For use in service manual

form SB4292E
sb4293e01
Feb. 2013

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 are listed with mark(*), they are not available for the initial
release of the manual. When items are updated, or supplements are added,
they will be provided separately.

Title form number

Service Manual Contents SB4293E00

Safety SB2003E01
Torque Specifications SB2004E00

DRIVE & CONTROL SYSTEM

MicroController Control Systems SB4294E00

POWER TRAIN

Power Train SB4295E01

VEHICLE SYSTEM

Vehicle System SB4296E00

Vehicle System D & A SB4297E00
Mast System SB4298E00
Hydraulic System Schematic SB4299E00
Electric System Schematic SB4300E01

OPERATION & MAINTENANC E

Operation & Maintenance Manual SB2351E

Models ; B10R-5, B13R-5, B15R-5, B16R-5

This document is the informational asset of Doosan Corporation. Thus, unauthorized

access, revision, distribution and copying of this document are strictly prohibited.

WARNING
SAFETY
WARNING
The proper and safe lubrication and
maintenance for this machine, recommended
by DOOSAN, are outlined in the OPERATION
& MAINTENANCE GUIDE for this machine.
Improper performance of lubrication or
maintenance procedures is dangerous and
could result in injury or death. Read and
understand the OPERATION & mud or debris from steps, walkways or work
MAINTENANCE GUIDE before performing any
lubrication or maintenance.
The service man or mechanic may be unfamiliar
with many of the systems on this machine. This
makes it important to use caution when performing
service work. A knowledge of the system and/or
components is important before the removal or
disassembly of any component.
Because of the size of some of the machine
components, the serviceman or mechanic should
check the weights noted in this Manual, Use proper
lifting procedures when removing any components.
Following is a list of basic precautions that should
always be observed.
1. Read and understand all Warning plates and
decals on the machine before operating,
lubricating or repairing the product.
2. Always wear protective glasses and protective
shoes when working around machines. In
particular, wear protective glasses when
pounding on any part of the machine or its
attachments with a hammer or sledge. Use
welders gloves, hood/goggles, apron and other
protective clothing appropriate to the welding job
being performed. Do not wear loose-fitting or torn
clothing. Remove all rings from fingers when
working on machinery.
3. Do not work on any machine that is supported
only by lift jacks or a hoist. Always use blocks or
jack stands to support the machine before
performing any disassembly.
4. Lower the forks or other implements to the
ground before performing any work on the
machine. If this cannot be done, make sure the
forks or other implements are blocked correctly
to prevent them from dropping unexpectedly.
1 of 2
SB2003E01
July. 2012
WARNING
Do not operate this machine unless you have
read and understand the instructions in the
OPERATOR'S GUIDE. Improper machine
operation is dangerous and could result in
injury or death.
5. Use steps and grab handles (if applicable) when
mounting or dismounting a machine. Clean any
platforms before using. Always face machine when
using steps, ladders and walkways. When it is not
possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
perform safe repair operations.
6. To avoid back injury, use a hoist when lifting
components which weigh 23 kg (50 lb.) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are of the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes are
not to be side loaded during a lifting operation.
7. To avoid burns, be alert for hot parts on machines
which have just been stopped and hot fluids in lines,
tubes and compartments.
8. Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located at
opposite ends of the cover or device and pry cover
loose to relieve any spring or other pressure, before
removing the last two bolts or nuts completely.
9. Be careful when removing filler caps, breathers and
plugs on the machine. Hold a rag over the cap or
plug to prevent being sprayed or splashed by
liquids under pressure. The danger is even greater
if the machine has just been stopped because fluids
can be hot.
10. Always use tools that are in good condition and be
sure you understand how to use them before
performing any service work.
11. Reinstall all fasteners with same part number. Do
not use a lesser quality fastener if replacements
are necessary. Do not mix metric fasteners with
standard nuts and bolts.
12. If possible, make all repairs with the machine
parked on a level, hard surface. Block machine so
it does not roll while working on or under machine.
13. Disconnect battery and discharge any capacitors
(electric trucks) before starting to work on
machine. Hang "Do Not Operate" tag in the
Operator's Compartment.
14. Repairs, which require welding, should be
performed only with the benefit of the appropriate
reference information and by personnel
adequately trained and knowledgeable in welding
procedures. Determine type of metal being
welded and select correct welding procedure and
electrodes, rods or wire to provide a weld metal
strength equivalent at least to that of parent
metal.
15. Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will it
be damaged in operation by contacting sharp
corners, or by rubbing against some object or hot
surface. Do not connect wiring to a line
containing fluid.
16. Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.
17. Always support the mast and carriage to keep
carriage or attachments raised when
maintenance or repair work is performed, which
requires the mast in the raised position.
18. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Pin hole (very small) leaks can
result in a high velocity oil stream that will be
invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.
19. Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat,
vibration or rubbing against other parts during
operation. Shields that protect against oil spray
onto hot exhaust components in event of a line,
tube or seal failure must be installed correctly.
20. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
2 of 2
21. Do not operate a machine if any rotating part is
damaged or contacts any other part during
operation. Any high speed rotating component
that has been damaged or altered should be
checked for balance before reusing.
22. On LP equipped lift trucks, be sure to close the
valve on the LP tank before service work is
performed. Always close the valve on the LP
tank when the lift truck is being stored. Do not
check for LP leaks with an open flame.
23. Caution should be used to avoid breathing dust
that may be generated when handling
components containing asbestos fibers. If this
dust is inhaled, it can be hazardous to your
health. Components in DOOSAN products that
may contain asbestos fibers are brake pads,
brake band and lining assemblies, clutch plates
and some gaskets. The asbestos used in these
components is usually bound in a resin or sealed
in some way. Normal handling is not hazardous
as long as airborne dust which contains asbestos
is not generated.
If dust which may contain asbestos is present, there
are several common sense guidelines that should be
followed.
a. Never use compressed air for cleaning.
b. Avoid brushing or grinding of asbestos containing
materials.
c. For clean up, use wet methods or a vacuum
equipped with a high efficiency particulate air
(HEPA) filter.
d. Use exhaust ventilation on permanent machining
jobs.
e. Wear an approved respirator if there is no other
way to control the dust.
f. Comply with applicable rules and regulations for
the work place (for example in the U.S.A., OSHA
requirements as set forth in 29 CFR 1910. 1001).
g. Follow environmental rules and regulations for
disposal of asbestos.
h. Avoid areas where asbestos particles may be in
the air.
 SB2004E00
Dec.1998

Specifications
TORQUE
SPECIFICATIONS

This document is the informational asset of Doosan Corporation.

Thus, unauthorized access, revision, distribution and copying of this document are strictly prohibited.
STANDARD TORQUE FOR METRIC FASTENERS

NOTE : Take care to avoid mixing metric and inch dimensioned fasteners.
Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or
possible injury. Exceptions to these torques are given in the Service Manual where
needed.

NOTE : Prior to installation of any hardware, be sure components are in near new
condition. Bolt and nut threads must not be worn or damaged. Hardware must be
free of rust and corrosion. Clean hardware with a non-corrosive cleaner and apply
engine oil to threads and bearing face. If thread lock or other compounds are to be
applied, do not apply engine oil.

METRIC NUTS AND BOLTS

THREAD
SIZE STANDARD TORQUE
(mm) (N i m) (lb i ft)
M6 12 ±3 9 ± 2
M8 28 ±7 20 ± 5
M10 55 ± 10 40 ± 7
M12 100 ± 20 75 ± 15
M14 160 ± 30 120 ± 22
M16 240 ± 40 175 ± 30
M20 460 ± 60 340 ± 44
M24 800 ± 100 600 ± 75
M30 1600 ± 200 1200 ± 150
M36 2700 ± 300 2000 ± 225

METRIC TAPERLOCK STUDS

THREAD
SIZE STANDARD TORQUE
(mm) (N i m) (lb i ft)
M6 8 ± 3 6 ± 2
M8 17 ± 5 13 ± 4
M10 35 ± 5 26 ± 4
M12 65 ± 10 48 ± 7
M16 110 ± 20 80 ± 15
M20 170 ± 30 125 ± 22
M24 400 ± 60 300 ± 45
M30 650 ± 80 480 ± 60
M36 870 ± 100 640 ± 75

1 of 7
STANDARD TORQUE FOR INCH FASTENERS

Exceptions to these torques are given in the Service

Manual where needed.

INCH NUTS AND BOLTS

THREAD
SIZE STANDARD TORQUE
inch (N i m) (lb i ft)
1/4 12 ± 3 9 ± 2
5/16 25 ± 6 18.0 ± 4.5
3/8 47 ± 9 35 ± 7
7/16 70 ± 15 50 ± 11
1/2 105 ± 20 75 ± 15
9/16 160 ± 30 120 ± 20
5/8 215 ± 40 160 ± 30
3/4 370 ± 50 275 ± 35
7/8 620 ± 80 460 ± 60
1 900 ± 100 660 ± 75
1-1/8 1300 ± 150 950 ± 100
1-1/4 1800 ± 200 1325 ± 150
1-3/8 2400 ± 300 1800 ± 225
1-1/2 3100 ± 350 2300 ± 250

INCH TAPERLOCK STUDS

THREAD
SIZE STANDARD TORQUE
inch (N i m) (lb i ft)
1/4 8 ± 3 6 ± 2
5/16 17 ± 5 13 ± 4
3/8 35 ± 5 26 ± 4
7/16 45 ± 10 33 ± 7
1/2 65 ± 10 48 ± 7
5/8 110 ± 20 80 ± 15
3/4 170 ± 30 125 ± 22
7/8 260 ± 40 190 ± 30
1 400 ± 60 300 ± 45
1-1/8 500 ± 70 370 ± 50
1-1/4 650 ± 80 480 ± 60
1-3/8 750 ± 90 550 ± 65
1-1/2 870 ± 100 640 ± 75

2 of 7
 O-RING FACE SEAL FITTINGS

O-RING FACE SEAL FITTING

O-RING GROOVE

STRAIGHT THREAD O-RING

O-RING FACE SEAL NUT O-RING PORT FITTING END
IDAS001B

STRAIGHT THREAD O-RING

FITTING (FOR O-RING FACE
SEAL FITTING ONLY)
THREAD
SIZE STANDARD TORQUE
inch (N i m) (lb i ft)
5/16-24 5.0 ± 1.5 45±15 lb i in
3/8-24 12 ± 2 110±20 lb i in
7/16-20 20 ± 4 15 ± 3
1/2-20 30 ± 5 22 ± 4
9/16-18 40 ± 5 30 ± 4
3/4-16 100 ± 15 75 ± 10
7/8-14 135 ± 15 100 ± 10
1 1/16-12 200 ± 25 150 ± 20
1 3/16-12 250 ± 25 185 ± 20
1 5/16-12 300 ± 40 225 ± 30
1 5/8-12 300 ± 40 225 ± 30
1 7/8-12 300 ± 40 225 ± 30
2 1/2-12 300 ± 40 225 ± 30

O-RING FACE SEAL FITTING NUT

THREAD
SIZE STANDARD TORQUE
inch (N i m) (lb i ft)
9/16-18 16 ± 3 12 ± 2
11/16-16 30 ± 4 22 ± 3
13/16-16 50 ± 7 37 ± 5
1-14 90 ± 10 65 ± 7
1 3/16-12 120 ± 15 90 ± 10
1 7/16-12 160 ± 20 120 ± 15
1 11/16-12 190 ± 20 140 ± 15
2-12 215 ± 25 160 ± 20

3 of 7
 FITTING INSTALLATION

HYDRAULIC LINE INSTALLATION
1. For a metal tube to hose installation, install the tube
and tighten all bolts finger tight.
2. Tighten the bolts at the rigid end.
3. Install the hose and tighten all bolts finger tight.
4. Put the hose in a position so that it does not make
contact with the machine or another hose.
5. Tighten the bolts on both connections.
6. Start the engine.
7. Move the implement control levers to all positions.
8. Look at the hose during movement of the
implement. Make sure hose is not in contact with
the machine or other hoses.
9. Shut off the engine.
10. If necessary, put the hose in a new position where it
will not make contact when the implement is moved.
1. Put locknut (3), backup washer (4) and O-ring seal
(5) as far back on fitting body (2) as possible. Hold
these components in this position. Turn the fitting
into the part it is used on until backup washer (4) just
makes contact with the face of the part it is used on.
2.To put the fitting assembly in its correct position, turn
the fitting body (2) out (counterclockwise) a
maximum of 359û. Tighten locknut (3) to the torque
shown in the correct chart for the fitting used.
NOTE: If the fitting is a connector (straight fitting), the
hex on the body takes the place of the locknut. To
install this type fitting, tighten the hex against the face
of the part it goes into.
TORQUES FOR FLARED AND O-RING FITTINGS
The torques shown in the charts that follow are to be
used on the nut part of 37û Flared, 45û Flared and
Inverted Flared fittings (when used with steel tubing),
O-ring plugs, O-ring fittings and swivel nuts when
used in applications to 3000 psi (20 700 kPa).

ASSEMBLY OF FITTINGS WITH STRAIGHT

THREADS AND O-RING SEALS HOSE CLAMP-BAND TYPE

This type of fitting is used in many applications. The tube

end of the fitting will be different in design so that it can
be used in many different applications. However, the
installation procedure of the fitting is the same. If the tube
end of the fitting body is the same as in the illustration
(either an elbow or a straight body) it will be necessary to
assemble the sleeve on the tube before connecting the
tube to the end.

2
1 IDAS003B

4 CLAMP TORQUE ON RETIGHTENING

3 WIDTH NEW HOSE TORQUE
7.9 mm 0.9 ± 0.2 N i m 0.7 ± 0.2 N i m
(.312 in) 8 ± 2 lb i in 6 ± 2 lb i in
5
13.5 mm 4.5 ± 0.5 N i m 3.0 ± 0.5 N i m
(.531 in) 40 ± 5 lb i in 25 ± 5 lb i in
IDAS002B 6 15.9 mm 7.5 ± 0.5 N i m 4.5 ± 0.5 N i m
ELBOW BODY ASSEMBLY (.625 in) 65 ± 5 lb i in 40 ± 5 lb i in
(1) End of fitting body (connects to tube). (2) Fitting body.
(3) Lock-nut. (4) Backup washer. (5) O-ring seal. (6) End of fitting
that goes into other part.

4 of 7
 37û FLARED AND STRAIGHT THREAD O-RING FITTINGS

37û FLARED O-RING SWIVEL NUTS

FITTING-PLUG
IDAS004B

37û FLARED AND STRAIGHT THREAD O-RING FITTINGS

(EXCEPT O-RING FACE SEAL FITTINGS)

NOMINAL TUBE O.D. THREAD STANDARD TORQUE

SIZE
METRIC INCH inch (N i m) (lb i ft)
3.18 .125 5/16 5.0 ± 1.5 4 ± 1
4.76 .188 3/8 11.0 ± 1.5 8 ± 1
6.35 .250 7/16 16 ± 2 12 ± 1
7.94 .312 1/2 20 ± 5 15 ± 4
9.52 .375 9/16 25 ± 5 18 ± 4
9.52 .375 5/8 35 ± 5 26 ± 4
12.70 .500 3/4 50 ± 7 37 ± 5
15.88 .625 7/8 65 ± 7 48 ± 5
19.05 .750 1-1/16 100 ± 10 75 ± 7
22.22 .875 1-3/16 120 ± 10 90 ± 7
25.40 1.000 1-5/16 135 ± 15 100 ± 11
31.75 1.250 1-5/8 180 ± 15 135 ± 11
38.10 1.500 1-7/8 225 ± 15 165 ± 11
50.80 2.000 2-1/2 320 ± 30 240 ± 22

TIGHTENING OTHER FITTINGS

Hi Duty (Shear sleeve) Tube Fittings
After tube has been put through the nut and makes
contact against the tube shoulder in the fitting body,
turn the nut with a wrench until a small decrease in
torque is felt. This is an indication that the sleeve has
been broken off the nut. Hold the tube to prevent IDAS005B
turning and tighten the nut 1-1/2 turns.

Hi Seal Fittings
Put nut and sleeve over the tubing with the short
heavy end of the sleeve facing the end of tubing. Put
the tube end against the counterbore in the body of
the fitting and tighten until nut is over the last thread IDAS006B
on the body. The remainder of space is used
whenever the fitting is removed and installed again.

5 of 7
 45û FLARED AND 45û INVERTED FLARE FITTINGS

INVERTED
45û FLARED 45û FLARED
IDAS007B

45û FLARED AND 45û INVERTED FLARE FITTINGS

NOMINAL TUBE O.D. THREAD STANDARD TORQUE

SIZE
METRIC INCH inch (N i m) (lb i ft)
3.18 .125 5/16 5.0 ± 1.5 4 ± 1
4.76 .188 3/8 8.0 ± 1.5 6 ± 1
6.35 .250 7/16 11 ± 2 8 ± 1
7.94 .312 1/2 17 ± 3 13 ± 2
9.52 .375 5/8 30 ± 3 22 ± 2
11.11 .438 11/16 30 ± 3 22 ± 2
12.70 .500 3/4 38 ± 4 28 ± 3
15.88 .625 7/8 50 ± 5 37 ± 4
19.05 .750 1-1/16 90 ± 8 65 ± 6
22.22 .875 1-1/4 100 ± 10 75 ± 7

TIGHTENING OTHER FITTINGS

Ermeto Tube Fittings
Put nut and sleeve over the tube with head or
shoulder end of sleeve next to nut. Push tube into
counterbore of fitting body as far as possible. Turn
nut clockwise until sleeve holds tube and prevents
movement. Tighten the nut 1-1/4 turns more to seat IDAS008B
sleeve and give a locking action. When necessary to
assemble again, put sleeve over tube and tighten nut
until a sudden increase in torque is felt. Then tighten
1/6 to 1/3 turn more to seat the sleeve.

Flex Fittings
Put nut and sleeve over the tubing and push tube in
to counterbore of fitting body as far as possible.
Tighten the nut until it is against the hex part of the
fitting body.
IDAS009B

6 of 7
AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS

O-RING 45û FLARE

IDAS010B

AIR CONDITIONING FITTINGS

O-RING FITTING END 45û FLARE FITTING END

THREAD STEEL TUBES ALUMINUM TUBES

SIZE STANDARD TORQUE STANDARD TORQUE STANDARD TORQUE
inch N im (lb i ft) N im (lb i ft) N im (lb i ft)
5/8-18 18 ±4 13 ± 3 30 ± 3 22 ± 2 23 ± 3 17 ± 2
3/4-16 37 ±4 27 ± 3 52 ± 5 38 ± 4 33 ± 4 24 ± 3
7/8-14 40 ±4 30 ± 3 60 ± 7 44 ± 5 38 ± 4 28 ± 3
1 1/16-14 45 ±5 33 ± 4 75 ± 8 55 ± 6 50 ± 5 37 ± 4

TAPERED PIPE THREAD FITTINGS

STANDARD TORQUE
PIPE
THREAD THREADS WITH THREADS WITHOUT
SIZE 1E2200E SEALANT SEALANT
inch Nim (lb i ft) Nim (lb i ft)
1/16-27 15 11 20 15
1/8-27 20 15 25 18
1/4-18 25 18 35 26
3/8-18 35 26 45 33
1/2-14 45 33 60 45
3/4-14 60 45 75 55
1-11 1/2 75 55 90 65
1 1/4-11 1/2 95 70 110 80
1 1/2-11 1/2 110 80 130 95
2-11 1/2 130 95 160 120

7 of 7
 SB4294E00
July 2007

Micro Controller
Control System
Specification
System Operation
Testing & Adjusting

B10R-5, B13R-5, B15R-5, B16R-5

 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.

DOOSAN 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 DOOSAN 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. DOOSAN dealers have the most current information
available.

1
Index

Specifications Eye Software Interface

Component Measurements .................................. 5 General Information..........................................100

Controller AS Specification................................... 6
Instrument Panel Layout ...................................... 8
Fuses .................................................................. 9
Assembly Layout of Controller.............................. 9
Assembly Layout of Motors .................................. 9
Control Panel Layout ......................................... 10
Systems Operation
Glossary ............................................................ 11
General Information ........................................... 13
Installation and Wiring........................................ 17
Installation........................................................100
Features...........................................................101
Main Menu .......................................................102
Troubleshooting of Eye Program ......................129
Appendix
Appendix A : Parameter List .............................130
Appendix B : Error Code List ............................133
Appendix C : Contraction for dot matrix display. 139
F1. Alarm Code ..................................139
F2. Calibration Code...........................140
F3. Diagnostic Code ...........................142

Testing and Adjusting

Preparation Tests and Check............................. 23

Programmable Parameters ................................ 25
Some Functions Management............................ 30

Diagnostic and Troubleshooting

General Description ........................................... 31

Alarm List .......................................................... 31
Troubleshooting Problem List............................. 40
System Tests and Adjustments .......................... 82
Electrical System Adjustment ............................. 83

Instrument Panel

Instrument Panel................................................ 86
Display Keys Utilization...................................... 90
Parameter Calibration ........................................ 91
Sensor Initial Setting .......................................... 94
Default Setting ................................................... 94
Diagnostic Mode ................................................ 95
List of diagnostic (Table 9) ................................. 96
Accessing Stored Error Codes ........................... 97

Micro Controller Control System 3 Index

Specifications
Component Measurements

24V

SPECIFICATIONS
Multimeter Setting (+) Test Lead (-) Test Lead Results
Resistance +BATT Each U,V,W About 1.9 Mohms
Resistance -BATT Each U,V,W About 1.9 Mohms
Resistance U Terminal V Terminal About 4.0 – 5.0 Mohms
Resistance U Terminal W Terminal About 4.0 – 5.0 Mohms
Resistance V Terminal W Terminal About 4.0 – 5.0 Mohms

Micro Controller Control System 5 Specifications

Controller AS Specification

TYPE 24 V
BATTERY VOLTAGE 12-32 V
MAXIMUM IMPULSIVE DRIVE INVERTER CURRENT 600 A
MAXIMUM IMPULSIVE PUMP INVERTER CURRENT 600 A
SWITCHING FREQUENCY 3-6-9 KHz
EFFICIENCY 95 %
PROTECTION LEVEL IP65
MECHANICAL SIZE 382x220x123
WEIGHT 6.5 Kg
VIBRATION 5g 10-500Hz in X,Y,Z axis
TEMPERATURE RANGE - 30 °C ¸ + 40 °C
MAXIMUM MODULE TEMPERATURE 100°C
CONTROLLER Complies with EN 1175-1 EN 12895-1
MAIN CONTACTOR 600A
MAIN FUSE 700A
KEY FUSE 10A

Micro Controller Control System 6 Specifications

Drive Motor Specification Pump Motor Specification

TYPE 24 V TYPE 24 V
POWER 5 KW POWER 7 KW
VOLTAGE 16 V VOLTAGE 16 V
CURRENT 240 A CURRENT 335 A
RATED SPEED 1866 RPM RATED SPEED 1550 RPM
MAXIMUM SPEED 4500 RPM MAXIMUM SPEED 4500 RPM
FREQUENCY 65 Hz FREQUENCY 55 Hz
Cos φ 0.874 Cos φ 0.902
SERVICE S2 60' SERVICE S3 15%
INSULATION CLASS F INSULATION CLASS F
PROTECTION DEGREE IP 22 PROTECTION DEGREE IP 22
BEARINGS 6208 2RS BEARINGS 6208 2RS
WEIGHT 32 Kg WEIGHT 32 Kg

Micro Controller Control System 7 Specifications

Instrument Panel Layout

(STANDARD)

(OPTION)

Micro Controller Control System 8 Specifications

Fuses Assembly Layout of Motors
Line .................................................................... 700A PUMP MOTOR
Key ........................................................................ 10A
Horn ...................................................................... 10A
DC / DC Converter................................................ 10A
Light ..................................................................... 10A
Option light............................................................ 10A

Assembly Layout of Controller

DRIVE MOTOR

Micro Controller Control System 9 Specifications

Control Panel Layout

NOTE: Apply a small amount of D557047 Thermal Joint Compound on control panel plate and mating surface
prior to assembly. Communication cable’s 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 Board. Use a screw driver to hold screws

(2) Drive Motor Power Unit. Use a hex bit socket(5mm) wrench(100mm) or L-wrench to hold bolts
(3) Pump Motor Power Unit
(4) FUSE. Use a socket wrench(13mm) and a wrench(13mm) to hold bolts
(5) Line Contactor
(6) Bus Bar. Use a socket wrench(13mm) and a socket wrench(17mm) to hold bolts

Micro Controller Control System 10 Specifications

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 A device that converts an analog voltage into a pattern of digital HIGH and LOW
Converter 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 Electrically trying to rotate the drive motor opposite to the direction of truck
(EAB) 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.

Micro Controller Control System 11 Systems Operation

 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.

Micro Controller Control System 12 Systems Operation

General Information
Advantage of AC motor Comparison between AC and DC
motor
AC induction motors are the most diffused for power
conversion in industrial application. In the battery- Motor Characteristics
fed 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. AC Motor systems DC Motor system
1 Little components More complex
To reach the traction requirements the AC control
has to be very advanced and the motor parameters 2 Decreasing price Increasing price
have to be known by the control algorithms.
3 More reliable Less reliable
The reason of their recent diffusion are related to
the technological development and to deeper Practically Continuous maintenance
4
studies about this matter. maintenance free to brushes

The advantages of using AC motors instead of 5 High speed Low speed

DC motors are many: High torque
Low torque performance
6 performance at high
1. More robust and easy to build at high speed
speed
2. Less complex and more reliable
3. Practically maintenance free (no continuous High braking Poor braking
brush maintenance) 7 performance at high performance at high
4. Higher speed speed speed
5. More performance at high speed especially in 8 Safer Less safe
regeneration
6. Absence of contactors for speed inversion
7. Continuous torque control during inversion (no
Controller Characteristics
delay with zero torque)
8. Safer because AC motor is not supplied and it
doesn’t work in case of short circuit AC Motor systems DC Motor system
9 Complex controller Simple controller
See following tables and relative explanation for a
comparison between AC and DC motor systems. Presence of auxiliary
10 No auxiliary contactor
contactors
4 quadrants Torque discontinuity and
11
continuous transition delay
Precise and smooth
12 Poor regulation
regulation

Micro Controller Control System 13 Systems Operation

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 have 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.

Micro Controller Control System 14 Systems Operation

Main ITC (Intelligent Torque Control)
features
Most important features of Intelligent Torque
Control system developed by DHIM the
following:
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.
2. Two asynchronous three-phase drive motors
equipped with magnetic sensors(64 impulses/
rotation).
3. An asynchronous three-phase pump motor for
lifting equipped with magnetic sensor (64
impulses/ rotation).
4. Instrument Panel.
Micro Controller Control System
Software control algorithm is customized in order to
best fit lift truck characteristics; you can set the
value of a wide range of parameters, in order to
optimize system performance and to adjust the
settings of main functions in compliance with user’s
needs.
User can interact with control board making use of a
software application (named EYE) developed by
DHIM, or with COMPACT display. In both cases, it’s
possible to obtain an exhaustive “on line” diagnostic
for all lift truck functional parameters and also to
adjust them.
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 .
(Standard)
Instrument Panel (option)
15 Systems Operation
Basic ITC ITC system characteristics

Following basic hardware and software You can obtain high performance for the lift
functions characterize DHIM Company system: truck with DHIM system, thanks to following
specific features:
1. Protection against reverse battery polarity
2. Anti-roll-back, with adjustable ramp stop time 1. DSPs (Digital Signal Processor) high
3. Anti-roll-down performance control with custom software: this
4. Regenerative braking is resident in the internal FLASH memory, and
5. Electrically assisted braking allows to control 3 independent AC motors.
6. Management of static return to off function 2. One serial asynchronous RS232 interface for
(SRO) PC communication in order to obtain:
7. Drive speed compensation (load/unload) a. Software update
8. Drive speed acceleration/deceleration b. Diagnosis of truck functionalities
9. Drive speed reduction c. Parameters modification, in order to
10. Redundant control of acceleration pedal customize the system
(applying a control switch or a double 3. One accelerator (0 - 5 V) and all on/off
potentiometer) emergency micro-switches interface.
11. Continuous lift speed control 4. One encoder (0 - 5 V) interface for traction and
12. Pump speed compensation (load/unload) pump motors.
13. Lift speed acceleration/deceleration 5. Motor torque control by speed and current loop.
14. Continuous control of main contactor applied to 6. Controlled acceleration and deceleration ramps
DC power line of drive and pump motors in order to avoid
15. Seat switch open check with delay time uncontrolled jolts of the load due to oversights
16. Battery discharged indicator with adjustable of the operator.
reset value 7. Automatic truck speed limitation depending on
17. Overtemperature protection for inverters and steering angle.
motors 8. Ramp stop of the lift truck.
18. Low and high battery voltage limit 9. Automatic energy recovery at each truck
19. Drive/pump speed feedback braking.
20. Zero speed drive in ramp 10. LIN (Local Interconnect Network) display
21. Standby for supply interface.
22. Diagnostics and stored error code 11. Automatic truck speed limitation, depending on
23. Power line fault detection (fuse/contactor) the height of the load lifted(option).
24. Continuous temperature measuring (Controller, 12. Automatic truck maximum speed limitation, in
drive/pump motor) 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

Micro Controller Control System 16 Systems Operation

Installation and Wiring
General

1. A metallic container encloses control board (Fig.

1).

2. There are three power modules assembled to

main board as shown in Fig. 4

3. A 24 pins AMP connector (named K1,K2),

permits to interface control board to lift truck
Fig. 1: Logic control board
electrical/electronic sub-devices. See Fig. 5 for
a view of K1- 24 ways connector.

4. Power modules shall be connected also to

battery supply (wire named +B and -B) and to
corresponding motor phases.

Working on electrical systems is potentially

dangerous; you should protect yourself
against :
Uncontrolled operation: some conditions could
Fig. 2: Power module
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
manufacturer’s safety
Fig. 3: Main contactor and fuse, bus bar

Micro Controller Control System 17 Systems Operation

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

Fig. 4: Power modules assembly with main contactor and fuse,

logic board.

Fig. 5: View of accessible terminals on 24 ways connect

Micro Controller Control System 18 Systems Operation

System Circuit

Power Circuit

If divide greatly composition of electric controller

system of this vehicles, is consisted of 1 Logic
control board, Power Unit (Drive, Pump) 2, Line
Contactor 1.

Each power unit controls each motor's speed, logic

control board vehicles situation and driver's select
receiving feedback vehicles control.

Micro Controller Control System 19 Systems Operation

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 battery is connected and the key switch is
closed, current flows from battery positive through
the key fuse, key switch, wire #4 to the logic control
board (logic) contactor K1-8A.
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.
Micro Controller Control System
When the seat switch is closed, current will flow
from the logic K1-7A through the seat switch to
controller negative. The logics then activates the
line contactor by allowing current to flow from K1-8B
through the line contactor coil (+) and K1-7C the line
contactor coil (-).
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.
20 Systems Operation
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 700 rpm) that specify in pump
motor calibration.

Lift Control Circuit Location Components

(2) Lift Sensor. (3) Magnet.

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

moves closer to the lift sensor (2). The sensor
1 detects the increasing magnetic field and sends an
increasing voltage to the valve control card.
The input to the logics at K2-7A.
The logics use these changing voltages to
determine what speed to operate the pump motor.
The logics then controls the pump power unit.

Location Components
(1) Valve control card.

This control panel accepts 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.

Micro Controller Control System 21 Systems Operation

Thermal protection circuit Accessory Circuits

Control Panel Horn Circuit

If the Power Unit’s MOSFETs are overheat, a The horn will operate when the battery is connected
thermal senders mounted in the MOSFET heatsink and the horn button is pushed. Current flows from
will give a voltage signal to logic. If the temperature battery positive through horn fuse, horn switch and
is over than preset value(100°C), the Instrument horn, back to battery negative.
Panel will display a “Run Time” diagnostic symbol
and E1, E3. The logics will decrease the speed of
the drive motors and the pump motor. The amount DC-DC Converter Circuit (OPTIONAL)
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.

Drive Motor

If the drive motor overheats a thermal sensor

mounted in the stator coil of drive motor will warn at
a predetermined temperature (155°C).
If reach in overheating temperature, the Instrument
Panel will display a “Run Time” diagnostic symbol
and E4.
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
Hydraulic Pump Motor protects it from reverse connection of the battery
voltage.
If the drive motor overheats a thermal sensor
mounted in the stator coil of drive motor will warn at Notice: Do not connect the 12 volt negative output
a predetermined temperature (155°C). of the DC-DC converter to battery negative.
If reach in overheating temperature, the Instrument Damage to system components could
Panel will display a “Run Time” diagnostic symbol occur.
and E6. To decrease the amount of current allowed
to flow through the pump motor, the logics will The DC-DC converter changes the lift truck battery
reduce the speed. When the pump motor cools off, voltage to 12 volts. This 12 volts is used to power
the truck will return to normal operation. “MOTOR accessories such as floodlights, brakes/side lights
TEMPERATURE” will be stored for Pump Motor and backup alarms.
overheating in memory.
The positive of the 12 volt output is common to the
positive of the battery voltage. The negative of the
12 volt output is pulsed to maintain a steady 12 volt
supply.

Micro Controller Control System 22 Systems Operation

Testing and Adjusting Battery Load Test

1. Turn the range switch on the multimeter to read

Preparation Tests and Check battery voltage.

Battery Tests 2. Connect the battery.

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.

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.

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

load test.

3. If the truck is not operational and the battery is Battery Voltage Test.
suspected, perform a cell voltage or specific (1) Positive cable connection. (2) Negative cable
connection.
gravity test.
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 22.0V the battery

needs to be charged or repaired before
continuing to troubleshoot.

Micro Controller Control System 23 Testing and Adjusting

Cell Voltage Test
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.
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.
Hydrometer 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.
NOTE: The indication between cells should not
differ more than 1.020 If it does, the battery needs
an equalizing charge or needs to be repaired.
Battery Maintenance
NOTE: It is important that all batteries are 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.
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.
Micro Controller Control System
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.
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 43°C (110˚F) either while operating or
charging. Overcharging a battery will cause
overheating and warp the battery plates.
Maximum battery life will result from maintaining
25˚C (77˚F) electrolyte temperature. Most of the
charging equipment is fully automatic but should
be checked periodically to assure proper
working order.
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.
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.
24 Testing and Adjusting
Visual Checks
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.
2. Verify there is no mechanical binding or
interference in the contactor.
3. Visually check the parking brake switch, the
hydraulic switches and accelerator linkage for
adjustment or interference problems.
Resistance to Chassis Checks
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. We briefly
explain what’s the meaning of each programmable
parameter, and which is the effect of its changes in
lift truck performance.

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).

Micro Controller Control System 25 Testing and Adjusting

Drive Motor (H mode)

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
as high it is as quickly the truck decreases
Deceleration
5 its speed if the truck driver is turning the rpm/s 0 1,000 5,000
steering ramp 1
wheel quickly
as high it is as quickly the truck decreases
its speed in relation to the drive speed of
Deceleration
6 truck. This parameter increases the rpm/s 0 0 1,000
steering ramp 2
deceleration ramp while the driver is steering
at high speed.
Buzzer on If it’s ON, the buzzer will be alarmed when OFF = 0 (Default)
30 digit
forward direction the direction switch is moved to forward. ON = 1
Buzzer on If it’s ON, the buzzer will be alarmed when OFF = 0 (Default)
31 digit
reverse direction the direction switch is moved to reverse. ON = 1
The cooling Fan runs when the temperature
Starting of motors reaches to set value. And the
32 185 311
35 temperature of cooling Fan stops when the motors cools ℉(℃)
(0) (85) (155)
motor's Fans down below 60℃ from set value(The
minimum of stop temperature is 25℃).
Slow speed If parameter is set to 0, speed limitation Disable = 0
40 digit
button enable button is disable. Enable = 1 (Default)
Drive maximum Drive motors maximum current (expressed
41 % 20 100 100
current in per cent of high energetic mode value)
Maximum forward lift truck speed with no
Forward
42 speed limitation rpm 1,000 3,850 4,000
maximum speed
(no alarms present and turtle not active)
Maximum reverse lift truck speed with no
Reverse
43 speed limitation rpm 1,000 3,850 4,000
maximum speed
(no alarms present and turtle not active)
Drive limitation Maximum lift truck speed with speed
44 rpm 500 2,000 3,500
maximum speed limitation (turtle active)
High lift switch 1 Maximum travel speed when switch 1 was
46 rpm 0 1,000 4,000 option
drive max speed "ON"
Steer limitation drive Maximum speed reference in the angle in
47 rpm 400 1500 2,000
maximum speed which the internal wheel is mechanically still.
Lift truck acceleration with accelerator pedal
48 Acceleration ramp rpm/s 40 900 2,000
pressed
49 Inversion ramp Lift truck deceleration in inversion rpm/s 40 900 2,000
Lift truck deceleration with accelerator pedal
50 Release ramp rpm/s 40 500 2,000
released
Lift truck deceleration with pedal brake
51 Pedal brake ramp rpm/s 40 1,000 2,000
pressed
If the truck speed is greater then this
threshold, the speed reference becomes a
52 Creep speed rpm 100 300 2,000
parabolic function of the accelerator
potentiometer voltage.
Diameter of drive
53 Drive tire's diameter mm 300 424 700
tires
High lift switch 2 Maximum travel speed when switch 1 and
54 rpm 0 1,000 4,000 option
drive max speed switch 2 was "ON"
Parameter that softens the drive inversion
59 Partial release ramp ramp if the traction motors are working with rpm/s 10 35 500
low rpm
If parameter is set to1, speed limitation is
Disable = 0(Default)
94 Slow speed active; otherwise lift truck speed is managed digit
Enable = 1
as usual.
If parameter is set to 1, values are
Normal = 0 (Default)
95 British unit expressed in British unit, otherwise in digit
British unit = 1
international ones.
Display
96 Display's brightness adjustment digit 0 5 8
brightness

Micro Controller Control System 26 Testing and Adjusting

 If this parameter is set to 1, it is possible to
Disable = 0 (Default)
97 E-S-H enable change the value of the power mode with digit
the display Enable = 1
Time meter / If parameter is set to 1, odometer indication
Timer meter = 0(Default)
98 Odometer on appears on display ; otherwise display digit
Odometer = 1
display shows the hour meter.
99 Maintenance time Can set truck's maintenance period. h 0 0 10,000

Sensors and Potentiometers

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Minimum Accelerator sensor voltage with pedal
23 mV 200 1,000 4,500
accelerator released
Maximum Accelerator sensor voltage with pedal
24 mV 2,000 3,600 4,500
accelerator completely pressed
Lift sensor voltage with lift lever completely
32 Maximum lift mV 3,000 11,500 12,000
pressed
33 Minimum lift Lift sensor voltage with lift lever released mV 0 2,300 12,000
Lift lever potentiometer voltage to which the
34 Middle lift lifting becomes proportional to the shift of mV 1,000 2,750 12,000
the lever

Pump Motor

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
if it's OFF, the pump motor works like it does now,
that is, the reference speed of pump motor, in
case of many simultaneous commands (LIFT +
TILT, LIFT + AUX1, TILT + AUX1.......), will be the
Lift priority for OFF = 0 (Default)
27 highest of every single command; if it's ON the digit
speed reference ON = 1
reference speed of pump motor, in case of many
simultaneous commands, will be the lowest of
those reference speed required by every single
command.
Weight of the
36 Load measurement kg 0 0
load on the forks future
37 No load pressure Load measurement bar·10 0 0 2,200 option
38 Load pressure Load measurement bar·10 0 0 2,200
Limitation 212 311
39 Start temperature of performance reduction ℉(℃)
temperature (100) (155)
Lift maximum Pump motor maximum current with lift
61 % 20 100 100
current function active
Auxiliary Pump motor maximum current with lift lever
62 % 10 66 100
maximum current released
Lift maximum
63 Maximum lift speed rpm 1,500 3,000 3,000
speed
64 Tilt speed Pump motor speed with lift function active rpm 500 900 2,000
Auxiliary 1
65 Pump motor speed with 1st auxiliary function active rpm 500 900 2,800
function speed
Auxiliary 2 Pump motor speed with 2nd auxiliary function
66 rpm 500 900 2,800
function speed active
Auxiliary 3 Pump motor speed with 3rd auxiliary function
67 rpm 500 900 2,800
function speed active
Lift minimum
68 Minimum lift speed rpm 500 700 1,500
speed
High lift 1 switch Maximum pump motor speed with forks above the
69 rpm 0 1,500 3,000 option
lift max speed critical height
70 Hydro speed Pump motor speed when steering rpm 400 700 800

Micro Controller Control System 27 Testing and Adjusting

 Pump motor speed with direction command lever
71 Hydro idle speed not in neutral, acceleration pressed and no pump rpm 200 500 600
command active
Pump
72 Lift acceleration rpm/s 1,000 7,000 10,000
acceleration ramp
Pump Pump motor deceleration after the end of a
73 rpm 1,000 7,000 10,000
deceleration ramp command
High lift 2 switch Maximum lift speed when switch 1 and switch 2
74 rpm 0 1,500 3,000 option
lift max speed was "ON"
High lift 1 switch
75 Maximum tilt speed when switch 1 was "ON" rpm 0 500 2,000 option
tilt max speed
High lift 2 switch Maximum tilt speed when switch 1 and switch 2
76 rpm 0 500 2,000 option
tilt max speed was "ON"
High lift 1 switch
Maximum auxiliary 1 speed when switch 1 was
77 auxiliary 1 max rpm 0 500 2,800 option
"ON"
speed
High lift 2 switch
Maximum auxiliary 1 speed when switch 1 and
78 auxiliary 1 max rpm 0 500 2,800 option
switch 2 was "ON"
speed
High lift 1 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1 was
79 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1 and
80 rpm 0 500 2,800 option
function max switch 2 was "ON"
speed
High lift 1 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1 was
83 rpm 0 500 2,800 option
function max "ON"
speed
High lift 2 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1 and
84 rpm 0 500 2,800 option
function max switch 2 was "ON"
speed

Micro Controller Control System 28 Testing and Adjusting

Timers

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Time interval between seat switch opening
11 Seat switch delay s 1 3 9
and drive and pump motors stopping
Time delay between last command given to
12 Chat time a drive or pump motor and chat mode s 1 6 9
signaling
Time interval when pump motor works (with
13 Hydro time s 1 10 20
hydro speed) after the end of a command
Stop on slop Without stepping on pedal brake, time that is
26 s 1 5 10
timer doing stop in slope

Battery

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
Battery reset Minimum battery voltage necessary to reset
9 V*10 226 230 249
value battery discharged voltage alarm

Program Service

Parameter Mini Def Maxi Re

Parameter Parameter Description Unit
No mum ault mum mark
99 Maintenance time Maintenance period decision h 0 0 10,000
Maintenance time Disable = 0 (Default)
14 Maintenance time inserting enable digit
inserting enable 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)

PARAMETER ECONOMIC MODE STANDARD MODE HIGH MODE

Maximum drive current 62 76 100
Maximum forward speed [rpm] 2900 3300 3850
Maximum reverse speed [rpm] 2900 3300 3850
Drive acceleration ramp [rpm/s] 700 800 900
Drive inversion ramp [rpm/s] 700 800 900
Drive release ramp [rpm/s] 500 600 700
Lift maximum current 85 85 100
Maximum lift speed [rpm] 1800 2600 3000

Micro Controller Control System 29 Testing and Adjusting

Some Functions Management
Static Return to Off
To ensure operator safety, when switching on the lift
truck, a number of inputs are analyzed; 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.
If the anomalous input assumes the correct value,
main breaker is closed and it’s now possible go on
with usual truck management.
The analyzed 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)
Pump Motor Modes
Control of a command lever moving when
starting
When switching on the key, in case an hydraulic
command is active, the lift, lateral shift, 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).
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)
Micro Controller Control System
Buzzer Management
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. Parking lever is pot pulling and no one is in the
seat.
4. The trucks moves in reverse/forward direction
(Select the truck-Setup Menu or Calibration No.
30,31)
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)
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.
If the battery is discharged for at least two
consecutive sampling periods, low battery voltage
alarm is signaled 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
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.
30 Testing and Adjusting
Diagnostic and Troubleshooting
General Description Alarm List
Diagnostic information about anomalous working Maximum battery voltage
condition is provided by COMPACT display or by
PC (using EYE software utility). 1. Eye alarm code: 1
This chapter explains how to manage any detected 2. Display alarm code: F0
fault and how to return to a normal working 3. Alarm level: 1
situation; suggestions to be applied in case of each 4. Alarm cause: battery voltage, measured by a
possible alarm are listed in a growing order, i.e. circuit inside logic, exceeds 34V.
from the least to the most serious one.
If the controller detects such a fault, refer to
If an alarm condition is detected by main board, following troubleshooting procedure:
software control inhibits some lift truck functions, to 1. Such an alarm can be caused also by the
guarantee operator’s safety. presence of regeneration currents; when lift
Anomalous working conditions are indicated by truck is on release or reverse braking ramp,
different alarm levels, classified as follows, motors work as generators, and battery voltage
depending on their effects on the system: can exceed overvoltage limit. In a case like that,
1. Main breaker is opened and both pump and the battery condition should be verified ( if the
drive motors are stopped; buzzer and red led on battery is new it is necessary to do some
the upper right corner of COMPACT display, charge-discharge cycles before reaching the
signal the presence of such an alarm. rating declared by the constructor) or has a high
2. Pump and drive motors are stopped. internal resistance. If the case is the second
3. Drive motors speed is limited to 2000 rpm. and it is not possible to change the battery, the
Moreover, in presence of such an alarm, first solution may be to reduce the release and
command given to pump motor is inhibited 3 reverse braking ramp.
seconds after activation, together with all pump 2. Incorrect wiring to battery positive or negative
motor functions (except hydro functions). terminals.
4. Drive and pump motors speed is limited to 800 3. Verify if battery is still in good conditions.
rpm; buzzer signals the presence of such an 4. Replace the logic.
alarm.
5. Drive motors speed is limited to 800; over Minimum battery voltage
temperature alarms are signaled by. buzzer
activation. 1. Eye alarm code: 2
6. Pump motor speed is limited to 800; buzzer 2. Display alarm code: F1
signals the presence of such an alarm. 3. Alarm level: 1
7. No effects on system performance. 4. Alarm cause: battery voltage, measured by an
※ 2000 rpm = about 7 km/hr [4.4 mph] internal circuit, is lower than 11.5V.
800 rpm = about 2.8 km/hr [1.75 mph]

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).

Following section gives useful suggestions covering

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

Micro Controller Control System 31 Diagnostic and Troubleshooting

In case of minimum battery voltage alarm, follow Eeprom alarm
these steps:
1. Incorrect wiring to battery, or corroded positive 1. Eye alarm code: 5
or negative terminals; 2. Display alarm code: F
2. Verify battery conditions: if the electrolyte inside 3. Alarm level: 1
is partially exhausted, an under voltage alarm 4. Alarm cause: eeprom does not work properly, or
can sometimes be detected from the controller; one of memorized values is out of correct limits.
even in case of low battery charge (<10%), high
current rates (i.e. both pump and drive motors In case of alarm follow this procedure:
working in full load conditions) could cause an 1. Load default values for eeprom variables, both
under voltage alarm, in particular in presence of using PC with serial communication software
an exhausted battery. and Instrument panel;
3. Replace the logic. 2. Replace the logic.

Pedal trimmer fault Pre-charge capacitors low voltage

alarm (Capacitors not charged)
1. Eye alarm code: 3
2. Display alarm code: F2 1. Eye alarm code: 6
3. Alarm level: 2 2. Display alarm code: A
4. Alarm cause: voltage measured on accelerator 3. Alarm level: 1
circuit exceeds the value calculated averaging 4. Alarm cause: voltage level of pre-charge
calibration and reachable voltages; moreover, capacitors is less then 70 % of nominal battery
start switch seems to be open. level. It could happen, in example, if the power
module is working with main breaker open.
In case of such an alarm, follow these Capacitors voltage decreases cause energy
troubleshooting steps : spent to keep motors in motion.
1. Verify if the accelerator initial set-up is correct; if
not, repeat calibration procedure. (You can use In case of alarm follow this procedure:
both PC with serial communication software and 1. Verify if main breaker coil and power terminals
Instrument panel). are in good conditions;
2. Verify if the following the 24pin main connector 2. Verify if supply lines power fuse is damaged;
terminals are correctly wired to their 3. Verify if main breaker coils are correctly wired to
correspondent inputs in accelerator circuit: their correspondent inputs :
a. K2-1C (5 V) a. K1-8B (positive terminal)
b. K1-6C (ground) b. K1-7C (negative terminal)
c. K2-6A (pedal output-A) 4. Replace main breaker;
d. K2-4A (pedal output-B) 5. Replace logic.
3. In case of correct wiring, replace the accelerator
itself.
4. Replace logic

Micro Controller Control System 32 Diagnostic and Troubleshooting

Inverter desaturation or overcurrent Pump motor power module
alarm overtemperature

1. Eye alarm code: 1. Eye alarm code: 10

8 (for drive motor power module)
25 (for pump motor power module)
2. Display alarm code:
F3 (for drive motor power module)
F5 (for pump motor power module)
3. Alarm level: 1
4. Alarm cause: actual current exceeds limits ;
1100Apeak
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 power module 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 power
module.
2. Replace the power module;
3. Replace logic.
If turning lift truck on again, alarm is active,
then :
1. Replace the power module;
2. Replace the motor.
2. Display alarm code E3:
3. Alarm level: 6
4. Alarm cause: the power module temperature
(measured with a temperature connector),
exceeds 100 °C, or is inside [95 °C, 100 °C]
range at least 30 s.
In case of alarm follow this procedure:
1. Alarm could be caused by ineffective
temperature dissipation. Verify thermal coupling
between power module block and aluminum
plate, and between aluminum 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 pump of
the logic to the pump power module;
3. If temperature readings seem too high in
function of total time interval of lift truck using,
replace pump power module causing the alarm.
You can read temperature measures using
“Instrument Panel” display or “EYE”
communication software.
4. Replace logic.

Power module capacitors pre-charge

too fast

1. Eye alarm code: 9

2. Display alarm code: A
3. Alarm level: 1
4. 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. Inspect whether the main connector is not loose.
2. Inspect whether the drive connector is not loose.
3. Replace the main breaker.
4. Replace the drive power module.
5. Replace the logic.

Micro Controller Control System 33 Diagnostic and Troubleshooting

Capacitors too charged on start
1. Eye alarm code: 11
2. Display alarm code: A
3. Alarm level: 1
4. 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)
In case of alarm follow this procedure:
1. Verify the correctness of wiring from pump
motor and relative power module;
2. Replace wire connecting "pump" with the
corresponding power module or if not possible
because the pump motor power module box
integrates the outlet wire, substitute the power
module box
3. Verify if main breaker has stuck closed
terminals: in such a case replace it
4. Replace the wire connecting "drive" in logic to
right drive motor power module: a defective wire
could give a wrong measure for capacitors
voltage
5. Replace the logic.
Low battery alarm
1. Eye alarm code: 12
2. Display alarm code: EL
3. Alarm level: 3
4. Alarm cause: battery voltage level is lower than
minimum charge value expected, referred to
table 3 in Instrument panel technical
documentation.
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.
Micro Controller Control System
Drive motor overtemperature
1. Eye alarm code: 13
2. Display alarm code: E4
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 25°C). 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.
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.
34 Diagnostic and Troubleshooting
Pump motor overtemperature Main breaker fault

1. Eye alarm code: 14 1. Eye alarm code: 17

2. Display alarm code: E6 2. Display alarm code: 17
3. Alarm level: 6 3. Alarm level: 1
4. Alarm cause: The measure of pump motor 4. Alarm cause: overcurrent on main breaker coil.
temperature exceeds 155 °C.
In case of alarm follow this procedure:
In case of alarm follow this procedure: 1. Replace main breaker
Presence of alarm with cold motors: 2. Replace logic.
1. With a handheld multimeter in resistance
operating mode, you have to measure about Watchdog timer alarm
10kohm at ambient temperature of 25°C
between the two wires of the temperature 1. Eye alarm code: 18
connector. If the measure is not correct it is 2. Display alarm code: F
necessary to replace the temperature connector. 3. Alarm level: 1
2. Disconnect the temperature sensor and check 4. Alarm cause: improper communication between
the wiring insulation between signal wire and DSPs present on logic, or/and defective logic.
ground wire (towards logic);
3. Replace logic. In case of alarm follow this procedure:
1. Using EYE program interface, try to program
Presence of alarm with hot motors: control board flash memory;
1. If temperature value (you can read it from 2. Replace logic.
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.

Motor current offset alarm

1. Eye alarm code: 15 for drive motor

36 for pump motor
2. Display alarm code: F6 for 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 wire connecting inverter to logic.
2. Replace inverter.
3. Replace logic.

Micro Controller Control System 35 Diagnostic and Troubleshooting

Drive motor power module Alarm on 5 V encoder voltage
overtemperature
1. Eye alarm code: 37
1. Eye alarm code: 20 for right drive motor 2. Display alarm code: FH
2. Display alarm code: E1 for right drive motor 3. Alarm level: 1
3. Alarm level: 5 4. Alarm cause: K2-1C terminal (5 V output)
4. Alarm cause: power module temperature, voltage is lower than 4.3 V.
measured with a probe, exceed 100 °C.
In case of alarm follow this procedure:
In case of alarm follow this procedure: 1. Verify if 5 V output is grounded, cause an
1. Alarm could be caused by ineffective incorrect encoder wiring.
temperature dissipation; verify thermal coupling 2. Verify if 5 V output is grounded, cause any
between power module block and aluminum encoder malfunction. In that case, replace the
plate and between aluminum plate and truck defective one.
ballast. The presence of the correct amount of 3. Replace logic.
thermal grease in the coupling are essential to
ensure a correct heat exchange; Alarm on 12 V output voltage
2. Check cable connecting the communication
output connector of the logic to the 1. Eye alarm code: 38
corresponding power module; 2. Display alarm code: FA
3. If temperature readings seem too high in 3. Alarm level: 1
function of total time interval of lift truck using, 4. Alarm cause: K1-3C terminal (12 V output)
replace power module unit causing the alarm. voltage is lower than 10.5 V.
You can read temperature measures using
“ Instrument Panel” display or “EYE” In case of an alarm on 12 V output voltage,
communication software. follow this procedure:
4. Replace logic. 1. Verify if 12 V output is grounded, cause an
incorrect wiring to:
Serial communication alarm a. Steering sensor
b. Buzzer
1. Eye alarm code: 21 c. Display
2. Display alarm code: F 2. Replace defective device;
3. Alarm level: 1 3. Replace logic.
4. 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.

In case of alarm follow this procedure:

1. Switch on the system and the turn it on again.
2. Program pump and drive DSP again; maybe
software present in flash memory was corrupted.
(REFLASH)
3. Try to the default setting (LOAD EEPRON
DEFAULT-TOTAL LOAD EEPROM)
4. Replace the logic.

Micro Controller Control System 36 Diagnostic and Troubleshooting

Pump motor commands active on Seat switch open on start
start
1. Eye alarm code: 63
1. Eye alarm code: 50 2. Display alarm code: EE (flash)
2. Display alarm code: FL 3. Alarm level: warning; main breaker is opened
3. Alarm level: warning; while the fault condition is and pump and drive motors are stopped.
active, all pump motor functions (except hydro 4. Alarm cause: when you start working, you find
functions) are inhibited. seat switch open, or, after the main breaker is
4. Alarm cause: you find a pump motor command closed, the seat switch remains opened for at
active when you turn your system on. least “ seat switch delay” s.

In case of alarm follow this procedure: In case of alarm follow this procedure:
1. Before starting to operate, turn off any active 1. Verify if seat switch is defective;
command (both levers and switches); 2. Replace the logic.
2. Be sure that lift, tilt and auxiliary command
switches, are not active; Wrong start
3. Replace the valve board.
1. Eye alarm code: 64
Battery miss matching 2. Eye alarm code: EE
3. Alarm level: warning; main breaker is opened
1. Eye alarm code: 60 and pump and drive motors are stopped.
2. Display alarm code: 60 4. Alarm cause: when you start working, you find
3. Alarm level: 7 accelerator pedal pressed or a forward/ reverse
4. Alarm cause: battery is not suitable voltage to switch active.
controller
In case of alarm follow this procedure:
Drive motor shunt down temperature 1. Verify if a switch was active or the pedal
pressed, when you turn on the lift truck;
1. Eye alarm code: 61 2. Verify if start, forward or reverse switches are
2. Display alarm code: 61 stuck close;
3. Alarm level: 1 3. Verify if pedal circuit voltage exceeds 1/3 its
4. Alarm cause: The measure of drive motor maximum range (measured in Volt);
temperature exceeds 165 °C. 4. 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 a
resistance of about 10 kohm between the two
wires of the temperature connector (execute the
measure at ambient temperature of 25°C) . 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 the 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.

Micro Controller Control System 37 Diagnostic and Troubleshooting

Pump motor shunt down temperature Pump motor Encoder alarm

1. Eye alarm code: 65 1. Eye alarm code: 76

2. Display alarm code: 65 2. Display alarm code: 76
3. Alarm level: 1 3. Alarm level: 1
4. Alarm cause: The measure of pump motor 4. Alarm cause: an encoder channel is
temperature exceeds 165 °C. disconnected, and motor is working.

In case of alarm follow this procedure: In case of alarm, follow this procedure:
Presence of alarm with cold motors: 1. Verify if the encoder is correctly connected to:
1. With a handheld multimeter in resistance a. Motor itself
operating mode, you have to measure about b. Ground : K2- 1B terminal
10kohm at ambient temperature of 25°C c. + 5 V: K2- 1C terminal
between the two wires of the temperature d. A channel:
connector. If the measure is not correct it is K2- 3C terminal (for right drive motor
necessary to replace the temperature encoder)
connector; e. B channel:
2. Disconnect the temperature connector and K2- 2C terminal (for right drive motor
check the wiring insulation between signal wire encoder)
and ground wire ( towards logic); 2. If correctly wired, replace the encoder;
3. Replace the logic. 3. Replace logic.

Presence of alarm with hot motors:

1. If temperature value (you can read it from
Alarm of motor thermal sensor
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
1. Eye alarm code:
inefficient motor refreshing, or by operating out
77 (for drive motor thermal sensor)
of nominal maximum ranges.
79 (for pump motor thermal sensor).
2. Display alarm code:
Drive motor encoder alarm 77 (for drive motor thermal sensor)
79 (for pump motor thermal sensor).
1. Eye alarm code: 74 3. Alarm level: 7
2. Display alarm code: Fc 4. Alarm cause: Temperature difference between
3. Alarm level: 1 both motors results greater than 70 °C
4. Alarm cause: an encoder channel is
disconnected, and motor is working. In case of alarm, follow this procedure:
1. Verify if the wiring is correct;
In case of alarm follow this procedure: 2. Replace the sensor;
1. Verify if the encoder is correctly connected to: 3. Replace logic.
a. Motor itself
b. Ground : K2- 1B terminal
c. + 5 V: K2- 1C terminal
d. A channel:
K2- 5C terminal (for right drive motor
encoder)
B channel:
e. K2- 4C terminal (for right drive motor
encoder)
2. If correctly wired, replace the encoder;
3. Replace logic.

Micro Controller Control System 38 Diagnostic and Troubleshooting

Alarm of a inverter temperature Steering sensor alarm
thermal sensor
1. Eye alarm code: 91
1. Eye alarm code: 2. Display alarm code: F9
80 (for drive motor power module thermal 3. Alarm level: 5
sensor) 4. Alarm cause: steer circuit voltage is out of
82 (for pump motor power module thermal nominal range.
sensor)
2. Display alarm code: In case of a steering sensor alarm follow this
80 (for drive motor power module thermal procedure:
sensor) 1. Verify correctness of wiring with :
82 (for pump motor power module thermal a. K1-3C (12 V),
sensor) b. K1-6C (ground)
3. Alarm level: 7 c. K2-1A (steering sensor input);
4. Alarm cause: Temperature difference between 2. If correctly wired, replace steering sensor;
both inverters is greater than 70°C. 3. Replace logic.

In case of alarm follow this procedure:

1. Check the wiring connecting logic and inverter; Capacitors pre-charge too slow
2. Replace the inverter;
3. If alarm is still present, replace logic. 1. Eye alarm code: 98
2. Display alarm code: A
CRC(Cyclic Redundancy Check) fault 3. Alarm level: 1
alarm 4. Alarm cause: pre-charge capacitor voltage
grows too slowly, when you turn on the system.
1. Eye alarm code: 83
2. Display alarm code: 83 In case of alarm follow this procedure:
3. Alarm level: 1 1. Check assembly of the 24pin main connector.
4. Alarm cause: Faulty eeprom or mismatching 2. Check cable connecting the Drive/Pump output
software release. of the logic with the corresponding inverter.
3. Replace the logic;
In case of alarm follow this procedure:
1. Restore eeprom with EYE application software, Capacitors pre-charge timeout
using the “RESTORE” item present in main
page 1. Eye alarm code: 99
2. Try to the default setting (LOAD EEPROM 2. Display alarm code: A
DEFAULT-TOTAL LOAD EEPROM) 3. Alarm level: 1
3. if alarm is still present, replace the logic.CRC : 4. Alarm cause: pre-charge capacitor voltage
Cyclic Redundancy Checking error. grows too slowly, when you turn on the system.

Bank CRC(Cyclic Redundancy Check) In case of alarm follow this procedure:

restored 1. Check assembly of the 24pin main connector.
2. Check cable connecting the Drive/Pump output
1. Eye alarm code: 84 of the logic with the corresponding inverter.
2. Display alarm code: 84 3. Replace the logic;
3. Alarm level: 1
4. 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
2. Try to the default setting (LOAD EEPROM
DEFAULT-TOTAL LOAD EEPROM)

Micro Controller Control System 39 Diagnostic and Troubleshooting

Troubleshooting Problem List
Problem # TROUBLESHOOTING PROBLEM LIST EYE Abrm code
1 CVMS does not work, with no lift truck operation. -
2 CVMS does not work at all, lift truck operation normal. -
Display portion 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. 20
11 Display="E3", The max speed of pump motor is reduced. 10
12 Display="E4", The max speed of drive motor is reduced. 13
13 Display="E6", The max speed of pump motor is reduced. 14
Display="EL", The max speed and max torque of drive &pump motor is reduced
14 12
to minimum value
15 Display="EE", No left truck operation 64
16 Display="EE(Flashing)", No left truck operation 63
17 Display="F", No lift truck operation 5, 18, 21
18 Display="F0", No Left truck operation 1
19 Display="F1", No Left truck operation 2
20 Display="F2", No left truck operation 3
21 Display="F3", No left truck operation 8
22 Display="F5", No left truck operation 25
23 Display="F6", No left truck operation 15
24 Display="F8", No left truck operation 36
25 Display="F9",The max speed of pump motor is reduced. 91
26 Display="FA", No Left truck operation 38
27 Display="Fc", No left truck operation 74
28 Display="FH", No left truck operation 21, 37
29 Display="FL", No left truck operation 50
30 Display="A", No lift truck operation 6, 9, 11, 98, 99
31 Display="60", Lift truck operation 60
32 Display="61", No lift truck operation 61
33 Display="65", No lift truck operation 65
34 Display="76", No left truck operation 76
35 Display="77", Lift truck operation 77
36 Display="79", Lift truck operation 79
37 Display="80", Lift truck operation 80
38 Display="82", Lift truck operation 82
39 Display="83", No lift truck operation 83
40 Display="84", No lift truck operation 84
41 Display does work normal, Lift truck operation abnormal. -

Micro Controller Control System 40 Diagnostic and Troubleshooting

 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

Push horn button to close horn switch. Make correction to cables.

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 K1-8A Measure voltage on horn (wire #90) with
depressing the horn switch.
Battery Less than Check continuity the negative wire of horn
Voltage Battery voltage
Battery Less than
Voltage Battery voltage
Replace logics.

Replace horn or Repair or replace

check the battery. open wire
Replace key switch or repair broken wire
#23 between key switch and K1-5B.

Micro Controller Control System 41 Diagnostic and Troubleshooting

 PROBLEM 2

CVMS does not work at all, lift truck operation normal.

If only part of CVMS works.

POSSIBLE CAUSE

Open circuit from K1-3C to CVMS connector PIN 8;

Open circuit from K1-6C to CVMS connector PIN 7;
CVMS defect.

CHECKS

Make sure CVMS connector is connected to CVMS.

If connected If not connected

Connect multimeter positive lead to K1-3C Connect CVMS connector.

and negative lead to K1-6C.
Measure the voltage.

12 volts 0 volts

Replace the CVMS module. Repair or replace open circuit between 5 wires
from controller to CVMS.

Micro Controller Control System 42 Diagnostic and Troubleshooting

 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

Check for shorts to battery negative from Repair or replace open wire.
PIN 7 to PIN 8 on CVMS connector.

No shorts found Shorted

Replace logics. Repair or replace shorted wire.

Micro Controller Control System 43 Diagnostic and Troubleshooting

 PROBLEM 4

Direction switch circuit defect.

POSSIBLE CAUSE

Direction switch defect; Wiring to direction

switch defect;

CHECKS

Disconnect the battery.

Disconnect main connector.
Check continuity from K1-6C to K1-5A harness connector;
With direction lever in forward should have a closed circuit,
in neutral should be open.

Check OK Check failed

Check continuity from K1-6C to K1-6A. Disconnect direction switch connector.

With direction lever in reverse should have a Check continuity between Pin2 and Pin3.
closed circuit, in neutral should be open.
Check OK Check failed
Check OK Check failed

Replace logics. Repair or replace direction switch.

Check wiring for open/short circuits Check wiring for open/short circuits
between harness connector K1-6C and K1-6A. between harness connector K1-6C and K1-5A.
Repair any open/short circuit found. Repair any open/short circuit found.

Replace direction switch.

Micro Controller Control System 44 Diagnostic and Troubleshooting

 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 Circuit fails

“Diagnostics” “Diagnostics”

Perform Problem 11,12 Tilt Key switch ON.

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

Battery Voltage 0 Volt

Measure voltage from Pin7 to Pin5 battery Repair or replace broken wire
negative as the lever is pulled and released. between Pin1 and Pin5(wire #30)
or between Pin5 and battery
9.0 to 11.0 and .2v 9.0 to 11.0 and .2V negative(-).
Measured NOT measured

Replace logics. 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.

Micro Controller Control System 45 Diagnostic and Troubleshooting

 PROBLEM 6

Tilt switch circuit defect.

POSSIBLE CAUSE

Tilt switch defect; Wiring defect; Logics defect.

CHECKS

Disconnect main connector. Pull tilt lever to maximum.

Check continuity from K1-3A to K1-6C.
Continuity No continuity

Replace logics. Check continuity of wire #13.

Continuity No continuity

Check continuity from K1-3A of wire #13 to Repair or replace wire.

Pin5 of valve board connector.

Continuity No continuity

Replace tilt switch. Repair or replace wire.

Micro Controller Control System 46 Diagnostic and Troubleshooting

 PROBLEM 7

Auxiliary switch circuit defect.

POSSIBLE CAUSE

Wiring defect; Auxiliary switch defect; Logics defect.

CHECKS

Disconnect main connector. Pull auxiliary lever to

maximum. Check continuity from K1-6C to K2-7B or K2-8B.

Continuity No continuity

Replace logics. Check continuity of wire #12 or #24.

Continuity No continuity

Check continuity from K1-6C of wire #30 to Repair or replace wire.

Pin1 of valve board connector.

Continuity No continuity

Replace AUX switch. Repair or replace wire.

Micro Controller Control System 47 Diagnostic and Troubleshooting

 PROBLEM 8

Park brake switch circuit defect.

POSSIBLE CAUSE

Wiring defect; Park brake switch defect; Logics defect.

CHECKS

Disconnect main connector. Release park brake lever.

Check continuity from K1-4B to K1-6C.

Continuity No continuity

Replace logics. Check continuity of wire #22.

Continuity No continuity

Check continuity from K1-4B of wire Repair or replace wire.

#22 to terminal of park brake switch.

Continuity No continuity

Replace park brake switch. Repair or replace wire.

Micro Controller Control System 48 Diagnostic and Troubleshooting

 PROBLEM 9

Pedal brake switch circuit defect.

POSSIBLE CAUSE

Wiring defect; Pedal brake switch defect; Logics defect.

CHECKS

Disconnect main connector. Push down the brake pedal.

Check continuity from K1-6C to K1-5B.

Continuity No continuity

Replace logics. Check continuity of wire #23.

Continuity No continuity

Check continuity from K1-6C of wire Repair or replace wire.

#30 to Pin2 of pedal brake switch.

Continuity No continuity

Replace park brake switch. Repair or replace wire.

Micro Controller Control System 49 Diagnostic and Troubleshooting

 PROBLEM 10

Display=“E1”
The max speed of drive motor is reduced.

POSSIBLE CAUSE

Drive power module over temperature.

Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

Check temperature of drive If repeat occur, check drive motor

power module seem too high. current draw or operating cycle for
excessive ramp climbing or towing.
You can read temperature
measures using ”COMPACT”
display or “EYE” software.

Yes No

Replace right power module Repair logic board

Micro Controller Control System 50 Diagnostic and Troubleshooting

 PROBLEM 11

Display=“E3”
The max speed of pump motor is reduced.

POSSIBLE CAUSE

Pump power module over temperature.

Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

Check temperature of pump I If repeat occur, check pump

power module seem too high
You can read temperature
measures using “COMPACT”
display or “EYE” software.
motor current draw or operating
cycle for excessive ramp climbing
or towing

Yes No

Replace pump power module Repair logic board

Micro Controller Control System 51 Diagnostic and Troubleshooting

 PROBLEM 12

Display=“E4”
The max speed of drive motor is reduced

POSSIBLE CAUSE

Right drive motor over temperature ; Drive motor thermal

sensor defect; Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a If repeat occur, check drive

resistance about 10kohm motor current draw or operating
between two wires of the cycle for excessive ramp climbing
thermal sensor of drive motor or towing

Yes No

Replace control board Replace thermal sensor

Micro Controller Control System 52 Diagnostic and Troubleshooting

 PROBLEM 13

Display=“E6”
The max speed of pump motor is reduced.

POSSIBLE CAUSE

Right drive motor over temperature ;

Drive motor thermal sensor defect ;
Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a If repeat occur, check pump motor

resistance about 10kohm current draw or operating cycle for
between two wires of the excessive ramp climbing or
thermal sensor of pump motor. towing

Yes No

Replace control board. Replace thermal sensor.

Micro Controller Control System 53 Diagnostic and Troubleshooting

 PROBLEM 14

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 22.0V.

Voltage OK Voltage low

With key on, seat switch and main Check battery

contactor closed, measure voltage connection ;
at BATT+ on controller.
Charge or replace battery
Battery voltage

Replace logic

Micro Controller Control System 54 Diagnostic and Troubleshooting

 PROBLEM 15

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 Lift truck operation ok

Check accelerator, Inform operator of correct start-up

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

If no faulty component is
found, replace logics.

Micro Controller Control System 55 Diagnostic and Troubleshooting

 PROBLEM 16

Display=“EE(Flashing)”
No left truck operation

POSSIBLE CAUSE

No operator in seat; Seat switch defect;

Open wire.

CHECKS

Disconnect main connector Check continuity from wire #10

to wire #51 .Should be closed circuit when seat is
pressed on and open circuit when seat release.

No continuity Check OK

Disconnect seat switch connector. Replace logics

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

Continuity No continuity

Replace seat switch

Check wiring for open circuits

Between harness #10 and #51.
Repair any open circuit found.

Micro Controller Control System 56 Diagnostic and Troubleshooting

 PROBLEM 17

Display=“F”
No lift truck operation

POSSIBLE CAUSE

Improper communication between DSP,

Logic board defect.

CHECKS

Try default setting and pedal/steering/lift resetting.

OK If not ok

Normal operating. Replace logic board

Micro Controller Control System 57 Diagnostic and Troubleshooting

 PROBLEM 18

Display=“F0”,
Lift truck operation.

POSSIBLE CAUSE

Battery voltage exceeds 34V.

Failed logic

CHECKS

Disconnect battery, measure voltage at battery

connector terminal.

More than 34V Not

Battery discharge Replace logic board

Micro Controller Control System 58 Diagnostic and Troubleshooting

 PROBLEM 19

Display=“F1”
Lift truck operation.

POSSIBLE CAUSE

Battery voltage is lower than 11.5V.

Failed logic

CHECKS

Disconnect battery, measure voltage at battery

connector terminal.

Lower than 11.5V Not

Battery charge Replace logic board

Micro Controller Control System 59 Diagnostic and Troubleshooting

 PROBLEM 20

Display=“F2”
No lift truck operation.

POSSIBLE CAUSE

Accelerator sensor failure. Accelerator

connector disconnect. Failed logic.

CHECKS

Check Accelerator connector.

Connection Disconnection

Accelerator resetting; value must be lower Connect Accelerator

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

Continuity No continuity

Replace logic board

Micro Controller Control System 60 Diagnostic and Troubleshooting

 PROBLEM 21

Display=“F3”
No lift truck operation.

POSSIBLE CAUSE

Drive power module overcurrent.

(Actual current exceeds limit 1100A)
Failed logic board or power module.

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 drive motor

Measure the resistance between U,V,W terminals on

the drive power module.

About 4.4 Mohm 0 ohm or open

Replace logic board Replace drive power module.

Micro Controller Control System 61 Diagnostic and Troubleshooting

 PROBLEM 22

Display=“F5”
No lift truck operation.

POSSIBLE CAUSE

Pump power module overcurrent.

(Actual current exceeds limit 1100A)
Failed logic board or power module.

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 and

shell on the pump motor.

About 4.4 Mohm 0 ohm or open

Replace logic board Replace pump power module

Micro Controller Control System 62 Diagnostic and Troubleshooting

 PROBLEM 23

Display=“F6”
No lift truck operation.

POSSIBLE CAUSE

Disconnect communication cable from drive power

module to drive motor; Drive power module defect.
Logic board defect.

CHECKS

Check the cable connecting from drive power

module to drive motor.
Connection Disconnection

Connect communication cable

Check current of drive power module 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 drive power module

Micro Controller Control System 63 Diagnostic and Troubleshooting

 PROBLEM 24

Display=“F8”
No lift truck operation.

POSSIBLE CAUSE

Disconnect communication cable from pump power

module to Pump motor; Pump power module defect;

Logic board defect.

CHECKS

Check the cable connecting from pump power module to

Pump motor.
Connection Disconnection

Connect communication cable

Check current of pump power module 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 power module

Micro Controller Control System 64 Diagnostic and Troubleshooting

 PROBLEM 25

Display=“F9”
The max speed of pump motor is reduced.

POSSIBLE CAUSE

Steering angle sensor fault.

Wiring defect.

CHECKS

Check continuity from K1-3C(12V) to pin3.; Check continuity

from K1-6C(Gnd) to pin1.; Check continuity from K2-1A(out) to
pin2.
Check the housing.

Repair or replace wire Replace angle sensor

Micro Controller Control System 65 Diagnostic and Troubleshooting

 PROBLEM 26

Display=“FH”
No lift truck operation.

POSSIBLE CAUSE

5V Encoder not ok.

Voltage of K2-1C terminal is lower than 4.3V

CHECKS

Measure voltage from K2-1C terminal of encoder to

K2-1B (GND) terminal of encoder.

5 voltage Lower than 4.3 voltage

Replace logic board Replace defective one

(Drive, pump encoder,
accelerator)

Micro Controller Control System 66 Diagnostic and Troubleshooting

 PROBLEM 27

Display=“Fc”
No lift truck operation.

POSSIBLE CAUSE

Drive motor encoder defect.

An encoder channel is disconnected and
motor is working.

CHECKS

Check drive motor encoder connection.

If correct If not correct

Check continuity from K2-4C to Connect correctly encoder

encoder (pin 4) and from K2-5C connector
to encoder (pin 3).
Check the diagnostic No.49

If correct If no correct

Replace logic board Repair or replace wire

Micro Controller Control System 67 Diagnostic and Troubleshooting

 PROBLEM 28

Display=“FA”
Lift truck operation.

POSSIBLE CAUSE

12V output not ok.

Voltage of K1-3C terminal is lower than 10.5V.

CHECKS

Measure voltage from K1-3C to K1-6C.

12 voltage Lower than 10.5 voltage

Replace logic board Replace defective device one

(Instrument, steering sensor,
valve board)

Micro Controller Control System 68 Diagnostic and Troubleshooting

 PROBLEM 29

Display=“FL”
No lift truck operation.

POSSIBLE CAUSE
Valve control card defect,
Lift setting fault. Tilt/AUX1/AUX2 switch detect

CHECKS

Key switch on. Seat switch on.

Measure voltage at K2-7A

Over minimum setting voltage No voltage

Resetting lift calibration. Replace logic board

Ok If not ok

Adjust valve board

Ok If not ok

Check and adjust the

Tilt/AUX1/AUX2 switch

Ok If not ok

Replace valve board

Micro Controller Control System 69 Diagnostic and Troubleshooting

 PROBLEM 30

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 85~90Ω Other resistance

Check continuity from K1-8B to Replace main contactor

main contactor terminal.

Check continuity from K1-7C to

main contactor terminal.

Continuity No continuity

Check power fuse Repair or replace wire

Normal Open

Replace logic board Replace logic board

Micro Controller Control System 70 Diagnostic and Troubleshooting

 PROBLEM 31

Display=“60”
Lift truck operation

POSSIBLE CAUSE

Battery miss matching;

Logic board fail

CHECKS

Check battery voltage at the system.

OK If not ok

Replace logic board Replace battery

Micro Controller Control System 71 Diagnostic and Troubleshooting

 PROBLEM 32

Display=“61”
No lift truck operation.

POSSIBLE CAUSE

Blocking overtempature of drive motor.;

Drive motor thermal sensor defect;
Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a If repeat occur, check drive

resistance about 10kohm motor current draw or operating
between two wires of the cycle for excessive ramp
thermal sensor of drive motor. climbing or towing

YES NO

Replace control board. Replace thermal sensor.

Micro Controller Control System 72 Diagnostic and Troubleshooting

 PROBLEM 33

Display=“65”
No lift truck operation.

POSSIBLE CAUSE

Blocking over temperature pump motor.;

Pump motor thermal sensor defect;
Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

You have to measure a If repeat occur, check drive

resistance about 10kohm motor current draw or operating
between two wires of the cycle for excessive ramp
thermal sensor of pump motor. climbing or towing

YES NO

Replace control board. Replace thermal sensor.

Micro Controller Control System 73 Diagnostic and Troubleshooting

 PROBLEM 34

Display=“76”
No lift truck operation.

POSSIBLE CAUSE

Pump motor encoder fail.

An encoder channel is disconnected and
motor is working.

CHECKS

Check drive motor encoder connection.

If correct If not correct

Check continuity from K2-2C to Connect correctly encoder

encoder (pin 4) and from K2-3C connector
to encoder (pin 3).

If correct If no correct

Replace logic board. Repair or replace wire.

Micro Controller Control System 74 Diagnostic and Troubleshooting

 PROBLEM 35

Display=“77”
Lift truck operation

POSSIBLE CAUSE

Thermal sensor wire of drive motor open.

Logic board fail

CHECKS

Check continuity from K2-1B to thermal sensor pin1.

Check continuity from K2-3B to thermal sensor pin2.

Continuity No continuity

Replace thermal sensor. Repair or replace wire.

Micro Controller Control System 75 Diagnostic and Troubleshooting

 PROBLEM 36

Display=“79”
Lift truck operation

POSSIBLE CAUSE

Thermal sensor wire of pump motor open.

Logic board fail

CHECKS

Check continuity from K2-1B to thermal sensor pin1.

Check continuity from K2-2B to thermal sensor pin2.

Continuity No continuity

Replace thermal sensor. Repair or replace wire.

Micro Controller Control System 76 Diagnostic and Troubleshooting

 PROBLEM 37

Display=“80”
Lift truck operation

POSSIBLE CAUSE

Wrong drive power module’s thermal sensor.

Logic board fail

CHECKS

Check temperature of drive power module.

(You can read temperature measures using ”COMPACT”
display or “EYE” software)

Normal Abnormal

Replace logic board. Replace drive power module

Micro Controller Control System 77 Diagnostic and Troubleshooting

 PROBLEM 38

Display=“82”
Lift truck operation

POSSIBLE CAUSE

Wrong pump power module thermal sensor

Logic board fail

CHECKS

Check temperature of pump power module.

(You can read temperature measures using “COMPACT”
display or “EYE” software)

Normal Abnormal

Replace logic board. Replace pump power module

Micro Controller Control System 78 Diagnostic and Troubleshooting

 PROBLEM 39

Display=“83”
No lift truck operation

POSSIBLE CAUSE

Faulty eeprom or mismatching software release

Logic board fail

CHECKS

Restore EEPROM (default setting) with EYE application,

Eye software install

Normal Still problem

Replace logic board.

Micro Controller Control System 79 Diagnostic and Troubleshooting

 PROBLEM 40

Display=“84”
No lift truck operation

POSSIBLE CAUSE

CRC alarm

CHECKS

System turn off/on again. Try default setting.

Eye software reinstall.

Normal Still problem

Replace logic board.

Micro Controller Control System 80 Diagnostic and Troubleshooting

 PROBLEM 41

Display does work normal

Lift truck operation abnormal.

POSSIBLE CAUSE

Encoder defect;
Logic board defect

CHECKS

In case detected motor is operating, RPM of defected motor

is about zero(0) rpm and current of defected motor is
waving from 100A to 600A.
You can see diagnostic mode of display panel.
Parameter No.
15, 16, 17: Drive motor current,
21, 22, 23: Pump motor current
2: Drive motor rpm
9: Pump motor rpm
49 : Drive motor encoder channels
51 : Pump motor encoder channels
Or you can see test mode of eye program by Pc.

OK If not ok

Check cable (U,V,W) of

detected motor
YES If not ok

Replace defected motor

Check wiring for open circuit.

Wiring No.#16,#31,#32,#33 of drive motor and
#16,#31,#35,#36 of pump motor.
Check connection of encoder connector.

OK If not ok

Replace encoder

Micro Controller Control System 81 Diagnostic and Troubleshooting

System Tests and Adjustments
Test Equipment
There are various pieces of electric truck test
equipments are that DOOSAN recommends for all
service personnels. This equipment is available
from a number of world wide manufactures and
local electronic suppliers. Contact your DOOSAN
dealer or the factory for further recommendations.
Micro Controller Control System
Hydrometer
Hydrometers are usually available from any battery
supplier. Battery maintenance is a crucial part 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 DOOSAN recommends for all
service personnels. This equipment is available
from a number of world wide manufacturers and
local electronic suppliers. Contact your DOOSAN
dealer or the factory for further recommendations.
Handheld Multimeter
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 recommended
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.
82 Diagnostic and Troubleshooting
Electrical System Adjustment
Parking Brake Switch
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.
Parking Brake Switch Adjustment
(1) Switch. (2) Plate. (3) Bolts.
1. Close the seat switch and turn the key to ON.
3. Release the parking brake and put the truck in
forward.
4. Reposition plate (2) so the switch (1) actuator is
against the bracket. Tighten bolts (3).
5. Engage the parking brake and the park brake
symbol will be displayed. Repeat the procedure
until adjustment is correct.
Micro Controller Control System
Lift Sensor
1. Disconnect the battery and discharge the head
capacitor.
1
3
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.
2. Loosen setscrew (4).
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).
4. Tighten setscrew (4). Check lift sensor circuit.
The valve control card may need adjusting.
5. Set lift sensor initial setting.
Refer to “Sensor Initial Setting”.
83 Diagnostic and Troubleshooting
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

procedure.

Micro Controller Control System 84 Diagnostic and Troubleshooting

Instrument Panel
LCD Instrument panel shows information about
system main analogue and digital parameters,
as follows:
1. Truck speed
2. Park brake insertion
3. Seat switch closure
4. Low speed insertion
5. Battery charge level
6. Energetic operating mode

(Standard)

(Option)

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).

Micro Controller Control System 85 Diagnostic and Troubleshooting

Instrument Panel Display Segments

Monitoring Systems The display gives the following information about the
operating state of the system:
Indicator (Compact Display)
Lift truck speed (expressed in km/h or
mp/h)

Handbrake active, indicated by the

warning symbol

Safety contact open, indicated both by

EE blinking message visualized in
timemeter area and by relative symbol
(OPTION)

With any directional switch active and safety contact

(STANDARD) still open, lift truck can’t 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, odometer

Steering angle (OPTION)

Maintenance time expiry, indicated by

warning symbol (OPTION)

Slow speed operation, indicated by

(OPTION)
Lift truck speed level, range from 0 (NO
speed) to 9 (MAXIMUM speed) segment,
as in symbol (OPTION)

Battery level, indicated by a 9 segments

symbol.

In following Table 1, you can read the generic relation

between battery charge level and number of
visualized bars . See Table 2. Display signals with
alarm code EL the fact battery is completely
discharged.

Micro Controller Control System 86 Instrument Panel

Relation between battery charge level and Table 3 : Contraction for dot matrix display Alarm Code
number of visualized bars Display
Description Contraction
Code
Table 1 : Case of a generic system CONTACTOR
17 Main breaker fault
BATTERY CHARGE FAULT
DISPLAY INDICATION Battery/inverter
LEVEL 60 BATT MISMATCH
mismatch
No segments Discharged battery
Blocking
1 flashing segment 10 % R-MOTOR
61 Overtemperature of
1 segment 20 % SHUTDOWN
motor (over 165℃)
2 segments 30 % Blocking
3 segments 40 % Overtemperature of P-MOTOR
65
4 segments 50 % pump motor (over SHUTDOWN
5 segments 60 % 165℃)
6 segments 70 % P-MOTOR
76 Pump motor Encoder
ENCODER.
7 segments 80 %
Wrong traction R-M TEMP
8 segments 90 % 77
motor thermal switch SENSOR
9 segments Full charged battery Wrong pump motor P-M TEMP
79
thermal probe SENSOR
Table 2 : Case of an 36V system (BC25S – 36V) Wrong traction
R-INV T
BATTERY CHARGE BATTERY VOLTAGE 80 module thermal
SENSOR
LEVEL [V] probe
Discharged battery Voltage < 22.0 V Wrong pump module
82 P-INV T SENSOR
thermal probe
10 % 22.0 V ÷ 22.5 V
83 CRC fault CRC FAULT
20 % 22.5 V ÷ 22.9 V 84 Bank CRC restored CRC RESTORED
30 % 22.9 V ÷ 23.3 V Capacitors not
40 % 23.3 V ÷ 23.7 V A FAST CHARGE
charged : fast charge
50 % 23.7 V ÷ 24.1 V Trans.precharge in
60 % 24.1 V ÷ 24.4 V A Short / Cap. Too TOO CHARGED
70 % 24.4 V ÷ 24.7 V charged
80 % 24.7 V ÷ 25.0 V Capacitors not
CAP SLOW
90 % 25.0 V ÷ 25.2 V A charged :
CHARGE
slow charge
Full charged battery Voltage > 25.2 V
Capacitors not TIME OUT
A
charged : time out CHARGE
Capacitors not CAP NOT
A
charged CHARGED
Drive module R-INV
E1
Overtemperature OVERTEMP
Pump module P-INV
E3
Overtemperature OVERTEMP
Drive motor R-MOTOR
E4
Overtemperature OVERTEMP
Pump motor P-MOTOR
E6
Overtemperature OVERTEMP
EE Wrong start WRONG START
EE
(FLASHI Seat switch SEAT SW OPEN
NG)
EL Low battery voltage LOW BATT VOLT
F Wrong Eeprom EEPROM FAULT
WD Timer/Enable WD TIMER
F
micro signals FAULT
F Serial communication COMM FAULT
Maximum battery
F0 MAX BATT VOLT
voltage
Minimum battery
F1 MIN BATT VOLT
voltage
F2 Pedal trimmer fault ACCEL FAULT

Micro Controller Control System 87 Instrument Panel

 Drive module R-INVERTER enabled: in case you have chosen one of L1, L2
F3
Desat/overcurrent FAULT or L3 operating modes, and lift truck is stopped,
Pump module P-INVERTER one of the segments of speed indicator symbol
F5
Desat/overcurrent FAULT (see Table 4) blinks to show selected energetic
Drive motor R-MOTOR I mode.
F6
current Offset OFFSET
Pump motor current P-MOTOR I
F8 Table 4 : selected energetic mode (OPTIONAL
Offset OFFSET
DISPLAY)
STEER SENSOR
F9 Steer sensor fault DISPLAY
OUT
FH 5V encoders not ok 5V NOT OK VISUALISATION OPERATING MODE
Drive motor R-MOTOR (from symbol left side)
Fc 1st segment L1 (Limit 1)
Encoder ENCODER
FA 12V out not ok 12V NOT OK 5st segment L2 (Limit 1)
Pump input on at the 9st segment L3 (Limit 1)
FL PUMP SIGN ON
start

Otherwise symbol indicates, as usual,

Lift truck operation mode
selected operating mode.
Pressing E-S-H button, you can set
energetic operating mode for your
NOTE: as usual, if lift truck is moving,
system.
symbol indicates speed level
This function is enabled using EYE menu named
Calibration – ESH, to select desired operating
mode. In particular you can choose either 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 can’t
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.

NOTE: Percent values can be modified only with

EYE Calibration – E-S-H menu.

NOTE: Pressing PROGRAMMABLE WORKING you

can manage economic, standard or high operating
mode too.

COMPACT display shows different symbols in

function of selected energetic mode:

- E-S-H management disabled: no symbol

visualized.
- E-S-H management enabled: active mode
is indicated by symbol.

- PROGRAMMABLE WORKING management

Micro Controller Control System 88 Instrument Panel

NOTE: if active mode is one of L1, L2 or L3 Low oil level of the brakes; red colour LED.
limitations and you change operating mode (from
PROGRAMMABLE WORKING to E-S- H), software Seat Belt warning (OPTION): red color
automatically sets operating mode to economic one LED for 10 seconds.

Alarm message, indicated by an alpha-numerical

code in the display area where usually lift truck
speed appears.
See Table 3 for the meaning of alarm codes.
E1~E6 Over-temperature warning, indicated by the
warning light In case the temperature of power
transistors exceeds the warning limit and relative
light blink.
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
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
In case the truck does not move forward or
reverse direction, check to see if the service
brake switch is activated.

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 5).
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.

Table 5
CODE MEANING

C1 3 WHEEL

24 BATTERY VOLTAGE

16 MAX. CAPACITY

LED Indicators

On left side, COMPACT display has four LED

indicators which, when switched on, give
information as follows:

Alarm message; red color LED (OPTION)

Message of lamps; green color LED

(OPTION)

Indicator lights activated; green color

LED(OPTION)

Micro Controller Control System 89 Instrument Panel

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 E-S-H key

follows: With this key, you can modify the device operating
condition, in a circular sequence, as described in
ENTER key Table 6 :
1. When you switch your device on, this key,
pressed for 3 consecutive seconds, allows Current Working Working Condition After
entering both to parameter calibration and to Condition the Key Pressure
diagnostic mode.
Economic (E) Standard (S)
2. During usual operations, this key, pressed for 3
consecutive s, allows you to access merely to Standard (S) High (H)
diagnostic mode. High (H) Limitation 1 (L1)
Limitation 1 (L1) Limitation 2 (L2)
Remember that if the display is operating in
Limitation 2 (L2) Limitation 3 (L3)
diagnostic mode during typical operations, you can
exit this procedure pressing once ENTER key. Limitation 3 (L3) Economic (E)
Moreover, ENTER key is used to confirm the new Table 6
value of the parameter in calibration procedure.
Notice: You can modify system operating modes
only after enabling their management with EYE
UP key applicative software.
1. Pressing of this key, in calibration and
diagnostic mode, you increase the number of Notice: Pressing this key when you are in
the parameter displayed. diagnostic mode you can see a circular list of 10
2. In calibration phase, you increase the numeric latest alarms.
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).

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.

Micro Controller Control System 90 Instrument Panel

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:
To enter calibration mode:
1. Switch on your system, with ENTER key
pressed 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: 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 doesn’t 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.
Micro Controller Control System
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 time-
meter area.
Moreover, appear a number of segments
proportional to the parameter value.
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.
Notice: Remember that parameter values can be
modified only by discrete increments.
See Table 7 for the list of all adjustable
parameters and relative minimum available
variations.
Alarm reset:
Select parameters 10 and 17 to the following
values:
Parameter 10 = 48
Parameter 17 = 26
Notice: If you press the E-S-H key in the Calibration
mode’s value change, you can change the
ciphers of the value.
91 Instrument Panel
Table 7 (H mode)

No Parameter Unit Minimum Default Maximum Remark

5 Deceleration steering ramp 1 rpm/s 0 1,000 5,000
6 Deceleration steering ramp 2 rpm/s 0 0 1,000
9 Battery reset value V*10 226 230 249
First parameter for calibration enable
10
(1st password)
11 Seat switch delay s 1 3 9
12 Chat time s 1 6 9
13 Hydro time s 1 10 20
Disable = 0 (Default)
14 Maintenance time inserting enable digit
Enable = 1
Second parameter for calibration enable
17
(2nd password)
23 Minimum accelerator mV 200 1,000 4,500
24 Maximum accelerator mV 2,000 3,600 4,500
26 Stop on slop timer s 1 5 10
OFF = 0 (Default)
27 Lift priority for speed reference digit
ON = 1
OFF = 0 (Default)
30 Buzzer on forward direction digit
ON = 1
OFF = 0 (Default)
31 Buzzer on reverse direction digit
ON = 1
32 Maximum lift mV 3,000 11,500 12,000
33 Minimum lift mV 0 1000 12,000
34 Middle lift mV 1,000 2,750 12,000
35 Starting temperature of motor's Fans ℉(℃) 0 140(85) 311(155)
36 Weight of the load on the forks (option) kg 0 0
Future
37 No load pressure (option) bar·10 0 0 2,200
option
38 Load pressure (option) bar·10 0 0 2,200
39 Limitation temperature ℉(℃) 0 212(100) 311(155)
Disable = 0
40 Slow speed button enable digit
Enable = 1 (Default)
41 Drive maximum current % 20 100 100
42 Forward maximum speed rpm 1,000 3,850 4,000
43 Reverse maximum speed rpm 1,000 3,850 4,000
44 Drive limitation maximum speed rpm 500 2,000 3,500
46 High lift switch 1 drive max speed rpm 0 1,000 4,500 Option
47 Steer limitation drive maximum speed rpm 400 1,500 2,000
48 Acceleration ramp rpm/s 40 900 2,000
49 Inversion ramp rpm/s 40 900 2,000
50 Release ramp rpm/s 40 800 2,000
51 Pedal brake ramp rpm/s 40 1,000 2,000
52 Creep speed rpm/s 100 300 2,000

Micro Controller Control System 92 Instrument Panel

 No Parameter Unit Minimum Default Maximum Remark
53 Diameter of drive tires mm 300 424 700
54 High lift switch 2 drive max speed rpm 0 1,000 4,500 Option
59 Partial release ramp rpm/s 10 35 500
61 Lift maximum current % 20 100 100
62 Auxiliary maximum current % 10 66 100
63 Lift maximum speed rpm 1,500 3,000 3,000
64 Tilt speed rpm 500 900 2,000
65 Auxiliary 1 function speed rpm 500 900 2,800
66 Auxiliary 2 function speed rpm 500 900 2,800
67 Auxiliary 3 function speed rpm 500 900 2,800
68 Lift minimum speed rpm 500 700 1,500
69 High lift 1 switch lift max speed rpm 0 1,500 3,000 Option
70 Hydro speed rpm 400 700 800
71 Hydro idle speed rpm 200 500 600
72 Pump acceleration ramp rpm/s 1,000 7,000 10,000
73 Pump deceleration ramp rpm/s 1,000 7,000 10,000
74 High lift 2 switch lift max speed rpm 0 1,500 3,000 Option
75 High lift 1 switch tilt max speed rpm 0 500 2,000 Option
76 High lift 2 switch tilt max speed rpm 0 500 2,000 Option
77 High lift 1 switch side shift max speed rpm 0 500 2,800 Option
78 High lift 2 switch side shift max speed rpm 0 500 2,800 Option
79 High lift 1 switch auxiliary 2 function max speed rpm 0 500 2,800 Option
80 High lift 2 switch auxiliary 2 function max speed rpm 0 500 2,800 Option
83 High lift 1 switch auxiliary 3 function max speed rpm 0 500 2,800 Option
84 High lift 2 switch auxiliary 3 function max speed rpm 0 500 2,800 Option
Disable = 0 (Default)
94 Slow speed digit
Enable = 1
Normal = 0 (Default)
95 British unit digit
British unit = 1
96 Display brightness digit 0 5 8
Disable = 0
97 E-S-H enable digit
Enable = 1 (Default)
Timer meter = 0 (Default)
98 Time meter / Odometer on display digit
Odometer = 1
99 Maintenance time h 0 0 10,000

Micro Controller Control System 93 Instrument Panel

Sensor Initial 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.
- Replacing Logic
- Updating flash memory (Update EEPROM) or
Resetting EEPROM
- Replacing or adjusting Sensor
- Default Setting
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 visualization
are active); enter calibration mode and set
parameter 23 to the value measured.
Default Setting
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 dS (default set);
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 8
(*)

Maximum value calibration: read sensor voltage Econom Standar Hige

value from display, with pedal completely pressed; Parameter
ic Mode d Mode Mode
enter calibration mode and set parameter 24 to the
Maximum drive
value measured. 62 76 100
current
Maximum forward
LIFT LEVER SENSOR (parameter 5): 2,900 3,300 3,850
speed [rpm]
Enter diagnostic mode to visualize lift lever voltage.
Maximum reverse
Minimum value calibration: read from display sensor 2,900 3,300 3,850
voltage with lift lever released; enter calibration speed [rpm]
mode and set parameter 33 to the value read. Drive acceleration
700 800 900
ramp [rpm/s]
Maximum value calibration: read from display Lift maximum
85 85 100
sensor voltage with lift lever completely pressed; current
enter calibration mode and set parameter 32 to the Maximum lift speed
1,800 2,600 3,000
value measured. [rpm]
Central value calibration: enter calibration mode and Drive inversion ramp
700 800 900
modify parameter 34. [rpm/s]
Drive release ramp
500 600 700
STEERING SENSOR [rpm/s]
Notice: You do not need the initial setting of Table 8 (*) Its values are actually implemented into the
STEERING SENSOR because this steering switch software of 48 V lift truck
is only a proximity switch for low or high signal.
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.

Notice: Parameter 94 is visualized only in case E-

S-H management procedure is enabled with relative
EYE software calibration menu.

Micro Controller Control System 94 Instrument Panel

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 9, you have a list of the parameters

you can analyze with their respective displaying
order :

Micro Controller Control System 95 Instrument Panel

List of diagnostic (Table 9)
Parameter No. Description Unit
1 Drive motor speed [rpm]
2 Drive motor speed reference [rpm]
5 Lift voltage [mV]
6 Battery voltage [V·10]
7 Drive motor power module temperature [℃ / °F]
8 Pump motor power module temperature [℃ / °F]
9 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]
15 Drive motor phase current U [A rms]
16 Drive motor phase current V [A rms]
17 Drive 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 Drive motor temperature [℃ / °F]
26 Pump motor temperature [℃ / °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]
37 Auxiliary 1 function (Side shift) switch [digit]
38 Auxiliary 2 function switch [digit]
39 Auxiliary 3 function switch [digit]
40 High lift switch 1 [digit]
41 Tilt switch [digit]
42 High lift switch 2 [digit]
43 Main breaker command [digit]
44 5V out [digit] [digit]
45 12V out [mV] [mV]
46 24V out [digit] [digit]
47 Buzzer command [digit] [digit]
48 Fans command [digit] [digit]
49 Drive motor encoder channels -
51 Pump motor encoder channels -
52 Lift pressure [bar · 10] [bar • 10]
53 Pressure sensor voltage [mV] [mV]
54 Weight of the load on the forks [kg] [kg]

Micro Controller Control System 96 Instrument Panel

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.
In particular, if the selected parameter is:
Analogue input: Instrument panel shows the
parameter value, expressed in the unit of Table 9
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:
1. Seat switch active, for any selected digital input.
To exit diagnostic mode, type ENTER key again.
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.
Micro Controller Control System
Accessing Stored Error Codes
The B16R-5 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.
The stored error codes are accessed at diagnostic
mode by using E-S-H button.
1. Access the diagnostic mode.
2. Press E-S-H button. And then, the stored error
code will be shown with SMU hours, if any.
3. By pressing UP or DOWN key, more error
codes can be shown.
4. Pressing again E-S-H key, you return to
diagnostic mode.
97 Instrument Panel
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 harness’s
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

Micro Controller Control System 98 Eye Software Interface

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

Micro Controller Control System 99 Eye Software Interface

General Information PC-Controller Communication

Minimum Requirements Connect serial port of PC and harness with picture

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

Installation

Serial port
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

USB port

4. Graphic card 1Mb

5. Windows 98SE/NT/XP/ME/2000
6. 1024x768 resolution video adapter

Recommended Requirements

1. 1GHz Pentium class or higher microprocessor

2. 512Mb of RAM
3. Serial port or USB port
4. Graphic card 2Mb
5. Windows 98SE/NT/XP/ME/2000
6. 1024x768 resolution video adapter

Micro Controller Control System 100 Eye Software Interface

Features
If EYE software installation is successful, starting the application from Windows “Programs” Menu, or using short-
cut 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.

Micro Controller Control System 101 Eye Software Interface

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

Micro Controller Control System 102 Eye Software Interface

Password Insertion

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

Micro Controller Control System 103 Eye Software Interface

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

You can select active menus directly from main panel menu bar (any grayed 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)

Fig.9: Submenu selection

Micro Controller Control System 104 Eye Software Interface

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 don’t 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 can’t communicate\ interact with inverter panel.

Configuration Menu (Setup)

Fig.10: Setup menu

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

Micro Controller Control System 105 Eye Software Interface

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 60°C is signaled by a red color; temperature above 90°C is signaled 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 signaling 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

Micro Controller Control System 106 Eye Software Interface

Pump

Fig.12: Pump menu

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 60°C is signaled by a red color; temperature above 90°C is signaled by a flashing display.
5. Request RPM and motor speed, with an arrow signaled 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

Micro Controller Control System 107 Eye Software Interface

Battery

Fig.13: Battery menu

Following items appear in Battery menu front panel:

1. Battery and inverter voltage
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.

Micro Controller Control System 108 Eye Software Interface

Timers

Fig.14: Timers menu

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

Micro Controller Control System 109 Eye Software Interface

Calibration

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 can’t 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 111)
2. “Timers“: Timers calibration (Refer to page 112)
3. “Steering“: Steering sensor (Refer to page 113)
4. “Pedal“: Pedal accelerator calibration (Refer to page 114)
5. “Lift“: Lift calibration (Refer to page 115)
6. “ESH“: E/S/H parameters calibration and limits (Refer to page 116)
7. “Steering parameters“: Steering parameters calibration (Refer to page 118)
8. “Program service“: Program service interval setting (Refer to page 119)
9. “Drive motor“: Drive motors parameters calibration (Refer to page 120)
10. “Pump motor“: Pump motors parameters calibration (Refer to page 121)
11. “Critical height switches“: Speed limits calibration in case of critical height (Refer to page 122)(*)
12. “Weight sensor“: Weight sensor calibration (Refer to page 123) (*)
13. “Truck setup“: Some lift truck parameters setup (Refer to page 124) (*)
14. “Load eeprom default“: EEPROM configuration (Refer to page 125)
15. “Parameters image”: Parameter store or Restore. (Refer to page 126)
16. "Data Logging" : Data acguistion (Refer to page 127)
17. "Flash" : Flash programming (Refer to page 129)

(*): Optional menu

Micro Controller Control System 110 Eye Software Interface

Battery reset voltage calibration

Fig.15: Battery reset and Discharged battery voltage 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

Discharged battery voltage : If battery’s performance is bad, select the discharged battery voltage high.

Micro Controller Control System 111 Eye Software Interface

Timers calibration

Fig.16: Timers calibration menu

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

Micro Controller Control System 112 Eye Software Interface

Accelerator pedal calibration

Fig.18: Accelerator pedal calibration menu

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. Release accelerator pedal.
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.

Micro Controller Control System 113 Eye Software Interface

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.

Micro Controller Control System 114 Eye Software Interface

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.

Micro Controller Control System 115 Eye Software Interface

Fig.21: Parameters externally changed

If PROGRAMMABLE WORKING section is enabled, pressing MODIFY LIMITS button you enter Fig. 22 window;
you can now modify percent 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 percent, 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 percent value is referred to High mode data.

Micro Controller Control System 116 Eye Software Interface

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

Micro Controller Control System 117 Eye Software Interface

Program service calibration

Fig. 24: "Program service" menu

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

Micro Controller Control System 118 Eye Software Interface

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.

Micro Controller Control System 119 Eye Software Interface

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

Micro Controller Control System 120 Eye Software Interface

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 signaled 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

Micro Controller Control System 121 Eye Software Interface

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

Micro Controller Control System 122 Eye Software Interface

Lift truck setup

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

Micro Controller Control System 123 Eye Software Interface

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, don’t 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

Micro Controller Control System 124 Eye Software Interface

Parameters Image menu

Fig 35: Parameters image menu

In that menu, You can store and restore about calibration parameters except lift, pedal, steering setting value.

Parameter Store
1. Press Export button
2. Store calibration parameters

Parameter Restore (other trucks)

1. Press Import button
2. Restore calibration parameters

Micro Controller Control System 125 Eye Software Interface

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 can’t 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.

Micro Controller Control System 126 Eye Software Interface

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.

Micro Controller Control System 127 Eye Software Interface

Flash

Fig. 38: Flash programming phase

To upgrade main controller software, with Flash menu (Fig. 38) follow these steps:
1. Disable all commands
2. Verify if “C:\Source_SME\Source_SNG_FILE” directory exists (otherwise create it)
3. Source directory must contain only 1 source file.(XX-XX-XX 0015.SNG0)
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

Micro Controller Control System 128 Eye Software Interface

Troubleshooting of Eye Program
Generality
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
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
Serial Communication
If application doesn’t 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
Micro Controller Control System
Flash Programmation
If panel programming phase fails, when you try
to load source files:
1. Verify if “C:\Source_SME\Source_SNG_FILE”
directory exists
2. Verify if “C:\Source_SME\Source_SNG_FILE”
directory contains only 1 source file.
3. Be sure that source files are the ones provided
by DI’s Homepage.
If you program memory successfully, but
inverter doesn’t work correctly:
1. Be sure that source files are the ones provided
by S.M.E
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
Other Problems
Application works slowly:
1. Verify if your PC complies minimal requirements
Application doesn’t 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. Don’t modify window size
Monitor doesn’t display correctly text and
“objects”
1. Verify if monitor refresh frequency is at least
75Hz
2. Verify if your PC complies minimal requirements
129 Eye Software Interface
Appendix A : Parameter List
Parameter Mini Def Maxi Re
Parameter Parameter Description Unit
No mum ault mum mark
Deceleration as high it is as quickly the truck decreases
5 steering ramp its speed if the truck driver is turning the rpm/s 0 1,000 5,000
1 wheel quickly
as high it is as quickly the truck decreases its
Deceleration speed in relation to the drive speed of truck.
6 steering ramp This parameter increases the deceleration rpm/s 0 0 2,000
2 ramp while the driver is steering at high
speed.
Battery reset Minimum battery voltage necessary to reset
9 V*10 226 230 249
value battery discharged voltage alarm
Seat switch Time interval between seat switch opening
11 s 1 3 9
delay and drive and pump motors stopping
Time delay between last command given to a
12 Chat time s 1 6 9
drive or pump motor and chat mode signaling
Time interval when pump motor works (with
13 Hydro time s 1 10 20
hydro speed) after the end of a command
Maintenance
Disable = 0 (Default)
14 time inserting Maintenance time inserting enable digit
Enable = 1
enable
Steering Steering sensor voltage with wheels turned
18 mV 500 10,300 11,500
anticlockwise on right
Steering Steering sensor voltage with wheels turned
19 mV 500 1,200 11,500
clockwise on left
Steering
20 Steering voltage with wheels straight ahead mV 500 6,300 11,500
middle
Minimum Accelerator sensor voltage with pedal
23 mV 200 1,000 4,500
accelerator released
Maximum Accelerator sensor voltage with pedal
24 mV 2,000 3,600 5,000
accelerator completely pressed
Stop on slop Without stepping on pedal brake, time that is
26 s 1 5 10
timer doing stop in slope
if it's OFF, the pump motor works like it does now, that is,
the reference speed of pump motor, in case of many
simultaneous commands (LIFT + TILT, LIFT + AUX1,
Lift priority for
TILT + AUX1.......), will be the highest of every single OFF = 0 (Default)
27 speed digit
command; if it's ON the reference speed of pump motor, ON = 1
reference
in case of many simultaneous commands, will be the
lowest of those reference speed required by every single
command.
Buzzer on
If it’s ON, the buzzer will be alarmed when the OFF = 0 (Default)
30 forward digit
direction switch is moved to forward. ON = 1
direction
Buzzer on
If it’s ON, the buzzer will be alarmed when the OFF = 0 (Default)
31 reverse digit
direction switch is moved to reverse. ON = 1
direction
Lift sensor voltage with lift lever completely
32 Maximum lift mV 3,000 11,500 12,000
pressed
33 Minimum lift Lift sensor voltage with lift lever released mV 0 1,000 12,000
Lift lever potentiometer voltage to which the
34 Middle lift lifting becomes proportional to the shift of the mV 1,000 2,750 12,000
lever
The cooling Fan runs when the temperature
Starting of motors reaches to set value. And the
℉ 185 311
35 temperature of cooling Fan stops when the motors cools 0
(℃) (85) (155)
motor's Fans down below 140℉(60℃) from set value(The
minimum of stop temperature is 77℉(25℃)).
Weight of the
36 Load measurement kg 0 0
load on the forks
future
No load
37 Load measurement bar·10 0 0 2,200 option
pressure
38 Load pressure Load measurement bar·10 0 0 2,200

Micro Controller Control System 130 Appendix

Parameter Mini Def Maxi Re
Parameter Parameter Description Unit
No mum ault mum mark
Limitation 212 311
39 Start temperature of performance reduction ℉(℃) 0
temperature (100) (155)
Slow speed If parameter is set to 1, speed limitation Disable = 0
40 digit
button enable button is enabled. Enable = 1 (Default)
Drive
Drive motors maximum current (expressed in
41 maximum % 20 100 100
per cent of high energetic mode value)
current
Forward Maximum forward lift truck speed with no
42 maximum speed limitation rpm 1,000 3,850 4,000
speed (no alarms present and turtle not active)
Reverse Maximum reverse lift truck speed with no
43 maximum speed limitation rpm 1,000 3,850 4,000
speed (no alarms present and turtle not active)
Drive limitation
Maximum lift truck speed with speed
44 maximum rpm 500 2,000 2,500
limitation (turtle active)
speed
High lift switch
Maximum travel speed when switch 1 was
46 1 drive max rpm 0 1,000 4,500 Option
"ON"
speed
Steer limitation
Maximum speed reference in the angle in
47 drive maximum rpm 400 1,500 2,000
which the internal wheel is mechanically still.
speed
Acceleration Lift truck acceleration with accelerator pedal
48 rpm/s 40 900 2,000
ramp pressed
Inversion
49 Lift truck deceleration in inversion rpm/s 40 900 2,000
ramp
Lift truck deceleration with accelerator pedal
50 Release ramp rpm/s 40 900 2,000
released
Pedal brake Lift truck deceleration with pedal brake
51 rpm/s 40 1,000 2,000
ramp pressed
If the truck speed is greater then this
threshold, the speed reference becomes a
52 Creep speed rpm 100 300 2,000
parabolic function of the accelerator
potentiometer voltage.
Diameter of
53 Drive tyre's diameter mm 300 424 700
drive tires
High lift switch
Maximum travel speed when switch 1 and
54 2 drive max rpm 0 1,000 4,500 Option
switch 2 was "ON"
speed
Parameter that softens the drive inversion
Partial release
59 ramp if the traction motors are working with rpm/s 10 35 500
ramp
low rpm
Lift maximum Pump motor maximum current with lift
61 % 20 100 100
current function active
Auxiliary
Pump motor maximum current with lift lever
62 maximum % 10 66 100
released
current
Lift maximum
63 Maximum lift speed rpm 1,500 3,000 3,000
speed
64 Tilt speed Pump motor speed with lift function active rpm 500 900 2,000
Auxiliary 1 Pump motor speed with 1st auxiliary function
65 rpm 500 900 2,800
function speed active
Auxiliary 2 Pump motor speed with 2nd auxiliary function
66 rpm 500 900 2,800
function speed active
Auxiliary 3 Pump motor speed with 3rd auxiliary function
67 rpm 500 900 2,800
function speed active
Lift minimum
68 Minimum lift speed rpm 500 700 1,500
speed
High lift 1
Maximum pump motor speed with forks
69 switch lift max rpm 0 1,500 3,000 Option
above the critical height
speed
70 Hydro speed Pump motor speed when steering rpm 400 700 800

Micro Controller Control System 131 Appendix

Parameter Mini Def Maxi Re
Parameter Parameter Description Unit
No mum ault mum mark
Pump motor speed with direction command
Hydro idle
71 lever not in neutral, acceleration pressed and rpm 200 500 600
speed
no pump command active
Pump
72 Lift acceleration rpm/s 1,000 7,000 10,000
acceleration ramp
Pump Pump motor deceleration after the end of a
73 rpm 1,000 7,000 10,000
deceleration ramp command
High lift 2 switch Maximum lift speed when switch 1 and switch
74 rpm 0 1,500 3,000 Option
lift max speed 2 was "ON"
High lift 1 switch
75 Maximum tilt speed when switch 1 was "ON" rpm 0 500 2,000 Option
tilt max speed
High lift 2 switch Maximum tilt speed when switch 1 and switch
76 rpm 0 500 2,000 Option
tilt max speed 2 was "ON"
High lift 1 switch
Maximum auxiliary 1 speed when switch 1
77 auxiliary 1 max rpm 0 500 2,800 Option
was "ON"
speed
High lift 2 switch
Maximum auxiliary 1 speed when switch 1
78 auxiliary 1 max rpm 0 500 2,800 Option
and switch 2 was "ON"
speed
High lift 1 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1
79 rpm 0 500 2,800 Option
function max was "ON"
speed
High lift 2 switch
auxiliary 2 Maximum auxiliary 2 speed when switch 1
80 rpm 0 500 2,800 Option
function max and switch 2 was "ON"
speed
High lift 1 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1
83 rpm 0 500 2,800 Option
function max was "ON"
speed
High lift 2 switch
auxiliary 3 Maximum auxiliary 3 speed when switch 1
84 rpm 0 500 2,800 Option
function max and switch 2 was "ON"
speed
If parameter is set to1, speed limitation is
Disable = 0 (Default)
94 Slow speed active; otherwise lift truck speed is managed digit
Enable = 1
as usual.
If parameter is set to 1, values are expressed Normal = 0
95 British unit digit
in British unit, otherwise in international ones. British unit = 1 (Default)
Display
96 Display's brightness adjustment digit 0 5 8
brightness
If this parameter is set to 1, it is possible to
Disable = 0
97 E-S-H enable change the value of the power mode with the digit
Enable = 1 (Default)
display
Time meter / If parameter is set to 1, odometer indication
Timer meter = 0 (Default)
98 Odometer on appears on display ; otherwise display shows digit
Odometer = 1
display the hour meter.
Maintenance Can set truck's maintenance period.
99 h 0 0 10,000
time (Maintenance period decision)

Micro Controller Control System 132 Appendix

Appendix B : Error Code List
EYE Error
Description Level Cause Troubleshooting
Code Code
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
Maximum Battery voltage, measured charge-discharge cycles before reaching the
1 F0 battery 1 by a circuit inside logic, rating declared by the constructor) or has a
voltage exceeds 34 V 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
Minimum Battery voltage, measured alarm can sometimes be detected from the
2 F1 battery 1 by an internal circuit, is controller; even in case of low battery charge
voltage lower than11.5 V (<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 accelerator initial set-up is correct;
if not, repeat calibration procedure.(You can
use both PC with serial communication
software and Instrument panel).
Voltage measured on
2. Verify if the following the 42pin main connector
accelerator circuit exceeds
terminals are correctly wired to their
the value calculated
Pedal correspondent inputs in accelerator circuit:
3 F2 2 averaging calibration and
trimmer fault - K2-1C(5 V)
reachable voltages;
- K1-6C (ground)
moreover, start switch
- K2-6A (pedal output-A)
seems to be open.
- K2-4A (pedal output-B)
3. In case of correct wiring, replace the
accelerator itself.
4. Replace the logic.
Eeprom does not work 1. Load default values for eeprom variables, both
Eeprom properly, or one of using PC with serial communication software
5 F 1
alarm memorized values is out of and Instrument panel.
correct limits. 2. Replace the logic.
Voltage level of pre -
charge capacitors is less
1. Verify if main breaker coil and power terminals
then 70 % of nominal
Pre -charge are in good conditions.
battery level.
capacitors 2. Verify if supply lines power fuse is damaged.
It could happen, in
low voltage 3. Verify if main breaker coils are correctly wired
example, if the power
6 A alarm 1 to their correspondent inputs :
module is working with
(Capacitors - K1-8B (positive terminal)
main breaker open.
not - K1-7C (negative terminal)
Capacitors voltage
charged) 4. Replace the main breaker.
decreases cause energy
5. Replace the logic.
spent to keep motors in
motion.

Micro Controller Control System 133 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
Drive motor 1. With such an alarm present when you turn on
8 F3 power 1 lift truck, disconnect the power cable between
module the malfunctioning power module and the
corresponding motor (first, turn off the system,
of course).
If turning lift truck on again, alarm is not active,
then:
Actual current exceeds
1. Replace the cable connecting logic and
Pump motor limits 1100 A
power module.
25 F5 power 1
2. Replace the power module.
module
3. Replace the logic.
If turning lift truck on again, alarm is active,
then :
1. Replace the power module.
2. Replace the motor.
1. Inspect whether the main connector is not
power loose.
Pre-charge capacitors
module 2. Inspect whether the drive connector is not
voltage increases too fast
9 A capacitors 1 loose.
when you turn the system
pre-charge 3. Replace the main breaker.
on.
too fast 4. Replace the drive power module.
5. Replace the logic.
1. Alarm could be caused by ineffective
temperature dissipation.
Verify thermal coupling between power module
block and aluminium plate, and between
aluminium plate and truck ballast.
The presence of a correct amount of thermal
The power module
grease in the coupling is essential to ensure an
Pump motor temperature
efficient heat exchange.
power (measured with a
2. Replace cable connecting the output pump of
10 E3 module 6 temperature connector),
the logic to the pump power module;
overtemper exceeds 100℃, or is
3. If temperature readings seem too high in
ature inside [95℃, 100℃] range
function of total time interval of lift truck using,
at least 30 s.
replace pump power module causing the
alarm.
You can read temperature measures using
Instrument panel or “EYE” communication
software.
4. Replace the logic.
1. Verify the correctness of wiring from pump
When you turn on the
motor and relative power module
system, capacitors are not
2. Replace wire connecting "pump" with the
completely discharged by
corresponding power module or if not possible
pump motor.
because the pump motor power module box
In fact, if you turn
integrates the outlet wire, substitute the power
Capacitors suddenly on the lift truck,
module box
11 A too charged 1 after a turning off,
3. Verify if main breaker has stuck closed
on start capacitors voltage level is
terminals: in such a case replace it
too high. You have to
4. Replace the wire connecting "drive" in logic to
discharge them before
right drive motor power module: a defective
checking the presence of
wire could give a wrong measure for capacitors
any fault (both of
voltage
capacitors and of logic)
5. Replace the logic.

Micro Controller Control System 134 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
Battery voltage level is
lower than minimum 1. Measure battery voltage with a tester and, if
Low battery charge value expected, different from the value reported on Instrument
12 EL 3
alarm referred to table 3 in panel, replace the logic;
Instrument panel technical 2. Otherwise recharge battery.
documentation.
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 25°C) .
If the measure is not correct it is necessary to
replace the temperature connector;
Drive motor The measure of drive 2. Disconnect the temperature connector and
13 E4 over 5 motor temperature check the wiring insulation between signal wire
temperature exceeds 155℃. an ground wire (towards logic);
3. Replace the 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 25°C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor The measure of pump 2. Disconnect the temperature connector and
14 E6 over 6 motor temperature check the wiring insulation between signal wire
temperature exceeds 155℃. and ground wire (towards logic);
3. Replace the 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 power module to
Drive motor
Non-zero phase currents logic.
15 F6 current 1
when you turn lift truck on. 2. Replace the power module.
offset alarm
3. Replace the logic.
Main Overcurrent on main 1. Replace the main breaker.
17 17 1
breaker fault breaker coil. 2. If alarm is still present, replace the logic.
Improper communication
1. Using EYE program interface, try to program
Watchdog between DSPs present on
18 F 1 logic flash memory. (default setting)
timer alarm logic, or/and defective
2. Replace the logic .
logic.

Micro Controller Control System 135 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
1. Alarm could be caused by ineffective
temperature dissipation; verify thermal coupling
between power module 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
Drive motor power module ensure a correct heat exchange;
power temperature, measured 2. Check cable connecting the communication
20 E1 module 5 with a connector, exceed output connector of the logic to the
overtemper 100℃, or is inside corresponding power module;
ature [100℃] range at least 30 s. 3. If temperature readings seem too high in
function of total time interval of lift truck using,
replace power module unit causing the alarm.
You can read temperature measures using
“Instrument panel” or “EYE” communication
software.
4. Replace the logic.
Error in serial 1. Switch on the system and the turn it on again.
communication between 2. Program pump and drive DSP again; maybe
Serial the two DSP; DSP present software present in flash memory was
21 F communicat 1 on logic make a mutual corrupted. (REFLASH)
ion alarm software control, to insure 3. Try to the default setting (LOAD EEPRON
fast diagnosis of such a DEFAULT-TOTAL LOAD EEPROM)
fault. 4. Replace the logic.
1. Replace the wire connecting power module to
Pump motor
Non-zero phase currents logic.
36 F8 current 1
when you turn lift truck on. 2. Replace the power module.
offset alarm
3. Replace the logic.
1. Verify if 5 V output is grounded, cause an
incorrect encoder wiring.
Alarm on 5 logic K2-1C terminal
2. Verify if 5 V output is grounded, cause any
37 FH V encoder 1 (5 V output) voltage is
encoder malfunction. In that case, replace the
voltage lower than 4.3 V.
defective one.
3. Replace the logic.
1. Verify if 12 V output is grounded, cause an
incorrect wiring to:
Alarm on 12 logic K1-3C terminal - Steering sensor
38 FA V output 1 (12 V output) voltage is - Buzzer
voltage lower than 10.5 V. - Display
2. Replace defective device;
3. Replace the logic.
1. Before starting to operate, turn off any active
Pump motor
You find a pump motor command (both levers and switches);
commands
50 FL 1 command active when you 2. Be sure that lift, tilt and auxiliary command
active on
turn your system on. switches, are not active;
start
3. Replace the valve board.
Battery miss Battery is not suitable
60 60 1 Check battery voltage at the system.
matching voltage to controller.

Micro Controller Control System 136 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
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 25°C) .
If the measure is not correct it is necessary to
replace the temperature connector;
Drive motor The measure of right drive 2. Disconnect the temperature connector and
61 61 shutdown 1 motor temperature check the wiring insulation between signal
temperature exceeds 165℃. wire an ground wire ( towards logic);
3. Replace the 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.
When you start working,
you find seat switch open,
Seat switch
EE or, after the main breaker 1. Verify if seat switch is defective;
63 open on 1
(flash) is closed, the seat switch 2. Replace the logic.
start
remains opened for at least
“ seat switch delay” s.
1. verify if a switch was active or the pedal
pressed, when you turn on the lift truck;
When you start working,
2. verify if start, forward or reverse switches are
you find accelerator pedal
64 EE Wrong start 1 stuck close;
pressed or a forward/
3. verify if pedal circuit voltage exceeds 1/3 its
reverse switch active.
maximum range (measured in Volt);
4. Replace the logic.
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 25°C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor The measure of pump 2. Disconnect the temperature connector and
65 65 shutdown 1 motor temperature check the wiring insulation between signal wire
temperature exceeds 165℃. and ground wire ( towards logic);
3. Replace the 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. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K2-1B terminal
Drive motor An encoder channel is
- + 5 V: K2-1C terminal
74 Fc Encoder 1 disconnected, and motor
- A channel: K2-5C terminal
alarm is working.
- B channel: K2-4C terminal
2. If correctly wired, replace the encoder;
3. Replace the logic.

Micro Controller Control System 137 Appendix

EYE Error
Description Level Cause Troubleshooting
Code Code
1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K2-1B terminal
Pump motor An encoder channel is
- + 5 V: K2–1C terminal
76 76 encoder 1 disconnected, and motor
- A channel: K2–3C terminal
alarm is working.
- B channel: K2–2C terminal
2. If correctly wired, replace the encoder;
3. Replace the logic.
Alarm of
drive motor
77 77
thermal
Temperature difference 1. Verify if the wiring is correct;
connector
7 between both motors 2. Replace the connector;
Alarm of
results greater than 70℃. 3. Replace the logic.
pump motor
79 79
thermal
connector
Alarm of
drive motor
80 80 7
module Temperature difference 1. Check the wiring connecting control unit and
connector between both power power module;
Alarm of modules results greater 2. Replace the power module;
pump motor than 70℃. 3. If alarm is still present, replace the logic.
82 82 7
module
connector
1. restore eeprom with EYE application software,
using the “RESTORE” item present in main
Faulty eeprom or page
CRC fault
83 83 1 mismatching software 2. Try to the default setting (LOAD EEPROM
alarm
release. DEFAULT-TOTAL LOAD EEPROM)
3. if alarm is still present, replace the logic.
CRC : Cyclic Redundancy Checking error.
There was an eeprom 1. Switch on the system and the turn it on again
Bank CRC
84 84 1 restore, caused by a CRC 2. Try to the default setting (LOAD EEPROM
restored
alarm. DEFAULT-TOTAL LOAD EEPROM)
1. verify correctness of wiring with :
- K1-3C (12 V),
Steering
Steer circuit voltage is out - K1-6C (ground)
91 F9 sensor 5
of nominal range. - K2-1A (steering sensor input);
alarm
2. if correctly wired, replace the steering sensor;
3. Replace the logic.
1. Check assembly of the main connector.
Pre-charge capacitor
Capacitors 2. Check cable connecting the Drive/Pump
voltage grows too slowly,
98 A pre -charge 1 output of the logic with the corresponding
when you turn on the
too slow power module.
system.
3. Replace the logic;
Pre-charge capacitors 1. Check assembly of the main connector.
Capacitors voltage does not reach the 2. Check cable connecting the Drive/Pump
99 A pre-charge 1 rated battery voltage output of the logic with the corresponding
too slow within a limit time, when power module.
you turn on the system. 3. Replace the logic;

Micro Controller Control System 138 Appendix

Appendix C : Contraction for dot matrix display.
F1. Alarm Code

[Display Code] [Description] [Contraction]

17 Main breaker fault CONTACTOR FAULT
60 Battery/controller mismatch BATT MISMATCH
61 Drive Motor Shutdown Temperature R-MOTOR SHUTDOWN
65 Pump Motor Shutdown Temperature P-MOTOR SHUTDOWN
76 Pump motor Encoder P-MOTOR ENCODER
77 Wrong drive motor thermal sensor R-M TEMP SENSOR
79 Wrong pump motor thermal sensor P-M TEMP SENSOR
80 Wrong drive power module thermal probe R-INV T SENSOR
82 Wrong pump module thermal probe P-INV T SENSOR
83 CRC fault CRC FAULT
84 Bank CRC restored CRC RESTORED
A Capacitors not charged : fast charge FAST CHARGE
A Trans. precharge in short/Cap. too charged TOO CHARGED
A Capacitors not charged : slow charge CAP SLOW CHARGE
A Capacitors not charged : time out TIME OUT CHARGE
A Capacitors not charged CAP NOT CHARGED
E1 Drive power module Overtemperature R-INV OVERTEMP
E3 Pump module Overtemperature P-INV OVERTEMP
E4 Drive motor Overtemperature R-MOTOR OVERTEMP
E6 Pump motor Overtemperature P-MOTOR OVERTEMP
EE Wrong start WRONG START
EE(FLASING) Seat switch SEAT SW OPEN
EL Low battery voltage LOW BATT VOLT
F Eeprom EEPROM FAULT
F WD Timer/Enable micro signals WD TIMER FAULT
F Serial communication COMM FAULT
F0 Maximum battery voltage MAX BATT VOLT
F1 Minimum battery voltage MIN BATT VOLT
F2 Pedal trimmer fault ACCEL FAULT
F3 Drive power module Desat/overcurrent R-INVERTER FAULT
F5 Pump module Desat/overcurrent P-INVERTER FAULT
F6 Drive motor current Offset R-MOTOR I OFFSET
F8 Pump motor current Offset P-MOTOR I OFFSET
F9 Steer sensor fault STEER SENSOR OUT
FH 5V encoders not ok 5V NOT OK
Fc Drive motor Encoder R-MOTOR ENCODER
FE 24V out 24V NOT OK
FA 12V out not ok 12V NOT OK
FL Pump input on at the start PUMP SIGN ON

Micro Controller Control System 139 Appendix

F2. Calibration Code

[Display Code] [Description] [Contraction]

5 Deceleration steering ramp 1 STEERING DECEL1
6 Deceleration steering ramp 2 STEERING DECEL2
9 Battery reset value BATT RESET VALUE
ST
10 First parameter for calibration enable 1 PASSWARD
11 Seat switch delay SEAT SW DELAY
12 Chat time CHAT TIME
13 Hydro time HYDRO TIME
14 Maintenance time inserting enable SERVICE TIME ON
ND
17 Second parameter for calibration enable 2 PASSWARD
18 Steering sensor value : handle turned on the Max. left HANDLE TURN-L
19 Steering sensor value : handle turned on the Max. right HANDLE TURN-R
20 Steering sensor value : wheels on straight position WHEEL STRAIGHT
23 Accelerator pedal minimum value ACCEL MIN VALUE
24 Accelerator pedal maximum value ACCEL MAX VALUE
26 Stop on slop timer SLOP TIMER
27 Lift priority for speed reference LIFT PRI SPEED
30 Buzzer on forward direction FORWARD ALARM
31 Buzzer on reverse direction BACK UP ALARM
32 Lift sensor maximum value LIFT MAX VALUE
33 Lift sensor minimum value LIFT MIN VALUE
34 Lift sensor middle value LIFT START VALUE
35 Starting temperature of motor’s Fans START MOTOR FAN
36 Weight of the load on the forks LOAD WEIGHT
37 No load pressure NO LOAD PRESSURE
38 Load pressure LOAD PRESSURE
39 Limitation temperature LIMIT TEMP
40 Slow speed button enable SLOW SPEED FIX
41 Drive maximum current DRIVE MAX I
42 Forward maximum speed FWD MAX SPEED
43 Reverse maximum speed REV MAX SPEED
44 Drive limitation max speed D LIMIT MAX SPD
46 High lift switch 1 drive max speed HIGH1 DRIVE MAX
47 Steer limitation drive max speed STEER LIMIT SPD
48 Drive acceleration ramp D ACCEL RAMP
49 Drive inversion ramp D INVERSION RAMP
50 Drive release ramp D RELEASE RAMP
51 Pedal brake ramp PEDAL BRAKE RAMP
52 Creep speed CREEP SPEED
53 Diameter of drive tires TIRES DIA
54 High lift switch 2 drive max speed HIGH2 DRIVE MAX
59 Partial release ramp PARTIAL RELEASE
61 Lift max current LIFT MAX CURRENT
62 Auxiliary max current AUX MAX CURRENT
63 Lift max speed LIFT MAX SPEED
64 Tilt max speed TILT MAX SPEED
65 Auxiliary 1 function speed AUX 1 SPEED
66 Auxiliary 2 function speed AUX 2 SPEED
67 Auxiliary 3 function speed AUX 3 SPEED
68 Lift min speed LIFT MIN SPEED
69 High lift 1 switch lift max speed HIGH1 LIFT LIMIT
70 Hydro speed HYDRO SPEED
71 Hydro idle speed IDLE SPEED
72 Pump acceleration ramp PUMP ACCEL RAMP
73 Pump deceleration ramp PUMP DECEL RAMP
74 High lift 2 switch lift max speed HIGH2 LIFT LIMIT

Micro Controller Control System 140 Appendix

 75 High lift 1 switch tilt max speed HIGH1 TILT LIMIT
76 High lift 2 switch tilt max speed HIGH2 TILT LIMIT
77 High lift 1 switch auxiliary 1 max speed HIGH1 AUX1 LIMIT
78 High lift 2 switch auxiliary 1 max speed HIGH2 AUX1 LIMIT
79 High lift 1 switch auxiliary 2 function max speed HIGH1 AUX2 LIMIT
80 High lift 2 switch auxiliary 2 function max speed HIGH2 AUX2 LIMIT
83 High lift 1 switch auxiliary 3 function max speed HIGH1 AUX3 LIMIT
84 High lift 2 switch auxiliary 3 function max speed HIGH2 AUX3 LIMIT
94 Slow speed SLOW SPEED
95 British unit BRITISH UNIT
96 Display brightness LCD BRIGHTNESS
97 E-S-H enable E-S-H
98 Time meter / Odometer on display TIMER-ODOMETER
99 Maintenance time SERVICE PERIOD

Micro Controller Control System 141 Appendix

F3. Diagnostic Code

[Display Code] [Description] [Contraction]

1 Drive motor speed RIGHT MOTOR SPD
2 Drive motor speed reference R-MOTOR REF SPD
5 Lift lever voltage LIFT SENSOR OUT
6 Battery voltage BATT VOLTAGE
7 Drive motor power module temperature R-INVERTER TEMP
8 Pump motor power module temperature P-INVERTER TEMP
9 Pump motor speed PUMP MOTOR SPD
10 Pump motor speed reference P-MOTOR REF SPD
11 Accelerator potentiometer voltage ACCEL 1ST OUT
12 Accelerator second Potentiometer voltage ACCEL 2ND OUT
13 Steering sensor voltage STEER SENSOR OUT
15 Drive motor phase current R-MOTOR I-U
16 Drive motor phase current R-MOTOR I-V
17 Drive motor phase current R-MOTOR I-W
21 Pump motor phase current P-MOTOR I-U
22 Pump motor phase current P-MOTOR I-V
23 Pump motor phase current P-MOTOR I-W
24 Drive motor temperature R-MOTOR TEMP
26 Pump motor temperature P-MOTOR TEMP
27 Seat switch hour meter SEAT H METER
28 Drive motor hour meter DRIVE H METER
29 Pump motor hour meter PUMP H METER
30 Seat switch SEAT SWITCH
31 Park brake switch PARK SWITCH
32 Start switch SRART SWITCH
33 Reverse traction direction switch REV SELECT SW
34 Forward traction direction switch FWD SELECT SW
35 Pedal brake switch PEDAL BRAKE SW
37 Auxiliary 1 switch AUX 1 OUTPUT
38 Auxiliary 2 switch AUX 2 OUTPUT
39 Auxiliary 3 switch AUX 3 OUTPUT
40 High lift 1 switch HIGH LIFT 1 SW
41 Tilt switch TILT SWITCH OUT
42 High lift 2 switch HIGH LIFT 2 SW
43 Main breaker command CONTACTOR
44 5V out 5V OUT
45 12V out 12V OUT
46 24V out 24V OUT
47 Buzzer command BUZZER
48 Fans command FANS
49 Drive motor encoder channels R-MOTOR ENCODER
51 Pump motor encoder channels P-MOTOR ENCODER
52 lift pressure LIFT PRESSURE
53 Pressure sensor voltage PRESSURE OUTPUT
54 Weight of the load on the forks LOAD WIGHT

Micro Controller Control System 142 Appendix

 SB4295E01
Feb.2013

Power Train
Specification
Systems Operation
Testing & Adjusting
Disassembly & Assembly

B10R-5, B13R-5, B15R-5, B16R-5

 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

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.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DOOSAN 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 DOOSAN is used, you must satisfy 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. DOOSAN dealers have the most current
information available.

1
 Index

Specifications
General Tightening Torques ................................. 5
General tightening torque
for bolts, nuts and taperlock studs ..................... 5
Drive Motor .......................................................... 7
(AC).................................................................. 7
Wheel Mounting ................................................... 8
Motor and Transfer ............................................... 9
Brake ..................................................................10

Systems Operation
General Information.............................................11
Drive Motor .........................................................12
<AC> ...............................................................12
Thermal Sensor Tests......................................12
Sensor Bearing ................................................13
Motor and Transfer ..............................................14
Brake ..................................................................14
Connecting the hydraulic brake system ............14
Connecting the brake cable..............................14
Replenishing With Transmission Fluid ..............15
Front Axle ...........................................................16
Front Axle Tightening Torque ...........................17
Testing and Adjusting ......................................17
Drive Axle ...........................................................18
- GK25LD (A473022) .......................................18
- GK26LD (101587-00013) ...............................20

Testing and Adjusting

Troubleshooting ..................................................21
Visual Checks ..................................................21
Checks During Operation .................................21

Disassembly and Assembly

Front Axle ...........................................................25
Drive Axle ...........................................................31
- GK25LD (A473022) .......................................31
- GK26LD (101587-00013) ...............................54

Power Train 3 Index

Specifications
General Tightening Torques

General tightening torque

for bolts, nuts and taperlock studs
The following charts give the thread
standard torque
standard torque values for bolts, size
nuts and taperlock studs of SAE
Grade 5 or better quality.
Exceptions are given in other inches lb·ft N·m*
sections of the Service Manual
where needed.
1/4 9 ±3 12± 4
5/16 18 ±5 25± 7
Use these torques for 3/8 32 ±5 45± 7
bolts and nuts with
standard threads 7/16 50 ± 10 70 ± 15
(Conversions are approximate) 1/2 75 ± 10 100 ± 15
9/16 110 ± 15 150 ± 20
5/8 150 ± 20 200 ± 25
3/4 265 ± 35 360 ± 50
7/8 420 ± 60 570 ± 80
standard thread
1 640± 80 875 ± 100
1-1/8 800 ±100 1100 ± 150
1-1/4 1000 ± 120 1350 ± 175
1-3/8 1200 ± 150 1600 ± 200
1-1/2 1500 ± 200 2000 ± 275
5/16 13 ±2 20± 3
Use these torques for 3/8 24 ±2 35± 3
bolts and nuts on
7/16 39 ±2 50± 3
hydraulic valve
bodies. 1/2 60 ±3 80± 4
5/8 118 ±4 160± 6
1 5±2 7± 3
5 10±3 15± 5
Use these torques for 3 20±3 30± 5
studs with taperlock
threads. 7 30±5 40± 10
1 40±5 55± 10
9 60± 10 80 ± 15
5 75±10 100 ± 15
3 110± 15 150 ± 20
taperlock stud
7 170± 20 230 ± 30
1 260± 30 350 ± 40
1-1/8 320 ± 30 400 ± 40
1-1/4 400 ± 40 550 ± 50
1-3/8 480 ± 40 650 ± 50
1-1/2 550 ± 50 750 ± 70
*1 newton meter(N•m) is approximately the same as 0.1 mkg.

Power Train 5 Specifications

 Metric fasteners
metric ISO thread

thread size torque

(mm) (N·m)* (lb·ft)
M6 12 ±4 9±3
M6 12 ±4 9±3
M8 25 ±7 18±5
[Usually, material strength identification on bolt
head is with numbers (i.e., 8.8, 10.9, etc.)] M10 55 ±10 40 ±7
M12 95 ±15 70 ±10
The chart on the right gives the torque for bolts and
nuts with Grade 8.8. M14 150 ±20 110 ±15
M16 220 ±30 160 ±20
NOTICE : Caution must be taken to avoid mixing
metric and standard (customary) fasteners. M18 325 ±50 240 ±35
Mismatched or incorrect fasteners can result in M20 450 ±70 330 ±50
vehicle
damage or malfunction, or possible personal injury. M22 600 ±90 440 ±65
Original fasteners removed from the vehicle should M24 775 ±100 570 ±75
be saved for assembly when possible. If new ones
are required, caution must be taken to replace with M27 1150 ±150 840 ±110
one that is of same part no. and grade or better. M30 1610 ±200 1175 ±150
M33 2000 ±275 1450 ±200
M36 2700 ±400 2000 ±300
ISO-International Standard Organization
Hose clamps-worm drive band type

intitial assembly reassembly or

clamp torque on new hose retightening torque
width
(N·m)* (lb·ft) (N·m)* (lb·ft)
15.9 mm (.625 inch) 7.5 ±0.5 65 ±5 4.5±0.5 40 ±5
13.5 mm (.531 inch) 4.5 ±0.5 40 ±5 3.0±0.5 2 ±5
7.9 mm (.312 inch) 0.9 ±0.2 8 ±2 0.7±0.2 6 ±2
*1 newton meter(N•m) is approximately the same as 0.1 mkg.

Power Train 6 Specifications

Drive Motor

(AC)

Thermal switch

Warning temperature ...............155 ± 4°C (311 ±10°F)

Power Train 7 Specifications

Wheel Mounting

IOPS002I

(1) Nut. (2) Bolt.

(1) Torque for drive wheel mounting nut ..................

........................... 190 N·m±10 N·m (140±7 lb·ft)

(2) Torque for bolt that hold housing to mast ...........

......................... 300 N·m±30 N·m (222±22 lb·ft)

Power Train 8 Specifications

Motor and Transfer

IOPS003I

(1) Socket head bolt. (2) Bolt.

(1) Torque for socket head bolts that hold transfer

and drive motor .........23 N·m±5 N·m (17±4 lb·ft)

(2) Torque for bolt that hold transfer to frame ..........

................................80 N·m±5 N·m (59±4 lb·ft)

Power Train 9 Specifications

Brake

Actuating stroke for the hand brake cable

(1) Bleeder port. (2) Brake line (hydraulic line). (3) Brake cable.

(1) Torque for bleeder port ......................................

................................50 N·m±5 N·m (37±4 lb·ft)

(2) Torque for brake line..........................................

................................50 N·m±5 N·m (37±4 lb·ft)

(3) Torque for brake cable .......................................

................................50 N·m±5 N·m (37±4 lb·ft)

Power Train 10 Specifications

Systems Operation
General Information

3
IOPS005S
Power Flow
(1) Drive axle. (2) Drive motor. (3) Front axle.

The powertrain for the B16R-5 MODEL Lift Trucks

consist of three main components; drive motor (2),
Drive axle (1) and Front axles (3)

Electric storage batteries are used as a power

source for the drive motor (2). The drive motor turns
drive axle (1), which turn the rear drive wheel.

Power Train 11 Systems Operation

Drive Motor
<AC>

Thermal Sensor Tests

Tools Needed
Digital Multimeter or Equivalent 1

1. With the digital multimter in resistance operating

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

Power Train 12 Systems Operation

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 13 Systems Operation

Motor and Transfer Brake

Actuating stroke for the hand brake cable

2

1
1

3 5
2
IOPS003I 4
(1) Socket head bolt. (2) Drive motor. (3) Drive axle.

1. Place the drive motor (2) carefully on the Drive

axle (3) and join the gearings of motor spline and (1) Bleeder port. (2) Brake line (hydraulic line).
pinion gear carefully. (3) Brake cable. (4) Rod. (5) axle lever.

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 transfer lines
up with that of motor.
3. Screw motor and transfer together with six socket
head bolts (1). Tighten the bolts to a torque of .....
................................23 N·m±5 N·m (17±4 lb·ft).
Connecting the hydraulic brake
system
Connect the brake line (hydraulic line) (2) according
to the assembly position.
Tightening torque of bleeder port (1) and brake line
(2) is ............................ 50 N·m±5 N·m (37±4 lb·ft).

Connecting the brake cable

Screw the brake cable (3) to a torque of..................
.................................... 50 N·m±5 N·m (37±4 lb·ft).

If the rods (4) have much play, adjust the rods (4) for
axle levers (5) not to be pulled.

Power Train 14 Systems Operation

Replenishing With Transmission
Fluid

Approx. 0.5L

1
2

IOPS006I

(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.

Screw the air breather (1) with the sealing washer

(2). Tighten the air breather to torque of ..................
........................................ 70 ±10 N·m (52 ± 7 lb·ft).

Apply LOCTITE No.572 to thread of drain plug (3)

and tighten to a torque of ..................... 70 ± 10 N·m
(52 ± 7 lb·ft)

Bleed the brake system after filling of brake fluid.

Refer to Brake System Air Removal of Lift Trucks
Vehicle System

Power Train 15 Systems Operation

Front Axle
Sealed up structure of hydraulic disk brake system
Front axle is composed of Drive shaft ① and Brake
secures good brake performance even in the high
②
humid or dusty area
It is assembled with rear wheel drive power train,
Because it is possible to use the brake semi-
that is role of service brake and parking brake
permanently, there is no need to replace or change
the lining as drum type brake do. Parking brake's
lever system is the serration type, so it is possible to
adjust the play.
Because it is easy to maintain the gap of both brake
efficiency and minimum disproportional braking
deviation is acquired.
Major components are 4 disk plates④, 5 steel plates
⑤, service piston⑦. Braking force is applied by
restricting the driving force from drive shaft② and
spline collar⑨

Specification

Axle oil MOBIL #424

Front Axle
Oil quantity 0.5 L
Service brake Oil disk brake 1 Drive shaft 2 Tapered bearing
Brake oil AZOLLA-ZS10 3 Housing 4 Disk brake
Lever 5 Steel plate 6 Parking piston
Brake revolution 7 Parking lever 8 Parking lever shaft
Type 9 Brake cover 10 Spline collar
Parking brake
( Single type 11 Service piston
with service
brake)

Power Train 16 Systems Operation

Front Axle Tightening Torque Testing and Adjusting

NO PROBLEM CAUSE

(1) lubricating oil shortage.

(2) Incorrect oil specification.

1 Regular noise
(3) Shaft bearing sdjustment
failure or defect.

Oil leakage at the drive

wheel.

Lubricating oil a. Too high oil level.

2
leakage
b. Incorrect oil specification.

c. Clogged housing reather.

(1) Drive shaft damaged.

Drive wheel - Shaft bearing loosening.

3
stopping
(2) Nut at Drive shaft too
tighted

1 Drive shaft 25±5 kg.㎝

2 Lock nut 2100±100 kg.㎝
3 Brake housing bolt 360±10 kg.㎝

Power Train 17 Systems Operation

Drive Axle
- GK25LD (A473022)
1. Transmission schematic

No. 1 Transmission housing

No. 2 Wheel shaft not illustrated gear set, consisting of input pinion, helical gear, bevel pinion shaft and crown
gear

No. 3 Housing top section (with integrated input pinion)

No. 4 Housing cover

No. 5 Centering ring

No. 6 Lock plate

No. 7 Final stop (2x)

No. 8 Oil filler- and oil inspection plug

No. 9 Oil drain plug

Fig.I-1

Power Train 18 Systems Operation

2. Tightening torques for screws in Nm according to ZF-Standard 148

If not especially indicated, tightening torques can be taken from the following chart:

Metric ISO standard thread DIN 13, sheet 13 Metric ISO-fine thread DIN 13, sheet 13
Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2, 8 4, 1 4, 8 M 8x1 24 36 43
M5 5, 5 8, 1 9, 5 M 9x1 36 53 62
M6 9, 5 14 16, 5 M 10x1 52 76 89
M7 15 23 28 M 10x1,25 49 72 84
M8 23 34 40 M 12x1,25 87 125 150
M10 46 68 79 M 12x1,5 83 120 145
M12 79 115 135 M 14x1,5 135 200 235
M14 125 185 215 M 16x1,5 205 300 360
M16 195 280 330 M 18x1,5 310 440 520
M18 280 390 460 M 18x2 290 420 490
M20 390 560 650 M 20x1,5 430 620 720
M22 530 750 880 M 22x1,5 580 820 960
M24 670 960 1100 M 24x1,5 760 1100 1250
M27 1000 1400 1650 M 24x2 730 1050 1200
M30 1350 1900 2250 M 27x1,5 1100 1600 1850
M33 1850 2600 3000 M 27x2 1050 1500 1800
M36 2350 3300 3900 M 30x1,5 1550 2200 2550
M39 3000 4300 5100 M 30x2 1500 2100 2500
M 33x1,5 2050 2900 3400
M 33x2 2000 2800 3300
M 36x1,5 2700 3800 4450
M 36x3 2500 3500 4100
M 39x1,5 3450 4900 5700
M 39x3 3200 4600 5300

Friction coefficient: μ total 0,12 for screws and nuts without aftertreatment as well as for phosphatized nuts.
Tighten by hand!

Power Train 19 Systems Operation

- GK26LD (101587-00013)

Components and accessories of a GK26LD transmission

1. Gearbox housing
2. Housing cover
3. Wheel shaft with locating and contact surfaces for wheel
4. Top part of housing with gearing (shown) or without gearing
5. Steering pinion
6. Alternative top part of housing for chain steering connection with chain tensioner
7. Steering lock
8. Integrated input pinion with motor connection profile
9. Oil filler plug and oil level check
10. Oil drain plug
11. Mounting plate for frame connection

Power Train 20 Systems Operation

Testing and Adjusting
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".
Checks During Operation
Drive Motor
Before an analysis is made of any electric drive
motor problem, always make reference to the
Troubleshooting section of the MicroController
System Operation module.
WARNING
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.
NOTICE
To prevent damage to electrical components, make
sure the air line is equipped with a water filter when
they are cleaned with air.
Power Train
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.
Do not operate the drive motors without a load,
as too much speed may cause damage to the
motor and injury to personnel.
<AC>
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.
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.
21 Testing And Adjusting
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).
4. Control panel operation not correct :
See the MicroController System Operation
module.
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.
6. Speed sensor is breakdown.
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.
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.
These can cause MOSFETS to become defective,
control panel failure or drive fuse to go bad.
Power Train
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.
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 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.
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.
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.
22 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].
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.
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. Dirty motor :
Remove metallic or carbon dust with air pressure.
4. Wet motor :
To dry the motor, heat it to 90°C (194°F).
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
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:
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 DOOSAN Inc.
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:
1. Drive control overheated and the thermal switch
opens :
NOTE: The thermal switch will warning if the
temperature is 155 ± 4°C (311 ± 10°F).
Transmission
Problem 1 : Abnormal movement of drive shaft
to axial direction.
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.
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.
23 Testing And Adjusting
Problem 3 : Gear noise during driving.
Probable cause :
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.
Problem 5 : Long brake pedal stroke.
Probable cause :
1. Excessive lining wear :
Check the stroke of brake piston rod. Keep the
stroke within 3~5 mm by adding shim.
2. Failure of brake master cylinder :
Change the seals in the brake master cylinder.
Problem 6 : Decreased oil level in brake oil
reservoir or leakage through brake piston rod.
Probable cause :
1. Damage on seals of brake piston rod :
Change the quad ring, back up ring and wear
rings on piston rod.
2. Scratch on brake piston bore :
Replace transmission housing cover with new one.
Power Train
Problem 7 : Noise during brake application.
Probable cause :
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.
Problem 8 : Poor brake performance.
Probable cause :
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.
Problem 9 : Leakage from drive shaft.
Probable cause :
1. Faulty oil seal of drive shaft :
Check oil seal and drive shaft for damages in the
sealing area.
Problem 10 : Transmission overheats.
Probable cause :
1. Transmission oil level is either too high or too
low :
Check oil level.
2. Wheel bearings with an excessive prestress :
Check rolling torque of drive shaft.
24 Testing And Adjusting
Disassembly and
Assembly
Front Axle
Disassembly

1. Loosen the oil drain plug in the axle housing and

drain oil.

3. Loosen the lock nut.

4. Remove 5 disc and 4 plate from the spline collar

and disassemble the spline collar then, remove 3
brake pin.

2. Loosen 10 socket head bolts from the housing

cover and then, remove the housing cover. (But it
will be hard to remove because of dowelpin)

5. Remove the drive shaft with using a hydro

presser or plastic hammer a plastic hammer.
Shaft seal will be damaged.

Power Train 25 Disassembly and Assembly

 Disassembly of Housing Cover

6. Remove bearing cone then, remove bearing cup

from housing. (there is one more bearing cup
opposite side of the housing) 1. Remove the actuator.

7. Remove bearing cone then, remove oil seal from

drive shaft.

8. Remove 8 wheel bolt using plastic hammer. 2. Remove piston using a tool and then, remove 2
square ring from the housing.

Power Train 26 Disassembly and Assembly

 Reassembly of Housing Cover

3. After removing the snap ring, remove the roller

and 2 washers.
1. Assemble bush with applying locktight #620 and
assemble using jig, needle bearing too.

4. After removing the snap ring, remove the parking

lever and washer to remove shaft. 2. Assemble shaft in the reverse order to
disassembly.

Power Train 27 Disassembly and Assembly

3. Assemble the parking lever. 2. Assemble piston and actuator.

Reassembly of Axle Body

3. Assemble 2 bearing cup each other.

1. After assembling dowel pin, assemble square ring

with oil (MOBIL #424) to the housing.

Power Train 28 Disassembly and Assembly

 CAUTION
Apply grease or oil to shaft seal and then,
assemble it from the direction of outre side of
housing.

4. Apply liquid gasket #1215 to the oil seal while

heating inner race of bearing to max 100℃

6. Assemble bearing cone with plastic hammer

5. After assembling bearing cone and oil seal,

assemble drive shaft.

Power Train 29 Disassembly and Assembly

 Measuring play of drive shaft end

Measure shim thickness by following method.

Assemble Shim with Nut at the tightening torque of

2000~2500 kg•cm

Measure rolling resistance of taper roller bearing

• Tightening torque : 20~35 kg•cm

If Torque is more then add a shim

If Torque is less then subtract a shim

After finding final shim thickness, apply locktight

#277 on locknut, and lock it.

7. After assembling spline collar, brake pin and

dowel pin, assemble disc and plate.

8. Apply liquid gasket #1102 to housing, assemble

housing cover.

9. Tighten 8 bolts to the housing.

Apply loctite #271 or #277 on the thred of bolt.

• Tightening torque : 500~700 kg·cm

Power Train 30 Disassembly and Assembly

Drive Axle 1. Drain off transmission oil
- GK25LD (A473022) Place a suitable receptacle under the oil drain plug
(Pos.1) and unscrew it with a 6 mm Allen wrench.
Disassembly Drain transmission oil completely into the receptacle.
Do not drain transmission oil into the sewerage
Prior to disassembly clean transmission carefully. system or into the soil! Observe oil drain time!
A great help is a bright, spacious working place, free
of dirt and chips.
The necessary working steps are described and
illustrated in the correct sequence.
Parts only available as assembly groups will not be
stripped any further.
Please observe strictly the instructions of the vehicle
manufacturer for removing the transmission
from the vehicle.
For dis- and reassembly we recommend to use a
fixture as shown in below figure.

Fig. III1-1

2. Remove housing top section

Loosen and remove the socket head bolts (Pos.1)

on the bottom side of the transmission housing as
well as inside the housing top section.
see Fig. III2-1 and Fig. III2-1a
5x M8x35
2x M8x50
8x M10x45
Fixture

Fig. III2-1

Power Train 31 Disassembly and Assembly

This transmission version has the housing top
section additionally fastened to the transmission
housing by means of 2 socket head bolts (Pos.2),
hexagon nuts (Pos.3) and washers (Pos.4). Fig. III2-
1a and Fig. III2-2

Fig. III2-4

2.1 Remove input from the housing top

section and dismantle it

Fig. III2-1a Fig. III2-2
For motor fixing the centering ring (Pos.2) is bolted
onto the pivoting bearing (Pos.1).
Two final stops (Pos.3) on the chain tread and the
lock plate (Pos.4) connected with the centering ring
are required for the steering lock.
Only in case of damage the lock plate and the 2
final stops have to be removed and replaced.
By means of two assembly levers press cover assy
(Pos.2) cautiously against the bearing outer ring
(with radial shaft seal, grooved ball bearing, O-ring
and input pinion) out of the bearing bore.
Do not damage the input pinion toothing!
Damages might cause louder running noises!

Fig. III2-1

NOTE: Prior to remove the grooved ball bearing

Fig. III2-3 (Pos.3), the helical gear has to be taken off
first, as indicated in Chapter III, Sect. 7.1.
Slightly beat with a plastic hammer or a copper
mandrel from the bottom against the top section
(Pos.1), so that it loosens from the transmission
housing. Cautiously lift off and remove the housing
top section.

Housing top section can only be replaced

completely. Centering ring can be reused.

Remove cyl. pins, breather valve and grease

nipples only in case of damage. Check housing
top section acc. to chapter „Reassembly“,
Section 15.1 and keep it properly.

Power Train 32 Disassembly and Assembly

Pull grooved ball bearing (Pos.3) with a bearing
extractor out of the bore hole in the housing top
section and remove it.

Fig. III2.1-3

By means of two assembly levers press input pinion

(Pos.4) cautiously out of the cover and remove it. Fig. III2.1-5a
Do not damage the input pinion toothing!
Damages might cause louder running Use O-ring only once.
noises! For reassembly a new O-ring is to
be used!

Fig. III2.1-4 Fig. III2.1-5

Remove radial shaft seal (Pos.5) from the cover, Unsnap and remove circlip (Pos.8) with the aid of
only if unavoidable! a screw driver from the housing top section.

->radial shaft seal will be destroyed at removal!

->use new radial shaft seal for reassembly!

By means of bush press radial shaft seal and

grooved

ball bearing (Pos.6) out of the cover (Pos.7) and

remove them. Remove O-ring (Pos.8) from the slot
in the cover.

Fig. III2.1-5 and Fig. III2.1-5.a

Fig. III2.1-6

Power Train 33 Disassembly and Assembly

3. Remove housing cover
Remove hexagon bolts (Pos.1) in the housing cover.
Loosen and remove housing cover (Pos.2) from the
housing by slightly beating with a plastic hammer
against the outer edge.
Fig. III3-1
4. Remove wheel shaft and crown gear
Place transmission into the fixture and fasten it with
screws. Screw 2 wheel nuts onto the wheel bolts
and hold the wheel shaft with a lever.
Screw off the hexagon bolt with a hexagonal
spanner WAF=24 mm and remove it with the
washer from the wheel shaft.
Fig. III4-1
Power Train
Drive wheel shaft (Pos.1) with the aid of a copper
mandrel and a hammer out of the housing and
remove it.
Take care that the wheel shaft is not damaged
during removal.
During disassembly of the wheel shaft the sealing
ring (Pos.2) on the wheel shaft and the radial shaft
seal in the housing can be damaged and should
always be replaced!
Then carefully remove the crown gear (Pos.3) from
the housing.
Fig. III4-2
34 Disassembly and Assembly
5. Remove bearing inner rings from wheel shaft
and crown gear
If the taper roller bearings are to be reused, we
recommend to use puller „M“. (see Chapter I Special
Tools)
5.1 Remove bearing inner ring from wheel shaft
Place clamping pliers of the puller onto the rollers of
the bearing inner ring.
By means of union nut tightly connect clamping
pliers with the rollers.
Bolt spindle to the wheel shaft face and remove the
bearing inner ring cautiously and evenly at all sides.
Take off the sealing ring (Pos.1) from the wheel
shaft.
Avoid damage at the wheel bolt threads at
counter-supporting!
Protect wheel bolt thread against damage with
suitable fixtures.
Fig. III5-1
Power Train
5.2 Remove bearing inner ring from crown gear
Proceed as described under Sect. 5.1 for removal of
the bearing inner ring from the crown gear. Crown
gear should be clamped on the work bench and
pressure piece “N” be inserted into the crown gear
bore hole to support the spindle. Fig. III5-1
For replacement of the taper roller bearings, the
following steps are required:
• Open bearing cage (Pos.1) by cutting and
remove the rollers (Pos.2)
• Cautiously remove the bearing inner ring with a
puller (e.g. three-armed puller)over the bearing
collar (->).
• Remove sealing ring (Pos.3) from wheel
• shaft. Fig. III5-2
35 Disassembly and Assembly
6. Press wheel bolts out of the wheel shaft

Wheel bolts (Pos.1) can only be pressed out at

removed wheel shaft.

Make these 2 steps only in case of emergency!

Do not damage wheel bolt threads at pressing
out!

• Place wheel shaft (Pos.2) into a suitable bush

and press out wheel bolts with a press.

• By means of a copper mandrel and a hammer

drive wheel bolts out of the wheel shaft.

• Be especially careful at this step, since at

replacement or installation of the new wheel bolt
with the old wheel shaft, the position of both
parts to each other must exactly be obtained
again. Fig. III7-1

7.2 Drive out bevel pinion shaft

Drive out bevel pinion shaft with the aid of a plastic

hammer from the bearing seat. Take off and remove
the taper roller bearing inner ring (Pos.2) from the
bearing bore hole.

Take care that the bevel pinion shaft is not

damaged during removal!

Fig. III6-1

7. Remove bevel pinion shaft

7.1 Remove helical gear

Bevel pinion shaft can only be removed, when

crown gear was taken off before. Unscrew hexagon
nut (Pos.1).

Use hexagon nut only once!

Fig. III7-2
Pull off and remove helical gear (Pos.2) from bevel
pinion shaft (Pos.3) with the aid of a puller (three-
armed puller). Fig. III7-1

Power Train 36 Disassembly and Assembly

7.3 Press off taper roller bearing inner ring from
the bevel pinion shaft

By means of bush „B“ press off the bearing inner

ring

(Pos.1) from the bevel pinion shaft (Pos.2).

Fig. III8-1

9. Remove thread protective shield (Gamma

ring)

By means of robust screw driver and a plastic

hammer cautiously drive out and remove the thread
Fig. III7-3 protective shield from the adhesive point on the
housing neck
8. Remove taper roller bearing outer rings and
radial shaft seal Use the thread protective shield only once. For
reassembly a new thread protective shield must
Cautiously drive the bearing outer rings (Pos.1;2;3 be used!
and 4) for supporting of the wheel- and bevel pinion
shaft with the aid of a copper mandrel and a
hammer out of the housing.
Take care that shim rings (Pos.5;6;7 and 8) are not
damaged during removal of the bearing outer rings.

Put bearing outer ring to the respective bearing

inner ring. Do not reuse deformed or damaged
shim rings!

By means of a copper mandrel or robust screw

driver and a hammer drive out and remove radial
shaft seal (Pos.9) from the housing.

During disassembly of the wheel shaft the radial

shaft seal can be damaged and must always be
replaced!

Fig. III9

Power Train 37 Disassembly and Assembly

Reassembly
Introduction
Clean all parts with a suitable cleaning agent
and remove residues of LOCTITE.
Keep away cleaning agent from your skin, do not
drink it or inhale its vapours! Wear safety
gloves and goggles! In case of skin contact
rinse immediately with a lot of water! If by
mistake
the cleaning agent was swallowed, call medical
aid immediately!
Observe regulations for prevention of accidents!
Check all parts for wear, damages and cracks, if
required replace them. In case of damaged running
teeth, the gear set parts have to be replaced per set.
Always replace damaged taper roller bearings
(inner- and outer ring).
Do not reuse deformed shim rings and worn thrust
washers. Touch up seal faces or smoothen them
with a fine file.
For reassembly the following new parts should
be used:
Place measuring bush D into the housing- bearing
bore and measure dimension F.
Determine housing dimension E by the following
equation.
E = L - F + d/2
which means:
L = Length of the measuring bush "D" (dimension
marked on it 77.50 mm)
F = Difference dimension from bearing seat
diameter to front face measuring bush "D"
d/2 = Measure housing borehole
By means of the equation :
X=E-B-T
it is possible to calculate the thickness
of the shim rings (Pos.1). which means:
B = Installation dimension of bevel pinion shaft is
100.00 mm (Factory setting of the installation
dimension with a tolerance of ±0 is marked on the
bevel pinion shaft!)
T = Bearing width of the bearing (Pos.2)

• Hexagon nut for bevel pinion shaft and helical gear

fastening

• Hexagon bolt and washer for crown gear fastening

• Radial shaft seal on the wheel shaft

• Spring washers and lock washers

• Deformed or damaged shim rings

• Sealing rings on oil drain- and oil filler plug

1. Determination of installation dimension for

bevel pinion shaft

The bevel gear set, consisting of bevel gear shaft Fig. IV1-1
and bevel gear, is provided with certain installation
dimensions. The installation dimension of the bevel
pinion shaft is 100.00 mm. The correct adjustment of
the bevel pinion shaft is required for an exact setting
of the contact pattern and the torsional backlash of
the gearing. Shim ring thickness and the correct
adjustment of the bevel pinion shaft respectively can
be determined acc. to the following method:
Fig. IV1-1

Power Train 38 Disassembly and Assembly

2. Preassemble housing

2.1 Bearing for bevel pinion shaft

Shim ring thickness determined in Sect. 1. has to be

obtained by combining shim rings of variable
thicknesses. Place shim rings (Pos.1) into the
bearing seat.

Install bearing outer ring (Pos.2) into bearing seat in

the housing.

A tolerance of ±0,05 from the determined dimension

is permissible.

Fig. IV2-2

Fig. IV2-1

2.2 Bearing for wheel shaft

Place shim ring pack (Pos.1 and Pos.3, removed at

disassembly) for presetting into both bearing seats.
By means of a copper mandrel and a hammer install
the bearing outer rings (Pos.2 and Pos.4) of the
wheel shaft bearing into the bearing bore until
contact on both sides of the housing.

Do not reuse distorted shim rings.

Radial shaft seal between taper roller bearings

and the thread protective shield are only allowed
to be pressed in when the bearing is adjusted.

Power Train 39 Disassembly and Assembly

3. Preassemble wheel shaft

3.1 Press in wheel bolts

Wheel bolts (Pos.1) can only be pressed in when

the wheel shaft is removed.

Make these steps only in case of emergency! For

pressing-in take care that the flattened side on
the bolt collar shows to the center of the wheel
shaft.

Place wheel shaft (Pos.2) into a suitable bush and

press in wheel bolts with a press. Be especially
careful at this step, since at pressing in of the new
wheel bolt with the old wheel shaft, the position of
both parts to each other must exactly be obtained
again.

Fig. IV3-2

4. Press bearing inner ring onto the crown gear

By means of sleeve „H“ press bearing inner ring

(Pos.1) onto the crown gear (Pos.2) until contact.

Fig. IV3-1

3.2 Install sealing ring and bearing inner ring

onto the wheel shaft

Push sealing ring (Pos.1) on the wheel shaft (Pos.2).

By means of sleeve „H“ press bearing inner ring
(Pos.3) onto the wheel shaft until contact.

Only when the bearing is adjusted, the sealing Fig. IV4-1

and the taper roller bearing can be filled with
grease SHELL Alvania R3.

Power Train 40 Disassembly and Assembly

5. Preassemble bevel pinion shaft
By means of bush „C“ cautiously install bearing
inner ring (Pos.1) until contact. If no press is
available, the bearing can be installed in accordance
with the following Note.
NOTE : Heat bearing inner ring up to max. 90°C and
install it until contact. Install subsequently
until contact after cooling down!
Fig. IV5-1
6. Install bevel pinion shaft into the housing
Wet cage and space between rollers of the bearing
inner ring with transmission oil. Insert preassembled
bevel pinion shaft from the bottom into the housing
and by means of clamping fixture “F” apply a slight
preload to the bearing outer ring in the housing.
Fig. IV6-1
Fig. IV6-1
Power Train
7. Measure bearing play of bevel pinion shaft
and adjust bearing preload
7.1 Measure bearing play
With the following method the thickness of the shim
ring(s) (Pos.1) to be added is determined.
Dim. C = Distance from collar of bevel pinion shaft
to contact bearing outer ring.
Dim. S = Distance from plane face of bearing outer
ring to plane face of bearing inner ring.
Fig. IV7-1a
Calculate shim ring thickness (Pos.1) by means of
equation
Z=C+S
Add shim ring corresponding with thickness Z.
Example: C= 0.7 measured on housing and shaft
S= 0.08 measured on bearing
Z = 0.7+ 0.08 = 0.78mm
As per experience +0.02 mm will be added to
Dimension Z, so that a bearing preload from 0.02 to
0.07 mm is set.
Z = 0.78 + 0.02 = 0.8mm
A bearing preload of 0.07 mm shall be achieved!
Fig. IV7-1
41 Disassembly and Assembly
Shim ring thickness (thickness Z) determined in
Sect.7. has to be obtained by combining shim rings
of variable thicknesses. Place shim ring(s) (Pos.1)
into the bearing seat. Install bearing outer ring
(Pos.2) by means of a copper mandrel and a
hammer into bearing seat of the housing until
contact with the shim ring. Then install by means of
bush “G” the bearing inner ring (Pos.3) for the bevel
pinion shaft bearing onto the bevel pinion shaft until
contact. Fig. IV7-1b
Fig. IV7-1b
Attention
Prior to helical gear installation, the grooved ball
bearing must be installed into the housing seat first.
(see Fig. IV7-b.1)
Drive grooved ball bearing (Pos.1) with assembly
drift „V“ into the bearing bore of the housing until
contact.
Fig. IV7-b.1
Power Train
Carefully push the helical gear (Pos.1) onto the
spline profile of the bevel pinion shaft and mount it
until contact.
Hold helical gear with a suitable strap wrench,
unscrew and tighten the hexagon nut. Do not
damage helical gearing at counter-supporting.
Tightening torque of the hexagon nut:
.................................................. 150 N·m (111 ft·lb)
Use a new hexagon nut. Peen hexagon nut after
contact pattern check!
Fig. IV7-1c
Press bevel pinion shaft down by hand and rotate it
several times, so that the taper rollers in the bearing
rings are aligned.
Position dial gauge as shown in Fig. IV7-1d and put
the dial gauge indicator to “Zero”.
Mark position of the dial gauge on the helical gear
with a color pencil.
With both hands press bevel pinion shaft upwards
and read the bearing play on the dial gauge. (as
shown in Fig. IV7-1d)
For checking no bearing play is allowed to be
measurable!
42 Disassembly and Assembly
 8. Mount wheel shaft and crown gear into the
housing

Radial shaft seal between the taper roller bearings

has to been installed into the housing, only when
bearing preload of the wheel shaft was determined.

Insert crown gear (Pos.1) into the housing.

Cautiously install the wheel shaft (Pos.2) into the
crown gear toothing. Bolt together the crown gear
and the wheel shaft with hexagon bolt (Pos.3) and
washer (Pos.4).

Tightening torque of hexagon bolt : 245 N·m

Fig. IV8-1

Use hexagon bolt and washer only once!

Fig. IV7-1d

This step has to be made with utmost caution

and several times, in order to check the adjusted
bearing preload.
A direct checking of the now adjusted bearing
preload is not possible. However, the bevel
pinion shaft must be rotatable by hand.

7.2 Adjust bearing preload

Bearing preload: 0.02 to 0.07 mm

Remove helical gear and bevel pinion shaft. Add

necessary shim rings to obtain the required bearing
preload and install the bevel pinion shaft as
indicated in Chapter IV, Sect.7.1.
Apply a thin layer of LOCTITE No. 270 onto inner Fig. IV8-1
toothing of the helical gear (hub spline). Install
helical gear as in Chapter IV, Sect.7.1.

Remove excess LOCTITE with a cloth.

Power Train 43 Disassembly and Assembly

9. Measure and adjust torsional backlash on the Apply marking ink onto 3-4 tooth flanks of the crown
crown gear gear and have it to get in mesh with the bevel pinion
shaft several times.
For measurement of the torsional backlash on the Check contact pattern as described under Section
crown gear, the bevel pinion shaft has to be blocked 10.
against torsion, e.g. with a wooden wedge.
Position dial gauge with magnetic stand right-angled
to a tooth flank and measure the torsional backlash
rotating the wheel shaft.

Torsional backlash 0.03 - 0.11 mm

A mean value is to be achieved.

Fig. IV9-1a

Torsional backlash is corrected by adding or

removing of the shim ring(s). see Fig. IV-9-1b

Fig. IV10-1

Fig. IV9-1a

Fig. IV9-1b

Power Train 44 Disassembly and Assembly

10. Contact pattern check

For a contact pattern check it is necessary to apply
marking ink onto 3-4 tooth flanks of the crown gear.
Have the ink-marked tooth flanks get into mesh with
the bevel pinion several times. A better recognition
of the contact pattern is possible, when the bevel
pinion is braked slightly.
The contact patterns obtained have to be compared
with the specified contact pattern as regards size
and position. The specified contact patterns are
indicated in below diagram.
Insignificant deviations of the ideal shape are
possible and permissible. These deviations are
firstly due to the varying contact pressures during
contact pattern checking.
If there are considerable deviations it has to be
checked if the installation dimensions were correctly
kept.
As a rule wrong installation dimensions are the
cause for wrong contact patterns.
Only when at a repeated checking of the installation
dimensions no correct contact patterns are
obtainable,
the position of the contact pattern should be
corrected according to the diagram as shown below.

Installation specifications

Correctcontact
Concave flank Concave flank
pattern

Correct contact pattern adjustment by changing of

Tooth contact on crown gear false contact patterns
the installation dimension in direction of the arrow
1. Contact on tip

2. Contact on root

Setting specifications:
On principle all gear sets have to be mounted in
accordance with the installation dimension (A).
Only in case of incorrect contact patterns the
installation dimension (A) has to be changed.
The extent of a change depends on the position of
the contact patterns.

Power Train 45 Disassembly and Assembly

11. Measure bearing play on wheel shaft and
adjust bearing preload

Press wheel shaft down by hand and rotate it

several times, so that the taper rollers in the
bearing rings are aligned. Position dial gauge as
shown in Fig. IV11-1a and put the dial gauge
indicator to “Zero”. Mark position of the dial gauge
on the wheel shaft with a colour pencil.
With two levers (robust assembly levers) press
wheel shaft upwards and read the bearing play on
the dial gauge.

By using shim rings a minimum bearing play of

approx. 0.02 mm shall be achieved. Only then the
final preload is to be adjusted.

Fig. IV11-1b

After setting of the bearing preload check the

torsional backlash once more.
If the bearing friction torque (see Sect. 13.1) or
the torsional backlash are beyond the
requested values a new adjustment is required.
The final value has to be obtained by adding or
removing of shim rings (see Fig. IV11-1b).

If for correction of the torsional backlash shim

rings (Pos.2) are removed or added at bearing
point „2“, those have to be added or removed
from the shim ring pack (Pos.1) at bearing
point „1“. Fig. IV11-1b

After correct adjustment of the bearing preload and

Fig. IV11-1a the torsional backlash the wheel shaft has to be
removed once again in order to install the thread
Remove wheel shaft, by means of a copper protective shield and the radial shaft seal. Please
mandrel and a hammer drive taper bearing outer observe Sections 12 and 13.
ring out of the housing. (also see Chapter III,
Sect.8.).
Determine shim ring thickness (Pos.1) and install
with shim ring into bearing seat of housing until
contact. Fig. IV11-1b

Required bearing preload: 0.05 to 0.10 mm

It is not possible to check the bearing preload

adjusted now. At a check no bearing play is
allowed to be measurable. However the wheel
shaft must be rotatable by hand.

Power Train 46 Disassembly and Assembly

12. Install thread protective shield (Gamma
ring)

Spray seat for thread protective shield with

LOCTITE Fast Cleaner. Have fast cleaner work
and thoroughly remove the dissolved dirt with a
clean cloth. Spray surface again and have it dried.
Fig. IV12-1.

Hazardous when breathed or swallowed!

Avoid contact with eyes or skin! Do not spray
near open flame and glowing parts!

Apply LOCTITE No. 270 onto seat for the thread

protective shield on the housing and press on the
thread protective shield (Pos.1) by means of
assembly drift „S“ until contact.

Fig. IV13-1a

Fill sealing ring and taper roller bearings on the

wheel shaft (Pos.2) with SHELL Alvania R3 grease.
Cautiously install wheel shaft (Pos.2) into the
crown gear toothing.

Remove excess LOCTITE with a clean cloth.

Bolt together the crown gear and the wheel shaft

with hexagon bolt (Pos.3) and washer (Pos.4). Fig.
IV13-1b
Bolt 2 wheel nuts onto the wheel bolts and lock
wheel shaft with a lever. (see Chapter III, Sect.4,
Fig. III4-1)

Tightening torque: 245 N·m

Fig. IV12-1

13. Install radial shaft seal into the housing

Remove wheel shaft and crown gear (also see

Chapter III, Sect.4.). Drive out taper roller bearing
outer ring from the housing. Provide outer
diameter of radial shaft seal (Pos.1) with a thin
layer of LOCTITE No. 574 and install it by means
of assembly drift “T” into the housing.
Fig. IV13-1a

Observe installation dimension A:.......................

GK 25 LD 3.0 +0.5 mm

Apply a thin layer of LOCTITE No. 270 onto

surface of inner toothing (hub spline) of the crown
gear (Pos.1).

Apply LOCTITE only to the inner toothing of Fig. IV13-1b

the crown gear.

Power Train 47 Disassembly and Assembly

13.1 Check bearing friction torque

Rotate wheel shaft several times in order to have

aligned the taper rollers in the bearing rings.
No bearing play must be measurable during
the check!
However, the wheel shaft must be rotatable by
hand.
The bearing preload described in Sect.11 is
correctly adjusted when a bearing friction torque of
9 ...12 Nm is reached.
Use an electronic torque spanner (Pos.1) to check
the bearing friction torque.

If the bearing friction torque is beyond the

requested values, a new adjustment is required.
(see Sect.11.)

Fig. IV14-1

15. Check pivoting bearing (housing top

section)

The housing top section has to be replaced, if:

• the peened cover disc on the pivoting bearing

has loosened

Fig. IV-13.1-1 • the pivoting bearing is difficult to rotate or

sticking

14. Install housing cover • the cage segments or balls are damaged

Apply a thin layer of LOCTITE sealing compound • the maximum bearing play is exceeded.
No. 574 onto plane face of the housing.
Apply one drop each of LOCTITE 243 onto threads The housing top section can only replaced
of the hexagon bolts (Pos.2). completely!

If tapped holes are drilled through the housing,
the hexagon bolts must be sealed completely
with LOCTITE.
Fasten housing cover (Pos.1) with hexagon bolts
(Pos.2) onto the housing.
Fig. IV14-1
Checking of housing top section:
Clamp the housing top section onto the assembly
table. Screw 3 eye bolts into the outer ring of the
pivoting bearing. Have the pivoting bearing rotated
several times.

Tightening torque: 9,5 N·m

Power Train 48 Disassembly and Assembly

Fig. IV15-1 Fig. IV15-2

Position three dial gauges onto the pivoting

bearing and put the dial gauge indicator to „Zero“.
Mark position of the dial gauge on the pivoting
bearing with a colour pencil.
Pull with approx. 50 kg at the pivoting bearing by
means of a medium pillar swivel crane and a
spring balance.
Have the pivoting bearing rotated several times
and put it back to the marking.
see Fig. IV15-1
Max. bearing play of pivoting bearing: 0,03 mm
16. Install input into the housing top section
Cautiously install the input pinion (Pos.1) through
the helical gearing.
Do not damage toothing of input pinion and
helical gear! Damage might cause louder
running noises!
By means of a copper mandrel cautiously install
the input pinion (Pos.1) into the bearing bore or
onto the bearing seat until contact.

15.1 Install breather valve

Drive breather valve (Pos.1) by means of press-in

mandrel „U“ carefully into the housing top section.
Fig. IV15-2

Take care for mounting that the cap of the breather

valve can still move freely.

15.2 Install hydraulic-type lubricating nipple

Screw in hydraulic-type lubricating nipple (Pos.2)

with an open-jaw spanner into the housing top
section until contact. Fig. IV16-1

Tightening torque: 10 N•m

Fig.IV15-2

Power Train 49 Disassembly and Assembly

Install the grooved ball bearing (Pos.2) with a
suitable bush onto the bearing seat of the input
pinion until contact.

Fig. IV16-4

Insert O-ring (Pos.5) into slot of the cover.

Fig. IV16-2 Use new O-ring for installation!

Slightly wet O-ring with transmission oil.
Preassemble cover (Pos.3) as follows:

• Install radial shaft seal (Pos.4) by means of an

assembly drift “V” with the correct side until
contact.

Do not damage sealing lip of the shaft seal.

Apply a thin layer of grease onto the sealing
lip!

Fig. IV16-5

Insert and snap in circlip (Pos.6) into bore hole of

the housing top section.

Fig. IV16-3

Cautiously put cover (Pos.3, with radial shaft seal

preassembled) onto the pinion shaft and install it.
By means of a plastic hammer mount cover until
contact.

Fig. IV16-6

Power Train 50 Disassembly and Assembly

16.1 Install housing top section

Provide sealing surface of the housing with a thin

layer of LOCTITE 574.

Plane faces of the housing and the housing top

section have to be cleaned carefully before
with
LOCTITE Fast Cleaner and must be free of
grease !

Place housing top section onto the transmission

housing, so that the cylindrical pins in the
transmission housing are positioned in the fitting
bores of the top section.

Fig. IV16.1-3

Fig. IV16.1-1

Screw in the socket head bolts (Pos.1) at the

bottom side of the transmission housing as well as
inside the housing
top section and tighten them uniformly.
In addition also the 2 socket head bolts (Pos.2),
hexagon nuts (Pos.3) and washers (Pos.4)
See Fig.IV16.1-2; Fig.IV16.1-3 and Fig.IV16.1-4

Fig. IV16.1-4

Fig. IV16.1-2

Power Train 51 Disassembly and Assembly

16.2 Check axial play of the input in housing
top section

Have wheel shaft rotated several times. For

measurement of the axial play of the input, a dial
gauge with a magnetic stand is to be positioned
right-angled onto the plane face of the input pinion
and the dial indicator must be put to “Zero”. Mark
position of the dial gauge on the plane face with a
colour pencil. With both hands press input pinion
upwards and downwards. Read the axial bearing
play on the dial gauge.
Fig. IV16.1-5
Axial play of grooved ball bearing 0.1 - 0.4 mm.
When checking a bearing play has to be
measurable.

Fig. IV16.2-1

Place centering ring (Pos.2) for motor fixing onto

the pivoting bearing (Pos.1) and bolt it with the
pivoting bearing. (Also observe instructions in the
manual “Operating instructions for helical bevel
gear transmissions GK 25 LD”.)

Observe min. screw-in depth of the 6 fixing

bolts (Pos.3)!

Steering lock is installed as follows:

• screw two final stops (Pos.4) onto the chain

tread

• place lock plate (Pos.5) into the groove in the

centering ring and connect it with the pivoting
bearing by means of screws.

• Tightening torques of the screws acc. To ZF-

standard (see Chapter I)

For assembly please observe the specified

mounting position of the steering lock in the
relating installation drawing!

Power Train 52 Disassembly and Assembly

17. Relubrication of pivoting bearing

Under normal operating conditions the pivoting

bearing has to be relubricated once a year.
After cleaning with a steam jet device or similar,
the pivoting bearing has to be relubricated. For the
operation in a heavily dust-loaded or humid
environment (e.g. cold store application) the
pivoting bearing has to be relubricated 2x per
month at least.
We recommend a grease of the quality SHELL
Alvania R3 or grease of an equal composition and
an equal specification.

Procedure:

a. The pivoting bearing has two grease

nipples(Pos.1).

b. Over the two grease nipples press in the grease

with a grease gun into the pivoting bearing.
Transmission has to be turned slowly.

Required grease volume for dry pivoting earing

approx. 55 g.

c. Rotate transmission several times, so that the

grease istributes completely.

d. Remove the grease pressed out of the pivoting

bearing ith a cloth.
Fig. IV17-1

Fig. IV17-1

Power Train 53 Disassembly and Assembly

 Drive Axle
- GK26LD (101587-00013)
Disassembly
Clamp the unit.

(S) Assembly truck 5870 350 000

(S) Clamping device AA00 852 804

CAUTION

Fig. 1
The following figures show a different
clamping device. ZF offers only the device
shown in fig. 1.

Loosen all screw plugs and drain the oil.

DANGER
Waste oil to be disposed of ecologically and
according to the legal provisions!.

Fig. 2

Components and upper housing part

Geared steering version

Loosen the screw plug on top of the motor (arrow).

Turn the eyebolt into the motor shaft behind and fix
the lifting device.

Fig. 3

Loosen the cylindrical screws on the motor (see

arrow) and remove the motor by means of the
lifting device.

Fig. 4

Power Train 54 Disassembly and Assembly

 Loosen the cylindrical screws. Loosen the frame
plate by means of slight hits with a plastic hammer
and remove it.

Fig. 5

If necessary, remove the cylindrical screws (steering

stop).

Fig. 6

Loosen countersunk screws (arrows 1) and lift off

the steering stop (arrow 2).

Fig. 7

Power Train 55 Disassembly and Assembly

 Chain steering version

Loosen the screw plug on top of the motor (arrow).

Turn the eyebolt into the motor shaft behind and fix
the lifting device.

Fig. 8
Loosen bolted motor connection.

Fig. 9
Remove motor by means of the lifting device.

Fig. 10
Loosen Torx screws on the connection plate.

Fig. 11

Power Train 56 Disassembly and Assembly

 Carefully remove the connection plate using a screw
driveror a suitable assembly tool.

Fig. 12
Lift off the shaft seal on the connection plate.

Fig. 13
Pull the slotted pin out of the chain tightener.

Fig. 14

Remove cylindrical screws on the bottom of the

chain tightener.

Remove chain tightener.

Fig. 15

Power Train 57 Disassembly and Assembly

 Remove the adjusting washer.
Remove O ring (see arrow).

Fig.16

Loosen bolted connection on upper housing part.

Fig. 17

Carefully loosen upper housing part by means of

slight hits and remove it.

Fig. 18
Force bushing and input pinion out of the upper
housing part.

CAUTION
Apply force only to the bushing.

Fig. 19

Power Train 58 Disassembly and Assembly

 Remove bearing inner ring out of the upper housing
part.

Fig. 20

Force out both bearing outer rings on the upper

housing part one after the other.

Fig. 21

If required, force out breather on upper housing part.

Fig. 22

Dismantle retaining ring on the input pinion.

Fig. 23

Power Train 59 Disassembly and Assembly

 Support the bushing with a suitable sleeve as
illustrated.
Force input pinion out of the bushing.

CAUTION
Pay attention so that the input pinion does not
drop.
Protect the input pinion by means of a soft pad.

Fig. 24

Force the input pinion out of the ball bearing, as

illustrated.

CAUTION
Pay attention so that the input pinion does not
drop.
Protect the input pinion by means of a soft pad.

Fig. 25

Remove the ball bearing from the bushing.

Fig. 26

Position the taper roller bearing on the bearing inner

ring with a suitable sleeve. Then press the bushing
out of the bearing inner ring.

Fig. 27

Power Train 60 Disassembly and Assembly

 Input and output

Use lever to remove protective cap from the gear

shaft.

Fig. 28

Install locking device (S) on the gear shaft (see

arrow) thus blocking the gear shaft against rotation.
Loosen both hexagon nuts on the bevel gear shaft
one after the other. Remove disk.

(S) Locking device 5870 240 002

Fig. 29

If necessary, block gear shaft against rotation by

means of the locking device (S) (see previous
figure) and dismantle the wheel bolt with suitable
pliers.

CAUTION
It is possible to unscrew the wheel bolts with
dismounted and mounted gear shaft.

Fig. 30
Disengage snap ring from the annular groove on the
housing.

Fig. 31

Power Train 61 Disassembly and Assembly

 Lift off the cover on the cast brackets.

Fig. 32

Remove O ring (see arrow).

Fig.33

Install locking device (S) on the gear shaft (see

arrow) thus blocking the gear shaft against rotation.
Loosen both hexagon nuts on the gear shaft one
after the other.
Remove disk.

(S) Locking device 5870 240 002

Fig. 34

Carefully remove the gear shaft from the crown

wheel using a plastic hammer.

CAUTION
Pay attention: gear shaft releases downwards.

Fig. 35

Power Train 62 Disassembly and Assembly

 Press off the bearing inner ring from the gear shaft.

(S) Cut-off device 5870 300 028

Fig. 36

Remove the crown wheel from the housing.

Fig. 37

Remove the bearing inner ring out of the housing.

Fig.38

Carefully remove the bevel gear shaft out of the spur

gear using a plastic hammer (bearing inner ring
below) and take out from the bottom.

CAUTION
Pay attention: Bevel gear releases downwards.

Fig. 39

Power Train 63 Disassembly and Assembly

 Support the bearing inner ring with a suitable sleeve
and press it off the bevel gear shaft.

Fig. 40

Remove spur gear from the housing.

Fig. 41

Remove bearing inner ring from the housing.

Fig. 42

Force bearing outer ring out of the housing and

remove the
adjusting washer behind.

CAUTION
Pay attention so that the releasing adjusting
washer does not drop. Mark installation position.
Assembly aid.

Fig. 43

Power Train 64 Disassembly and Assembly

 Force out the opposite bearing outer ring.

Fig. 44

Lift-off shaft seal.

CAUTION
If the shaft seal is stuck, you can force it out
from the opposite side.

Fig. 45

Force bearing outer ring out of the housing and

remove the
adjusting washer behind.

CAUTION
Pay attention so that the releasing adjusting
washer does not drop. Mark installation position.
Assembly aid.

Fig. 46

Force out the opposite bearing outer ring.

Fig. 47

Power Train 65 Disassembly and Assembly

 Reassembly

Input and output

CAUTION
If either crown wheel or bevel gear shaft is
damaged, both parts must be jointly replaced.

Legend:

1 = Bevel gear shaft

2 = Crown wheel
3 = Adjusting washer of contact pattern
4 = Adjusting washer of backlash (circumferent.
backlash)
5 = Taper roller bearing
6 = Taper roller bearing
7 = Gear shaft

CAUTION
If a new taper roller bearing (fig. 1 item 5) is used,
determine the bearing width and compare it with
Fig. 1 the previous bearing to match the adjusting
washer (item 3).

Determine thickness of the adjusting washer

removed during disassembly. Determine bearing
width of the new and the old taper roller bearing and
calculate thickness of adjusting washer.

CALCULATION EXAMPLE A:

Bearing width (old bearing) e.g. . . . . . . . 22.35 mm

Adjusting washer (old) e.g. . . . . . . . . . . + 0.30 mm
Bearing width (new bearing) e.g. . . . . – 22.25 mm
Adjusting washer (new) e.g. 0.40 mm
Fig. 2

Insert the adjusting washer into the bearing hole on

the housing. Fit the bearing outer ring until contact is
obtained.

(S) Driver tool AA00 607 184

CAUTION
When installing the old taper roller bearing (fig. 1
item 5), use the adjusting washer removed
during disassembly.

Fig. 3

Power Train 66 Disassembly and Assembly

 Fit bearing outer ring into the bearing hole on the
housing until contact is obtained.
(S) Driver tool AA00 658 635

Fig. 4

Press-on the bearing inner ring until contact with the

bevel
gear shaft is obtained.

Fig. 5

Insert bearing inner ring into the bearing outer ring.

Fig. 6

Wet inner gearing at the spur gear evenly with

Loctite 270.

Fig. 7

Power Train 67 Disassembly and Assembly

 Place the spur gear on top of the housing.

CAUTION
Observe the installation position. Convex side of
spur gear to face upwards.

Mount the preassembled bevel gear shaft to the

spur gear from below.

Fig. 8

Press against the bevel gear shaft from below. Use

a suitable sleeve and a plastic hammer to bring the
spur gear carefully to contact position.

Fig. 9

Install the disk on the bevel gear shaft. Hand-tighten

a hex. nut without using a wrench until contact is
obtained.

Fig. 10

Position the counter support (S). Tighten the second

hexagon nut.

Tightening torque MA = 200 N·m

(S) Stop AA00 321 773

Fig. 11

Power Train 68 Disassembly and Assembly

 Check rolling torque of the bevel gear shaft bearing
0.7 … 1.3 N·m.

CAUTION
Try to achieve the lower value.

CAUTION
If rolling torque is incorrect, loosen both
hexagon nuts and repeat the work steps shown
Fig. 12 in fig. 10 … 12. Use the lower hexagon nut for
correction.

Drive in the bearing outer ring until contact is

obtained.
(S) Driver tool AA00 603 011

Fig. 13

Install shaft seal by means of driver tool (S).

(S) Driver tool AA00 603 138

CAUTION
Apply grease (Shell Alvania RL3) to the shaft
seal inner side.

CAUTION
When installing a new taper roller bearing (fig. 1
item 6), determine the bearing width and
Fig. 14
compare it with the previous bearing to match
the adjusting washer (item 4).

Determine bearing width of new and old taper roller

bearing as well as thickness of adjusting washer.

CALCULATION EXAMPLE B:

Bearing width (old bearing) e.g. . . . . . . . 32.10 mm

Adjusting washer (old) e.g. . . . . . . . . . . + 0.30 mm
Bearing width (new bearing) e.g. . . . . – 32.20 mm
Adjusting washer (new) e.g. 0.20 mm

Fig. 15

Power Train 69 Disassembly and Assembly

 Insert adjusting washer into the bearing hole and
force in bearing outer ring until contact is obtained.

(S) Driver tool AA00 658 776

CAUTION
When installing the old taper roller bearing (fig. 1
item 6), use the adjusting washer removed
during disassembly.

Fig. 16

Insert the bearing inner ring into the bearing outer

ring.

Fig. 17

Wet inner gearing at the crown wheel evenly with

Loctite 270.

Fig. 18

Position the crown wheel at the bearing inner ring,

as illustrated.

Fig. 19

Power Train 70 Disassembly and Assembly

 Press on the bearing inner ring until contact with the
gear shaft is obtained.

Fig. 20

Install the gear shaft on the crown wheel from below.

Secure with hexagon nut.

Fig. 21

Support unit on the gear shaft. Use a press to bring

crown wheel and suitable sleeve to contact position.

Fig. 22

Hand-tighten a hexagon nut without using a wrench

until contact is obtained.

Fig. 23

Power Train 71 Disassembly and Assembly

 Fix and support the locking device (S) on the gear
shaft.
Position the counter support (S) and adjust contact
position. Tighten the second hexagon nut.

Tightening torque MA = 550 Nm

(S) Locking device 5870 240 002

(S) Counter support AA00 857 163

Check rolling torque of the gear shaft bearing 13 …

22 N·m.

Fig. 24 CAUTION
Try to achieve the lower value.

CAUTION
When installing the old taper roller bearing (fig. 1
item 6), use the adjusting washer removed
during disassembly.

Place dial indicator at right angles to the tooth flank

of the crown wheel and check backlash (0.10 …
Fig. 25 0.18 mm).

CAUTION
In case of any deviation from the required
backlash correct the adjusting washer (fig. 16/fig.
1 item 4)
according to the following specification:
Insufficient backlash – install thinner adjusting
washer Excessive backlash – install thicker
adjusting washer

Then cover some drive and coast flanks on the

crown wheel with marking ink and rotate crown
Fig. 26
wheel in both directions several times.
Compare the obtained contact pattern with the
examples on page 0/4.

(S) Locking device 5870 240 002

CAUTION
If the contact pattern differs, use a suitable shim
forcorrection (figure 3/fig. 1 item 3).

Power Train 72 Disassembly and Assembly

 Grease the O-ring and install it into the annular
groove onthe cover (see arrow).

Fig. 27
Mount the preassembled cover into the housing until
contact is obtained.

CAUTION
Observe installation position. Bring recess for
taper roller bearing into the correct position. See
arrow.

Fig. 28

Insert snap ring into the annular groove on the

housing and fix the cover.

Fig. 29

Power Train 73 Disassembly and Assembly

 Upper housing part and components
If removed, or in case of a new part, flush-mount the
protection cap with the open side facing inwards.

Fig. 30

Press ball bearing onto the input pinion until contact

is obtained.

CAUTION
Apply assembly force only on the bearing inner
ring.

Fig. 31
Install preassembled input pinion into the bushing as
illustrated.

Press ball bearing onto the input pinion until contact

Fig. 32 is obtained.

CAUTION
Observe installation position. Snap ring to show
upwards/outwards.

CAUTION
Apply assembly force only on the bearing inner
ring.

Fig. 33

Power Train 74 Disassembly and Assembly

 Fix ball bearing on the input pinion by means of a
retaining ring.

Fig. 34

Press bearing inner ring onto the bushing as

illustrated.

Fig. 35

Insert both bearing outer rings onto the upper

housing part until contact is obtained.

Fig. 36

Place upper housing part on the preassembled

bushing, as illustrated. Place bearing inner ring as
illustrated and carefully bring into contact position by
means of a handoperated press.

Fig. 37

Power Train 75 Disassembly and Assembly

 Adjust rolling torque of the connection plate bearing
(fig. 38… 50).
Support the preassembled upper housing part on
the bushing. Determine dimension I from front side
of bearing inner ring to front side of bushing.
Dimension I e.g. . . . . . . . . . . . . . . . . . . . . 9.90 mm

Fig. 38

Determine dimension II on connection plate.

Dimension II e.g. . . . . . . . . . . . . . .. . . . . . 9.65 mm

CAUTION
Also see the following figure.

Calculate the adjusting washer thickness for rolling

torque adjustment of connection plate.

CALCULATION EXAMPLE C:
Fig. 39
Dimension I e.g. . . . . . . . . . . . . . . . . . 9.90 mm
Dimension II e.g. . . . . . . . . . . . . . . . – 9.65 mm
Bearing pre-load . . . . . . . . . . . . . . . . - 0.10 mm
Adjusting washer 0.15 mm

Legend:
1 = Connection plate
2 = Shaft seal
II = Dimension II (fig. 39)

Fig. 40

If removed, or in case of a new part, install

cylindrical pins (see arrows 1).

Wet mounting face (arrow 2) with Loctite 574.

Fig. 41

Power Train 76 Disassembly and Assembly

 Use a plastic hammer to bring the upper housing
part
carefully into contact position with the housing.

Fig. 42

Fix the upper housing part by means of cylindrical

screws.
Tightening torque (M8/10.9) MA = 30 N·m

Fig. 43

If removed, or in case of a new part, install breather

(S) on upper housing part by means of a driver tool.

(S) Press-fit mandrel AA00 852 929

Fig. 44

Place the adjusting washer determined in fig. 39

onto the bushing (e.g. s = 0.15 mm).

Grease the O-ring and place it into the annular

groove on the upper housing part (see arrow).

Fig. 45

Power Train 77 Disassembly and Assembly

 Flush-mount the shaft-seal into the connection plate.

CAUTION
Apply grease (Shell Alvania RL3) to the inner
side of the shaft seal.

CAUTION
Observe installation position. Also refer to fig.
40.

Fig.46 If removed, or in case of a new part, insert the

cylindrical pin (see arrow) into the hole near the
M12-threads, until contact is obtained.

Mount the connection plate on the input pinion/on

the bushing.

CAUTION
Ensure that the sealing lip on the shaft seal is
not turned up.

Fig. 47 CAUTION
Observe installation position. Cylindrical pin
(see arrow) to face the casting recess on the
upper housing part (dashed line).

Use a plastic hammer to bring the connection plate

carefully into contact position.

Fig. 48
Fix the connection plate by means of Torx screws.
Tightening torque MA = 79 N·m

CAUTION
Tighten screws crosswise.

Fig. 49

Power Train 78 Disassembly and Assembly

 Check rolling torque of connection plate bearing 18
… 25 N·m.

(S) Assembly fixture AA00 630 183

Fig. 50
Geared steering version

Mount steering stop as illustrated. Force in grooved

pins in alignment with the steering stop. Fix steering
stop by means of countersunk screws.

Tightening torque (M6/10.9) MA = 14 N·m

CAUTION
Secure countersunk screws with Loctite 243.

Fig. 51

If removed, or in case of a new part, install

cylindrical screws.

Tightening torque (M12/8.8) MA = 79 N·m

CAUTION
Mount cylindrical screws with Loctite 243.

Fig. 52

Place frame plate onto the connection plate and fix it

by means of cylindrical screws.

Tightening torque (M12/8.8) MA = 79 N·m

CAUTION
Secure cylindrical screws with Loctite 243.

Fig. 53

Power Train 79 Disassembly and Assembly

 Wet inner gearing at the input pinion evenly with
grease Klüberplex BEM 34-132.

Fig. 54

Apply grease Klüberplex BEM 34-132 evenly on the

shaft at the electric motor.

Fig. 55

Place electric motor onto the connection plate and

fix it by means of cylindrical screws.

Tightening torque (M8/8.8) MA = 23 N·m

CAUTION
Observe installation position. See disassembly.

Fig. 56

Turn screw plug into the electric motor.

CAUTION
For tightening torque see motor manufacturer.

Fig. 57

Power Train 80 Disassembly and Assembly

 Chain steering version

Mount the chain tightener in the order indicated by

the arrows.

Fig. 58

Force slotted pin into the upper housing part, to be

in alignment with the chain tightener.

Fig. 59

Fix the chain tightener by means of cylindrical

screws.

Tightening torque (M8/10.9) MA = 30 N·m

CAUTION
Secure cylindrical screws with Loctite 243.

Fig.60
Wet inner gearing at the input pinion evenly with
grease Klüberplex BEM 34-132.

Fig. 61

Power Train 81 Disassembly and Assembly

 Apply grease Klüberplex BEM 34-132 evenly on the
shaft at the electric motor.

Fig. 62

Place the electric motor onto the connection plate.

CAUTION
Observe installation position. See disassembly.

Fig. 63

Fix electric motor by means of cylindrical screws.

Tightening torque (M8/8.8) MA = 23 N·m

Fig. 64

Turn screw plug into the electric motor.

CAUTION
For tightening torque see motor manufacturer.

Fig.65

Power Train 82 Disassembly and Assembly

 Force protective cap onto the gear shaft until contact
is obtained, as illustrated.

Fig. 66
If removed or in case of a new part, install two
hexagon nuts to the long thread of the wheel stud
and lock them. Then turn the short thread of the
wheel bolt into the gear
shaft.
Tightening torque MA = 60 N·m

CAUTION
Observe installation position. See disassembly.

Fig. 67
DANGER
Prior to putting the unit into operation, fill in oil
according to the GK 26 LD assembly
instructions (ZFordernumber 4699 750 047).

Power Train 83 Disassembly and Assembly

 SB4296E00
July 2007

Vehicle System
Specification
System Operation
Testing & Adjusting

B10R-5, B13R-5, B15R-5, B16R-5

 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

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.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DOOSAN 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 DOOSAN 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. DOOSAN dealers have the most current
information available.

1
Index

Specifications Testing & Adjusting

Hydraulic Control Valve.......................................... 5 Troubleshooting....................................................28

Visual Checks..................................................28
Hydraulic Pump ..................................................... 6 Hydraulic System and Mast .............................28
Brake System ..................................................33
Sideshift Cylinder................................................... 6 Electric Motors.................................................34

Lift Cylinders.......................................................... 7 Hydraulic System..................................................37

Standard........................................................... 7
Full Free Triple Lift and..................................... 7
Full Free Lift Primary......................................... 7
Full Free Lift Secondary .................................... 8
Full Free Triple Lift Secondary .......................... 8
Relief Valve Pressure Check ...........................37
Lift Cylinders Air Removal................................38
Steering System Air Removal ..........................39
Steering System Air Removal ..........................39
Steering System Pressure Check ....................39

Tilt Cylinder............................................................ 9 Brake System.......................................................41

Brake System Air Removal ..............................41
Steering Wheel .................................................... 10 Pedal Adjustment ............................................42
Parking Brake Test ..........................................42
Priority Valve ....................................................... 10 Parking Brake Control Group Adjustment.........42

Steering Hydraulic Motor...................................... 10 Hydraulic Pump Motor ..........................................43

Instruction about sensor bearing’s exchange ...43
Steering Gear ...................................................... 11

Hydraulic Pump Motor.......................................... 12

Systems Operation

Hydraulic System................................................. 13

Control Valve ....................................................... 15

Lift Valve Neutral Position ............................... 15
Lift Position ..................................................... 16
Lift Lower Position........................................... 17
Tilt Neutral Position......................................... 18
Tilt Forward Position ....................................... 19
Tilt Back Position ............................................ 20
Relief Valve .................................................... 21

Steering System .................................................. 22

Hydraulic Steering system............................... 22
Steering Unit–Steering Gear ........................... 23

Brake System ...................................................... 26

Master Cylinder............................................... 26

Electric Motors..................................................... 27
Hydraulic Pump Motor..................................... 27

Vehicle Systems 3 Index

Specifications
Hydraulic Control Valve

IHCS101S

Main Relief Valve Auxiliary Relief Valve

AC Type
Pressure Pressure
24 [V] ± 250 kPa ± 35 psi ± 250 kPa ± 35 psi
B10/13R-5 Min. 360 [A] 15,900 2,306
14,000 2,040
B15/16R-5 Max. 380 [A] 17,500 2,538

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 5 Specifications

Hydraulic Pump Sideshift Cylinder

EHCS002B EHCS003B

Rotation is counterclockwise when seen from drive 1. Torque for head ............................270 ± 35 N•m
end. (200 ± 25 lb•ft)

Type of pump : Gear 2. Torque for piston nut.......................260 ± 25 N•m

(190 ± 20 lb•ft)
Displacement : 16 cc/rev

Vehicle Systems 6 Specifications

Lift Cylinders
Standard
1. Put Pipe Sealant on the last three threads of
bleed screw and tighten to a torque of...................
.........................................6 ± 1 N•m (53 ± 9 lb•in)
NOTE: All seals to be lubricated with hydraulic oil.
Vehicle Systems
Full Free Triple Lift and
Full Free Lift Primary
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 ± 1 N•m (53 ± 9 lb•in)
NOTE: All seals to be lubricated with hydraulic oil.
7 Specifications
Full Free Lift Secondary Full Free Triple Lift Secondary

1. Put Pipe Sealant on the last three threads of 1. Put Pipe Sealant on the last three thread of
bearing. bearing.

2. Put Pipe Sealant on the last three threads of 2. Put Pipe Sealant on the last three thread of bleed
bleed screw and tighten to a torque of .. 6 ± 1 N•m screw and tighten to a torque of............6 ± 1 N•m
(53 ± 9 lb•in) (53 ± 9 lb•in)

NOTE: All seals to be lubricated with hydraulic oil. NOTE: All seals to be lubricated with hydraulic oil.

Vehicle Systems 8 Specifications

Tilt Cylinder

EHCS008B

Tilt Tilt Angle Degrees Cyl. Closed – X Cyl. Open – YStroke Stroke – Z
Group Forward Backward mm in mm in mm in
A471399 3° 6° 385 15.2 458 18.0 73 2.9
A475110 3° 5° 385 15.2 449 17.7 64 2.5

1. Adjust pivot eye to dimension(Y) with cylinder

open (extended)

2. Torque for bolt .............................269.7 ± 34 N•m

(199 ± 25 lb•ft)

3. With mast at tilt back position shim as required to

permit no gap between eye(1) and spacer.
Torque for head............................269.7 ± 34 N•m
(199 ± 25 lb•ft)

4. Torque for jam nut........................402.1 ± 34 N•m

(296.6 ± 22 lb•ft)

Vehicle Systems 9 Specifications

Steering Wheel Priority Valve

2
EHCS017

Flow .............................Load sensing closed center.

EHCS016B

1. Torque for steering wheel nut ............. 80 ± 6 N•m

(60 ± 4 lb•ft)

2. Torque for bolt ........................... 15 N•m (11 lb•ft)

Steering Hydraulic Motor

2
1

1. Torque for steering motor bolt ......... 0.5 +0.3 N•m

(0.4+0.06 lb•ft)

2. Torque for steering motor bolt .........3.8 ± 0.6 N•m

(2.8 ± 0.44 lb•ft)

3. Torque for bolt ...............3 +0.5 N•m (2+0.36 lb•ft)

Vehicle Systems 10 Specifications

Steering Gear

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 ± 2.8 N•m

(125 ± 25 lb•in)

Tighten to a final torque of ...........28.2 ± 2.8 N•m

(250 ± 25 lb•in)

(5) Torque for plug ....................11.3 N•m (100 lb•in)

Plug to be flush (even) with or below mounting

surface.

Vehicle Systems 11 Specifications

Hydraulic Pump Motor

Thermal switch

Warning temperature ..... 155 ± 4℃(311 ± 10 ℉)

Vehicle Systems 12 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 valves. (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 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).
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.

Vehicle Systems 13 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 14 Systems Operation

Control Valve
Lift Valve Neutral Position

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 15 Systems Operation

Lift Position

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 16 Systems Operation

Lift Lower Position

ICCS011S
Control Valve For Lift (Shown In LOWER Postion)
(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 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 17 Systems Operation

Tilt Neutral Position

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 18 Systems Operation

Tilt Forward Position
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.
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
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 will be closed.
19 Systems Operation
Tilt Back Position

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 20 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.

IHCS104S

Relief Valve
(7) Passage for return oil. (11) Piston. (12) Dump valve.
(13) Spring chamber. (14) Pilot valve.

Vehicle Systems 21 Systems Operation

Steering System
Hydraulic Steering system

Hydraulic Schematic

1
6
4

7 5
2

9
Return 3 12
from 17
To control
15
16
Pump motor
10
P.T.O

14
11 13

steering system schematic

1. Steering unit 2. Hydraulic line 3. Hydraulic line 4. Hydraulic line 5. Hydraulic line 6. Hydraulic steering motor 7.Hydraulic line
8.Transmission PTO 9. Hydraulic line 10. Hydraulic pump 11. Hydraulic tank 12. Priority valve 13. Suction filter 14. Filter-return.
15. Hydraulic line 16. Hydraulic line. 17. Steered wheel

The steering system uses the hydraulic fluid for operation. The system has priority valve (12) which sends the
fluid to steering unit(1) as needed before the requirements of mast operation are filled.
The fluid is pulled from a hydraulic tank(11) to a hydraulic pump(10). Pump supplies a fluid through a hydraulic
hose(15) to a priority valve(12).
When the steering unit(1) is neutral position, pilot pressure in load sensing line(7) is reduced and the spool of
priority valve is moved to the left . The fluid flows though hydraulic line(16) to control valve.

During a right turn, pilot pressure is increased in load sensing line(7) and the spool of priority valve is moved
to the right. The fluid flows through hydraulic line(9) to the steering unit. From the steering unit the fluid flows
through a hydraulic line(5) for right turn. The return fluid flows through a hydraulic line(4) back through
steering unit, a hydraulic line(2) and into the hydraulic tank(11).

During a left turn, a pilot pressure is again increased in load sensing line(7) which moves the spool of priority
valve to the right. A fluid flows through a hydraulic line(9) to a steering unit. From the steering unit, the fluid
flows through a hydraulic line(4) to a hydraulic steering motor(6) to make a left turn. The return fluid flows
through a hydraulic line(5) back to steering unit, a hydraulic line(2) and into the hydraulic tank.

A check valve is installed into the port of steering unit connected to hydraulic line(9) to prevent a fluid back to
priority valve right after a turn is made,
Relief valve in priority valve will open if steering pressure goes above 10000(+500,-0) kpa or 1450(+70,0) psi.

Vehicle Systems 22 Systems Operation

Steering Unit–Steering Gear
IBCS037B
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.
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.
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
Oil Flow
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.
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.
23 Systems Operation
 IBCS039B IBCS040B

Steering Unit (Shown in a LEFT TURN Position) Spool And Sleeve

(1) Spool. (2) Sleeve. (3) Outlet to tank. (5) Inlet from pump. (1) Spool. (2) Sleeve. (18) Slots for spring.
(9) Pin. (10) Left turn port. (11) Right turn port. (13) Drive. (19) Holes for pin. (20) Small holes for oil flow.
(14) Passage. (15) Passage. (16) Gerotor. (17) Passage. (21) Grooves for oil flow.

When the steering wheel is turned to the left, spool The rate of flow the gerotor sections is determined
(1), pin (9) and drive (13) turn with it. After spool (1) by how fast the steering wheel is turned. The faster
has turned a small amount pin (9) will cause sleeve the steering wheel turns, the greater the flow and
(2) to move with the spool. They will rotate together the faster the vehicle will turn.
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 goes 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 24 Systems Operation

EHCS035B EHCS036B

Steering Unit (Shown in Manually Operated Right Turn Pump Gears In The Metering Section
Position) (6) Rotor. (7) Stator. (9) Pin. (13) Drive.
(3) Outlet to tank. (4) Ball check. (10) Left turn port.
(11) Right turn port. (15) Passage. (16) Gerotor. When the steering wheel is turned, in either direction,
(17) Passage.
pin (9) turns with the sleeve and spool and causes
drive (13) to turn also. The drive cause rotation of
If there is a pump failure or the engine stops and
rotor (6) inside of stator (7). This rotation of the rotor
can not be started again, the STEERING UNIT can
sends a controlled (metered) flow of oil back to the
be manually operated. Turning the steering wheel
spool sleeve combination where it is then directed to
will take oil from the tank and bring it in through
either port (10) or (11) and then to the steering
outlet (3). It will then open check valve (4) and go to
cylinder.
the gerotor (16) through passage (17). It will come
out of (16) through passage (15) and go to the right
If the unit is taken apart for any reason, it must be
turn port (11). This is the flow for a right turn. It
put back together with the relationship between pin
would be reversed for a left turn.
(9) and rotor (6) as shown.
During normal operation, check valve (4) will be held
closed by pressure oil from the pump.

Vehicle Systems 25 Systems Operation

Brake System
Master Cylinder

(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.

IOCS008I
When the brake pedal is first pushed, the piston
moves into the master cylinder and pushes brake
liquid through outlet into the brake lines.
Master Cylinder And Cylinder of Brake Lever
(1) Master Cylinder reservoir. (2) Master Cylinder.
The liquid pushed through outlet goes through the
(3) Brake Cylinder.
brake lines to the brake cylinder (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 26 Systems Operation

Electric Motors
Hydraulic Pump Motor

The motor is protected from over temperature by a

thermal sensor. If motor’s temperature reaches in
155 ± 4°C (311 ± 10°F) 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 pre-
settable.

Vehicle Systems 27 Systems Operation

Testing & Adjusting
Troubleshooting
Troubleshooting can be difficult. A list of possible
problems and corrections are on the pages that
follow.
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.
WARNING
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.
Visual Checks
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.
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
3. Check all oil lines and connections for damage or
leaks.
4. Check all the lift chains and the mast and carriage
welds for wear or damage.
Hydraulic System and Mast
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.
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.
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
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.
Lift, lower, tilt forward and tilt back the forks several
times.
1. Watch the cylinders as they are extended and
retracted. Movement must be smooth and regular.
28 Testing and Adjusting
2. Listen for noise from the pump.
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.
Hydraulic Oil Temperature
(Too Hot)
When the temperature of the hydraulic oil gets over
98.8°C (210°F), 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.
1. Hydraulic pump is badly worn.
2. Heavy hydraulic loads that cause the relief valve
to open.
3. The setting on the relief valve is too low.
4. Too many restrictions in the system.
5. Hydraulic oil level in the tank is too low.
6. High pressure oil leak in one or more circuits.
7. Very dirty oil.
8. Air in the hydraulic oil.
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 :
a. Return oil to the tank goes in above the level of
the oil in the tank.
b. Air leaks in the oil suction line between the
pump and the tank.
Vehicle Systems
Mast and Carriage
Problem: The hydraulic system will not lift the
load.
Probale Hydraulic Cause :
1. There is an air leak, which lets air into the
hydraulic system on the inlet side of the hydraulic
pump.
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).
Probable Mechanical Cause:
1. The mast is not in alignment with the other lifting
components and does not move freely.
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 : Lift cylinder extends too slowly.
Probable Hydraulic Cause :
1. Not enough oil supply to lift cylinder.
2. Defective lift cylinder seals.
Probable Mechanical Cause :
1. The mast is not in alignment with the other lifting
components and does not move freely.
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.
29 Testing and Adjusting
Probable Mechanical Cause : 5. Air in the hydraulic system.

1. Not enough lubricant on the parts of the mast that Probable Mechanical Cause:
move.
1. The mast is not in alignment with the other lifting
2. Load rollers(bearings) defective or not adjusted components and does not move freely.
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
1. Lift cylinder damaged or bent. and do not move(seized).

2. Load rollers(bearings) defective or not adjusted Problem : The lift or tilt cylinders do not hold
correctly. 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 1. The valve spools do not hold their positions
moves too slowly. because the springs for the valve spools are weak
or broken.
Probable Hydraulic Cause :
2. Control valve leakage caused by worn valve
1. There is an air leak, which lets air into the spools.
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.
Hydraulic Pump
5. Control valve tilt spool has a restriction.
Problem: Noise in the pump.
Probable Mechanical Cause :
Probable Cause :
1. Damage or failure of the piston rods on the tilt
cylinders. 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 5. Oil is dirty.
caused by foreign material and does not operate
freely. 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 30 Testing and Adjusting

Problem: The oil temperature is too high.
Probable Cause :
1. The oil level is low.
2. There is a restriction in an oil passage.
3. The relief valve setting is too low.
4. The oil is too thin.
5. There is air leakage in the system.
6. The pump has too much wear.
7. The system operates at too high a pressure.
Relief valve setting too high.
Attachment components cause a restriction during
movement.
Restrictions in flow control valve, check valve and
in oil lines.
Problem : Leakage at the pump shaft seal.
Probable Cause :
1. The shaft seal is worn.
2. The inner parts of the pump body are worn.
3. Operation with too low oil level in tank causes
suction on the seal.
4. Seal cut on shoulder of pump or keyway during
installation.
5. Seal lips are dry and hardened from heat.
Problem : There is failure of the pump to deliver
fluid.
Probable Cause :
1. Low level of the oil in the tank.
2. There is a restriction in the pump inlet line.
3. There is air leakage in the pump inlet line.
a. Loose bolts.
b. Defects in suction line.
4. The viscosity of the oil is wrong.
5. The pump has too much wear.
6. Failure of the pump shaft.
Vehicle Systems
7. The bolts of the pump do not have the correct
torque.
Hydraulic control valve
Problem:The control spools do not move freely.
Probable Cause:
1. The temperature of the oil is too high.
2. There is foreign material in the fluid.
3. The fitting connections in the valve body are too
tight.
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.
6. Bent lift or tilt spools.
7. Damage to the return springs of the spools.
8. The hydraulic oil is not at normal temperature for
operation.
Problem : Control valve spools have leakage
around the seals.
Probable Cause :
1. There is foreign material under the seal.
2. The valve spools are worn.
3. The seal plates are loose.
4. The seals have damage or are badly worn.
Problem : The load lowers when the lift spool is
moved from the NEUTRAL position to the RAISE
position.
Probable Cause :
1. There is foreign material in the check valve area.
2. The check valve poppet and seat show wear.
3. Sudden loss of pump oil pressure.
4. Damage to the relief valve which causes low oil
pressure.
31 Testing and Adjusting
Problem : Spools do not return to neutral.
Probable Cause:
1. The springs are broken.
2. The spool is bent.
3. The system or valve has foreign particles in it.
4. The control linkage is not in alignment.
5. The fastening bolts of the valve have too much
torque.
Problem : No motion or slow, then a too sudden
action of the hydraulic system.
Probable Cause :
1. The relief valve is not correctly set, or will not
move in base and/or is worn.
2. There is air in the system.
3. Dirt or foreign particles between relief valve
control poppet and its seat.
4. Valve body has a crack inside.
5. Spool not moved to a full stroke.
Lift and Tilt Cylinders
Problem : Leakage around the cylinder rod.
Probable Cause :
1. Cylinder head(bearing) seals are worn.
2. Cylinder rod is worn, scratched or bent.
Problem : There is leakage of oil inside the
cylinder or loss of lift or tilt power.
Probable Cause :
1. The piston seals are worn and let oil go through.
2. Cylinder has damage.
Problem: The tilt cylinder rods show wear.
Probalble Cause :
1. The cylinder are not in correct alignment.
2. Oil is dirty.
Vehicle Systems
Problem : Foreign material behind the wiper
rings causing scratches on the cylinder rod.
Probable Cause :
1. The wiper rings show wear and do not remove dirt
and foreign material.
Steering System
Problem : Too much force needed to turn
steering wheel.
Probable Cause :
1. Priority valve (if equipped) releases pressure oil at
a low setting
2. Pump oil pressure is low, worn pump.
3. Steering gear covers are too tight.
4. Steering column not aligned with steering gear.
5. Priority valve spool is held in one position.
6. Steering gear without lubrication.
7. Low fluid level in the hydraulic supply tank.
Problem : Steering wheel does not return to
center position correctly.
Probable Cause :
1. Steering gear covers are too tight.
2. Steering column is not in correct alignment.
3. Valve spool in the steering gear has a restriction.
4. Priority valve check valve permits lift and tilt
hydraulic oil to affect hydraulic circuit.
Problem : Oil leakage at the pump.
Probable Cause :
1. Loose hose connections.
2. Bad shaft seal.
32 Testing and Adjusting
Problem: Low oil pressure.
Probable Cause :
1. Low oil level.
2. Priority valve (if equipped) relief valve spring
weak.
3. Relief valve(priority valve) will not move from the
open position.
4. Oil leakage inside or outside of the system.
5. Bad pump.
Problem : Pump makes noise when turning the
steering wheel and does not move smoothly.
Probable Cause :
1. Air in the steering hydraulic circuit.
2. The pump has to much wear.
3. Loose connection of the oil line on the inlet side of
the pump.
4. The viscosity of the oil is wrong.
5. The oil level in the hydraulic tank is low.
Problem : Lift truck does not turn when steering
wheel is slowly turned.
Probable Cause :
1. The oil level of the tank is low.
2. There is air in the steering system.
3. The pump operation is not correct.
4. Dirt in the steering system.
5. Steering gear operation is not correct.
6. Restriction in the steer axle linkage.
Vehicle Systems
Problem : The temperature of the oil is too hot.
Probable Cause :
1. The viscosity of the oil is wrong.
2. Air is mixed with the oil.
3. The relief valve is set too high(priority valve).
4. There is a restriction in the return line circuit.
Brake System
Wet Disc Brake
Problem : Pedal resistance is not solid(spongy).
Probable Cause :
1. Leakage or low fluid level.
2. Air in the brake hydraulic system.
3. Master cylinder is loose.
Problem : Extra (excessive) pedal pressure
needed for braking action.
Probable Cause :
1. Mechanical resistance on the brake pedal.
2. Restriction in the brake line.
3. Bad master cylinder.
4. Discs look like glass(glazed) or are worn.
Problem : Pedal gradually goes to the floor.
Probable Cause :
1. Leakage or low fluid level.
2. Bad master cylinder.
33 Testing and Adjusting
Problem : Extra(excessive) pedal travel.
Probable Cause :
1. Pedal adjustment is not correct.
2. Leakage or low fluid level.
3. Air in the brake hydraulic system.
4. Bad master cylinder.
5. Discs are worn.
Problem : Brakes will not apply.
Probable Cause :
1. Leakage or low fluid level.
2. Air in the brake hydraulic system.
3. Linkage is not in correct adjustment or is bent.
4. Discs look like glass (glazed) or worn.
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.
3. Bad contact between the steel discs and friction
discs.
4. Brake discs uneven (out of flat).
5. Loose pressure plate bearing.
6. Bad disc and friction disc assembly.
Vehicle Systems
Parking Brakes
Problem : Brakes will not hold.
Probable Cause :
1. Parking brake assembly out of adjustment.
2. Parking brake control cable out of adjustment.
3. Worn brake discs.
Electric Motors
Before an analysis is made of any electric motor
problem, always make reference to the
troubleshooting section of MicroController Control
System module.
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 electrical shock. If a fire is present,
disconnect the electrical power and use a
carbon dioxide extinguisher to put the flame out.
Do not operate the drive motor without a load as
too much speed may cause damage to the motor
and injury to personnel.
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.
34 Testing and Adjusting
Problem 1 : Hydraulic pump motor will not
operate.
Probable Cause :
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.
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.
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.
4. Speed Sensor is breakdown.
5. Lift and drive system operation not correct. See
troubleshooting section of the Micro Controller
Control System module.
Vehicle Systems
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.
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. 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.
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.
35 Testing and Adjusting
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.

Problem 3 : Lift truck has slow hydraulic speeds.

Probable Cause :

1. Hydraulic pump motor overheated.

In case motor’s temperature reaches in 155°C

controller does overheat warning and reduce the
performance.

2. Pump motor control circuit overheated.

In case power unit’s temperature reaches in

100°C controller does overheat warning and
reduce the performance.

Vehicle Systems 36 Testing and Adjusting

Hydraulic System
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.
Control Valve Pressure Check
(1) Plug (6) Priority Valve.
Vehicle Systems
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).
5. Check the relief valve pressure setting again.
37 Testing and 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.

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.

3. With no load, left and lower the mast and carriage Lift Cylinder Air Removal (FFTL - Secondary Cylinders)
again through four complete cycles. (24) Bleed Screw.

5. Open bleed screws (23 and 24) no more than one

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.
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.).
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.
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.

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.

Lift Cylinder Air Removal (FFTL - Primary Cylinder)

(23) Bleed Screw.

Vehicle Systems 38 Testing and Adjusting

Steering System Air Removal
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.
WARNING
To prevent personal injury, do not operate
vehicle until air is removed. The steering will not
operate correctly until the air is removed.

7. When the oil in the tank is clear(not cloudy), the

NOTICE system is free of air.
To prevent damage to the steering pump, keep the
oil level in the hydraulic tank above the outlet to the 8. Fill the tank to the recommended level.
pump.
Steering System Pressure Check
2. Close the seat switch and turn the key switch on.
Add oil immediately to the tank as needed.

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.

Hydraulic Steering Gear

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.
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.
(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.

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 39 Testing and Adjusting

 WARNING
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
omponents 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 40 Testing and Adjusting

Brake System
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.

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
Reservoir Location
(not shown).
(1) Reservoir.

5. Fill the reservoir again, with the correct fluid, to

1. Fill reservoir (1) with the correct fluid to 12.7 mm
the level explained in Step 1.
(.50 in) from the filler cap. See the Operation And
Maintenance Manual for the correct brake fluid.

Vehicle Systems 41 Testing and Adjusting

Pedal Adjustment Parking Brake Test

The brake pedal must have enough free play to let 1. Drive the lift truck with a rated load up a 15%
the master cylinder piston return to the release incline.
positon and open the relief outlet.

Hydraulic pressure in the brake lines goes back WARNING

through the relief opening and releases the brakes. To prevent personal injury, the operator must be
If there is no pedal free play, the pressure can not ready to use the service brake if the parking
go back through the relief opening, and the brakes brake is not adjusted correctly and the lift truck
will tighten and not release. starts to move.

If there is too much free play, the brake pedal will be 2. Half way up the incline, stop the lift truck with the
low even with the correct brake adjustment. service brakes. Apply the parking brake.

The master cylinder push rod must be adjusted so 3. If the parking brake has the correct adjustment,
the brake pedal has 3.0 to 8.0 mm(.118 ± .315 in) of the lift truck will be held in this position.
free play from the pedals stop to the push rod
contact point with the master cylinder piston. 4. If the parking brake does not hold, do the steps in
Parking Brake Adjustment.
If the pedal free play adjustment is not correct, do
the procedure that follows :

Parking Brake Control Group

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.
EHCS048B
3. Hold rod (2) and tighten nut (3).
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 42 Testing and Adjusting

Hydraulic Pump Motor

Instruction about sensor bearing’s

exchange

Explain the instructions to change the sensor

bearing.

PUMP MOTOR : Look at exploded view of A474016

and related components

1. Unscrew 4 M4 screws

2. Remove the installed sensor

3. Position and push the new sensor into its housing

4. Verify if it’s completely inserted in its housing as,

on the contrary, it could be damaged sa soon as
the screw are screwd.

5. Screw the 4 M4 screws with a tightening torque of

................................................................1.2N•m

Vehicle Systems 43 Testing and Adjusting

 SB4297E00
July 2007

Vehicle System
Disassembly & Assembly

B10R-5, B13R-5, B15R-5, B16R-5

 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.

DOOSAN 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 DOOSAN 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. DOOSAN dealers have the most current
information available.

1
 Index

Hood (with seat) Assembly ....................................5

Overhead Guard ...................................................6
Hydraulic Control Valve .........................................7
Disassemble Hydraulic Control Valve ....................8
Assemble Hydraulic Control Valve.......................11
Hydraulic Pump Motor.........................................13
Hydraulic Pump...................................................15
Accelerator Control Switch ..................................17
Standard Lift Cylinder..........................................18
Secondary Lift Cylinder .......................................20
Primary Lift Cylinder ............................................23
Tilt Cylinder .........................................................26
Steer Sensor Group ............................................30
Steering Wheel....................................................31
Steering Column .................................................31
Steering Gear......................................................33
Assembly & Disassembly ....................................38
Priority Valve.......................................................42
Brake Master Cylinder .........................................43
Disassemble & Assemble Brake..........................44
Steer Wheel, Transfer and Drive motor................44
Control Panel ......................................................46
Drive Axle ...........................................................46
Counterwieght .....................................................47

WARNING
Disconnect batteries before performance of any
service work.

Vehicle Systems 3 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 5 Disassembly And Assembly

Overhead Guard
Remove & Install Overhead Guard

4. Remove 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.

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
8. Install overhead guard (3) in the reverse order of
a hoist as shown.
removal.

Vehicle Systems 6 Disassembly And Assembly

Hydraulic Control Valve 3. Support control valve (1). Remove four bolts (3)
from frame. And remove three bolts (4), nuts and
control value (1) from plate.
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.
Hydraulic oil under pressure can remain in the Refer to the Operation and Maintenance Manual
hydraulic system after the pump motor have for further information.
been stopped. Personal injury can result if the
pressure is not released before any work is End By :
done to the hydraulic system. To prevent
possible personal injury, turn the key switch off a. Install the hydraulic control valve switch group.
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 hydraulic control valve switch group.

1. Drain the hydraulic tank.

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 7 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

1 body.

2 7
8
10
IHCD105P 6

NOTE: For purpose of assembly, put identification

marks on all valve sections.

1. Remove three nuts (1) to separate the valve 11

sections. 9

2. Remove inlet section assembly (2) from the valve

IHCD108P
body.
6. Remove plug (7) and O-ring (8) from the lift
section assembly (6).
4 5
2
7. Remove O-ring (9), poppet (10) and spring (11)
from lift section assembly (6).

IHCD106P 12
13
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 8 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).

26 28

19 24 29
23

27
20
25 21
22 IHCD113P

IHCD111P
14. Remove O-ring (27), poppet (28) and spring (29)
11. Remove the wiper seals (19) and O-rings (20) from tilt section assembly (26).
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 9 Disassembly And Assembly

 15 45
14 44

33

32
34
43

IHCD115P IHCD118P

16. Remove two screws (32), seal plate (33) and tilt 20. Remove side shift section assembly (43) and
spool (34). 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

45
47
46

36

38 37

IHCD116P

18. Remove the wiper seals (35) and O-rings (36).

Check the condition of wiper seals and O-rings IHCD119P
and replace with new ones if needed.
22. Remove relief valve (46) and O-ring (47) from the
NOTE: Remove the spool end (37) from the spool. section assembly (45).
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 23
Do not use caustic (corrosive) materials to clean any
parts in this valve group. Caustic materials will cause
corrosion and damage to parts.
20
25 21
1. Make sure all valve parts are clean and free of dirt. 22

IHCD111P

4 5 4. Install the spring seats (23 and 24), centering

2 spring (22) and seal plate (25) on the lift spool.

5. Compress the spring with spool end (21) and

3 tighten spool end. Torque the spool end to 8 ~ 11
N•m (70 ~ 97 lb•in).

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 N•m (32 ~ 36 lb•ft).
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

IHCD109P IHCD119P

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
6

11 1
9
2
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 15. Install the nuts (1) that hold the valve sections
assembly. together. Tighten the single top nut to torque of 26
~ 32 N•m (19 ~ 23 lb•ft) and two bottom nuts to
torque of 24 ~ 29 N•m (18 ~ 21 lb•ft).
39 38 40
37 End By :

41 a. Install hydraulic control valve.

42

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 N•m (70 ~ 97 lb•in).

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

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 ass’y (2).

1. Prevent brake oil being drained from reservoir by

4. Disconnect cables from UVW terminal.
using tie wrap or equivalent material.
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

6. Disconnect suction hose (3) from priority valve to 9. Support pump motor with straps and move out
control valve. 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 N•m (40 ± 7 lb•ft).

12. Install the hydraulic pump motor and hydraulic

pump in reverse order of removal.

[Caution! When assembling & disassembling]

1. Do not apply any impact on the motor.

2. Ensure encoder (sensor bearing) cable not to be

7. Disconnect bulk hose from hydraulic pump. 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.

b. Close the hood.

8. Disassemble four bolts(4).

Vehicle Systems 14 Disassembly And Assembly

Hydraulic Pump
Disassemble Hydraulic Pump

Start By : 8

a. Remove hydraulic pump.

2
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 9

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
4 if needed.

14
13

EHCD051C

2. Remove O-ring seal (4) from the pump body.

4 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 15 Disassembly And Assembly

Assemble Hydraulic Pump

14
13

7
6

EHCD052C

EHCD055C 4. Install back-up ring (6) and seal (5) in the bushes
(7).
NOTE: When installing seal (13), make sure the lip
of the seal is positioned toward the inside of the pump 5. Install bushes (7) in the pump body.
housing.

1. Install seal (13) in the pump body.

4
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

2
O-ring (9) in the pump body.

8 3

EHCD050C

7. Install the bolts (1), washers (2) and pump cover

(3) onto the pump body. Tighten the bolts for
EHCD053C cover (3) to a torque of 39 to 40 N•m (28 to 30
lb•ft).
3. Install two gears (8) in the pump body.
End By :

a. Install the hydraulic pump.

Vehicle Systems 16 Disassembly And Assembly

Accelerator Control Switch
Remove And Install Accelerator Control
Switch

IOCD014P

1 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

IOCD0012P order of removal.

2. Remove rear floor plate (2).

IOCD013P

3. Remove front floor plate (3).

Vehicle Systems 17 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

EHCD103C

5. Remove screw bleeders (5) and steel ball (6) from

the rod-cover.

Vehicle Systems 18 Disassembly And Assembly

 Assemble Standard Lift Cylinder

7
12

8
10

EHCD104C
11
6. Remove O-ring seal (7) and back up ring (8) from EHCD105C
the rod-cover.
1. Install slide ring (12), back up ring (11) U-packing
(10) and wiper seal (9) on the inside of the
12 rodcover.

10 7

11
EHCD105C 8

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.

EHCD103C

3. Install the steel ball (6) and screw-bleeder (5) onto

the rod cover.

Vehicle Systems 19 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.

2. Remove rod-cover assembly (2) with tool.

Vehicle Systems 20 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
5 4
12

13

14

6 7 EHCD105C

7. Remove wiper seal (12), U-packing (13), back up

IOCD015I ring (14) and slide ring (15) from the rod-cover.

4. Remove wear rings (5), snap ring (7) and cushion

ring (6) from piston (4).

EHCD103C

5. Remove screw bleeders (8) and steel ball (9) from

the rod-cover.

Vehicle Systems 21 Disassembly And Assembly

Assemble Secondary Lift Cylinder
5 4

15

12

13

6 7
14 IOCD015I
EHCD105C

1. Install slide ring (15), back up ring (14) U-packing 4. Install cushion ring (6), snap ring (7) and wear
(13) and wiper seal (12) on the inside of the rings (5) onto the piston (4).
rodcover

10

11

EHCD101C

EHCD104C
5. Install rod (3) with a retaining ring into the cylinder
2. Install back up ring (11) and O-ring seal (10) onto body.
the rod-cover.

9
EHCD100C
EHCD103C
6. Install rod-cover assembly (2) on the cylinder rod
3. Install the steel ball (9) and screw-bleeder (8) onto and tighten using tool.
the rod cover.
End By :

a. Install secondary lift cylinder.*

* Refer to the topic "Assemble Mast" in this module.

Vehicle Systems 22 Disassembly And Assembly

Primary Lift Cylinder NOTE: The following steps are for the installation of
the primary lift cylinder.
Remove And Install Primary Lift
Cylinder

Start By : 1
2

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.

1
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
a. Remove primary lift cylinder.
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 23 Disassembly And Assembly

 Assemble Primary Lift Cylinder
3

EHCD109C 8
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
4 the inside.

2. Install wiper seal (6). Install the seal with the lip
5
toward the outside.

3. Install slide rings (9) in the head assembly.

EHCD110C 4

4. Remove O-ring seal (4) and back-up ring (5) from

the head assembly. 5

6
EHCD110C
7

NOTE: Install the back-up ring with the curved side

contacting the O-ring seal.
8
9 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), U-

packing (8) and slide rings (9) from the head
assembly.

Vehicle Systems 24 Disassembly And Assembly

 3

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 25 Disassembly And Assembly

Tilt Cylinder
Remove & Install Tilt Cylinder

Start By :

a. engage parking lever.

b. Lift mast until it is easy to access to tilt cylinder.

WARNING
If tilt cylinder is removed, the mast can fall. To
2. Remove grease hoses (1) and connector.
avoid possible personal injury, make sure the
mast is securely held in place or supported by a
hoist before removing the tilt cylinder.

c. Disconnect the battery cable.

d. Remove the battery.

3. Remove retainer bolt (3) and pin (4).

1. Disconnect tilt hoses (1).

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
4. Remove snap ring (5) and safety guard (6).
in the tank. Be cautious of hot hydraulic oil when
Remove retainer bolt (7) and pin (8).
any lines are disconnected in the hydraulic
system.
5. Remove tilt cylinder (10).

6. Install the tilt cylinder in the reverse order of

removal.

7. Refer to tilt cylinder information section for

adjusting tilt cylinder.

Vehicle Systems 26 Disassembly And Assembly

Disassemble & Assemble Tilt Cylinders

Start By : 7

a. Remove tilt cyliner.

1 EHCD115C

6. Remove spacer (6) with a O-ring seal and shims

from the cylinder rod (7) if they are installed.

2 7. Loosen the nut and bolt on the rod eye. Remove

EHCD113C cylinder rod (7).

1. Remove cover-rod (1) from the cylinder body.

9
NOTICE
Use extra care not to damage the highly 10
finished surface of the cylinder rod and the bore
of the cylinder body during disassembly and
assembly of the tilt cylinder.

2. Remove rod assembly (2) from the cylinder body.

EHCD116C

5 8. Remove slipper seal (9) and O-ring seal (10) from

4 the piston.
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 27 Disassembly And Assembly

 11
15
12 13

14

EHCD117C EHCD118C

9. Remove O-ring seal (11) and back up-ring (12) NOTE: U-packing (15) should be installed with the
from the cover-rod. 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
15 coverrod as shown.
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 28 Disassembly And Assembly

 5
4
9 3

10

EHCD116C EHCD114C

16. Install slipper seal (9) and O-ring seal (10) on the 19. Position the cylinder rod eye in a vise as shown.
piston.
20. Install cover-rod assembly (5) on the cylinder rod.

21. Install piston assembly (4) onto the cylinder rod.

7 The torque for the nut (3) is 260 ± 25 N•m (190 ±
20 lb•ft).

1
EHCD115C

17. Install cylinder rod (7) and shims. Tighten the nut
and bolt on the rod eye to a torque of 95 ± 15 N•m
(70 ± 10 lb•ft). 2

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 N•m (200 ± 25 lb•ft).

End By :

a. Install tilt cylinder.

Vehicle Systems 29 Disassembly And Assembly

Steer Sensor Group
Remove And Install Steer Sensor Group

Start By :

a. Raise the hood.

1. Disconnect harness connector.

5. Adjust clearance 2~3 pitches.

End By :

a. Close the hood.

b. Set “Sensor Initial setting”.

2. Remove two blots (1) and washers.

3. Remove steering angle sensor (3) from plate (2).

4. Install the tilt cylinder in the reverse order of

removal.

Vehicle Systems 30 Disassembly And Assembly

Steering Wheel Steering Column
Remove And Install Steering Wheel Remove Steering Column

Start By :

a. Remove steering wheel.

1

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 N•m (60 ± 5 lb•ft).

5. Install cap (1) on the steering wheel.

EHCD127C

3. Remove horn switch (6) from the steering column.

Vehicle Systems 31 Disassembly And Assembly

 8

7
15

18

14 17

EHCD128C

4. Remove two bolts (7), washers and bracket with a 7. Remove screw (14) and handle (15).
directional switch (8) from the support assembly. 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.

12

11

10 13
EHCD129C

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 32 Disassembly And Assembly

Steering Gear
10
7 9
6
Disassemble & Assemble Steering Gear
(Pump)

Start By :

a. Remove steering gear (pump). 4

8 3
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).
1
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

1. Remove the elbows (1) from pump body (2). 12 11

5
4
14
13
3 EHCD137C

2 5. Remove suction valve balls (12) and pins (11).

6. Remove screw (13) and check valve ball (14).

EHCD135C

2. Remove seven bolts (5) from gerotor housing (3)

and cap (4). 2

NOTICE
Make a note of the position of special bolt with
a pin. It is locatedmat a mark in line with check 16
valve.

EHCD138C 15

3. Separate housing (3) and cap (4) from pump body

7. Remove O-ring seal (15) from pump body (2).

8. Remove sleeve (16) from pump body (2).

Vehicle Systems 33 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 EHCD003B

follows :
a. Remove pin (18) from spool (17) and sleeve 13. Remove plug (31) and spring (32) from the pump
(16). body (2).
b. Remove spool (17) from sleeve (16).
c. Remove two bearing races (19), (20) and 14. Remove poppet (34) and relief valve housing (35)
bearing (21) from spool (17). from the pump body.
d. Remove six springs (23) and ring (22) from
spool (17).

25
37 36

26

24
EHCD143C

EHCD141C 15. Remove plug (36) and washer (37) from the pump
body.
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 34 Disassembly And Assembly

 25

26
37 36

24

EHCD143C EHCD141C

16. Install washer (37) and plug (36) into the pump 20. Install dust seal ring (26). Install O-ring seal (24)
body. with king-ring (25) into pump body (2).

22
32 21
2 19
35

33
34
23
20 18
EHCD003B EHCD140C

17. Install housing (35) and poppet (34) into the pump
body.
18. Install spring (32) and plug (31) into pump body
(2). Tighten plug (31) to a torque 11.3 N•m (100
lb•in).
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).

16
17
28 27

EHCD142C

23
19. Install washer (28) and plug (27) into pump body
(2) Tighten plugs to a torque 30 N•m (22 lb•ft). 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 35 Disassembly And Assembly

 2

16

EHCD138C 15 EHCD004B

24. Install sleeve (16) into pump body (2).

25. Install O-ring seal (15) into pump body (2). 10

7 9
6

12 11
4
8 3

EHCD136C

14 28. Install plate (6) onto pump body (2).

13
EHCD137C

26. Install check valve ball (14) and screw NOTICE

(13).Tighten the screw (13).
27. Install suction valve balls (12) and pins (11) in
their original positions into the pump body.
Make sure the notch of shaft (7) properly seats on
pin (18) when installed into body (2) and spool (17).
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 36 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

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 N•m (125 ± 25 lb•in).
b. Tighten bolts (5) in correct sequence to a
second torque of 28.2 ± 2.8 N•m (250 ± 25
lb•in).

End By :

a. Install steering pump.

Vehicle Systems 37 Disassembly And Assembly

Assembly & Disassembly
Hydraulic Steering Motor

Vehicle Systems 38 Disassembly And Assembly

Special Tools

SJ 151-9000-12.

Main holding tool (horse hole):

Code No. SJ151-9000-1.

SJ 151-9000-14.

Holding tool for motor with square mounting flange:

Mandrel: Mandrel: Code No. SJ 151-9000-12.
Code No. Code NO. 151-2097.10
SJ151-0414. SJ 151-9000-7 or Holding tool for MRWN.
SJ151F9000-7 Code No. SJ 151-9000-14.

Dismantling

Item Part to remove Comments

10 Castellated nut
11 Washer
12 Parallel key
Put the motor in a holding tool, with the output shaft downward.
28 Seal plugs
For end port version use 10 mm hexagon socket spanner.
Drain plug, washer
25, 24 Use a 17 mm spanner socket.
(if present)
21, 20 Screws, washers Use a 13 mm spanner socket.
19 End cover Remove end cover sideways
Gear wheel set O-rings (2
18, 16 Keep fingers under the gearwheel set to prevent the parts from falling out.
off)
14 Cardan shaft
17, 16 Distributor plate O-ring

Vehicle Systems 39 Disassembly And Assembly

 Item Part to remove Comments
Motors with integrated spigot flange:
Place the motor housing on the work bench and press the shaft out of the
motor housing.
Shaft and bearings should normally not be removed from OMRWN.
13 Output shaft
However, if necessary for inspection and cleaning, remove the shaft from the
housing front end. The rear bearing can thus remain in the housing.
After this, turn the motor.

Use Torx-spanner type T30, 9 mm screwdriver or 4 mm hexagon socket

1 Screws (6 off)
spanner.
2 Washer Only OMRWN
4 Splgot flange

Motors with integrated spigot flange:

Remove bearing and bearing race from the motor housing.
O-ring,
6, 7
bearing race
Motors with separate spigot flange:
Use a 2 mm screwdriver.

8 Needle bearing

Motors with integrated spigot flange:

With mandrel and plastic hammer, carefully knock out the shaft seal.
5 Shaft seal
3 Dust seal Motors with integrated spigot flange:
Knock out the shaft seal/dust seal with a plastic hammer.
Use mandrel SJ 151-9000-7 or SJ 151F9000-7

Only OMR/OMRWN with Ø32 mm/28.5 mm tapered shaft.

9 Bearing race
26 Check valves (2 off)
Use a 2 mm screwdriver.
Only OMR with check valves.
Pull the check valve out with, for example, a ground (shortened) 3.5 mm
screw tap.

Cleaning

Cleaning
Clean all parts carefully with low aromatic kerosene.

Inspection and replacement

Check all parts carefully and replace if necessary.

Lubrication
Before assembly, lubricate all parts with hydraulic oil
and grease rubber parts with Vaseline.

Vehicle Systems 40 Disassembly And Assembly

Assembly

Item Part to install Comments

Place the motor housing in the holding tool with the flange upwards.
Only OMR with check valves
26 Check valves (2 off) Grease the check valves (fitted with new O-rings) and fit them in their bores with
light blows using plastic hammer.
9 Bearing race Only OMR/OMRWN with Ø32 mm/28.5 mm tapered shaft.
Motors with integrated spigot flange:
Lubricate the shaft seal on the outside with hydraulic oil. Fit the shaft seal
correctly onto mandrel SJ 151-0414 and carefully press the shaft seal into
position in the motor housing.
5 Shaft seal
Motors with separate spigot flange:
Knock the seal into position in the spigot flange. Check that the seal lies against
the cover recess. Use mandrel SJ 151-9000-7 or SJ 151F9000-7
Place the dust seal ring in the spigot flange and knock it into position with a
3 Dust sealring plastic hammer and appropriate mandrel.
SJ 151-9000-7 or SJ 151F9000-7

Motors with integrated spigot flange:

Fit bearing and bearing race onto the shaft and mount together with the shaft.
Bearing race
7, 6
O-ring Motors with separate spigot flange:
Grease the O-ring with Vaseline and fit the bearing race and O-ring into the
spigot flange.

8 Needle bearing
4 Spigot flange Turn so that the holes line up.
2 Washer Only OMRW N

Tightening torque
Torx screws M6: 5-8 Nm [45-70 lbf•in]
Slotted screws M6: 5-8 Nm [45-70 lbf•in]
1 Screws(6 off)
Hexagon socket screws M5: 5-10 Nm [45-70 lbf•in]
Hexagon socket screws M5: 12-15 Nm [45-70 lbf•in]
After this, turn the motor.
Out put shaft

Grease the journals with hydraulic oil.

The rear shaft end most be marked before fitted. The mark must be positioned
vertically above a commutation slot leading up to the front annular channel.
13
For OMRW N, guide the shaft into the motor housing back with the rear needle
bearing fitted on the shaft. Bring the shaft in line with the back of the motor by
gently tapping the shaft with a plastic hammer. Check that the shaft rotates
easily.

151-1572.10
16 O-ring Grease the O-ring and put it in the O-ring groove of the housing.
17 Distributor plate Turn the distributor plate so that the holes line up.

Vehicle Systems 41 Disassembly And Assembly

Priority Valve Disassemble & Assemble Priority Valve

Remove & Install Priority Valve Start By :

Start By : a. Remove priority valve

a. Remove floorplate. NOTE: Mark the positions of all components for

purposes of reassembly.

WARNING
Hydraulic oil under pressure can remain in the
hydraulic system after the pump motor have
been stopped. Personal injury can result if the
1
pressure is not released before any work is 2
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, 4
removed or adjusted. Always move the lift truck 3
to a clean and level location away from the EHCD145C
travel of other machines.
1. Remove the spool assembly from valve body as
follows :
NOTE: For purposes of reassembly, put a. Remove plug (1). Check the condition of the
identification marks on all lines, tubes and hoses bush (2). Replace with new bush if worn or
before any disconnections are made. damaged.
b. Remove spool (3).
c. Remove spring (4).

1. Disconnect four hydraulic lines (1) from priority EHCD146C

valve (2). Plug and cap all openings to prevent
contamination and debris from entering the
system.
2. Support valve (2). Remove the two bolts (3) and
priority valve and mount assembly (2).
3. Install priority valve (2) in the reverse order of
removal.
End By :
a. Install the floorplate.
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.
3. Assemble the priority valve in the reverse order of
disassembly.
End By :
a. Install the priority valve.

Vehicle Systems 42 Disassembly And Assembly

Brake Master Cylinder
Remove And Install Brake Master 7 8
4
Cylinder 6
5

1 2. Disconnect hose (4) and tube (5) from the master

cylinder.

3. Remove the cotter pin and pin (6) from the clevis
IHCD120P and brake pedal assembly.

4. Remove two bolts (7) and master cylinder (8) from

the bracket.

5. Install the brake master cylinder in the reverse

order of removal.

2
6. Fill the brake reservoir and master cylinder with
brake fluid. See the Operation And Maintenance
Manual.

7. Bleed the brake system, and if necessary, adjust

3 the pedal free level. See Brake System Air
IHCD121P Removal And Pedal Adjustment in Testing And
Adjusting.
1. Remove floor mat (1) and floor plates (2), (3).

Vehicle Systems 43 Disassembly And Assembly

Disassemble & Assemble Brake Steer Wheel, Transfer and Drive
motor
Master Cylinder
Remove Steer Wheel
Start By :

a. Remove master cylinder.

2

2
1

1. Raise the rear of the machine and support with

wooden block as shown.

1. Remove head (1) and boot (2). 2. Remove five nuts (1).

2. Remove snap ring (3) from master cylinder. NOTE: Tighten the nuts (1) to a torque of 190 N•m
(140 lb•ft) when installing.

7 15 9 3. Remove steer wheel (2).

4 5
13 3

14
6 8 11 10
12

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 44 Disassembly And Assembly

Remove Transfer & Drive Motor

Start By :

a. Remove Counterweight. See removal of

Counterweight Section.

b. Remove steer wheel

3. Remove washers and bolts (4).

NOTE: Tighten the bolts (4) to a torque of 80 N•m

(59 lb•ft) when installing.

1 4. Remove transfer(5).

1. Disconnect cables from UVW terminal (1).

2. Remove six nuts (2). And disassemble Drive

motor.(3)

NOTE: Tighten the socket bolts (2) to a torque of 23

N•m (17 lb•ft) when installing.

Vehicle Systems 45 Disassembly And Assembly

Control Panel Drive Axle
Remove And Install Control Panel Remove & Install Drive Axle

(AC) NOTE: The procedure for removing and installing

the drive axle is the same for both sides.

WARNING
Battery voltage and high ampere are present.
Injury to personnel is possible. The power unit
must be discharged before any contact with the 2
control panel is made. Disconnect the battery
and discharge the power unit.
1

1. Raise the hood. Remove the side panels.

IOCD027P

1. Loosen 8 nuts (1) and put a jack or wooden block

under the lift truck.

2. Remove eight nuts (1) and drive tire (2).

2. Disconnect the main connectors.

3. Disconnect brake lines (3) and parking rods (4)

3. Remove the motors’ cables and battery cables.

4. Loosen six bolts and remove the control board.

5. Remove control panel assembly from the lift truck.

6. Install the control panel in the reverse order of

removal.
4. Remove six bolts and washers (5).

5. Install the steering column in the reverse order of

removal.

Vehicle Systems 46 Disassembly And Assembly

NOTE: Tighten six bolts and washer(5) to a torque Counterwieght
of 300 N•m (222 lb•ft) when installing.
Remove And Install Counterweight
NOTE: Tighten eight bolts (2) to a torque of 190
N•m (140 lb•ft) when installing.
Start By :

a. Remove battery.

1. Install two forged eyebolts at the top of the

counterweight. Attach a hoist.

2. Remove four bolts (1) and washers from the

counterweight (2).

3. Remove counterweight (2). The approximate

weight of the counterweight is as follows:

B10R-5.........................................500 kg (1102 lb)

B13R-5.........................................680 kg (1500 lb)
B15R-5.........................................750 kg (1653 lb)
B16R-5.........................................840 kg (1851 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 400 N•m (296 lb•ft). Apply the
Loctite NO.262 on the bolt thread.

End By :

a. Put the battery.

Vehicle Systems 47 Disassembly And Assembly

 SB4298E00
July 2007

Mast System
Disassembly & Assembly
Testing & Adjusting

B10R-5, B13R-5, B15R-5, B16R-5

 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

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.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DOOSAN 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 DOOSAN 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. DOOSAN dealers have the most current
information available.

1
 Index

Disassembly & Assembly

Forks......................................................................5
Backrest .................................................................5
Carriage .................................................................6
Mast .......................................................................9

Testing & Adjusting

Chain Adjustments ...............................................22

Chain Wear Test ..................................................22
Carriage and Mast Height Adjustment............23
Forks Parallel Check......................................23
Tilt Cylinder Alignment..........................................24
Drift Test .......................................................24
Tilt Cylinder Adjustment........................................25
Lift & Tilt Mounting Group Adjustment...................26
Mast mounting Group Adjustment.........................26

Mast System 3 Index

Disassembly & Assembly

Forks Backrest

Remove & Install Forks Remove & Install Backrest

1. Fasten a hoist to the backrest. Remove bolts (2)

that fasten the backrest to the carriage.

2. Remove backrest (1).

Backrest weighs 32 kg (71 lb).

3. Install backrest (1) in the reverse order of

removal.

1. Lift fork pin (1).

2. Use a suitable C-clamp, strap and hoist to support

the fork as shown.

3. Slide the fork to slot (2) in the middle of the

carriage.

4. Remove the fork. The weight of the fork is 35 kg

(77 lb).

5. Repeat steps 1 through 4 for the remaining fork.

6. Install the forks in the reverse order of removal.

7. Put the forks in position. Lower both fork pins (1)

to lock the forks in position.

Mast System 5 Disassemble & Assembly

Carriage
Remove & Install Carriage

Start By:

a. Remove forks.

b. Remove backrest.

4. Remove two nuts (6).

Remove carriage stop bolt (7).

1. Remove two bolts (1) from the cross head (2).

2. Remove cross head (2) from the cylinder rod (3).

5. Raise the inner mast to pull out carriage as

shown.
3. Remove hoses (5).
6. Remove carriage from bottom of inner mast (9).
Carriage weighs 64kg (141 lb).

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.

Mast System 6 Disassemble & Assembly

 End By:

a. Install backrest.

b. Install forks.

Disassemble Carriage

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
±30 N•m (220±22 lb•ft).

1. Remove the roll pins and pins (2) to disconnect

chains (1).

10. Install hoses (5).

2. Remove lower roller bearings (3) and the shims

from the carriage.

11. Install cross head (2) to cylinder rod (3).

12. Install hose guard (2) and bolts (1) to a torque of

8±2 N•m (6±1.5 lb•ft).

Mast System 7 Disassemble & 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.

CARRIAGE BEARING CHART

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)

3. Remove screw (5) and washer (4). * Permissible tolerance of ± 0.08 mm (.003in)
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
side-roller 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.

Use the procedure that follows to adjust carriage

load bearings. 2. Find narrowest point by ruler on the inner mast in
the area where the bearings make contact.

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
Carriage Adjustment
(A)] between the bearings and the narrowest
(3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw.
point of inner mast.
(7) Side-roller bearings. (8) Lower bearings. (9) Pin-adjust.
(10) Bolt. (A) Zero clearance.
4. Do step 2 through 3 for other sets of bearings.
(B) 4.0 to 6.0 mm. (.157 to .242 in) clearance.
(C) Minimum clearance. (D) 4.5 ± 0.5 mm

Mast System 8 Disassemble & Assembly

 Mast
Remove & Install Mast

Start By:

a. Remove forks.
Move the truck to the place where pit is set up.

5. Tighten screw (3) that holds the top and middle

bearings (4) to the carriage to a torque of 34±7
N•m (25±5 lb•ft).

1. Support mast assembly (2) with a hoist and strap

(1) as shown.

6. Position chains (6) on the carriage. Install pins (5)

and the roll pins.

End By:

a. Install carriage, raise the inner mast and insert the

carriage from the bottom of inner mast.

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 B10/13/15/16R-5 see article 6 prior to

disconnecting hose (3).

Mast System 9 Disassemble & Assembly

 6. Use the hoist to remove mast assembly from the
truck.

7. Install the mast in the reverse order of removal.

End By:

a. Install forks.

WARNING
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).

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.

5. B10/13/15/16R-5 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) are removed.

Mast System 10 Disassemble & 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.

4. Disconnect and remove chains (5) from the

bottom of the mast.

1. Remove hoses (1) along with the hose support

clamps (2).

5. Remove tube ass’y (9) and bolt (10) from

stationary mast and disconnect regulator (8) from
secondary cylinder.

2. Remove hose sheave (3).

3. Remove chain nut (4) from the top of the mast

(each side).

Mast System 11 Disassemble & Assembly

6. Remove top cylinder retainer bolts (11) from each
side of the mast. 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.

7. Remove cylinder retainer brackets (12) from each

cylinder.

10. Remove bearing mounting pins (15).

11. Check the condition of the bearings (16) located

in each of the mast mounting bracket.
Replace the bearings (16) with new if worn or
damaged.

8. Remove secondary cylinders (13). Each cylinder

weighs 38 kg (84 lb).

Mast System 12 Disassemble & Assembly

12. Move inner mast channel (20) downward. 17. Move intermediate mast channel (23) downward.

13. Remove bearings (17) and shims from the 18. Remove bearings (21) and the shims from the
intermediate mast channel (23). stationary mast channel.

14. Remove nylon pads (18) and shims. 19. Remove nylon pads (22) and the shims.

15. Remove bearings (19) and shims from the inner 20. Remove bearings (24) and the shims from the
mast channel (20). intermediate mast channel (23).

16. Fasten nylon straps and hoist to inner channel 21. Fasten nylon straps and a hoist to the
(20). Remove inner channel. The weight of the intermediate mast channel (23). Remove
inner channel is 110 kg (243 lb). intermediate mast channel. The intermediate
mast channel weighs 112kg (247 lb).

Mast System 13 Disassemble & 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.

A. Lower Bearing Adjustment of Intermediate 4. Find narrowest point by ruler on the stationary
Mast 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.

Mast Adjustment Lower Bearings

(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance. 5. Lifting by crane, insert intermediate mast into
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims. 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
be aring 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 ± 0.08 mm (.003 in)

Mast System 14 Disassemble & Assembly

6. Install 1mm shim and bearing (1) of stationary 9. Install 1mm shim and bearing (4) of intermediate
upper basically. lower basically.

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.

8. Install pads (3) to each side.

Refer to “Upper Pad Adjustment” of Disassebly & Mast Adjustment Lower Bearings
Assembly. (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).

Mast System 15 Disassemble & Assembly

10. Make sure intermediate mast lower bearings are 13. Install 1 mm shim to each bearing of stationary
properly shimmed in the stationary mast by mast upper basically. Bearing should be
rolling up and down and moving intermediate selected D580006 undersize bearing.
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.

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 14. Install 1mm shim and bearing (4) of intermediate
properly shimmed. There is to be contact zero lower basically.
clearance (C) between intermediate lower
bearings and stationary channel at
approximately 420 mm (16.5 in) channel lap.

B. Upper Bearing Adjustment of Stationary Mast

12. Lift by crane, insert intermediate mast into

stationary mast from the upper side.

Mast System 16 Disassemble & Assembly

 bearings. 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.

C. Upper Pad Adjustment

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.

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
15. Make sure stationary mast upper bearings are intermediate masts with the masts at full
properly shimmed by rolling up and down and extension. Lift by crane, and pull out
moving intermediate mast to right and left. If intermediate mast from stationary mast and
clearance between both masts can be detected, insert the shims behind each pad. In case of
pull out the intermediate mast from the standard and full free mast, the pads of
stationary mast with crane and add shim 0.5 mm stationary upper can be easily extruded by
or 1 mm to both stationary upper bearings. pulling down the inner mast from the bottom of
stationary mast.
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

Mast System 17 Disassemble & Assembly

D. Lower Bearing Adjustment of Inner Mast

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).

Mast Adjustment Lower Bearings

(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.

18. Select lower bearings (3) and (4) from the chart
to obtain minimum clearance (B) between
bearing and channel leg for full channel length. 20. Lifting by crane, insert inner mast (11) into
Use same bearing on left and right side. 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)

* Permissible tolerance L0.08mm (.003in)

21. Install 1 mm shim and bearing (13) of

intermediate upper basically.

Mast System 18 Disassemble & Assembly

 E. Upper Bearing Adjustment of intermediate
Mast

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.

25. Put a small amount of clean grease on mounting

22. Install 1mm shim and bearing (14) of inner lower bearing. Install mounting pins and screw into
basically. mast mounting brackets.
Refer to Mast Mounting Group Adjustment of
Testing & Adjusting.

26. If the bearings were removed from the tilt

cylinder pin bores (15), install new ones.

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 27. Install secondary cylinders (16) into the
inner mast is stuck and cannot move by rolling stationary mast.
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.

Mast System 19 Disassemble & Assembly

28. Install secondary cylinder mounting brackets 31. Connect chains (25) at the bottom of the mast.
(17) over the secondary cylinders.

32. Connect chains (26) at the chain bracket of

29. Install top cylinder retainer bolts (18) for the stationary mast upper.
secondary cylinders.
33. Install sheave (27) of lift hose.

33. Install sheave (27) of lift hose.

30. Install regulator (22) to secondary cylinder and

tube ass’y (23) and bolts (24) to stationary mast. 34. 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.

Mast System 20 Disassemble & Assembly

Testing & Adjusting 2. Select upper bearing from the chart to obtain
minimum clearance (C) between bearings and
channel leg for full channel length. Use same
Carriage Adjustment bearing at all two locations. (For G20SC-5,
GC20SC-5, B20T, D20SC-5, and B20X, bearings
NOTE: The standard, Full Free Lift and Full Free are same with upper, middle 4 locations.)
Triple Lift carriage load bearings are all adjusted the
same way. The Full Free Triple Lift carriage is
shown in the following illustrations. MAST And Carriage Bearings
Part No. Bearingsize Bearing O.D.*
To make the carriage clearance adjustments,
D580006 Undersize 98.5 mm (3.878 in)
carriage must be removed from the mast.
D580007 Standard 99.0 mm (3.898 in)
Use the procedure that follows to adjust carriage D580008 Oversize 99.5 mm (3.917 in)
load bearings.
* Permissible tolerance of ± 0.08mm (.003in)

3. Equally shim both sides until contact (A) is made

(zero clearance) between bearings and inner
mast at narrowest point

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. Torque for screw........... 34 ± 7 N•m (25 ± 5 lb•ft).

6. Refer to “Carriage Assembly* of Disassembly &

Assembly.

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 ± 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.

Mast System 21 Testing & Adjusting

Chain Adjustments 2. Make adjustments to chain anchor nuts (1) or
bolts (2) for equal tension of the mast and
Chain Adjustment Check carriage chains.

3. Put LOCTITE NO.242 Thread Lock on the

threads of the locknuts after the adjustment is
completed.

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
Chain Adjustment (2) Chain Anchor Bolts.

If the tension is not the same on both chains, do the

procedure that follows:
WARNING
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.
Chain Wear Test
Chain wear test is a measurement of wear of the
chain links and pins. Do the steps that follow to
check chain wear.
1. Lift the mast and carriage enough to put tension
on the lift chains.
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 X 100

158.8

WARNING
Do not put a lift truck into service if the chain
wear indication is 2% or more. A reading of 2%
Inner Lift Chains or more could cause damage or injury to
(1) Chain Anchor Nuts. persons.

1. Lift the mast and carriage and put blocks under

the mast and carriage to release the tension from 4. If the chain wear indication is 2% or more,
the lift chains. replace the lift chain.

Mast System 22 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.
2. Lower the carriage completely.
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. If not parallel, determine which one is defective

and replace it.

Forks Parallel Check

(Typical Example)
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>
B10/13/15/16R-5...................... 18 mm (0.708 in)

<FFL & FFTL>

B10/13/15/16R-5...................... 32 mm (1.259 in)

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.

Mast System 23 Testing & Adjusting

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
Tilt Angle Check (Typical Example)
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.
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.
Mast System
Drift Test
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:
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.
24 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. Measure any drift of the carriage for a ten minute Tilt Cylinder Adjustment
period. Drift for all models shall not exceed 100.0 (1) Pivot eye. (2) Bolt. (3) Rod.
mm (4.00 in).

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 miN•mum length from the
WARNING end of rod to the rear face of eye is 16 mm.
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.

To correct the tilt angle or tilt cylinder length, an

adjustment must be made to the tilt cylinder as
3. Tighten bolt (2) and the nut to a torque of 95± 5
follows :
N•m (70±10 lb•ft).

Mast System 25 Testing & Adjusting

Lift & Tilt Mounting Group (1) With chains adjusted for equal tension, run mast
to full lift. If mast does not kick (move) to one
Adjustment 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.

(2) Install bearing outer race to a depth of (F) .........

..............................4.5±0.8 mm (.177±.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.

Mast mounting Group Adjustment

2

1. Install roll pin (1) to a depth 2 ~ 3 mm (0.079 ~

0.118 in) from surface of bearing (2).

2. Apply the crean grease to a surface of bearing.

3. Apply Loctite No242 to bolts and tighten with a

torque 180±20 N•m (130 ± 15 lb•ft).

Mast System 26 Testing & Adjusting

 SB4299E00
July 2007

Hydraulic Schematic
B10R-5, B13R-5, B15R-5, B16R-5
 HYDRAULIC SCHEMATIC
MODEL : B10/13/15/16R-5

AC Type Main Relief Valve Pressure Auxiliary Relief Valve Pressure

24 [V] ± 250 kPa ± 35 psi ± 250 kPa ± 35 psi

B10/13R-5 Min. 360[A] 15,900 2,306

14,000 2,040
B15/16R-5 Max. 380[A] 17,500 2,538

D500097
 SB4300E01
May. 2008

Electric Schematic
B10R-5, B13R-5, B15R-5, B16R-5 (AC 24V)
WIRING SCHEMATIC - ELECTRIC
MODEL : B10/13/15/16R-5 (AC 24V)

A474000-02
ELECTRIC SCHEMATIC
OPTION LIGHT
 SB2351E01

Operation &
Maintenance Manual
FORKLIFTS
B10R-5, B13R-5
B15R-5, B16R-5

Original Instruction

1207
 Table of Contents

Table of Contents
Information Section Maintenance Section

Foreword .................................................................2 Inspection, Maintenance and Repair of Lift Truck

Safety Section
Important Safety Information....................................4
Safety ......................................................................5
Warning Signs and Labels .......................................5
General Hazard Information.....................................9
Lift Chains..............................................................10
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 (If Operator Restraint
System Equipped) .................................................28
Forks ..................................................................... 68
Tire Inflation Information........................................ 72
Torque Specifications............................................ 73
Lubricant Specifications ........................................ 75
Battery Discharge Indicator ................................... 77
Battery................................................................... 78
Cold Storage Applications ..................................... 80
Lubricant Viscosities and Refill Capacities ............ 81
Maintenance Intervals ........................................... 82
When Required ..................................................... 83
Every 10 Service Hours or Daily............................ 90
First 50 - 100 Service Hours or a Week................. 96
First 250 Service Hours or a Month ....................... 98
Every 250 Service Hours or Monthly ..................... 99
Every 500 Service Hours or 3 Months ................. 103
Every 1000 Service Hours or 6 Months ............... 108
Every 2500 Service Hours or 15 Months ............. 116

General Section
Environment Protection Section
Declaration of Conformity ......................................29
Specifications.........................................................30 Environment Protection ....................................... 117
Noise and Vibration ...............................................32
Capacity Chart .......................................................33
Serial Number........................................................34 Index Section
Operator’s Warning and Identification Plate...........35
Index ................................................................... 118

Operation Section

Operator’s Station and Monitoring Systems...........37

Lift Truck Controls..................................................44
Service Brake Pedal ..............................................44
Before Operating the Lift Truck ..............................48
Lift Truck Operation ...............................................51
Mono-Ped Control System (Option) .......................54
Finger Tip (Option).................................................55
Operating Techniques............................................58
Parking the Lift Truck .............................................62
Lift Fork Adjustment ...............................................64
Storage Information ...............................................65
Transportation Hints ..............................................66
Towing Information ................................................67

1
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.
This manual should be stored in the operator's
Read and understand the basic precautions listed in
compartment in the literature holder or seat back
the Safety Section before operating or performing
literature storage area.
lubrication, maintenance and repair on this lift truck.
This manual contains safety, operation,
transportation, lubrication and maintenance Operator Restraint System (If Equipped)
information. This manual contains safety, operation and
maintenance information for the DOOSAN operator
Some photographs or illustrations in this publication restraint system. Read, study and keep it handy.
show details or attachments that can be different
from your lift truck. Guards and covers might have
been removed for illustrative purposes. WARNING

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.
Your DOOSAN 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 DOOSAN
operator restraint system.

Whenever a question arises regarding your lift truck,

or this publication, please consult your DOOSAN Photographs or illustrations guide the operator
dealer for the latest available information. through correct procedures of checking, operation
and maintenance of the DOOSAN 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 DOOSAN operator restraint
system can minimize injuries. The DOOSAN
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.

2
 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.
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.
Note that DOOSAN 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.

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".

3
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.

DOOSAN 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 DOOSAN 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. DOOSAN dealers have the most current
information available.

4
 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.
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.
DOOSAN lift trucks are manufactured according to
the regulations and standards laid down in EU
Machinery Directive 98/37/EC and EMC directive
2004/108/EC. Please refer to the Directives 89/655/
EC and 89/391/EC and its amendments for the safe
use of DOOSAN lift trucks.
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.
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

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
DOOSAN Lift Truck dealers.

This label also provides allowable lift truck capacity

information.

5
Safety Section

General Warnings to Operator 17. Parking-Lower lifting mechanism to floor. Put

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 :
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.
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.
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.
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.
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.

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 equipped with overhead
guard or equivalent protection. Where load
requires it, use load backrest extension. Use
extreme caution if operating without these
devices.

6
 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
No Standing On Forks Warning, No Warning
Standing Under Forks Warning
WARNING
WARNING Operation without this device in place may be
hazardous. This guard conforms to
Do not stand or ride on the forks. Do not stand A.N.S.I.B56.1 and F.E.M. Section IV. This design
or ride on a load or pallet on the forks. Do not has been tested with an impact of appropriate
stand or walk under the forks. value.

IB9O004P
Located on the lift cylinder.
Located on the Overhead Guard.

7
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
Located beside the operator's station. cause the risk of serious injury or death.

Parking Brake Warning

WARNING

When leaving machine apply parking brake!

Parking brake is not automatically applied.

Located on the top left side of the cowl.

8
 Safety Section

Battery Disconnect Before Servicing General Hazard Information

Warning

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-)

Attach a "Do Not Operate" or similar warning tag to

start switch or controls before servicing or repairing
the lift truck.

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.

Wear a hard hat, protective glasses and other

protective equipment as required by job conditions.

Know the width of your attachments so proper

clearance can be maintained when operating near
Seat Switch Warning fences, boundary obstacles, etc.

Do not wear loose clothing or jewelry that can catch

WARNING on controls or other parts of the lift truck.

Install any seat to this seat frame. Switch must Keep the lift truck, especially the deck and steps,
shut off all power when operator is not seated. free of foreign material such as debris, oil tools and
other items which are not part of the lift truck.

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.

Always use the overhead guard. The overhead

guard is intended to protect the lift truck operator
from overhead obstructions and from falling objects.

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).

9
Safety Section

Do not raise loads any higher than necessary and Lift Chains
never raise a load higher than 1830 mm (72 in) with
the overhead guard removed.

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.
Do not drive lift truck up to anyone standing in front
of an object.
Obey all traffic rules and warning signs.
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.
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.
Inspect to be sure that chain link pins do not extend
outside of the bore hole.
If any single link pin is extended beyond its
connecting corresponding link, it should be
suspected of being broken inside of its bore hole.
Inspect the chain anchor and the anchor links for
wear.

Do not allow unauthorized personnel to ride on the
forks or any other part of the lift truck, at any time.
When working in a building or dock, observe floor
load limits and overhead clearances.
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.
Never put maintenance fluids into glass containers.
Use all cleaning solutions with care.
Do not use steam, solvent, or high pressure to
clean electrical components.
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.
For any checkup, repair, adjustments, maintenance
and all other work concerning your forklift truck,
please contact your DOOSAN 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 DOOSAN spare parts waive
any liability by DOOSAN.

Report all needed repairs.

10
 Safety Section

Operation Information Make sure the lift truck horn, lights, backup alarm (if
equipped) and all other devices are working
properly.
Mounting and Dismounting
Mount and dismount the lift truck carefully. Check for proper operation of mast and
attachments. Pay particular attention to unusual
Clean your shoes and wipe your hands before noises or erratic movement which might indicate a
mounting. problem.

Use both hands face the lift truck when mounting Make sure service and parking brakes, steering,
and dismounting. and directional controls are operational.

Use the handgrips for mounting and dismounting.
Do not try to climb on or off the lift truck when
carrying tools or supplies.
Do not use any controls as handholds when
entering or leaving the operator's station.
Make sure all personnel are clear of lift truck and
travel path.
Refer to the topic "Lift Truck Operation" in the
"Operation Section" of this manual for specific
starting instructions.

Never get on or off a moving lift truck. Never jump Starting the Lift Truck
off the lift truck.

Keep hands and steering wheel free of slippery

material.

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.

Adjust the seat so that full brake pedal travel can be

obtained with the operator's back against the seat
back.
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.
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.
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.
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.
An operator must constantly observe his lift truck
for proper operation.

11
Safety Section

Operating the Lift Truck
Always keep the lift truck under control.
Obey all traffic rules and warning signs.
Never leave the lift truck with the engine operating,
or with the parking brake disengaged.
Operate the engine only in a well ventilated area.
Always use overhead guards except where
operation conditions do not permit. Do not operate
lift truck in high stacking areas without overhead
guards.
When stacking, watch for falling objects. Use load
backrest extension and overhead guard.
Refer to the topic "Operation Techniques" in the
"Operation Section" of this manual.

Lower the mast, with or without load, before turning

or traveling. Tip over could result. Watch out for
overhead obstructions.
Always observe floor load limits and overhead
clearance.
Start, turn, and brake smoothly. Slow down for
turns, grades, slippery or uneven surfaces.
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 stunt ride or indulge in horseplay.
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.
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.
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.

Always look and keep a clear view of the path of z Move the direction control lever to NEUTRAL.
travel.
z Engage the parking brake.
Travel in reverse if load or attachment obstructs
visibility. Use extreme caution if visibility is z Turn the key switch off and remove the key.
obstructed.
z Turn the disconnect switch to OFF (If equipped).
Stay in designated travel path, clear of dock edges,
ditches, other drop- z Block the drive wheels when parking on an
offs and surfaces which cannot safely support the incline.
lift truck.

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

Maintenance Information
Perform all maintenance unless otherwise specified
as follows :
z Park the lift truck in authorized areas only.
z Park the lift truck level, with the forks lowered
and the mast tilted forward until the fork tips
touch the floor.
z Place the controls lever in neutral.
z Engage the parking brake.
z Remove the start switch key and turn the
disconnect switch OFF (if equipped).
z Block the drive wheels when parking on an
incline.
Pressure Air
Pressure air can cause personal injury. When using
pressure air for cleaning, wear a protective face
shield, protective clothing and protective shoes.
The maximum air pressure must be below 205 kPa
(30 psi) for cleaning purposes.
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.
Do not use a kinked or frayed wire rope cable.
Wear gloves when handling the wire rope cable.
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.
Wear protective glasses when striking a retainer pin
to avoid injury to your eyes.
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)
This is an attached guard located above the
operator's compartment and secured to the lift truck.
To avoid possible weakening of the Falling Objects
Protective Structure (FOPS), consult a DOOSAN
dealer before altering, by adding weight to, welding
on, or cutting or drilling holes into the structure.
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.
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.
Any altering done that is not specifically authorized
by DOOSAN invalidates DOOSAN’s 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.
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
DOOSAN dealer for mounting guidelines.
Safety Section
Burn Prevention
Oils
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.
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.
Remove the hydraulic tank filter cap slowly to
relieve pressure.
Relieve all pressure in air, oil fuel or cooling
systems before any lines, fittings or related items
are disconnected or removed.
Batteries
Only trained and designated personnel should
inspect, recharge or exchange batteries.
Always wear protective glasses when working with
batteries.
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.
Batteries give off flammable fumes which can
explode.
Highly explosive gases are especially hazardous
toward the end of the charging period as the battery
approaches a full charge condition.
Electrolyte is an acid and can cause personal injury
if it contacts skin or eyes.
Service batteries in accordance with battery
manufacture instructions.
Refer to the topic "Batteries" in the "Maintenance
Section" of this manual.
14
Fire or Explosion Prevention
All fuels, most lubricants and some coolant
mixtures are flammable.
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.
Store all oily rags or other flammable material in a
protective container, in a safe place.
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.
Remove all flammable materials such as fuel, oil
and other debris before they accumulate on the lift
truck.
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.
Repair any loose or damaged fuel and oil lines,
tubes and hoses. Leaks can cause fires. Contact
your DOOSAN dealer for repair or replacement.
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 End fittings damaged or leaking.
 Safety Section

z Outer covering chafed or cut and wire
reinforcing exposed.
z Outer covering ballooning locally.
z Evidence of kinking or crushing of the flexible
part of hose.
z Armoring embedded in the outer cover.
z End fittings displaced.
Make sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat during
operation.
Tire Information
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.
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
corrosion of rim components.
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.
Stand behind the tread and use a self-attaching
chuck when inflation a tire.
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.

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 approach a warm tire closer than the outside

of the area represented by the shaded area in the
above drawing.

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.

15
Safety Section

Operator Restraint System (If

Equipped)
Warning Signs and Labels
Your DOOSAN lift truck has the following tipover
warning decals.

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,
The "Survive in tipover" warning is located on the
etc. You must replace a label if it is damaged,
overhead guard. It shows the proper use of the
missing or cannot be read. If a label is on a part
operator restraint system.
that is replaced, make sure a new label is installed
on the replaced part. See you DOOSAN Lift Truck
dealer for new labels. Seat Adjustment

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.

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.

WARNING
Do NOT place your hand or fingers under the
seat. Injury may occur as the seat moves up
and down.

16
 Safety Section

If Optional Suspension Seat Equipped Weight adjustment

Forward and Backward Adjustment Pull the weight adjustment lever upwards and move
right or left side.
The seat can be adjusted by pushing the lever on Adjust to driver’s weight in 7 steps (50 ~ 110 kg)
the right side of seat.

NOTICE

Forward and Backward Do not place your hand or fingers under the seat.
Adjustment Injury may occur as the seat moves up and down.

Backrest Inclination

The backrest angle can be adjusted by using the

lever on the left side of seat.

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
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

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 Cut or frayed strap

z Worn or damaged hardware including anchor
1. If the seat belt is torn, if pulling motion is points
interrupted during extension of the belt, or if the z Buckle or retractor malfunction
belt cannot be inserted into the buckle properly, z Loose stitching
replace the seat belt assembly.
WARNING

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

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 DOOSAN truck comes equipped with a
DOOSAN operator restraint system. Should it
become necessary to replace the seat for any
reason, it should only be replaced with another
DOOSAN operator restraint system.
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.

18
 Safety Section

Hold the plate of the belt and allow the belt to

WARNING slowly retract.

If you fasten the belt across your abdomen, the

belt may injure your abdomen in an accident.

3. Be sure to fasten the belt across your hips, not

across your abdomen.

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.

Release the Seat Belt

Push the button of the buckle to release the belt.

The belt will automatically retract when released.

19
Safety Section
Avoiding Lift Truck Tipover
Lift Truck Stability
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.
20
Stability and Center of Gravity
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
z the height to which the load is lifted
z the amount of forward or backward tilt
z tire pressure
z dynamic forces created when the lift truck is
accelerated, braked or turned
z 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.
 Safety Section

Lift Truck Stability Base Remember that, unless otherwise indicated, the
capacity load shown on the nameplate is for a
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.

NOTE: If the load is not uniform, the heaviest

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.
WARNING
Dynamic forces (braking, acceleration, turning)
also affect stability and can produce tipover
even when the CG is within the stability triangle.
portion should be placed closer to the
backrest and centered on the forks.
NOTICE
1. Capacity/Nameplates originally attached to
forklifts sold by DOOSAN shall not be removed,
altered or replaced without DOOSAN’s approval.
2. DOOSAN assumes no responsibility for lift
trucks placed in service without a valid
DOOSAN Nameplate.
3. If necessary to change your specification,
contact your DOOSAN lift truck dealer.

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.

21
Safety Section
Safety Rules
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 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.
22
Do not operate a lift truck unless you are in the
operator’s seat. Keep hands and feet inside the
operator’s compartment. Do not put any part of
the body outside of the operator’s compartment.
Never put any part of body into the mast structure
or between the mast and the truck
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.
In case of a truck with the steering knob, Do not
operate the steering knob suddenly, to prevent
accident caused by quick turning.
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.

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 operate your truck without the load backrest
extension and overhead guard. Keep the load
against the backrest with the mast tilted backward.
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.
23
Safety Section
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 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 drive on slippery surfaces.
Sand, gravel, ice or mud can cause a tipover.
If unavoidable, slow down.
Safety Section

Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted forward.
load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards.
cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.

Look out for overhead obstructions when raising or Do not jump off if your truck starts to tip over.
stacking loads. Do not travel with a raised load. Do Stay in your seat to survive.
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.

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
Do not move loose loads that are higher than the incline.
load backrest. Go straight off and straight down. Use an assistant
Be alert for falling loads when stacking. when going up or down a ramp with a bulky load.
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

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 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.
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 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 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.
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.

Do not operate forklifts near flammable or

combustible materials.
To avoid the discoloration, deformation or
combustion of materials (such as lumber, veneer
board, paper products and other similar items),
always park at least 30 cm (12 inches) away from
them.

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

Forklift trucks are not cars. They often have small
tires, no suspension, and are very heavy.
The forklift's center of gravity will also change when
carrying loads.
Avoid uneven bumps, pot holes and other hazards
whenever possible.
There are many special attachments available to
replace the forks on a lift truck.
All carry safety implications and special training in
their operation is highly recommended.

The counterweight draw bar should not be used for

Carrying a load suspended on a chain or a cable
may unbalance a truck.
Take extra care around pedestrians with a
suspended load as it may sway or even strike them.
towing the forklift or for towing another forklift.
Towing is only advised in emergencies, by trained
operators and at low speed, no faster than 2 km/h,
to a convenient location for repair.

An unloaded forklift may be easier to tip over than a

loaded truck.
When traveling without a load, the risk of lateral
overturn is greater.

27
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.

Don’t jump.

Lean forward.

Hold on tight.

28
 General Section

Declaration of Conformity

We,

Manufacturer
Doosan Industrial Vehicle Co., Ltd.
(Manseok-dong) 468, Injung-ro, Dong-Gu, Incheon, Korea 401-010

Authorized Representative, Compiler of Technical File According to 2006/42/EC and Keeper of

Technical File According to 2000/14/EC
Doosan Industrial Vehicle Europe N.A, Mr. Y.W. Chung
1A Rue Achille Degrace 7080 Frameries, Belgium

herewith declare
that the following equipment conforms with the appropriate requirements of the Directives
2006/42/EC(Machinery Directive), 2000/14/EC as amended by 2005/88/EC(Noise Emission in
the environment by equipment for use outdoors), and 2004/108/EC (EMC Directive) based on
its design and type, as brought into circulation by us.

Description of the equipment :

Type : Lift Truck, Battery Powered Driven, Counterbalanced

Function : Lifting and Moving materials

Family : B16R-5 Series

Model Name : B10R-5, B13R-5, B15R-5, B16R-5

29
General Section

Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center kg
4 Load center distance mm
5 Power type eletric,diesel,gas,Lp-gas
6 Operator type stand-on, rider seated
7 Tire P=pneumatic,E=elastic,C=cushion
8 Wheels number of front/rear
DIMENSIONS
9 Lift with STD maximum fork height with rated load mm
10 two-stage mast free lift mm
11 Fork carriage ISO Class
12 Fork thickiness X width X length mm
13 forkspacing (maximumXminimum) mm
14 Tilt of mast foreward/backward deg
15 length without forks mm
16 width mm
17 Overall mast lowered height mm
18 dimensions mast extended height mm
19 overhead guard height mm
20 seat height (to SIP) mm
21 Outside turning radius mm
22 Load moment constant (from center of front wheel to fork face) mm
23 Aisle width with pallets 1000X1200 Crosswise mm
23a Aisle width with pallets 800X1200 Lengthwise mm
PERFORMANCE
24 travel,loaded/unloaded 24V km/h
25 Speeds lift,loaded/unloaded 24V mm/s
26 lowering,loaded/unloaded mm/s
28 Max. Drawbar pull loaded/unloaded (5 min. rating) kgf
30 Max. gradeability loaded/unloaded (5 min. rating) %
31 Steering Manual/power assisted/full power
WEIGHT
32 Total weight (with minimum weight of battery) kg
33 Axle load with load(vertical) front/rear kg
34 without load(vertical) front/rear kg
CHASSIS
35 number of front/rear
36 Tires Size front
37 rear
38 Wheelbase (forward x vertical x back) mm
39 Tread front/rear mm
40 Ground loaded at the lowest point mm
41 clearance at center of wheelbase mm
42 Service brake
43 Parking brake
DRIVE
44 Type
45 Battery Volt/Capacity-Max. V/AH
46 Weight (Minimun) kg
47 Electric motor Drive motor (1 HR Rating) 24V kw
48 Hydraulic motor (20% Duty) 24V kw
54 Speed control with electric drive Type
57 Relief pressure system/attachment Kpa
58 Noise level Leq dB(A)

30
 General Section

DOOSAN DOOSAN DOOSAN DOOSAN 1

B10R-5 B13R-5 B15R-5 B16R-5 2
1000 1250 1500 1600 3
500 500 500 500 4
electric electric electric electric 5
rider seated rider seated rider seated rider seated 6
P,E P,E P,E E 7
2/1x 2/1x 2/1x 2/1x 8

3000 3000 3000 3000 9

130 130 130 130 10
11
35x100x900 35x100x900 35x100x900 35x100x900 12
200x905 200x905 200x905 200x905 13
3/6 3/6 3/6 3/6 14
1710 1735 1760 1785 15
996 996 996 996 16
2025 2025 2025 2025 17
4045 4045 4045 4045 18
2067 2067 2067 2067 19
1010 1010 1010 1010 20
1380 1405 1430 1455 21
330 330 330 330 22
3039 3064 3089 3114 23
3161 3186 3211 3236 23a

12.5/13.5 12.0/13.0 12.0/12.5 12.0/12.5 24

320/520 310/520 300/520 300/520 25
500/450 500/450 500/450 500/450 26
290/837 357/765 385/765 354/765 28
19/25 19/25 16/25 15/25 30
full power full power full power full power 31

2451 2777 2951 3036 32

3007/445 3486/541 3958/493 4109/527 33
1275/1176 1321/1455 1408/1543 1388/1648 34

2/1 2/1 2/1 2/1 35

18x7-8 18x7-8 18x7-8 18x7-8 36
18x7-8 18x7-8 18x7-8 18x7-8 37
1111x1135x1185 1111x1135x1185 1161x1185x1235 1161x1185x1235 38
840/0 840/0 840/0 840/0 39
85 85 85 85 40
90 90 90 90 41
foot/hyd foot/hyd foot/hyd foot/hyd 42
hand/mach hand/mach hand/mach hand/mach 43

lead-acid lead-acid lead-acid lead-acid 44

24/875 24/875 24/1000 24/1000 45
445 600 676 676 46
5 5 5 5 47
7 7 7 7 48
Inverter AC Inverter AC Inverter AC Inverter AC 54
15900/15900 15900/15900 15900/15900 17500/15900 57
70.0(Tested model:B18T,48V) 58

31
General Section

Noise and Vibration

Noise Level [ Unit : dB(A) ] Vibration Level [ Unit : m/s²]

Sound Pressure Level

Model Human Vibration
at Operator's Ear (Leq.)

prEN 12053 prEN 13059

B10R-5
B13R-5
67.4 0.76
B15R-5
B16R-5
* Test Model : B16R-5

32
 General Section

Capacity Chart
SOLID SOFTER TIRE
Model
STD,FFL FFT
B10R-5

A: 2000~4000 mm MAST A: 4000 mm MAST D: 5000 mm MAST

B: 4500 mm MAST B: 4500 mm MAST E: 5500 mm MAST
C: 4750 mm MAST F: 6000 mm MAST
B13R-5

A: 2000~4000 mm MAST A: 4000 mm MAST D: 5000 mm MAST

B: 4500 mm MAST B: 4500 mm MAST E: 5500 mm MAST
C: 4750 mm MAST F: 6000 mm MAST
B15R-5

A: 2000~3700 mm MAST A: 4000 mm MAST D: 5000 mm MAST

B: 4000 mm MAST B: 4500 mm MAST E: 5500 mm MAST
C: 4500 mm MAST C: 4750 mm MAST F: 6000 mm MAST
B16R-5

A: 2000~3700 mm MAST A: 4000 mm MAST D: 5000 mm MAST

B: 4000 mm MAST B: 4500 mm MAST E: 5500 mm MAST
C: 4500 mm MAST C: 4750 mm MAST F: 6000 mm MAST

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

Hydraulic/Power Steering Motor Serial Number

Drive Motor Serial Number

34
 General Section

Operator’s 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.

Operator’s Warning Plate Identification, Lift Capacity and

Attachment Plate
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.
Located on the right side of the operator’s seat on
the battery cover.
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 truck’s 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 CTH - Container Top Handler.
installed on the lift truck when it left the factory. The
type of mast is indicated by an abbreviation. CSH - Container Side Handler

STD - Standard Mast(single inner member, low LP - Load Push Device, Non Sideshift.
free lift).
LPP - Load Push-Pull Device, Non Sideshift.
FF - Full Free Lift Mast (single inner member,
with high free duplex or multiple cylinder). C - General Clamp (other than Bale, Carton
or Roll).
FFT - Triple Lift Mast (two inner members) with
either low or full free lift. BC - Bale Clamp.

QUAD - Quadruple (Quad) Mast (three inner CC - Carton Clamp.

members).
RC - Roll Clamp.
SPEC - Special Mast, such as non-telescopic or
double mast, not within the other LS - Load Stabilizer.
classifications.
LH - Log Handler.
NOTE: When only a mast-type is listed on the
identification plate, a standard carriage and PWH - Pulp Wood Handler.
forks are used.
SS-ST - Sideshift-Side Tilt Carriage.
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

Operator’s 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.
OFF - Turn the key switch to OFF (1) to
disconnect the electrical circuits.
The seat switch is located under the operator’s seat.
OPEN - When the operator’s seat is in
the up position the electrical circuits are
disconnected.

ON - Turn the key switch the ON (2) to
connect 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”.
The power steering pump motor is activated when
the key switch is turned to ON and the seat switch
is closed.
CLOSE - When the operator’s 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.

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
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.
38
Display Segments
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
With any directional switch active and safety
contact still open, lift truck can’t 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
Slow speed operation, indicated by
Low oil level of the brakes.
Battery level, indicated by a 9
segments symbol.
In following Table 1 and 2, you can read the generic
relation between battery charge level and number
of visualized bars. Display signals with alarm code
EL the fact battery is completely discharged .
 Operation Section

Relation between battery charge level and The display gives the following contraction on the dot
number of visualized bars matrix display about the operating state of the system.
See table 3
Table 1 : Case of a generic system
Table 3 : Contraction for dot matrix display.
DISPLAY BATTERY CHARGE
Alarm Code
INDICATION LEVEL
No segments Discharged battery Display
1 flashing segment 10 % Description Contraction
Code
1 segment 20 % CONTACTOR
17 Main breaker fault
2 segments 30 % FAULT
3 segments 40 % Battery/inverter
60 BATT MISMATCH
4 segments 50 % mismatch
5 segments 60 % P-MOTOR
76 Pump motor Encoder
6 segments 70 % ENCODER
Wrong right traction R-M TEMP
7 segments 80 % 77
motor thermal switch SENSOR
8 segments 90 % Wrong pump motor P-M TEMP
9 segments Full charged battery 79
thermal probe SENSOR
Wrong right traction
Table 2 : Case of an 24V system 80 module thermal R-INV T SENSOR
BATTERY CHARGE BATTERY VOLTAGE probe
LEVEL [V] Wrong pump module
82 P-INV T SENSOR
thermal probe
Discharged battery Voltage < 22.0 V
83 CRC fault CRC FAULT
10 % 22.0 V ÷ 22.5 V
84 Bank CRC restored CRC RESTORED
20 % 22.5 V ÷ 22.9 V Capacitors not
30 % 22.9 V ÷ 23.3 V A FAST CHARGE
charged : fast charge
40 % 23.3 V ÷ 23.7 V Trans.precharge in
50 % 23.7 V ÷ 24.1 V A short/Cap. too TOO CHARGED
60 % 24.1 V ÷ 24.4 V charged
70 % 24.4 V ÷ 24.7 V Capacitors not
CAP SLOW
80 % 24.7 V ÷ 25.0 V A charged : slow
CHARGE
charge
90 % 25.0 V ÷ 25.2 V
Capacitors not TIME OUT
Full charged battery Voltage > 25.2 V A
charged : time out CHARGE
Capacitors not CAP NOT
A
charged CHARGED
Drive right module R-INV
E1
Overtemperature OVERTEMP
Pump module P-INV
E3
Overtemperature OVERTEMP
Drive right motor R-MOTOR
E4
Overtemperature OVERTEMP
Pump motor P-MOTOR
E6
Overtemperature OVERTEMP
EE Wrong start WRONG START
EE
(FLASI Seat switch SEAT SW OPEN
NG)
EL Low battery voltage LOW BATT VOLT
F Eeprom EEPROM FAULT
WD Timer/Enable WD TIMER
F
micro signals FAULT
F Serial communication COMM FAULT
Maximum battery
F0 MAX BATT VOLT
voltage
Minimum battery
F1 MIN BATT VOLT
voltage
F2 Pedal trimmer fault ACCEL FAULT

39
Operation Section

Drive right module R-INVERTER - E-S-H management disabled: no symbol

F3
Desat/overcurrent FAULT visualised.
Pump module P-INVERTER - E-S-H management enabled: active
F5
Desat/overcurrent FAULT mode is indicated by symbol
Drive right motor R-MOTOR I
F6
current Offset OFFSET
Pump motor current P-MOTOR I
F8 Otherwise symbol indicates, as usual,
Offset OFFSET
selected operating mode.
STEER SENSOR
F9 Steer sensor fault
OUT
FA 12V out not ok 5V NOT OK
Drive right motor R-MOTOR
Fc NOTE: as usual, if lift truck is moving, symbol
Encoder ENCODER
FE 24V out 24V NOT OK indicates speed level.
FH 5V encoders not ok 12V NOT OK
Pump input on at the
FL PUMP SIGN ON
start

NOTE: if active mode is one of L1, L2 or L3

Lift truck operation mode limitations and you change operating mode
(from PROGRAMMABLE WORKING to E-
Pressing E-S-H button, you can set S-H), software automatically sets operating
energetic operating mode for your system. mode to economic one.

Alarm message, indicated by an alpha-

This function is enabled using EYE menu named numerical code in the display area where
Calibration – ESH, to select desired operating usually lift truck speed appears.
mode. In particular you can choose between E-S-H See Table 4 for the meaning of alarm codes.
or PROGRAMMABLE WORKING :
Table 4 : Meaning of alarm codes.
- Pressing E-S-H (economic, standard, high) button, ALARM
you change energetic mode and update related ALARM DESCRIPTION
CODE
parameters with a value, corresponding to F Wrong eeprom + watch dog timer
selected operating mode, that operator can’t F0 Maximum battery voltage
modify.
F1 Minimum battery voltage
- Pressing PROGRAMMABLE WORKING you can
F2 Pedal trimmer fault
manage 3 further options (limit 1, limit 2, and limit
F3 Drive right module desat/overcurrent
3). You can set parameters value, that are
F5 Pump module Desat/overcurrent
expressed in per cent of high energetic mode;
changing active limitation (among L1, L2 or L3), F6 Drive right motor current offset
related per cent data are used to calculate actual F8 Pump motor current offset
parameters value. F9 Steer sensor fault
FA 12V out not ok
NOTE: Percent values can be modified only with Fc Drive right motor Encoder
EYE Calibration – E-S-H menu. FE 24V out not ok
FH 5V encoders not ok
NOTE: Pressing PROGRAMMABLE WORKING FL Pump inputs on at start
you can manage economic, standard or E1 Drive right module Overtemperature
high operating mode too. E3 Pump module overtemperature
E4 Drive right motor Overtemperature
COMPACT display shows different symbols in E6 Pump motor Overtemperature
function of selected energetic mode: EE Wrong start
EL Low battery voltage
EE
Seat switch opened
(flashing)
Alarm on pre - charge circuit of
A
internal capacitors
AL Key retention

40
 Operation Section

17 Main breaker fault LED Indicators

60 Battery / inverter mismatch
Wrong right traction motor thermal On left side, COMPACT display has four LED
77
probe indicators which, when switched on, give
79 Wrong pump motor thermal probe information as follows:
Wrong right traction module thermal
80
probe Low oil level of the brakes : red color LED.
82 Wrong pump module thermal probe
83 CRC fault Seat Belt warning (Option) : red color
84 Bank CRC restored LED for 10 seconds.

Hour meter separation point, usually blinking, stops No Alarm, No Movement (OPTION)
in following cases:
- Seat switch open. In case the truck does not move forward or reverse
- Serial communication between display and control direction, check to see if the service brake switch
unit not active (option) is activated.
- 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 5).
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.

Table 5
CODE MEANING
C1 3 WHEEL
24 BATTERY VOLTAGE
16 MAX. CAPACITY

41
Operation Section

Front and Rear Floodlights Switch Tilt Steering Column

Located on the right side of the instrument panel,
below the display panel.
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.
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.
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.
Seat Adjustment
Adjust the seat at the beginning of each shift or
when changing operators.
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
Located in the center of the steering to lock it.
wheel.
Push in on the horn button to sound the
horn.

42
 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.

43
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 operator’s 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.

44

Accelerator Pedal
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.
Accelerator Pedal - The accelerator pedal is located
on the floor of the operator’s compartment.
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.
Release the pedal to decrease travel speed.
Film for Function of Pedals
(If Equipped)
This film shows the function of the brake and
accelerator pedals.
45
Operation Section
Directional Control Lever
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.
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.
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.
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
Operation Section

motor will lose power. When this occurs, release Tilt Control Lever
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.

Lift Control Lever

The forks’ tilt control is located at the operator’s

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.

The forks’ lift control is located at the operator’s
right side front. The lift control lever is the lever at
the left.
Lower - Push the lever forward smoothly
to lower the lift forks.
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.
Raise - Pull the lever back smoothly to
raise the lift forks.
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.
Tilt Back- Pull the lever back smoothly to
tilt the forks back.
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.

NOTE: To prevent a sudden change of position of

the load, operate all lift, tilt and attachment
controls smoothly.

46
 Operation Section

Sideshift Attachment Control

(If Equipped)

The sideshift attachment control is located at the

operator’s 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.

47
Operation Section

Before Operating the Lift Truck

Walk-Around Inspection
7 8
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
3
2 6. Inspect the tires and wheels for proper inflation,
cuts, gouges, foreign objects and loose or
missing nuts.
1
7. Inspect the overhead guard for damage, loose
or missing mounting bolts.

8. Inspect the hydraulic system for leaks, worn

hoses or damaged lines.

1. Inspect the operator’s compartment for loose 9. Inspect the drive axle housing and the ground
items and clean any mud or debris from the for oil leaks.
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
5

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

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.
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.

48
 Operation Section

11. Release the battery restraint lever in front of 15. Adjust the steering wheel to comfortable
battery cover. Raise the seat and cover position. Grasp the steering wheel and raise the
assembly. handle to release the steering column. PULL
the steering column BACK or PUSH
12. Inspect the battery compartment for loose FORWARD to obtain the most comfortable
connections and frayed cables. position. RELEASE the knob and make sure
the steering column is locked in this position.
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 operator’s 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.

14. Position the seat by operating the lever and

moving the seat forward or backward to a
comfortable position.

49
Operation Section

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 a 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.

50
 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

Do not move directional control lever from one 3. Push down on the service brake pedal and
direction to the other(plug) when the drive wheels Prelease the parking brake.
are off the ground and rotating at full speed.

Damage can occur to the control panel.

1. Adjust the operator’s seat.

4. Turn the key switch to the ON position. Raise

the attachments.

2. Move the directional control lever into the

NEUTRAL position, if it is not already in this
position..

5. Move the directional control lever to the desired

direction of travel.

51
Operation Section

6. Release the service brake pedal.

7. Push down on the accelerator pedal to obtain

the desired travel speed. Release the pedal to
decrease travel speed.

8. To change the lift truck direction of travel,

electrical braking(plugging) can be used to slow
or stop the lift truck.

52

Electrical Braking (Plugging)
To slow, stop or change direction when traveling in
either direction, move the directional control lever
(1) to the opposite direction while keeping the
accelerator pedal (2) depressed.
The Micro-controller senses that the motors are
turning opposite to the lift truck and immediately
goes into the plugging mode.
Rotation of the motors is retarded at a
predetermined rate by electrical braking (plugging).
If the accelerator pedal is kept depressed, the
Microcontroller will slow the lift truck to a complete
stop and then accelerate in the opposite direction.
1. Move the directional control lever to the
opposite direction of lift truck travel.
53
Operation Section
2. Hold the accelerator pedal down until the lift
truck nearly comes to a complete stop. Release
the accelerator pedal.
3. Push down on the service brake pedal to bring
the lift truck to a complete stop and hold it.
4. If a change of direction is desired, continue to
push down on the accelerator pedal until the
desired travel speed in the opposite direction is
obtained.
5. To stop the lift truck where conditions do not
permit electrical braking(plugging). Release the
accelerator peadal (1). Push down on the
service brake pedal (2) and bring the lift truck to
a smooth stop.
Operation Section
Steering Knob (If Equipped)
There is a steering knob available for inclusion with
new truck deliveries. This option is solely intended
for slow travel situations when two handed steering
is not possible due to hydraulic operations.
WARNING
Loss of stability can occur when a lift truck
steering wheel is rotated quickly while the truck
is in motion. A steering knob will assist with
easy rotation of the steering wheel, but if a
steering knob is improperly used (e.g., rotating
the steering wheel quickly while the truck is in
motion), this can contribute to truck instability
and a tip over. A steering knob is intended for
slow travel maneuverability ONLY.
54
Mono-Ped Control System
(Option)
Forward-Push the left side (2) of the pedal
for FORWARD direction travel.
Neutral-The lift truck should not move
when the Mono-Ped pedal is released..
Reverse-Push the right side (1) of the
pedal for REVERSE direction travel.
The MONO-PED pedal controls the speed and
direction of the lift truck. Pushing on the right side of
the pedal (1) causes the lift truck to move in
REVERSE. The optional reverse lights and optional
back-up alarm will be ON in the REVERSE position.
Pushing on the left side of the pedal (2) causes the
lift truck to move in FORWARD.
The speed of the truck increases as the pedal is
depressed
 Operation Section

Finger Tip (Option)

Function of Knobs Tilt Control knob

If finger tip control option is equipped, the hall-effect

type electric knobs replace convention control valve
levers.

Lift Control knob

Tilt Forward - Push the knob forward

smoothly to tilt the lift forks forward.

Hold - Release the tilt knob. The knob will

Lower - Push the knob forward smoothly
to lower the lift forks.
Hold - Release the lift knob. The knob will
return to the center(hold) position and the
forks will remain in the position they are in.
Raise - Pull the knob back smoothly to
raise the lift forks.
return to the center(hold) position and the
forks will remain in the position they are in.
Tilt Back - Pull the knob back smoothly to
tilt the lift forks back.
NOTE: To prevent a sudden change of position of
the load, operate all lift, tilt and attachment
knobs smoothly.

NOTE: To prevent a sudden change of position of

the load, operate all lift, tilt and attachment
knobs smoothly.

55
Operation Section

Sideshift Attachment Control Warning Lamp

Sideshift Left - Push the knob forward The state of the finger tip ECU can be checked by
smoothly to shift the carriage to the left. the external warning lamp blinking.

Sideshift Hold - Release the sideshift Blinking Lamp State

attachment knob. The knob will return to
No Lighting Normal
the center(hold) position and sideshifting
action will stop. Lighting System Failure

Sideshift Right - Pull the knob back If the warning lamp is blinking, refer to "Diagnosis
smoothly to shift the carriage to the right. LED on finger tip ECU"
.

NOTE: To prevent a sudden change of position of

the load, operate all lift, tilt and attachment
knobs smoothly.

Emergency Switch

In case of emergency, push this button. Pushing

button makes the finger tip system on and off
alternately. So if the finger tip control dose not work,
then press this button once.

56
 Operation Section

Adjustment of Armrest Up and Down Adjustment

2 2

By using 2 knobs, adjust the position of the armrest To move the armrest down, turn the knob(2)
to give the operator the best comfortable position of counterclockwise.
arm.

knob #1 - Forward and backward adjustment

knob #2 - Clockwise and Counterclockwise rotation

adjustment

Forward and Backward Adjustment

2
1

To move the armrest up, turn the knob(2) clockwise.

1. Loosen the knob bolt(1).

2. Adjust the position of armrest forward or backward.

3. Tighten the knob bolt(1) to be locked tightly

57
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.

58

Traveling
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. Carry the load as low as possible, but maintain
clearance.
2. On grades, alway travel with the load on the
“uphill” side, as shown above.
3. Travel in reverse with bulky loads. This gives
you better vision.
59
Operation Section
Turning
1. When turning sharp corners, keep close to the
inside corner. Begin the turn when the inside
drive wheel meets the corner.
2. In narrow aisles, keep as far from the stockpile
as possible when making a turn into the aisle.
Allow for counterweight swing.
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.
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 3. Deposit the load and back away carefully to
midway between the two drive tires. free the forks.

4. Lower the carriage and forks to either travel

position or park position.

60
 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.

61
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 operator’s 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.

62
 Operation Section

6. Disconnect the battery.

7. Block the wheels if parking on an incline.

Parking Alarm Warning (If

Equipped)
When leaving the operator’s station without
engaging the parking brake, a warning buzzer will
sound.

63
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.

64
 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 period 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 rust
preventive and once is month operation has not
been 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.

65
Operation Section

Transportation Hints
6. Disconnect the battery.
Shipping
7. Block the tires and secure the lift truck with
Check travel route for overpass clearances. Make tiedowns.
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
To prevent the lift truck from slipping while loading, Information
or shifting in transit, remove ice, snow or other
slippery material from the loading dock and the
truck bed before loading. NOTICE

Improper lifting or tiedowns can allow load to shift

NOTICE and cause injury and/or damage.

Obey all state and local laws governing the weight,

width and length of a load. 1. Weight and instructions given herein apply to lift
Observe all regulations governing wide loads. trucks as manufactured by DOOSAN.

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
Remove ice, snow or other slippery material from prevent contact with the lift truck.
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 DOOSAN 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.

66
 Operation Section

Towing Information
Consult your DOOSAN 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.

You must provide shielding on the towing lift truck 1. Release the parking brake.
to protect the operator if the tow line or bar should
break.
NOTICE
Do not allow an operator to sit on the lift truck being Release the parking brake to prevent excessive
towed unless the steering and braking can be wear and damage to the parking brake system.
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 3. Turn the key switch OFF.
good condition and has enough strength for the
towing situation involved. For a disabled lift truck 4. Disconnect the battery.
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. 5. Fasten the tow bar to the lift truck.

Keep the tow line angle to a minimum. Do not 6. Remove any wheel blocks. Tow the lift truck
exceed a 30° angle from the straight-ahead position. slowly. Do not tow any faster than 2 km/h (1.2
Connect the tow line as low as possible on the lift mph).
truck being towed.

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
Normally, the towing lift truck should be at least as have been made before a lift truck that has been
large as the disabled lift truck. It should have towed to a service area is put back into
enough brake capacity, weight, and power to operation. Personal injury or death could result.
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.

67
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.
A fork failure during use can cause damage to the
equipment and the load. A fork failure can also
cause serious injury.
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 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.

z 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.

68
 Maintenance Section

Causes of Fork Failure z Repetitive Overloading

Repetitive cycling of loads which exceeds the

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.
Bent or Twisted Forks
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.
z 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.

Forks can be bent out of shape by extreme z Stress Risers

overloading, glancing blows against walls or other
solid objects or using the fork tip as a pry bar.
Bent or twisted forks are much more likely to break
and cause damage or injury. They should be
removed from service immediately.
Fatigue
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.
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.
Overloading
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.

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.

69
Maintenance Section
Fork Inspection
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.
Record the date and results of each inspection,
making sure the following information is included.
z Actual wear conditions, such as percent of
original blade thickness remaining.
z Any damage, failure or deformation which might
impair the use of the truck.
z 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.
70
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”
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”.
Daily Inspection
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”.
3. Remove all defective forks from service.
 Maintenance Section

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.”
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.
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

Maintenance and Repair information as may be applicable to the specific fork
involved.
1. Repair forks only in accordance with the Testing is not required for repairs to the positioning
manufacturer’s recomendations. lock or the markings.
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 Welding on brackets or new mounting

hangers.
z Repairing cracks or other damage by welding.
z 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.
z 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.
z Repair or replace the positioning locks on
hook type forks.
z 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
manufacturer’s 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.

71
Maintenance Section

Tire Inflation Information

Tire Inflation Tire Shipping Pressure
Ply Rating Shipping
Size or Pressure
Strength Index kPa psi
B10/13/15R-5
18 X 7-8 16 1000 145

The inflation pressures shown in the following chart

are cold inflation shipping pressures for tires on
DOOSAN lift trucks.

The operating inflation pressure is based on the

Personal injury or death could result when tires
are inflated incorrectly.
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 you’re
your tire supplier.

Use a self-attaching inflation chuck and stand

behind the tread when inflating a tire.
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.
Tire Inflation Pressures
Adjustment
A tire inflation in a warm shop area, 18°C to 21°C
(65°F to 70°F), 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.

72
 Maintenance Section

Torque Specifications
Metric Hardware - This lift truck is almost totally Torque for Standard Bolts, Nuts
metric design. Specifications are given in metric
and U.S. Customary measurement. Metric and Taperlock Studs
hardware must be replaced with metric hardware.
Check parts books for proper replacement.
NOTICE
NOTE: Use only metric tools on most hardware for
proper fit. Other tools could slip and The following charts give general torques for bolts,
possibly cause injury. nuts and taperlock studs of SAE Grade 5 or better
quality.

Torque for Standard Hose Clamps Torques for Bolts and Nuts With
- Worm Drive Band Type Standard Threads

Thread Size Standard Bolt & Nut Troque

NOTICE
Inch N•m1 lb•ft
The following chart gives the torques for initial 1/4 12±4 9±3
installation of hose clamps on new hoses and for 5/16 25±7 18±5
reassembly or retightening of hose clamps on 3/8 45±7 33±5
existing hose.
7/16 70±15 75±11
1/2 100±15 75±11
Initial Installation 9/16 150±20 110±15
Clamp Width Troque on New Hose 5/8 200±25 150±18
N•m1 lb•in 3/4 360±50 270±37
16 mm (.625 inch) 7.5 ± 0.5 65 ± 5 7/8 570±80 420±60
13.5 mm (.531 1 875±100 640±75
4.5 ± 0.5 40 ± 5 1 1/8 1100±150 820±110
inch)
8 mm (.312 inch) 0.9 ± 0.2 8±2 1 1/4 1350±175 1000±130
Reassembly or 1 3/8 1600±200 1180±150
Retightening Troque on 1 1/2 2000±275 1480±200
Clamp Width
existing hose 11 Newton meter (N•m) is approximately the same
N•m1 lb•in as 0.1 kg•m.
16 mm (.625 inch) 4.5 ± 0.5 40 ± 5
13.5 mm (.531
3.0 ± 0.5 25 ± 5
inch)
8 mm (.321 inch) 0.7 ± 0.2 6±2
11 Newton meter (N•m) is approximately the same
as 0.1 kg•m.

73
Maintenance Section

Torques for Taperlock Studs Torque for Metric Fasteners

Standard Taperlock Stud
Thread Size NOTICE
Torque
Inch N•m1 Ib•ft
Be very careful never to mix metric with U.S.
1/4 8±3 6±2 customary (standard) fasteners. Mismatched or
5/16 17±5 13±4 incorrect fasteners will cause lift truck damage or
3/8 35 + 5 26±4 malfunction and may even result in personal injury.
7/16 45 ±10 33 ±7
Original fasteners removed from the lift truck should
1/2 65 ±10 48 ±7
be saved for reassembly whenever possible. If new
5/8 110±20 80 ±15 fasteners are needed, they must be of the same
3/4 170±30 125 ±22 size and grade as the ones that are being replaced.
7/8 260 ±40 190 ±30
1 400 ±60 300 ±45 The material strength identification is usually shown
on the bolt head by numbers.(8.8, 10.9, etc.) The
1 1/8 500 ±70 370 ±50
following chart gives standard torques for bolts and
1 1/4 650 ±80 480 ±60 nuts with Grade 8.8.
1 3/8 750 ±90 550 ±65
1 1/2 870 ±100 640 ±75
NOTE: Metric hardware must be replaced with
11 Newton meter (N•m) is approximately the same metric hardware. Check parts book for
as0.1 kg•m. proper replacement.

METREC ISO2 THREAD

Thread Size Standard Torque
Metric N•m1 Ib•ft
M6 12±4 9±3
M8 25±7 18±5
M10 55±10 41 ±7
M12 95 ±15 70 ±11
M14 150±20 110 + 15
M16 220 ±30 160±22
M20 450 ±70 330 ±50
M24 775 ±100 570 ±75
M30 1600 ±200 1180±150
M36 2700 ±400 2000 ±300
11 Newton meter (N•m) is approximately the same
as 0.1 kg•m.

2ISO-International Standard Organization.

74

Lubricant Specifications
Lubricant Information
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
the“Lubricant 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.
Chain and Linkage Oils (DEO or
EO)
Use following engine oils are recommended for use
on chains and linkages.
·ㆍEuropean oil specification CCMC D3.
ㆍAPI Specification CD, CD/SF, CE
ㆍMilitary specifications MIL-L-2104D or E
75
Maintenance Section
Hydraulic Oil
The following commercial classifications can be
used in the hydraulic system.
ㆍISO 6743/4 HM
ㆍAFNOR NFE 48-603 HM
ㆍDIN 51524 TEIL 2 H-LP
ㆍHAGGLUNDS DENISON HFO-HF2
ㆍCINCINNATI P68, 69, 70
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.
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.
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 DOOSAN Lift Truck dealer for
purging instructions.
Maintenance Section

Axle Oil Lubricating Grease (MPGM)

NOTE: Do not use Gear Oil in the final drives or
differentials. Gear Oil can cause seal
material to fail and possibly leak oil.
NOTE: Failure to follow the recommendation will
cause shortened life due to excessive gear
wear.
Front Axle Oil
The API GL-4 specification oils could be used.
Rear Axle Oil
The API GL-5 specification oils could be used.
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.
NLGI No.2 grade is suitable for most temperatures.
Use NLGI No.1 or No.0 grade for extremely low
temperature.
Brake Fluid

NOTE: Multi-grade oils are not blended by

DOOSAN for use in transmissions. Multi-
grade oils which use high molecular weight
polymers as viscosity index improvers lose
their viscosity effectiveness by permanent
and temporary shear of the viscosity index
improver and therefore, are not
recommended for transmission and drive
train compartments.

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
Energol HP 10
BP
HLP 10
CALTEX Spindurn 10
ELF Spinelf 10
ESSO Nuto H 10 Spinesso 10
FINA Hydran 10
Velocite oil No. 6
MOBIL
Velocite oil E
Tllvs oil C10
SHELL
Morlina 10

76
 Maintenance Section

Battery Discharge Indicator

The battery discharge indicator should be observed
frequently before and during operation.
of the full charge as indicated by their specific
gravity. This specification varies with different
battery manufacturers. See the manufacturer’s
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.

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.

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%

77
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).
Do not smoke near batteries that are being
stored or when checking the electrolyte level.
Electrolyte is an acid solution and can cause
personal injury. Avoid contact with skin and
eyes.
Maximum life and performance of lift truck batteries
is dependent on the operator, battery charging,
maintenance and service.
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.
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.
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.
78
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.
Batteries that have been fully charged should have
a tag attached for identification.
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.
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.
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%.
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%.
 Maintenance Section

The battery’s maximum temperature is critical. The

electrolyte temperature should never exceed 43°C NOTICE
(110°F) either while operating or charging. If higher • DISPOSAL OF OLD BATTERY
temperatures are maintained through use or abuse,
reduced battery service life can be expected. Careless disposal of a battery can harm the
environment and can be dangerous to persons.
Battery condition is important for a long life. The Always dispose of a battery to an authorized
elecrolyte level should be maintained at the personnel only.
recommended levels and the battery should be kept Do not attempt to open or dismantle a battery or a
clean and dry. “Washing down” batteries at different cell.
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
manufacturer’s 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.

79
Maintenance Section

Cold Storage Applications

When an electric lift truck is operated in cold Hydraulic System
storage applications, at temperatures as low as -
20°C (-4°F), 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 truck’s 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.
Drain the hydraulic system and fill it with SAE 5.
MIL-H-5606A hydraulic oil
Battery
There is a reduction in battery capacity in cold Lift Chains
storage applications. For this reason, it is important
to : 1. Remove the chains Clean them in a
nonflammable cleaning solvent.
1. Be sure the battery is completely charged at the
start of each work cycle. 2. Put the chains in molybdenum disulfide
(MPGM) grease for one hour. Then, before
2. If possible, keep the lift truck in a warm storage installation, hang the chains, where they will not
area when it is not in use. move, for three hours.
3. Do not store a discharged battery at below
freezing temperature.

3. Put MPGM grease on the chains at one-week

intervals.

4. Check chains very carefully for wear on the link

Observe the battery discharge indicator frequently. plate edges, caused when they run over the
sheaves. Check the chains regularly for
cracked links, loss of shape in the holes, and
corrosion.

80
 Maintenance Section

Lubricant Viscosities and Refill Capacities

Lubricant Viscosities Refill Capacities

LUBRICANT VISCOSITIES FOR AMBIENT REFILL CAPACITIES-(APPROXIMATE)

(OUTSIDE) TEMPERATURES Compartment or U.S. Imperial
Liters
°C °F System Gal Gal
Compartment Oil
or System Viscosities Hydraulic & Power
Min Max Min Max 18 4.76 3.96
Steering System
Hydraulic and ISO VG 22 -30 +20 -22 +68 Drive Axle Housing 4.2 1.11 0.92
Power
ISO VG 32 -20 +30 -4 +86 Brake Reservoir 0.6 0.16 0.13
Steering
System ISO VG 46 -10 +40 +14 +104 Front Axle for each 0.5X2 0.13 0.11
ISO 6743/4
HM ISO VG 68 0 +50 +32 +122
Front axle API SAE
-20 +80 -4 +176
Housing GL-4 80W
Rear axle API SAE
-20 +50 -4 +122
Housing GL-5 80W/90
Brake
ISO VG 10 -30 +50 -22 +122
Reservoir

* 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.

81
Maintenance Section
Maintenance Intervals
NOTICE
Never exceed the Maintenance Intervals specified
in the manual. Defects and/or damage to the
important functional components may be resulted in.
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.
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.
When Required
Self Diagnostics - Test ...........................................83
Compact Display Keys...........................................83
Carriage Roller Extrusion – Adjust .........................87
Power Modules – Discharge ..................................88
Fuses - Replace.....................................................89
Seat - Lubricate .....................................................89
Every 10 Service Hours or Daily
Walk-Around Inspection - Inspect ..........................90
Mast Channels - Lubricate .....................................92
Battery - Check, Exchange, Charge.......................92
Indicator - Check....................................................94
Tires and Wheels - Inspect ....................................95
Back-up Alarm (If Equipped) - Test........................95
First 50 - 100 Service Hours or a Week
Axle Oil – Change..................................................96
First 250 Service Hours or a Month
Hydraulic Return Filter - Change............................98
82
Every 250 Service Hours or Monthly
Brake Oil Level - Check......................................... 99
Axle Oil Level - Check ........................................... 99
Parking Brake - Test............................................ 100
Hydraulic Oil Level - Check ................................. 101
Wheel Bolts - Check............................................ 101
Mast, Carriage, Lift Chains & Attachmemts -
Inspect, Lubricate ................................................ 102
Every 500 Service Hours or 3 Months
Tilt Cylinder - Check, Lubricate ........................... 103
Crosshead Rollers - Inspect ................................ 104
Mast Hinge Pins - Lubricate ................................ 105
Steering Mechanism - Lubricate.......................... 105
Axle Oil - Change ................................................ 105
Overhead Guard - Inspect ................................... 105
Control Panel - Clean, Inspect............................. 106
Directional Lever – Check ................................... 107
Every 1000 Service Hours or 6 Months
Drive Axle Oil - Change ....................................... 108
Drive and Pump Motor - Clean, Inspect............... 108
Tires and Wheels - Inspect, Check...................... 110
Lift Chains - Test, Check, Adjust ......................... 111
Fork - Inspect ...................................................... 113
Air Breather - Change ......................................... 115
Every 2500 Service Hours or 15 Months
Hydraulic Oil - Check, Change ............................ 116
Environment Protection
Environment Protection ....................................... 117
 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

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.

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.

The function of each of them is described as

follows:

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.
1. Park the lift truck level, with the forks lowered
and the mast tilted forward until the fork tips 2. During usual operations, this key, pressed for 3
touch the floor. consecutive s, allows you to access merely to
diagnostic mode.
2. Block the drive wheels.
Remember that if the display is operating in
3. Release the parking brake.
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.

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

4. Move the directional control lever to NEUTRAL. value of the parameter displayed.

5. Move the key switch to OFF.

83
Maintenance Section

TURTLE key Run Time Diagnostic

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.

3. "3. way of shifting from the visualization of "time

This operating mode enables you to test main
meter" and "odometer": you can do it by
analog and digital signals managed by your system.
pressing the "DOWN ARROW" button of
Compact display for 1 second in succession
Enter diagnostic mode if you are switching on your
during normal working of the display. "
lift truck:

E-S-H key 1. Press ENTER key (for 3 consecutive s) until the

symbol “15” lights up.
With this key, you can modify the device operating
condition, in a circular sequence, as described in 2. Press DOWN key to enter diagnostic mode; the
Table 7 : symbol “d” is visualized and it persists until the
first parameter has been selected.
WORKING
CURRENT WORKING
CONDITION AFTER Enter diagnostic mode if you are working as usual
CONDITION with your lift truck:
THE KEY PRESSURE
Economic (E) Standard (S)
1. Press ENTER key (for 3 consecutive s) until
Standard (S) High (H) symbol “d” appears; it will persist as long as the
High (H) Economic (E) first parameter has been selected.
Table 7
After diagnostic operation mode has been
NOTE: You can modify system operating modes enabled, you can choose the parameter you
only after enabling their management with want to analyse using UP and DOWN keys
EYE applicative software. (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 :

84
 Maintenance Section

PARAMETER NUMBER PARAMETER DESCRIPTION

1 Right traction motor speed [rpm]
2 Right traction motor speed reference [rpm]
5 Lift voltage [mV]
6 Battery voltage [V·10]
7 Right traction motor power module temperature [ºC / °F]
8 Pump motor power module temperature [ºC / °F]
9 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]
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]
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 [ºC / °F]
26 Pump motor temperature [ºC / °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]
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]

85
Maintenance Section

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)

86
 Maintenance Section

In diagnostic mode selected parameter is visualized Carriage Roller Extrusion – Adjust

as follows:
- In the area dedicated to speed and alarm
signals, appears parameter number( flashing)
- Its actual value is displayed in the area reserved
to the time meter.
In particular, if the selected parameter is:
1. Set the mast vertical.
2. Lower the carriage completely.
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.

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
To exit diagnostic mode, type ENTER key again. inner upright to the bottom of carriage bearing.
NOTE: If an alarm occurs when diagnostic mode is 5. The measurement (A) must be as follows in
enabled, and the system is working as Chart below.
usual, display returns automatically to its
typical visualization mode.
However you can enter diagnostic mode Height of carriage roller extrusion (A)
again, pressing ENTER key (for 3 STD mast FF mast FFT mast
consecutive -6 8 8
s), until the last parameter displayed before
exiting is visualized.

If the selected parameter is a temperature, also

thermal alarm symbol is visualized.

87
Maintenance Section

Power Modules – Discharge

Personal injury 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

The power modules are located in the control panel
at the rear of the lift truck.
power modules must be discharged. Put a 90
ohm, 30 watt resistor in position between the
terminals as shown. Hold the resistor in this
position for approximately ten seconds. This will
discharge the power modules.

4. Perform any necessary maintenance and repair

at this time.

5. Close the hood.

6. Connect the battery.

1. Disconnect the battery.

88
 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
DOOSAN Lift Truck dealer.

Check the operation of the seat adjusters. Make

sure that the seat slides freely on its track. Lightly
oil the seat slider tracks.

Horn - 10 amps
Lights(1) - 10 amps
Lights(2) - 10 amps
Fan - 10 amps
Key - 10 amps

Main Fuse - 700 amps

89
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

1. Inspect the operator’s compartment for loose
items and clean any mud or debris from the
floor plates.

2. Inspect the instrument panel for damage to the

display.

3. Test the horn and other warning devices for

proper operation.

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.

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.

7. Inspect the overhead guard for damage, loose

or missing mounting bolts.

8. Inspect the hydraulic system for leaks, worn

hoses or damaged lines.

90
 Maintenance Section

9. Inspect the drive axle housing and the ground

for oil leaks. Refer to “Drive Axle Oil” in “Every 12. Move the directional lever to NEUTRAL.
1000 Service Hours or 6 Months” section, if an
oil leak is found.

13. Turn the key switch to ON.

10. Adjust the operator’s seat.

14. Check the LCD display for battery discharge

status. A fully charged battery will be displayed
11. Adjust the steering wheel to a comfortable on the LCD display.
position.
15. Check the operation of parking brake, service
brake, controls and other devices that may be
equipped on your lift truck.

91
Maintenance Section

Mast Channels - Lubricate Battery - Check, Exchange,

Charge
Battery Access

Park the lift truck level, with the forks lowered and
the mast tilted forward until the fork tips touch the
floor.

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.

1. Disconnect the battery.

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.

92

Check Electrolyte
1. Inspect the battery compartment for loose
connections, frayed cables and properly
secured battery restraint.
2. Clean the top of the battery. If necessary, clean
the top of the battery with a solution of baking
soda and hot water.
NOTICE
Vent caps must be tight to prevent soda solution
from entering battery cells.
A clean battery top is essential to avoid conductive
paths on higher voltage batteries.
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.
93
Maintenance Section
3. Check the specific gravity of the battery. If the
specific gravity reading is below 1.150, the
battery must be charged.
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. Water is always added after
a battery is charged..
5. Lower the seat and battery cover. To closed
position and secure with the latch on the front of
the cover.
6. Connect the battery.
Battery Exchanging
NOTE: Batteries should be changed, water added
and charged only in areas where proper
protective and ventilation facilities are
provided.
1. Refer to “Battery Access” topic for battery
access.
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.
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

1. Refer to “Battery Access” topic for battery 3. Move the directional control lever to the
access. NEUTRAL position.
2. Connect the battery to the charger and charge
the battery. Observe safety warnings for 4. Close the seat switch.
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

Indicator - Check

5. Check the indicator LCD display for the

discharge state of the battery.

1. Turn the key switch to ON.

2. Engage the parking brake.

94
 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.
Check Inflation Pressure (If equipped with
pneumatic tires)
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.

Measure the tire air pressure on each tire.

95
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.

Axle Oil – Change

1
After the first 50 ~ 100 hour of operation,
subsequently after every 500 hours or 3 months.
2

5. Fill the drive axle housing with oil through air -

breather plug hole(①) , the accurate amount of
oil is defined by the opening of level checking
plug(②).

6. Maintain the oil level.

Front Axle Oil - Change
Park the lift truck level, with the parking brake 7. Screw the level checking plug(②) and air -
engaged and directional control lever in NEUTRAL. breather in with the seal ring.

1. Raise the mast and block in place. 8. Raise the mast and remove the blocking.

2. Turn the key switch to OFF.

3. Remove front tires.

4. Unscrew oil air - breather (Oil filling plug) (1),

level checking plug (2) and remove the drain
plug (3). Allow the oil to drain.

96
 Maintenance Section

Rear Axle Oil - Change

Park the lift truck level, with the parking brake

engaged and directional control lever in NEUTRAL.

1. Unscrew oil filling plug (level checking plug) (1)

and remove the drain plug(2). Allow the oil to
drain.

2. Fill the drive axle housing with oil through oil

filling plug hole and the accurate amount of oil is
defined by the opening of level checking plug.

3. Maintain the oil level.

4. Screw the oil filling plug in with the seal ring.

97
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.

98
 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 Axle Oil Level - Check

The brake system reservoir is located at the right
side of the steering column.
1. Remove the filler cap.
2. Maintain the brake fluid level in the brake
system reservoir.
3. Clean and install the filler cap.
Front Axle Oil Level
1. Park the lift truck on a level surface. Raise the
high enough to gain access to the housing
level/fill plugs.
2. Use blocking to secure the carriage in this
position.

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.

99
Maintenance Section

Rear Axle Oil Level Parking Brake - Test

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. Remove the oil filling and level plug.

2. Maintain lubricant level.

3. Install the oil filling and level plug.

2. Halfway up the incline, stop the lift truck by

applying the service brakes.

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.

100
 Maintenance Section

Hydraulic Oil Level - Check Wheel Bolts - Check

Steer Wheels

1. Operate the lift truck for a few minutes to warm

the oil.
1. Inspect tightness of wheel nuts in a sequence
2. Park the lift truck level, with the forks lowered, opposite each other 113 N•m (85 lb•ft).
mast tilted back (all cylinders retracted), parking
brake engaged, directional control lever in
NEUTRAL, and the key switch to OFF. Front Wheels
3. Open the floor plate.

4. Remove the dipstick

5. Maintain the oil level to the full mark on the

breather/dipstick.

6. Install the dipstick.

7. Install the access cover.

2. Inspect tightness of wheel nuts in a sequence

opposite each other to 180 N•m (135 lb•ft).

101
Maintenance Section

Mast, Carriage, Lift Chains & 5. Raise and lower the carriage a few times to
work lubricant into the chain links.
Attachmemts - Inspect, Lubricate

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.

1. Operate the lift, tilt and attachment controls.

Listen for unusual noises. These may indicate a
need for repair.

6. Inspect the chain anchors and individual links

for wear, loose pins or cracked leaves.

NOTE: Have all repairs and adjustments made as

required.

2. Inspect for loose bolts and nuts on the carriage

and load backrest. Remove any debris from the
carriage and mast.

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.

102
 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.

Tilt Cylinder - Check, Lubricate Mast Pivot Eyes - Check, Lubricate

Chassis Pivot Eyebolts - Lubricate

1. Lubricate the mast pivot eyes, one fitting on the

mast.
1. Raise the mast and block in place.

2. Check the mast pivot eye pins for loose retainer

2. Lubricate pivot eye pin, one fitting on tilt bolts and wear.
cylinder.

3. Check the pivot eye bolt for loose retainer bolt

and wear.

103
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.

Typical example

2. Check for damaged crosshead rollers, guards

and retainer rings.

104
 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.

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 N•m (45 ± 7 lb•ft).

Check the overhead guard for bent or cracked

sections. Repair if needed.

105
Maintenance Section

Control Panel - Clean, Inspect

Park the lift truck level, with the forks lowered,
parking brake engaged, directional control lever in
NEUTRAL, and the key switch to OFF.
Disconnect the battery.
Pressurized air can cause personal injury.
When using pressurized air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.

The maximum air pressure must be below 205

kPa (30 psi) for cleaning purposes.

2. Clean the control panel with 205 kPa (30 psi)

maximum air pressure, until dust is removed
from the control panel.

1. Open the hood.

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.

106
 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.

107
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

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.

1. Disconnect the battery.
8. Remove the floor plate.
2. Block the steer wheels.

3. Remove the battery. See topic, “Battery” in

“Every 10 Service Hours or Daily” section of this NOTICE
manual.
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.

108
 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.

9. Blow off the drive motor END SHIELD with 205

kPa (30 psi) maximum air pressure, until dust is
removed from the motor.

Typical example

10. Install the floor plate.

11. Slowly lift the front of the lift truck and remove
the stands. Lower the lift truck to the floor.
Remove the chains.

12. Install and connect the battery. Lower the

battery cover and adjust the seat.

109
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

Inspect tires for wear, cuts, gouges and foreign
objects. Look for bent rims and correct seating of
locking ring.
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.

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 180 N•m (135 lb•ft).

3. Reverse the lifting procedure for the front of the

lift truck and lower it to the ground.

110
 Maintenance Section

Lift Chains - Test, Check, Adjust Check for Equal Tension

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 Lift the carriage and the mast high enough for
check chain wear. getting tension on lift chains. Check the chains, and
make sure the tension is the same. Lift chains are
1. Lift the mast and carriage enough for getting required to check for equal tension about every
ension on lift chains. 1,000 service hours or 6 months.

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 (%)

= ( Actual measurement - Pitch** X 10
Pitch** X 10
**Chain Pitch = 15.88 mm(0.63 in)
Typical example for carriage equal tension
)x100
If the tension is not the same on both chains, take
the procedure as follows.

NOTE: If carriage height is not correct, make

adjustments by following procedures.

111
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,

Typical example for carriage chain of STD mast adjust chain for equal tension. If not, adjust mast
chain for correct mast height by adjusting anchor
nuts(3),(4).

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
3. Make adjustment anchor nut(1),(2) for equal chain tension.
chain tension.
4. Raise the inner mast and check equal chain
4. Set the mast vertical and raise the carriage and
check equal chain tension. If not equal, repeat tension. If not equal, repeat the same
the same procedure as step 1 through step 3. procedure as step 1 through step 3.

5. Put LOCTITE No. 242 Tread lock on the 5. Put LOCTITE No. 242 tread lock on the threads
threads of the anchor nuts(1),(2) after the of the anchor nuts(3),(4) after the adjustment is
adjustment is completed. completed.

112

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.
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.
Forks with cracks should be removed from ser-
vice.
"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.
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
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.
3. Check the straightness of the upper face of
blade (D) and the front face of shank (E) with a
straight edge.
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").
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
DOOSAN Lift Truck Dealer for further
information.
Maintenance Section
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.
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.
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.
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
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.
8. Check fork markings (N) for legibility. Renew
markings as required to retain legibility.
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.
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.
 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 floor plate.

2. Install a new air breather.

3. Close the floor plate.

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.

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.
5. Fill the hydraulic tank. See topic, “Refill
Capacities”. Install the dipstick /filler cap
assembly.
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 floor plate.

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
#
12 Months Inspection.............................................71
A Display Segments.................................................. 38
Accelerator Pedal ..................................................45
Adjustment of Armrest ...........................................57
After Storage..........................................................65
Air Breather - Change ..........................................115
API Specification CD, CD/SF, CE ..........................75
Attachment Abbreviations (Includes Special Forks) ..36
Avoiding Lift Truck Tipover ....................................20
Axle Oil - Change............................................96,105
Axle Oil Level - Check............................................99
Axle Oil ..................................................................76
B Environment Protection Section...............................1
Back-up Alarm (If Equipped) - Test........................95
Battery - Check, Exchange, Charge.......................92
Battery Access.......................................................92
Battery Charging....................................................94
Battery Discharge Indicator....................................77
Battery Disconnect Before Servicing Warning .........9
Battery Exchanging................................................93
Battery Restraint Warning........................................8
Battery ..............................................................78,80
Before Operating the Lift Truck ..............................48
Before Storage.......................................................65
Bent or Twisted Forks ............................................69
Better Battery Performance ...................................50
Brake Fluid ............................................................76
Brake Oil Level - Check .........................................99
C Fork Inspection ...................................................... 70
Capacity Chart .......................................................33
Carriage Chain Adjustment..................................112
Carriage Roller Extrusion – Adjust .........................87
Causes of Fork Failure...........................................69
Chain and Linkage Oils (DEO or EO) ....................75
Chassis Pivot Eyebolts - Lubricate.......................103
Check Electrolyte...................................................93
Check for Equal Tension......................................111
Check Inflation Pressure (If equipped with
pneumatic tires) .....................................................95
Cold Storage Applications......................................80
Compact Display Keys...........................................83
Control Panel - Clean, Inspect .............................106
Crosshead Rollers - Inspect.................................104
118
D
Daily Inspection ..................................................... 70
Declaration of Conformity ...................................... 29
Directional Control Lever ....................................... 45
Directional Lever – Check.................................... 107
DOWN key ............................................................ 84
Drive and Pump Motor - Clean, Inspect ............... 108
Drive Axle Oil - Change ....................................... 108
During Storage ...................................................... 65
E
E-S-H key .............................................................. 84
Electrical Braking (Plugging).................................. 53
Emergency Switch (If Equipped)............................ 43
Emergency Switch................................................. 56
Environment Management.......................................3
Environment Protection ....................................... 117
Every 10 Service Hours or Daily ............................ 90
Every 1000 Service Hours or 6 Months ............... 108
Every 250 Service Hours or Monthly ..................... 99
Every 2500 Service Hours or 15 Months ............. 116
Every 500 Service Hours or 3 Months ................. 103
F
Fatigue .................................................................. 69
Film for Function of Pedals (If Equipped)............... 45
Finger Tip (Option) ................................................ 55
First 250 Service Hours or a Month ....................... 98
First 50 - 100 Service Hours or a Week ................. 96
First Installation ..................................................... 70
Foreword .................................................................2
Fork - Inspect....................................................... 113
Forward and Backward Adjustment ....................... 57
Front and Rear Floodlights Switch......................... 42
Front Axle Oil - Change ......................................... 96
Front Axle Oil Level ............................................... 99
Front Axle Oil......................................................... 76
Front Wheels ....................................................... 101
Function of Knobs.................................................. 55
Fuses - Replace .................................................... 89
G
General Hazard Information ....................................9
General Section.......................................................1

H M
Hook-on type Fork .................................................64
Horn Button ...........................................................42
How to Survive in a Tipover (If Operator Restraint
System Equipped) .................................................28
Hydraulic Oil - Check, Change.............................116
Hydraulic Oil Level - Check..................................101
Hydraulic Oil ..........................................................75
Hydraulic Return Filter - Change............................98
Hydraulic System...................................................80
I Mast, Carriage, Lift Chains & Attachmemts - Inspect,
Identification, Lift Capacity and Attachment Plate....35
Important Safety Information....................................4
Improper Modification or Repair.............................69
Inching into Loads..................................................58
Index Section ...........................................................1
Index....................................................................118
Indicator - Check....................................................94
Information Section..................................................1
Inspection, Maintenance and Repair of Lift Truck
Forks......................................................................68
K O
Key Switch.............................................................37
L Operation.................................................................3
LED Indicators .......................................................41
Lift Chain Adjustment...........................................111
Lift Chain Wear Test ............................................111
Lift Chains - Test, Check, Adjust..........................111
Lift Chains.........................................................10,80
Lift Control knob.....................................................55
Lift Control Lever ...................................................46
Lift Fork Adjustment ...............................................64
Lift Truck Capacity Rating......................................35
Lift Truck Controls..................................................44
Lift Truck Operation ...............................................51
Lifting Drums or Round Objects .............................61
Lifting the Load ......................................................58
Literature Information...............................................2
Lubricant Information .............................................75
Lubricant Specifications .........................................75
Lubricant Viscosities and Refill Capacities.............81
Lubricant Viscosities ..............................................81
Lubricate one fitting .............................................105
Lubricate two fittings ............................................105
Lubricating Grease (MPGM) ..................................76
119
Index Section
Machine Lifting and Tiedown Information .............. 66
Maintenance and Repair........................................ 71
Maintenance Information ....................................... 13
Maintenance Intervals ........................................ 3,82
Maintenance Section ...............................................1
Maintenance ............................................................3
Mast Abbreviations ................................................ 36
Mast Chain Adjustment - FF,FFT Mast ................ 112
Mast Channels - Lubricate..................................... 92
Mast Hinge Pins - Lubricate................................. 105
Mast Pivot Eyes - Check, Lubricate ..................... 103
Lubricate.............................................................. 102
Military specifications MIL-L-2104D or E................ 75
Monitoring Systems Indicator ................................ 38
Mono-Ped Control System (Option)....................... 54
N
No Alarm, No Movement (OPTION) ...................... 41
No Riders Warning ..................................................8
Noise and Vibration ............................................... 32
Operating Techniques ........................................... 58
Operation Information ............................................ 11
Operation Section....................................................1
Operator Restraint System (If Equipped) ............... 16
Operator’s Station and Monitoring Systems........... 37
Operator’s Warning and Identification Plate........... 35
Operator’s Warning Plate ...................................... 35
Overhead Guard - Inspect ................................... 105
Overloading ........................................................... 69
P
Parking Alarm Warning (If Equipped) .................... 63
Parking Brake - Test............................................ 100
Parking Brake Lever .............................................. 44
Parking the Lift Truck............................................. 62
Power Modules – Discharge.................................. 88
Prepare for the Self Diagnostic - Test.................... 83
Index Section

R TURTLE key .......................................................... 84

Rear Axle Oil - Change ..........................................97

Rear Axle Oil Level ..............................................100 U
Rear Axle Oil..........................................................76
Refill Capacities .....................................................81 Unloading .............................................................. 60
Run Time Diagnostic .............................................84 Up and Down Adjustment ...................................... 57
UP key................................................................... 83
Use following engine oils are recommended for use
S on chains and linkages. ......................................... 75

Safety Rules ..........................................................22

Safety Section..........................................................1 W
Safety ...................................................................2,5
Seat - Lubricate .....................................................89 Walk-Around Inspection - Inspect .......................... 90
Seat Adjustment ...............................................16,42 Walk-Around Inspection......................................... 48
Seat Belt ................................................................18 Warning Lamp ....................................................... 56
Seat Switch............................................................37 Warning Signs and Labels.......................................5
Self Diagnostics - Test ...........................................83 Wheel Bolts - Check ............................................ 101
Serial Number........................................................34 When Required...................................................... 83
Serial Numbers Locations......................................34
Service Brake Pedal ..............................................44
Shipping.................................................................66
Sideshift Attachment Control (If Equipped) ............47
Sideshift Attachment Control .................................56
Specifications.........................................................30
Steer Wheels .......................................................101
Steering Knob (If Equipped)...................................54
Steering Mechanism - Lubricate ..........................105
Storage Information ...............................................65

Table of Contents ....................................................1

Tilt Control knob.....................................................55
Tilt Control Lever ...................................................46
Tilt Cylinder - Check, Lubricate ............................103
Tilt Steering Column ..............................................42
Tire Inflation Information ........................................72
Tire Inflation Pressures Adjustment .......................72
Tire Inflation ...........................................................72
Tire Shipping Pressure ..........................................72
Tires and Wheels - Inspect ....................................95
Tires and Wheels - Inspect, Check ......................110
Torque for Metric Fasteners...................................74
Torque for Standard Bolts, Nuts and Taperlock
Studs .....................................................................73
Torque for Standard Hose Clamps - Worm Drive
Band Type .............................................................73
Torque Specifications ............................................73
Torques for Bolts and Nuts With Standard Threads ...73
Torques for Taperlock Studs..................................74
Towing Information ................................................67
Transportation Hints ..............................................66
Traveling................................................................59
Turning ..................................................................59

120