ITC.224.2 11 Maintenance-TCM

Course Module: ITC.224.
MAINTENANCE
FB10~35-9
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Some products may be shown with optional equipment. 1
Course Module: ITC.224.2
Contents
• Objectives …………………………………………………………………………………………………... Page 3

• Recommended Oil and Quantity …………………………………………………………………………. Page 4
• Pre-Delivery Inspection (PDI) …………………………………………………………………………….. Page 5
• Display Settings ……………..……………………………………………………………………………... Page 6
• Calibrate the Battery Voltage ……………………………………………………………………………... Page 7
• Calibrate the Battery Indicator ……………………………………………………………………………. Page 8
• Start the Hour Meter ………………………………………………………………………………………. Page 9
• Save the Truck File …………………………………………………………………………..................... Page 10
• Set the Attachment Speed ………………………………………………………………………………... Page 11
• Set the Lift Lock ……………………………………………………………………………………………. Page 12
• Maintenance Interval ………………………………………………………………………………………. Page 13
• Maintenance Schedule ……………………………………………………………………………............ Page 14-15
Objectives
At the end of this chapter, you will learn and understand:

• The recommended oil and quantity used on the truck.
• The list of important tasks to perform during the pre-delivery inspection (PDI).
• The recommended maintenance interval.
Recommended Oil and Quantity
• The recommended oil and quantity is as follow:

• For lift chain, it is recommended to apply genuine chain coat or other SAE 30 equivalent lubricant.
Type of Oil / Lubricant
Location Truck Model Quantity
(Standard) (Cold Store / Full Cold Store)
1.0~2.5 ton 3.5 L
Front axle Gear Oil, SAE 10W
3.0~3.5 ton 5.9 L
2W300 21.6 L (17.0 L)
1.0~1.75 ton 2F300 22.6 L (17.0 L)
3F470 22.0 L (17.0 L)
2W300 23.7 L (18.8 L)
All hydraulic circuits Hydraulic Oil, Hydraulic Oil,
2.0~2.5 ton 2F300 24.6 L (18.8 L)
(Hydraulic oil tank) ISO VG32 ISO VG15
3F470 24.0 L (18.8 L)
2W300 28.7 L (23.8 L)
3.0~3.5 ton 2F300 30.0 L (23.8 L)
3F470 28.5 L (23.8 L)
1.0~1.75 ton 140-180 cc (60-102 cc)
All brake circuits
2.0~2.5 ton Brake Fluid, DOT 3 150-190 cc (60-102 cc)
(Brake oil reservoir)
3.0~3.5 ton 160-200 cc (60-102 cc)
All greasing points 1.0~3.5 ton Lithium Grease No.2 Low Temperature Grease As Required
Pre-Delivery Inspection (PDI)
• When performing the pre-delivery inspection, on top of your checklist, it is important to perform the following
tasks:
❑ Calibrate the Battery Voltage
❑ Calibrate the Battery Indicator
❑ Start the Hour Meter
❑ Save the Truck File
• And in some situation, perform the following tasks as required:

o Set the Attachment Speed
o Set the Lift Lock
Display Settings
User Access Manager Access Service Access

Key START
Hold and
press the following:
Press > 3s
Default: 0000
Master: 7105
Calibrate the Battery Voltage
• In some cases, the truck is ordered without any battery. The battery is sourced and
fitted locally. It is important to calibrate the battery voltage so the controller system
can detect the voltage accurately.
• Calibrate the Battery Voltage as follow:
i. Key switch “ON”.
ii. Measure the battery voltage*.
iii. On the display, go to Service Screen.
iv. Navigate to CALIBRATION > VOLTAGE.
v. Input the measured voltage.
vi. Press “OK” to complete the calibration.
• When the PS Controller is replaced, re-calibrate the battery voltage.

* If the battery voltage is measured when key switch “OFF”, the calibration will not be accurate as the voltage will drop slightly
when key switch “ON”.
Calibrate the Battery Indicator
• Sometimes, when the truck is fitted with an accessory (eg: heater), the battery
indicator may not show the full-charge level when the key switch “ON” with a fully-
charged battery.
• Calibrate the Battery Indicator as follow:
i. Key switch “ON”. Accessory (eg: heater) “ON”.
ii. Measure the battery voltage.
iii. On the display, go to Service Screen.
iv. Navigate to CALIBRATION > BATTERY INDICATOR.
v. Input the measured voltage.
vi. Press “OK” to complete the calibration.
• Range of offset: ± 1.0V
Start the Hour Meter
• By default, the hour meter is OFF when truck is shipped from

factory. The hour meter tracks the usage of the truck as to
schedule the next servicing. It is also used as a data for failure
analysis.
• Start the Hour Meter as follow:
i. On the display, go to Service Screen.
ii. Navigate to SETTING > VEHICLE > HOUR METER.
iii. Select START.
iv. Select KEY ON.
v. Press “OK” to save.
Save the Truck File
• All the truck settings are saved in the PS Controller. When the PS Controller is replaced, all the settings will
be defaulted. Setting up each parameter can be time-consuming.
• Using the B-80 Manager, save a copy of the truck settings to the laptop as follow:
i. Battery connected to truck.
ii. Key switch OFF.
iii. Connect B-80 Manager to truck.
iv. Click on SETTING.
v. Click on FILE SAVE.
Set the Attachment Speed
• In a standard configuration, the truck comes with a 3-way hydraulic

control valve and 2-way hydraulic piping. After installing a local-
sourced attachment (eg: side-shifter, fork-positioner, rotator etc.),
the attachment is not working.
• Check and set the number of levers as follow:
ii. Navigate to SETTING > HYDRAULIC > NUMBER OF
LEVERS.
iii. Set to the correct number of levers* (Default: 2).
iv. Press “OK” to save.
• Set the Attachment Speed as follow:
v. Navigate to HYDRAULIC > ATT1 SPEED*.
vi. Set to the required speed.
vii. Press “OK” to save.
* Depending on the attachment, eg: Side-shift fork-positioner needs 2 levers in addition to Lift and Tilt.
Set the number of levers to “4”. If the number of levers is set to “4”, set the speed for ATT1 & ATT2.
Set the Lift Lock
• Lift lock (lift interrupt) restricts lifting operation by the discharge level of the battery.
When the BDI level shows 1 red bar, the lift function is cut-off. Operator can only
drive forklift to the charging bay to charge the battery.
• This feature helps to protect the battery life span.
• This is a sale-option feature and by default, it is OFF.
• Set the Lift Lock as follow:
ii. Navigate to SETTING > OPTION > LIFT LOCK.
iii. Select ON.
iv. Press “OK” to save.
Maintenance Interval
• Refer to the OMM (Operating and Maintenance Manual) and Service Manual for the complete maintenance
checklist.
• The recommended maintenance interval is based on the normal forklift operating condition and assumption
that it is operated for 200 hours in a month.
• Should the truck be operating in corrosive and abrasive environments, the maintenance interval must be more
frequent.
Maintenance Interval Responsibility

Daily Customer / Operators
Weekly Customer / Operators
Monthly (every 200 hours) Technicians
Semiannually (every 1200 hours) Technicians
Annually (every 2400 hours) Technicians
Maintenance Schedule
Inspection and replacement interval Item

Daily • Inspect the brake fluid level of the reservoir tank
• Inspect the electrolyte level
Weekly • Inspect the above items
• Inspect hydraulic oil level
Monthly (every 200 hours) • Inspect the above items
• Lubricate the following:
• King pins (rear axle)
• Link pins (rear axle)
• Axle support (rear axle)
• Mast support
• Rear strip of mast
• Tilt cylinder rod end
• Lift chain
• Lift bracket side rollers
• Finger bar
• Inspect drive gear oil (refill if necessary)
Semiannually (every 1200 hours) • Inspect the above items
• Replace the following:
• Gear oil
• Brake fluid
• Hydraulic oil
Maintenance Schedule
L Tilt cylinder rod end Mast rear strip L
L Lift Bracket Side Roller Lift chain L
T
L Finger bar Brake Fluid
R
Battery water T
L Mast Support
T: Top-up
R: Replace King pin &
L: Lubricate T
Drive gear
Link pin
R L 10
Before Operation / Daily pts
50hr / Weekly
200hr / Monthly T Axle support L
Hydraulic oil
1200hr / Semi-annually R
Questions?
Thank you.

ITC.224.2 11 Maintenance-TCM

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Course Module: ITC.224.

• Objectives …………………………………………………………………………………………………... Page 3

At the end of this chapter, you will learn and understand:

Recommended Oil and Quantity

• The recommended oil and quantity is as follow:

Pre-Delivery Inspection (PDI)

• And in some situation, perform the following tasks as required:

User Access Manager Access Service Access

Calibrate the Battery Voltage

• When the PS Controller is replaced, re-calibrate the battery voltage.

Calibrate the Battery Indicator

• Range of offset: ± 1.0V

Start the Hour Meter

• By default, the hour meter is OFF when truck is shipped from

Save the Truck File

Set the Attachment Speed

• In a standard configuration, the truck comes with a 3-way hydraulic

Set the Lift Lock

Maintenance Interval Responsibility

Inspection and replacement interval Item

L Tilt cylinder rod end Mast rear strip L

L Lift Bracket Side Roller Lift chain L

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