (L1)
Limitation 2 (L2)
Limitation 3 (L3)
Economic (E)

Enter diagnostic mode if you are working as usual


with your lift truck:
1. Press ENTER key (for 3 consecutive s) until
symbol d appears; it will persist as long as the
first parameter has been selected.
After diagnostic operation mode has been
enabled, you can choose the parameter you
want to analyse using UP and DOWN keys
(parameter number increases using UP key and
decreases with DOWN key).

Table 7
NOTE: You can modify system operating modes
only after enabling their management with
EYE applicative software.

82

Maintenance Section

Here, in Table 11, you have a list of the


parameters you can analyze with their
respective displaying order :

83

Maintenance Section

PARAMETER NUMBER

PARAMETER DESCRIPTION

Right traction motor speed [rpm]

Right traction motor speed reference [rpm]

Left traction motor speed [rpm]

Left traction motor speed reference [rpm]

Lift voltage [mV]

Battery voltage [V10]

Right traction motor power module temperature [C / F]

Pump motor power module temperature [C / F]

Pump motor speed [rpm]

10

Pump motor speed reference [rpm]

11

Accelerator potentiometer voltage [mV]

12

Accelerator second potentiometer voltage [mV]

13

Steering sensor voltage [mV]

14

Left traction motor power module temperature [C / F]

15

Right traction motor phase current U [A rms]

16

Right traction motor phase current V [A rms]

17

Right traction motor phase current W [A rms]

18

Left traction motor phase current U [A rms]

19

Left traction motor phase current V [A rms]

20

Left traction motor phase current W [A rms]

21

Pump motor phase current U [A rms]

22

Pump motor phase current V [A rms]

23

Pump motor phase current W [A rms]

24

Right traction motor temperature [C / F]

25

Left traction motor temperature [C / F]

26

Pump motor temperature [C / F]

27

Seat switch hour meter [h]

28

Drive motor hour meter [h]

29

Pump motor hour meter [h]

30

Seat switch[digit]

31

Park brake switch [digit]

32

Start switch [digit]

33

Reverse traction direction switch [digit]

34

Forward traction direction switch [digit]

35

Pedal brake switch [digit]

84

Maintenance Section

36

3 / 4 wheels selection switch [digit]

37

Auxiliary 1 function (side shift) switch[digit]

38

Auxiliary 2 function switch [digit]

39

High lift switch [digit]

40

Tilt switch [digit]

41

Main breaker command [digit]

42

5V out [digit]

43

12V out [mV]

44

24V out [digit]

45

Buzzer command [digit]

46

Fans command [digit]

Table 11 : List of accessible parameters in diagnostic mode (from 1th to 46th)

85

Maintenance Section

In diagnostic mode selected parameter is visualized


as follows:

Carriage Roller Extrusion Adjust


1. Set the mast vertical.

- In the area dedicated to speed and alarm


signals, appears parameter number( flashing)

2. Lower the carriage completely.

- Its actual value is displayed in the area reserved


to the time meter.

3. On full free lift and full free triple lift models, the
bottom of the inner mast must be flush with the
bottom of the stationary mast.

In particular, if the selected parameter is:


Analogue input: COMPACT display shows the
parameter value, expressed in the
unit of Table 11
Digital input: if the command activated by the
operator corresponds to the
parameter selected, the value of the
quantity is visualized.
Other way the symbol e (error)
appears, except in following case:
- Seat switch active, for any selected
digital input.

4. Measure the distance from the bottom of the


inner upright to the bottom of carriage bearing.

To exit diagnostic mode, type ENTER key again.


NOTE: If an alarm occurs when diagnostic mode is
enabled, and the system is working as
usual, display returns automatically to its
typical visualization mode.
However you can enter diagnostic mode
again, pressing ENTER key (for 3
consecutive
s), until the last parameter displayed before
exiting is visualized.

5. The measurement (A) must be as follows in


Chart below.
Height of carriage roller extrusion (A)

If the selected parameter is a temperature, also


thermal alarm symbol is visualized.

86

STD mast

FF mast

FFT mast

-6

Maintenance Section

Power Modules Discharge

Personal injure could result if power modules


have not been discharged properly.
Battery voltage and high amperage are present.
The power modules must be discharged before
any contact with the electrical control system is
made.
Before touching any electrical components,
remove rings, watches and other metallic
objects from the hands and arms, then
discharge the power modules.

2. Open the hood.

3. Before touching any electrical components, the


power modules must be discharged. Put a 90
ohm, modules watt resistor in position bewtten
the terminals as shown. Hold the resistor in this
position for approximately ten seconds. This will
discharge the power modules.

The power modules are located in the control panel


at the rear of the lift truck.

4. Perform any necessary maintenance and repair


at this time.
5. Close the hood.
6. Connect the battery.

1. Disconnect the battery.

87

Maintenance Section

Fuses - Replace

Seat - Lubricate

The fuses are located in the control panel and fuse


box at the rear of the lift truck.
They protect the electrical system from damage
caused by overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, have the circuit checked and repaired.

NOTICE
Replace fuses with the same type and size only.
Otherwise, electrical damage can result.
If it is necessary to replace fuses frequently, an
electrical problem may exist. Contact your
DAEWOO Lift Truck dealer.

Check the operation of the seat adjusters. Make


surethat the seat slides freely on its track. Lightly oil
the seat slider tracks.

Horn
DC/DC converter
Lights(1)
Lights(2)
Fan
Key

- 10 amps
- 10 amps
- 10 amps
- 10 amps
- 10 amps
- 10 amps

Main Fuse - 700 amps

88

Maintenance Section

Every 10 Service Hours or Daily


You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Walk-Around Inspection - Inspect

6. Inspect the tires, valve stems and wheels for


cuts, gouges, foreign objects and loose or
missing nuts. Refer to Tires and Wheels in
Every 10 Service Hours or Daily section, if
repairs or replacement is necessary.

1. Inspect the operators compartment for loose


item and clean any mud or debris from the floor
plates.
2. Inspect the instrument panel for damage to the
Iindicator display.
3. Test the horn and other warning devices for
proper operation.

7. Inspect the overhead guard for damage, loose


or missing mounting bolts.

4. Inspect the mast and lift chains for wear, broken


links, pins and loose rollers.
5. Inspect the carriage, forks or attachments for
wear, damage and loose or missing bolts.

8. Inspect the hydraulic system for leaks, worn


hoses or damaged lines.

89

Maintenance Section

12. Move the directional lever to NEUTRAL.

9. Inspect the drive axle housing and the ground


for oil leaks. Refer to Drive Axle Oil in Every
1000 Service Hours or 6 Months section, if an
oil leak is found.

13. Turn the key switch to ON.


Type1
10. Adjust the operators seat.

Type2
11. Adjust the steering wheel to a comfortable
position.

90

Maintenance Section

14. Check the LCD display for battery discharge


status. A fully charged battery will be displayed
on the LCD display.

Battery - Check, Exchange,


Charge

15. Check the operation of parking brake, service


brake, controls and other devices that may be
equipped on your lift truck.

Battery Access
Park the lift truck level, with the forks lowered and
the mast tilted forward until the fork tips touch the
floor.

Mast Channels - Lubricate

1. Disconnect the battery.


The channels on the roller-type mast require a
break-in period. Apply a light film of lubricant on the
channels where the rollers ride. This will prevent
metal peel until the rollers set a pattern.

2. Tilt the steering column to the full upright


position and move the seat fully rearward.
3. Release the hood latch lever which retain the
seat and battery cover.

4. Raise the seat and battery cover.

91

Maintenance Section

3. Check the specific gravity of the battery. If the


specific gravity reading is below 1.150, the
battery must be charged.

Check Electrolyte

NOTICE
The battery should not be used if a difference in
specific gravity between two cells is greater
than .020. If this condition exists, the battery should
be put on an equalization charge. If this does not
correct the condition, consult your battery supplier.
4. Check the electrolyte level of all cells. Maintain
the electrolyte level about 13 mm (.50 inch)
above the plates. Add water as needed. Use
only distilled water. Add water before charging
the battery.

1. Inspect the battery compartment for loose


connections, frayed cables and properly
secured battery restraint.

5. Lower the seat and battery cover. To closed


position and secure with the latch on the front of
the cover.

2. Clean the top of the battery. If necessary, clean


the top of the battery with a solution of baking
soda and hot water.

6. Connect the battery.


NOTICE

Battery Exchanging
Vent caps must be tight to prevent soda solution
from entering battery cells.

NOTE: Batteries should be changed, water added


and charged only in areas where proper
protective and ventilation facilities are
provided.

A clean battery top is essential to avoid conductive


paths on higher voltage batteries.

1. Refer to Battery Access topic for battery


access.

To make the solution, add 0.5 kg (1 lb) of baking


soda to 4 liters (1 gallon) of water. Use a brush
having flexible bristles. Apply the soda solution to
the top of the battery until the cleaning action of the
soda stops. After cleaning action has stopped, rinse
batteries thoroughly with water. Dry the batteries
with low air pressure.

2. Cover the battery with hinged battery cover or


with plywood.
3. Install insulated battery tree and hoist, of
sufficient capacity, to the battery.
4. Remove the battery. Recharge the battery.
5. Install a fully charged battery.
6. Remove the battery tree. Remove hinged
battery cover or plywood from the top of the
battery.
7. Connect the battery.
8. Lower the seat and battery cover to closed and
secure with the latch on the front of the cover.
9. Adjust the seat position.

92

Maintenance Section

Battery Charging

When charging, proper provision must be made


for venting of the charging gases. Battery
container lids and the covers of battery
compartments must be opened or removed. The
vent plugs should stay on the cells and remain
closed.
With Battery Installed in Lift Truck
3. Move the directional control lever to the
NEUTRAL position.

1. Refer to Battery Access topic for battery


access.
2. Connect the battery to the charger and charge
the battery. Observe safety warnings for
charging batteries.
3. When the battery is fully charged, disconnect
the battery from the battery charger.
4. Connect the battery to the lift truck.
5. Lower the seat and battery cover to closed
position and secure with the latch on the front of
the cover.
6. Adjust the seat position

4. Close the seat switch.


Type1

Indicator - Check

Type2

1. Turn the key switch to ON.

5. Check the indicator LCD display for the


discharge state of the battery.

2. Engage the parking brake.

93

Maintenance Section

Tires and Wheels - Inspect

Inflate the tires, if necessary. See Tire Inflation


Information section of this manual.
Inspect tires and valve stems for wear, cuts, gouges
and foreign objects.

Back-up Alarm (If Equipped) - Test

Check all components carefully and replace any


cracked, badly worn, damaged and severely rusted
or corroded parts with new parts of the same size
and type. If there is any doubt, replace with new
parts. Do not, under any circumstances, attempt to
rework, weld, heat or braze any rim components.

With the key switch on, apply the service brake and
move the directional control lever into REVERSE.
The alarm should start to sound immediately. It will
continue to sound until the directional control lever
is moved to NEUTRAL or FORWARD.

Check Inflation Pressure (If equipped with


pneumatic tires)

Measure the tire air pressure on each tire.

94

Maintenance Section

First 50 - 100 Service Hours or a Week


You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Drive Axle Oil Change


After the first 50 ~ 100 hour of operation,
subsequently after every 500 hours or 3 months.

4. Fill the drive axle housing with oil through air breather plug hole() , the accurate amount of
oil is defined by the opening of level checking
plug().
5. Maintain the oil level.

Park the lift truck level, with the parking brake


engaged and directional control lever in NEUTRAL.
1. Raise the mast and block in place.

6. Screw the level checking plug() and air breather in with the seal ring.

2. Turn the key switch to OFF.

7. Raise the mast and remove the blocking.

3. Unscrew oil air - breather (Oil filling plug) (1),


level checking plug (2) and remove the drain
plug (3). Allow the oil to drain.

95

Maintenance Section

First 250 Service Hours or a Month


You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Hydraulic Return Filter - Change

Hot oil and components can cause personal


injury. Do not allow hot oil or components to
contact skin.

Park the lift truck level with the forks lowered,


parking brake engaged, directional lever in
NEUTRAL and the key switch to OFF.

1. Loosen the bolts of the hydraulic tank top plate


assembly.

2. Remove the return filter by hand and discard it.


3. Install a new filter assembly.
4. Install the tank top plate assembly and fasten
the bolts.

96

Maintenance Section

Every 250 Service Hours or Monthly


You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Brake Oil Level - Check

Drive Axle Oil Level - Check

G
The brake system reservoir is located at the right
side of the steering column.

1. Park the lift truck on a level surface. Raise the


high enough to gain access to the housing
level/fill plugs.

1. Remove the filler cap.


2. Use blocking to secure the carriage in this
position.

2. Maintain the brake fluid level in the brake


system reservoir.
3. Clean and install the filler cap.

3. Remove the housing level/fill plugs. Maintain


lubricant level to the bottom of the plug opening.
Install the level/fill plugs.
4. Remove blocking. Lower the carriage.

97

Maintenance Section

Parking Brake - Test

Hydraulic Oil Level - Check

NOTE: Be sure area around the lift truck is clear of


personnel and obstructions.
1. Drive the lift truck with a rated load up a 15%
incline.

To prevent personal injury, the operator must be


ready to use the service brake if the parking
brake is not adjusted correctly and the lift truck
starts to move.
1. Operate the lift truck for a few minutes to warm
the oil.
2. Park the lift truck level, with the forks lowered,
mast tilted back (all cylinders retracted), parking
brake engaged, directional control lever in
NEUTRAL, and the key switch to OFF.
3. Open the hood.
4. Remove the dipstick
5. Maintain the oil level to the full mark on the
breather/dipstick.
2. Halfway up the incline, stop the lift truck by
applying the service brakes.

6. Install the dipstick.


7. Install the access cover.

3. Engage the parking brake.


4. Release the service brake.
If the parking brake has the correct adjustment, the
lift truck will be held in place.
NOTE: The lift truck may move slightly while the
parking brake is engaging.
5. If the parking brake does not hold, adjust the
parking brake lever screw.

98

Maintenance Section

Wheel Bolts - Check

Mast, Carriage, Lift Chains &


Attachmemts - Inspect, Lubricate

Steer Wheels

1. Operate the lift, tilt and attachment controls.


Listen for unusual noises. These may indicate a
need for repair.

1. Inspect tightness of wheel nuts in a sequence


opposite each other 113 Nm (85 lbft).

Drive Wheels

2. Inspect for loose bolts and nuts on the carriage


and load backrest. Remove any debris from the
carriage and mast.
2. Inspect tightness of wheel nuts in a sequence
opposite each other to 140 Nm (105 lbft) for
the cushion tire In case of the solid softer tire,
tighten the nuts 180 Nm (135 lbft).

3. Inspect the forks and attachments for free


operation and damage. Have repairs made if
needed.

4. Brush in a film of oil on all links of the chain.

99

Maintenance Section

5. Raise and lower the carriage a few times to


work lubricant into the chain links.

NOTICE
Lubricate chains more frequently than normal
where the atmosphere can cause corrosion to
components, or when lift truck must work in rapid lift
cycles.

6. Inspect the chain anchors and individual links


for lwear, loose pins or cracked leaves.
NOTE: Have all reparis and adjustments made as
required.

100

Maintenance Section

Every 500 Service Hours or 3 Months


You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Mast Pivot Eyes - Check, Lubricate

Tilt Cylinders - Check, Adjust,


Lubricate
Chassis Pivot Eyebolts - Lubricate

1. Lubricate the mast pivot eyes, one fitting on


each side of the mast.
1. Remove floor plates.

2. Check the mast pivot eye pins for loose retainer


bolts and wear.
2. Lubricate pivot eyebolts, one fitting on each tilt
cylinder.

Cylinder Rod Extension - Adjust

3. Check the pivot eye pins for loose retainer bolts


and wear.

1. Tilt the mast to the full forward position.

101

Maintenance Section

Crosshead Rollers - Inspect


1. Operate the mast through a lift cycle. Watch the
chains move over the crosshead rollers. Make
sure the chain is tracking over the rollers
properly.

2. Measure the extended length of the cylinder


rods from the cylinder housing to the pivot eye.
The cylinder rods must be within 3.18 mm (.125
inch) of each other.
3. To adjust the cylinder rod extension, loosen bolt.
Typical example

4. Turn the cylinder rod in or out of pivot eye to


obtain the proper adjustment. Turning the rod
into pivot eye shortens the stroke. Turning the
rod out of pivot eye lengthens the stroke.

2. Check for damaged crosshead rollers, guards


and retainer rings.

5. Tighten bolt to a torque of 95 15 Nm (70 10


lbft). Check the cylinder rods again for even
travel.
6. With the mast at the tilt back position, install
shims as required to permit no gap between
pivot eye and spacer, so the mast does not
twist at full tilt back position.

102

Maintenance Section

Mast Hinge Pins - Lubricate

Steering Mechanism - Lubricate

Lubricate two fittings

Lubricate one fitting

1. Lower the forks and tilt the mast forward.

Lubricate fitting on steer axle.

Drive Axle Oil - Change


See topic, Drive Axle Oil - Change in First 50
100 Service Hours or a Week.

Overhead Guard - Inspect

2. Lubricate the mast hinge pins. One fitting on


each side of the mast. Total of two fittings.

Look for any loose or damaged bolts. Replace


damaged bolts or missing bolts with original
equipment part only. Retighten bolts to a torque of
60 10 Nm (45 7 lbft).
Check the overhead guard for bent or cracked
sections. Repair if needed.

103

Maintenance Section

Control Panel - Clean, Inspect


Pressure air can cause personal injury.

Park the lift truck level, with the forks lowered,


parking brake engaged, directional control lever in
NEUTRAL, and the key switch to OFF.

When using pressure air for cleaning, wear a


protective face shield, protective clothing and
protective shoes.

Disconnect the battery.

The maximum air pressure must be below 205


kPa (30 psi) for cleaning purposes.

1. Open the hood.

2. Clean the control panel with 205 kPa (30 psi)


maximum air pressure, until dust is removed
from the control panel.

Battery voltage and high amperage are present.


The Power Modules must be discharged before
any contact with the control panel is made.
Personal injury could result if it has not been
discharged properly.

3. Inspect all wiring for loose connections, frayed


cables and loose mounting bolts.
4. Inspect the fuses for looseness, corrosion and
broken connections.

104

Maintenance Section

Directional Lever Check

5. Close the hood and connect the battery.


Check the tightness of the directional lever
mounting bracket. Adjust if needed.
Check for ease of movement of directional lever.
Adjust if needed.
Check for loose wiring. Secure wiring if needed.

105

Maintenance Section

Every 1000 Service Hours or 6 Months


You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Drive Axle Oil - Change


B15/18/20T-2 (36V) Only
See topic, Drive Axle Oil - Change in First 50
100 Service Hours or a week.

Drive and Pump Motor - Clean,


Inspect
4. Fasten lift chains, of equal length, in lift
openings in the front of the lift truck.
5. Slowly lift the front of the lift truck, until the drive
wheels are just off the ground.
6. Put stands under the frame. Remove the
tension on the lift chains.
7. Remove the battery.
8. Remove the floor plate.
1. Disconnect the battery.
9. Connect the battery. Turn the key switch to ON
and apply pressure to the seat switch.

2. Block the steer wheels.


3. Remove the battery. See topic, Battery in
Every 10 Service Hours or Daily section of this
manual.

NOTICE
Do not move directional lever from one direction to
the other when the drive wheels are off the ground
and rotating.
Damage can be caused to the control panel.

106

Maintenance Section

.
Battery voltage and high amperage are present.
The Power Module must be discharged before
any contact with the control panel is made.
Personal injury could result if it has not been
discharged properly.

10. Operate the drive motor slowly. Blow off the


drive motor END SHIELD with 205 kPa (30 psi)
maximum air pressure, until dust is removed
from the motor.

Typical example

11. Install the floor plate.


12. Slowly lift the front of the lift truck and remove
the stands. Lower the lift truck to the floor.
Remove the chains.
13. Install and connect the battery. Lower the
battery cover and adjust the seat.

107

Maintenance Section

Tires and Wheels - Inspect, Check

Servicing and changing tires and rims can be


dangerous and should be done only by trained
personnel using proper tools and procedures. If
correct procedures are not followed while
servicing tires and rims, the assemblies could
burst with explosive force and cause serious
physical injury or death. Follow carefully the
specific information provided by your tire
serving man or dealer.

Do NOT inflate a tire that has been run while flat or


underinflated, without first checking to make sure
the locking ring on the wheel is not damaged and is
in position.
When tires are changed be sure to clean all rim
parts, and if necessary, repaint to stop detrimental
effects of corrosion.
Sand blasting is recommended for removal of rust.
Check all components carefully and replace any
cracked, badly worn, damaged and severely rusted
or corroded parts with new parts of the same size
and type. If there is any doubt, replace with new
parts. Do not, under any circumstances, attempt to
rework, weld, heat or braze any rim components.

Inspect tires for wear, cuts, gouges and foreign


objects. Look for bent rims and correct seating of
locking ring.
If equipped with pneumatic tires, check tires for
proper inflation. See topic, Tire Infaltion Pressure.
To inflate tires always use a clip-on chuck with
minimum 60 cm (24 inches) length of hose to an
inline valve and gauge.
Always stand behind the tread of the tire, NOT in
front of the rim.
Lift truck capacity is dependent on tire type. Your lift
truck dealer should be consulted for possible down
ratings when pneumatic tires are used to replace
solid (cushion) tires.

1. Install drive wheel. Install two nuts opposite


each other (180).
2. Install the remaining nuts. Tighten all nuts in a
crisscross sequence opposite each other (180)
to 140 25 Nm (105 20 lbft) for the cushion
for the solid softer tire or (180) to 180 25 Nm
(135 20 lbft) for the solid softer tire.
3. Reverse the lifting procedure for the front of the
lift truck and lower it to the ground.

108

Maintenance Section

Check for Equal Tension

Lift Chains - Test, Check, Adjust


Lift Chain Wear Test
Inspect the part of the chain that is normally
operated over the cross head roller. When the chain
bends over the roller, the movement of the parts
against each other causes wear.
Inspect to be sure that chain link pins do not extend
outside of the link hole. If any single link pin is
extended beyond its connecting corresponding link,
it should be suspected of being broken inside of its
link hole. Lift chains are required to check for wear
about every 1,000 service hours or 6 months.

Typical example

Chain wear test is a measurement of wear of the


chain links and pins. Take the following steps to
check chain wear.

Lift the carriage and the mast high enough for


getting tension on lift chains. Check the chains, and
make sure the tension is the same. Lift chains are
required to check for equal tension about every
1,000 service hours or 6 months.

1. Lift the mast and carriage enough for getting


ension on lift chains.

Personal injury can be caused by sudden


movement of the mast and carriage.
Keep hands and feet clear of any parts that can
move.

Lift Chain Adjustment


Typical example
2. Measure precisely ten links of chain distance at
the center of pins in millimeter.
3. Calculate chain wear rate*.
4. If the chain wear rate is 2% or more, replace
the lift chain.
* Chain wear rate (%)
=

Typical example for carriage equal tension

- Pitch** X 10
( Actual measurement
)x100
Pitch** X 10

If the tension is not the same on both chains, take


the procedure as follows.

**Chain Pitch = 15.88 mm(0.63 in)

NOTE: If carriage height is not correct, make


adjustments by following procedures.

109

Maintenance Section

Carriage Chain Adjustment

Mast Chain Adjustment - FF,FFT Mast

Make sure that carriage height is correct. If correct,


adjust the chain for equal tension. If not, adjust the
chain for correct carriage height by adjusting
anchor nuts(1),(2).
NOTE: See the previous section, Carriage Roller
Extrusion in When Required. for proper
height of carriage.
1. Fully lower the carriage and tilt mast forward or
lift the carriage and put blocks under the
carriage to release the tension from the lift
chains.

Typical example for FF mast

2. Loosen nut(1) and adjust nut(2) to get proper


distance from bottom of inner upright to the
bottom of carriage bearing.

Typical example for FFT mast


Make sure that mast height is correct. If correct,
adjust chain for equal tension. If not, adjust mast
chain for correct mast height by adjusting anchor
nuts(3),(4).

Typical example for carriage chain of STD mast

NOTE: See the previous section, Carriage Roller


Extrusion in When Required. for proper
inner mast height.
1. Lift the inner mast and put blocks under the
inner mast to release the tension from the lift
chains.
2. Loosen nut(3) and adjust nut(4) to make inner
mast rail flush with outer mast rail bottom.
Typical example for carriage chain of FF,FFT mast
3. Make adjustment anchor nuts(3),(4) for equal
chain tension.

3. Make adjustment anchor nut(1),(2) for equal


chain tension.
4. Set the mast vertical and raise the carriage and
check equal chain tension. If not equal, repeat
the same procedure as step 1 through step 3.

4. Raise the inner mast and check equal chain


tension. If not equal, repeat the same
procedure as step 1 through step 3.

5. Put LOCTITE No. 242 Tread lock on the


threads of the anchor nuts(1),(2) after the
adjustment is completed.

5. Put LOCTITE No. 242 tread lock on the threads


of the anchor nuts(3),(4) after the adjustment is
completed.

110

Maintenance Section

Every 2000 Service Hours or Yearly


You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Steer Wheel Bearings Reassemble

2. Remove wheel nuts (1). Remove steer wheel


(2).
1. Turn steer wheel 90 with lug nuts exposed.

3. Remove the cover. Bend lockwasher tab back


and remove locknut (3). Remove the
lockwasher, washer and spacers. Remove the
hub group seal and the bearings.

NOTE: When lifting the rear of the lift truck, apply


the parking brake and block the drive tires.
Using two equal length chains, place chain
hooks under counterweight lip, at each end
of the steer wheel opening or a hydraulic
floor jack and a block of wood in the center
of the wheel opening. Raise the lift truck
slowly and block under the counterweight at
the outer ends. Lower the lift truck on the
blocking.

5
4

4. Inspect the bearings and the seal for wear or


damage. Replace if necessary. Reassemble the
bearing. Install bearing (4) and seal (5).
Lubricate seal lip (5) lightly with bearing
lubricant.

111

Maintenance Section

6
8
7

5. Install hub group(6) . Pack area (7) with bearing


lubricant. Install bearing (8). Install the spacers,
washer, lockwasher and locknut (3). Hand
tighten the locknut.

6. Install the steer wheel. Put two nuts opposite


each other (144) in B15/18/20T-2(36V) or
(180) in B13/15/18/20T-2(48V). Tighten both.
Install all remaining nuts. Tighten all nuts in a
crisscross sequence opposite each other (144)
to a torque of 14025 Nm (10520 lbft) in
B15/18/20T- 2(36V) or (180) to 18025 Nm
(13520 lbft) in B13/15/18/20T-2(48V).

7. While rotating the wheel, tighten the locknut to


34 Nm (24 lbft). Loosen the nut completely.
Tighten the nut again to a torque of 113 Nm
(82 lbft) and lock within this range. Install the
cover.
8. Raise the lift truck and remove the blocking.
Lower the lift truck to the floor.

112

Maintenance Section

exceeds 93 degrees or deviates by more than 3


degrees from an original angle other than 90
degrees, as may be found in some special
appli- cation forks.

Fork - Inspect

Forks should be inspected, at a minimum, every 12


months. If the truck is being used in a multi-shift or
heavy duty operation, they should be checked
every six months.

3. Check the straightness of the upper face of


blade (D) and the front face of shank (E) with a
straight edge.

1. Inspect the forks carefully for cracks. Special


attention should be given to the heel section (A),
all weld areas and mounting brackets (B).
Inspect the top and bottom hooks on forks used
on hook type carriages and tubes on shaft
mounted forks.

The fork should be withdrawn from service if the


deviation from straightness exceeds 0.5 percent of
the length of the blade and/or the height of the
shank respectively 5 mm/1000 mm (0.18"/36").

Forks with cracks should be removed from service.


"Wet Test" magnetic particle inspection is
gener- ally preferred due to its sensitivity and
the ease of interpreting the results. Portable
equipment is usually recommended so it can be
moved to the lift truck.
Inspectors should be trained and qualified in
accordance with The American Society for Non
Destructive Testing, Level II Qualifications.

4. Check the difference in height of one fork tip to


the other when mounted on the fork carrier. A
difference in fork tip height can result in uneven
support of the load and cause problems with
entering loads.
The maximum recommended difference in fork
tip elevation (F) is 6.5 mm (0.25") for pallet
forks and 3 mm (0.125") for fully tapered forks.
The maximum allowable difference in fork tip
eleva- tion between the two or more forks is 3
percent of blade length (L).
Replace one or both forks when the difference
in fork tip height exceeds the maximum
allowable difference. Contact your local
DAEWOO Lift Truck Dealer for further
information.

2. Check the angle between the upper face of the


blade and the front face of the shank. The fork
should be withdrawn from service if angle (C)

113

Maintenance Section

at both ends of the carriage and in the path of


the bottom fork hook. The load backrest
extension may be used in place of the stop
blocks in some cases.
Shaft mounted forks may use set collars or
spac- ers on the shaft to either side of the fork.
They may also use U bolts, pins, or similar
devices which engage the fork through the top
structure of the carriage.

5. Check the fork blade (J) and shank (H) for wear
with special attention to the heel (G). The fork
should be withdrawn from service if the
thickness is reduced to 90 percent or less of the
original thickness.
Fork blade length may also be reduced by wear,
especially on tapered forks and platens.
Remove the forks from service when the blade
length is no longer adequate for the intended
loads.

8. Check fork markings (N) for legibility. Renew


markings as required to retain legibility.

6. Check the fork mountings (K) for wear, crushing


and other local deformation, which can cause
excessive side to side wobble of the forks.
Excessive clearance on hook type forks may
allow them to fall from the carrier. Forks which
show visible signs of such damage should be
removed from service.

9. a. Lift the mast and operate the tilt control lever,


until the top surface of the forks is parallel
with the floor. Place two straight bars that are
the same width as the carriage, across the
forks as shown.
b. Measure the distance from the bottom of
each end of the two bars to the floor. The
forks must be parallel within 3 mm (.12 in)
for Full Tapered and Polished (FTP) forks,
all other forks 6.4 mm (.25 in), for their
complete length.

7. Check the positioning lock and other fork


retention devices to make sure they are in place
and working.
Hook type forks use a spring loaded pin (M),
located in the top hook, to engage notches in
the top carriage bar to hold the fork in place.

c. Put one fork, one third from the tip, under a


fixture that will not move. Then operate the
tilt control with caution until the rear of the
truck lifts just off the floor. Follow the same
proce- dure with the second fork. Repeat
Step a.

When adjusting the fork spacing, the forks are


prevented from sliding off the end of the
carriage by stop blocks. These stop blocks are

114

Maintenance Section

Air Breather - Change


Park the lift truck level, with the forks lowered,
parking brake engaged, directional lever in
NEUTRAL and the key switch to OFF.
1. Open the hood.
2. Install a new air breather.

3. Close the hood.

115

Maintenance Section

Every 2500 Service Hours or 15 Months


You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Hydraulic Oil - Check, Change

4. Remove the dipstick/filler cap assembly.


5. Fill the hydraulic tank. See topic, Refill
Capacities. Install the dipstick /filler cap
assembly.

1. Operate the lift truck a few minutes to warm the


oil.
Park the lift truck level, with the forks lowered,
parking brake engaged, directional lever in
NEUTRAL and the key switch to OFF.

6. Turn the key switch to ON and close the seat


switch. Operate the hydraulic controls and
steering system through a few cycles, to fill the
filter and lines.
7. Check for oil leaks.
8. Retract all cylinders.
9. Turn the key switch to OFF.
10. Maintain the oil level to the FULL mark on the
dipstick. Add oil if necessary.

2. Remove the hydraulic tank drain plug. Allow the


oil to drain. Clean and install the plug.
3. Open the hood.

116

Environment Section

Environment Protection
When servicing this lift truck, use an authorized
servicing area and an approved container to collect
coolant, oil, fuel, grease, electrolyte and any other
potential environmental pollutant before any lines,
fittings or related items are disconnected or
removed. After servicing, dispose of those materials
in an authorized place and container. When
cleaning the lift truck, be sure to use an authorized
area.

117

Index Section

Index
A

DOWN key ........................................................... 82


Drive and Pump Motor - Clean, Inspect .............. 106
Drive Axle Lubricant ............................................. 73
Drive Axle Oil - Change ............................... 103,106
Drive Axle Oil Change ....................................... 95
Drive Axle Oil Level - Check ................................. 97
Drive Wheels ........................................................ 99
During Storage ..................................................... 62

Accelerator Pedal ................................................. 46


After Storage......................................................... 62
Air Breather - Change ......................................... 115
Attachment Abbreviations (Includes Special Forks)
............................................................................. 36
Avoiding Lift Truck Tipover ................................... 20

B15/18/20T-2 (36V) Only .................................... 106


Back-up Alarm (If Equipped) - Test....................... 94
Battery ............................................................. 75,77
Battery - Check, Exchange, Charge...................... 91
Battery Access...................................................... 91
Battery Charging................................................... 93
Battery Discharge Indicator................................... 74
Battery Disconnect Before Servicing Warning ........ 9
Battery Exchanging............................................... 92
Battery Restraint Warning....................................... 8
Before Operating the Lift Truck ............................. 49
Before Storage...................................................... 62
Bent or Twisted Forks ........................................... 66
Better Battery Performance .................................. 51
Brake Fluid ........................................................... 73
Brake Oil Level - Check ........................................ 97

Electrical Braking (Plugging)................................. 54


Emergency Switch (If Equipped)........................... 44
Environment Management...................................... 3
Environment Protection ...................................... 117
E-S-H key ............................................................. 82
Every 10 Service Hours or Daily ........................... 89
Every 1000 Service Hours or 6 Months .............. 106
Every 2000 Service Hours or Yearly................... 111
Every 250 Service Hours or Monthly .................... 97
Every 2500 Service Hours or 15 Months ............ 116
Every 500 Service Hours or 3 Months ................ 101

F
Fatigue ................................................................. 66
Film for Function of Pedals (If Equipped).............. 46
First 250 Service Hours or a Month ...................... 96
First 50 - 100 Service Hours or a Week ................ 95
First Installation .................................................... 67
Foreword ................................................................ 2
Fork - Inspect...................................................... 113
Fork Inspection ..................................................... 67
Front and Rear Floodlights Switch........................ 43
Fuses - Replace ................................................... 88

C
Capacity Chart ...................................................... 32
Capacity Chart With Side Shifter........................ 33
Carriage Chain Adjustment................................. 110
Carriage Roller Extrusion Adjust ........................ 86
Causes of Fork Failure.......................................... 66
Chain and Linkage Oils (DEO or EO) ................... 72
Chassis Pivot Eyebolts - Lubricate...................... 101
Check Electrolyte.................................................. 92
Check for Equal Tension..................................... 109
Check Inflation Pressure (If equipped with
pneumatic tires) .................................................... 94
Cold Storage Applications..................................... 77
Compact Display Keys.......................................... 81
Control Panel - Clean, Inspect ............................ 104
Crosshead Rollers - Inspect................................ 102
Cylinder Rod Extension - Adjust ......................... 101

G
General Hazard Information ................................. 10

H
Hook-on type Fork ................................................ 61
Horn Button .......................................................... 43
How to Survive in a Tipover.................................. 27
Hydraulic Oil ......................................................... 72
Hydraulic Oil - Check, Change............................ 116
Hydraulic Oil Level - Check .................................. 98
Hydraulic Return Filter - Change .......................... 96
Hydraulic System.................................................. 77

D
Daily Inspection .................................................... 67
Directional Control Lever ...................................... 46
Directional Lever Check................................... 105
Display Segments................................................. 38

118

Index Section

No Alarm, No Movement (OPTION....................... 42


No Riders Warning ................................................. 8
Noise .................................................................... 31
Noise and Vibration .............................................. 31

Identification, Lift Capacity and Attachment Plate . 35


Important Safety Information................................... 4
Improper Modification or Repair............................ 66
Inching into Loads................................................. 55
Index................................................................... 118
Indicator - Check................................................... 93
Inspection, Maintenance and Repair of Lift Truck
Forks..................................................................... 65

O
Operating Techniques .......................................... 55
Operation................................................................ 3
Operation Information ........................................... 11
Operator Restraint System (If Equipped) .............. 16
Operators Station and Monitoring Systems.......... 37
Operators Warning and Identification Plate.......... 35
Operators Warning Plate ..................................... 35
Overhead Guard - Inspect .................................. 103
Overloading .......................................................... 66

K
Key Switch............................................................ 37

L
LED Indicators ...................................................... 41
Lift Chain Adjustment.......................................... 109
Lift Chain Wear Test ........................................... 109
Lift Chains........................................................ 11,77
Lift Chains - Test, Check, Adjust......................... 109
Lift Control Lever .................................................. 47
Lift Fork Adjustment .............................................. 61
Lift Truck Capacity Rating..................................... 35
Lift Truck Controls................................................. 45
Lift Truck Operation .............................................. 52
Lifting Drums or Round Objects ............................ 58
Lifting the Load ..................................................... 55
Literature Information.............................................. 2
Lubricant Information ............................................ 72
Lubricant Specifications ........................................ 72
Lubricant Viscosities ............................................. 79
Lubricant Viscosities and Refill Capacities............ 79
Lubricate one fitting ............................................ 103
Lubricate two fittings ........................................... 103
Lubricating Grease (MPGM) ................................. 73

P
Parking Alarm Warning (If Equipped) ................... 60
Parking Brake - Test............................................. 98
Parking Brake Lever ............................................. 45
Parking the Lift Truck............................................ 59
Power Modules Discharge................................. 87
Prepare for the Self Diagnostic - Test................... 81
Refill Capacities.................................................... 79

R
Run Time Diagnostic 82
S
Safety .................................................................. 2,5
Safety Rules ......................................................... 22
Seat - Lubricate .................................................... 88
Seat Adjustment ................................................... 43
Seat Switch .......................................................... 37
Self Diagnostics - Test.......................................... 81
Serial Number....................................................... 34
Serial Numbers Locations..................................... 34
Service Brake Pedal ............................................. 45
Shipping ............................................................... 63
Sideshift Attachment Control (If Equipped) ........... 48
Specifications ....................................................... 28
Steer Wheel Bearings - Reassemble.................. 111
Steer Wheels ........................................................ 99
Steering Mechanism - Lubricate ......................... 103
Storage Information .............................................. 62

M
Machine Lifting and Tiedown Information.............. 63
Maintenance ........................................................... 3
Maintenance and Repair....................................... 68
Maintenance Information ...................................... 13
Maintenance Intervals........................................ 3,80
Mast Abbreviations ............................................... 36
Mast Chain Adjustment - FF,FFT Mast ............... 110
Mast Channels - Lubricate .................................... 91
Mast Hinge Pins - Lubricate................................ 103
Mast Pivot Eyes - Check, Lubricate .................... 101
Mast, Carriage, Lift Chains & Attachmemts - Inspect,
Lubricate............................................................... 99
Monitoring Systems Indicator................................ 38

T
12 Months Inspection ........................................... 68
Tilt Control Lever .................................................. 47

119

Index Section

Tilt Cylinders - Check, Adjust, Lubricate ............. 101


Tilt Steering Column ............................................. 43
Tire Inflation.......................................................... 69
Tire Inflation Information ....................................... 69
Tire Inflation Pressures Adjustment ...................... 69
Tire Shipping Pressure ......................................... 69
Tires and Wheels - Inspect ................................... 94
Tires and Wheels - Inspect, Check ..................... 108
Torque for Metric Fasteners.................................. 71
Torque for Standard Bolts, Nuts and Taperlock
Studs .................................................................... 70
Torque for Standard Hose Clamps - Worm Drive
Band Type ............................................................ 70
Torque Specifications ........................................... 70
Torques for Bolts and Nuts With Standard Threads
............................................................................. 70
Torques for Taperlock Studs................................. 71
Towing Information ............................................... 64
Transportation Hints ............................................. 63
Traveling............................................................... 56
Turning ................................................................. 56
TURTLE key ......................................................... 82

U
Unloading ............................................................. 57
UP key .................................................................. 82
Use following engine oils are recommended for use
on chains and linkages. ........................................ 72

W
Walk-Around Inspection........................................ 49
Walk-Around Inspection - Inspect ......................... 89
Warning Signs and Labels ...................................... 5
Wheel Bolts - Check ............................................. 99
When Required..................................................... 81
G

120

DAEWOO HEAVY INDUSTRIES &


MACHINERY LTD. AROUND THE WORLD
: Sales office

: Parts depot

ED U.K.
(Northhampton, UK)
EDSA
(Frameries, Belgium)

ED France
(Paris France)

DMV
(Dusseldorf, Germany)

ED Italy
(Milano, Italy)

DWYC Beijing
(China)
DWYC
(Yantai, China)

DHIAC
(Cleveland, USA)

H.Q.
(Seoul, Korea)

(Atlanta, Georgia)
DWYC Shanghai
(China)

DME
(Sao Paulo, Brazil)

Head Office
Hwasu-Dong 7-11, Dong-Gu, Incheon, Korea.
Tel : 82-32-760-1114 Fax : 82-32-762-1546

Seoul Office
8th floor Daewoo Heavy Industries & Machinery Bidg, 14-34,
Youido-Dong, Youngdungpo-Gu, Seoul, Korea
Tel : 82-2-2167-3511 Fax : 82-2-2167-3530

NORTH AMERICA
Daewoo Heavy Industries America Corp.
2905 Shawnee Industrial Way, Suwanee,
Georgia 30024, U.S.A.
Tel : 1-770-831-2200 Fax : 1-770-831-0480

Daewoo Heavy Industries America Cleveland Office


4350 Renaissance Parkway, Warrensville Heights, OH44128,
U.S.A.
Tel : 1-216-595-1212 Fax : 1-216-595-1214

SOUTH AMERICA
Daewoo Maquinas E Equipamentos Ltda
AV Tres Andradas 819-jd. Piratininga-CEP
06230-050-Osasco-SP-Brazil
Phone : 55-11-3686-0177 Fax : 55-11-3686-0970

Daewoo Maschinen Vertriebs Gmbh Vertrieb


Gabelstapler
Hans-Bockler strasse 29, D-40764,Langenfeld-Fuhrkamp,
Germany
Tel : 49-2173-8509-91 Fax : 49-2173-8509-80

Euro Daewoo S.A


1A Rue, Achille Degrace, 7080 Frameries, Belgium
Tel : 32-65-61-3245 Fax : 32-65-67-6622

Euro Daewoo France S.A


Ave Du Bois De La Pie 33-49 Zac Paris Nordii BP 50069,95947
Roissy Cdg Cedex Paris, FRANCE
Tel : 33-1-48-63-1533 Fax : 33-1-48-63-0045

Euro Daewoo Italy S.A


Via Flume,13 I-20059 Vimercate(MI),ITALY
Tel : 39-039-6083202 Fax : 39-039-6083210

ASIA & OCEANIA


Daewoo Heavy Industries Yantai Co.,Ltd
E-10,Wuzhishan Road,Eco.& Tech, Development Zone,
Yantai, Shandong, China
Tel : 86-535-639-9150 Fax : 86-535-638-2004

Daewoo Heavy Industries Yantal Co.,Ltd

EUROPE

No.21 Xiao Yun Road Dong sanhuan beilu, chaoyang


District, Beijing, China(100027)
Tel : 86-10-6462-3181 ext)301 Fax : 86-10-6462-3278

Euro Daewoo U.K. Ltd

Daewoo Heavy Industries Yantai Co.,Ltd

12 Kildey Road Brackmills Industrial Estates Northhampton


NN4 7BK, U.K.
Tel : 44-1604-825600 Fax : 44-1604-825650

Room c,14F, Zhaofeng Universe Building 1800


Zhongshan W.Road Shanghai, Chain(200233)
Tel : 86-21-6440-1821 Fax : 86-21-6640-0842