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For use in service manual

form SB4197E
sb4206e01
Feb. 2012

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 SB4206E00


Safety SB2003E00
Torque Specifications SB2004E00

DRIVE & CONTROL SYSTEM

MicroController Control System SB4207E01

POWER TRAIN

Power Train SB4208E01

VEHICLE SYSTEM

Vehicle System SB4209E00


Vehicle System D & A SB4210E00
Hydraulic System Schematic SB4204E00
Electric System Schematic SB4212E01

OPERATION & MAINTENANC E

Operation & Maintenance Manual SB2347E

Models ; B22X-5, B25X-5, B30X-5, B35X-5


SB2003E00
Dec. 1998

WARNING

SAFETY

WARNING WARNING

The proper and safe lubrication and maintenance Do not operate this machine unless you have
for this machine, recommended by DOOSAN, are read and understand the instructions in the
outlined in the OPERATION & MAINTENANCE OPERATOR'S GUIDE. Improper machine
GUIDE for this machine. operation is dangerous and could result in
Improper performance of lubrication or injury or death.
maintenance procedures is dangerous and could
result in injury or death. Read and understand the
OPERATION & MAINTENANCE GUIDE before 5. Use steps and grab handles (if applicable) when
performing any lubrication or maintenance. mounting or dismounting a machine. Clean any mud or
debris from steps, walkways or work platforms before
using. Always face machine when using steps, ladders
Theserviceman or mechanic maybe unfamiliar with many and walkways. When it is not possible to use the
of the systems on this machine. This makes it important designed access system, provide ladders, scaffolds, or
to use caution when performing service work. A work platforms to perform safe repair operations.
knowledge of the system and/or components is 6. To avoid back injury, use a hoist when lifting
important before the removal or disassembly of any components which weigh 23 kg (50 lb.) or more. Make
component. sure all chains, hooks, slings, etc., are in good
Because of the size of some of the machine condition and are of the correct capacity. Be sure
components, the serviceman or mechanic should check hooks are positioned correctly. Lifting eyes are not to
the weights noted in this Manual, Use proper lifting be side loaded during a lifting operation.
procedures when removing any components. 7. To avoid burns, be alert for hot parts on machines
Following is a list of basic precautions that should always which have just been stopped and hot fluids in lines,
be observed. tubes and compartments.

1. Readand understand all Warning plates and decals 8. Be careful when removing cover plates. Gradually
on the machine before operating, lubricating or back off the last two bolts or nuts located at opposite
repairing the product. ends of the cover or device and pry cover loose to
relieve any spring or other pressure, before removing
2. Always wear protective glasses and protective shoes the last two bolts or nuts completely.
when working around machines. In particular, wear
protective glasses when pounding on any part of the 9. Be careful when removing filler caps, breathers and
machine or its attachments with a hammer or sledge. plugs on the machine. Hold a rag over the cap or plug
Use welders gloves, hood/goggles, apron and other to prevent being sprayed or splashed by liquids under
protective clothing appropriate to the welding job pressure. The danger is even greater if the machine
being performed. Do not wear loose-fitting or torn has just been stopped because fluids can be hot.
clothing. Remove all rings from fingers when working 10. Always use tools that are in good condition and be
on machinery. sure you understand how to use them before
3. Do not work on any machine that is supported only by performing any service work.
lift jacks or a hoist. Always use blocks or jack stands 11. Reinstall all fasteners with same part number. Do not
to support the machine before performing any use a lesser quality fastener if replacements are
disassembly. necessary. Do not mix metric fasteners with
4. Lower the forks or other implements to the ground standard nuts and bolts.
before performing any work on the machine. If this 12. If possible, make all repairs with the machine parked
cannot be done, make sure the forks or other on a level, hard surface. Block machine so it does
implements are blocked correctly to prevent them not roll while working on or under machine.
from dropping unexpectedly.
1 of 2
WARNING

13. Disconnect battery and discharge any capacitors 21. Do not operate a machine if any rotating part is
(electric trucks) before starting to work on machine. damaged or contacts any other part during
Hang "Do Not Operate" tag in the Operator's operation. Any high speed rotating component that
Compartment. has been damaged or altered should be checked
for balance before reusing.
14. Repairs, which require welding, should be
performed only with the benefit of the appropriate 22. On LP equipped lift trucks, be sure to close the
reference information and by personnel adequately valve on the LP tank before service work is
trained and knowledgeable in welding procedures. performed. Always close the valve on the LP tank
Determine type of metal being welded and select when the lift truck is being stored. Do not check for
correct welding procedure and electrodes, rods or LP leaks with an open flame.
wire to provide a weld metal strength equivalent at
23. Caution should be used to avoid breathing dust that
least to that of parent metal.
may be generated when handling components
15. Do not damage wiring during removal operations. containing asbestos fibers. If this dust is inhaled, it
Reinstall the wiring so it is not damaged nor will it can be hazardous to your health. Components in
be damaged in operation by contacting sharp DOOSAN products that may contain asbestos
corners, or by rubbing against some object or hot fibers are brake pads, brake band and lining
surface. Do not connect wiring to a line containing assemblies, clutch plates and some gaskets. The
fluid. asbestos used in these components is usually
bound in a resin or sealed in some way. Normal
16. Be sure all protective devices including guards and
handling is not hazardous as long as airborne dust
shields are properly installed and functioning
which contains asbestos is not generated.
correctly before starting a repair. If a guard or shield
must be removed to perform the repair work, use If dust which may contain asbestos is present, there are
extra caution. several common sense guidelines that should be
followed.
17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance a. Never use compressed air for cleaning.
or repair work is performed, which requires the
b. Avoid brushing or grinding of asbestos containing
mast in the raised position.
materials.
18. Loose or damaged fuel, lubricant and hydraulic
c. For clean up, use wet methods or a vacuum
lines, tubes and hoses can cause fires. Do not
equipped with a high efficiency particulate air
bend or strike high pressure lines or install ones
(HEPA) filter.
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks d. Use exhaust ventilation on permanent machining
with your hands. Pin hole (very small) leaks can jobs.
result in a high velocity oil stream that will be
e. Wear an approved respirator if there is no other
invisible close to the hose. This oil can penetrate
way to control the dust.
the skin and cause personal injury. Use cardboard
or paper to locate pin hole leaks. f. C
 omply with applicable rules and regulations for
the work place (for example in the U.S.A., OSHA
19. Tighten connections to the correct torque. Make
requirements as set forth in 29 CFR 1910. 1001).
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibration g. Follow environmental rules and regulations for
or rubbing against other parts during operation. disposal of asbestos.
Shields that protect against oil spray onto hot
h. Avoid areas where asbestos particles may be in the
exhaust components in event of a line, tube or seal
air.
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
SB2004E00
Dec.1998

Specifications
TORQUE
SPECIFICATIONS
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 4515 lb i in
3/8-24 12 2 11020 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. 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
1. For a metal tube to hose installation, install the tube into the part it is used on until backup washer (4) just
and tighten all bolts finger tight. makes contact with the face of the part it is used on.
2. Tighten the bolts at the rigid end. 2.To put the fitting assembly in its correct position, turn
3. Install the hose and tighten all bolts finger tight. the fitting body (2) out (counterclockwise) a
maximum of 359. Tighten locknut (3) to the torque
4. Put the hose in a position so that it does not make shown in the correct chart for the fitting used.
contact with the machine or another hose.
NOTE: If the fitting is a connector (straight fitting), the
5. Tighten the bolts on both connections. hex on the body takes the place of the locknut. To
6. Start the engine. install this type fitting, tighten the hex against the face
of the part it goes into.
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 TORQUES FOR FLARED AND O-RING FITTINGS
the machine or other hoses.
The torques shown in the charts that follow are to be
9. Shut off the engine.
used on the nut part of 37 Flared, 45 Flared and
10. If necessary, put the hose in a new position where it Inverted Flared fittings (when used with steel tubing),
will not make contact when the implement is moved. 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
37 FLARED AND STRAIGHT THREAD O-RING FITTINGS

37 FLARED O-RING SWIVEL NUTS


FITTING-PLUG
IDAS004B

37 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
45 FLARED AND 45 INVERTED FLARE FITTINGS

INVERTED
45 FLARED 45 FLARED
IDAS007B

45 FLARED AND 45 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 45 FLARE

IDAS010B

AIR CONDITIONING FITTINGS


O-RING FITTING END 45 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
SB4207E01
Oct.2006

MicroController
Control System
Specification
System Operation
Testing & Adjusting

B22X-5, B25X-5, B30X-5, B35X-5


for Electric Lift Trucks
Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, and 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 Instrument Panel
Assembly Layout of Controller............................... 9 Accessing Stored Error Codes...........................114
Assembly Layout of Motors ................................... 9 Default Setting....................................................110
Component Measurements ................................... 5 Diagnostic Mode.................................................111
Control Panel Layout ........................................... 10 Display Keys Utilization ......................................106
Controller AS Specification .................................... 6 Instrument Panel ................................................102
Drive Motor Specification....................................... 7 Indicator (Compact Display).......................... 102
Fuses ..................................................................... 9 LED Indicators............................................... 105
Instrument Panel Layout........................................ 8 Monitoring Systems....................................... 102
Pump Motor Specification...................................... 7 No Alarm, No Movement............................... 105
List of diagnostic.................................................112
Parameter Calibration ........................................107
Systems Operation Sensor Initial Setting ..........................................110
General Information ............................................. 13
Advantage of AC motor ................................... 13
Basic ITC ......................................................... 16
Eye Software Interface
Comparison between AC and DC motor ......... 13 Features .............................................................119
ITC system characteristics .............................. 16 General Information............................................117
Main ITC(Intelligent Torque Control) features . 15 Installation ..........................................................118
Glossary............................................................... 11 Main Menu..........................................................120
Installation and Wiring ......................................... 17 Calibration ..................................................... 129
Accessory Circuits ........................................... 26 Configuration Menu (Setup) .......................... 124
General ............................................................ 17 Data Logging ................................................. 146
Hydraulic Pump Motor Circuit.......................... 25 Flash.............................................................. 148
K1 connector: list of all terminals..................... 19 Not Actual Software / Eeprom Crc Fault ....... 123
System Circuit.................................................. 23 Password Insertion........................................ 121
Thermal protection circuit ................................ 26 Submenus ..................................................... 123
Test ............................................................... 125

Testing and Adjusting


Preparation Tests and Check .............................. 27
Troubleshooting of Eye Program
Programmable Parameters.................................. 30 Flash Programmation .........................................149
Adjustable Parameters Description ................. 30 Generality ...........................................................149
E-S-H Energetic Modes Parameters ............... 35 Other Problems ..................................................149
Some Functions Management............................. 36 Serial Communication ........................................149
B.D.I. Measure Management........................... 36 Software Installation ...........................................149
Buzzer Management ....................................... 36
Pump Motor Modes ......................................... 36
Static Return to Off .......................................... 36 Appendix
Appendix A : 80[V] Parameter List .....................150
Appendix B : Error Code List..............................153
Diagnostic and Troubleshooting Appendix C : Contraction for dot matrix display. 160
Alarm List ............................................................. 37 C.1. Alarm Code............................................ 160
General Description ............................................. 37 C.2. Calibration Code.................................... 161
Electrical System Adjustment .............................. 99 C.3. Diagnostic Code .................................... 163
System Tests and Adjustments ........................... 98
Troubleshooting Problem List.............................. 47

3
Specifications
Component Measurements

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

5
Controller AS Specification

BATTERY VOLTAGE 46~106 V


MAXIMUM IMPULSIVE DRIVE INVERTER CURRENT 320 A
MAXIMUM IMPULSIVE PUMP INVERTER CURRENT 405 A
SWITCHING FREQUENCY 9 KHz
EFFICIENCY 95 %
PROTECTION LEVEL IP54
MECHANICAL SIZE 580x248x187
WEIGHT 24 Kg
VIBRATION 5g 10-500Hz in X,Y,Z axis
TEMPERATURE RANGE - 30 C + 40 C
MAXIMUM MODULE TEMPERATURE 100C
CONTROLLER Complies with EN 1175-1 EN 12895-1
MAIN CONTACTOR 250A
MAIN FUSE 425A
KEY FUSE 10A

6
Drive Motor Specification Pump Motor Specification

POWER 10 KW POWER 21 KW
VOLTAGE 55.9 V VOLTAGE 50 V
CURRENT 139 A CURRENT 348 A
RATED SPEED 1900 RPM RATED SPEED 1540 RPM
MAXIMUM SPEED 4500 RPM MAXIMUM SPEED 4500 RPM
FREQUENCY 63 Hz FREQUENCY 77 Hz
Cos 0.85 Cos 0.79
SERVICE S2 60' SERVICE S3 15%
INSULATION CLASS F INSULATION CLASS F
PROTECTION DEGREE IP 20(with AXLE) PROTECTION DEGREE IP 54
BEARINGS 6206 2RS BEARINGS 6208 2RS
WEIGHT 46 Kg WEIGHT 95 Kg

7
Instrument Panel Layout

8
Fuses Assembly Layout of Motors
Line ..................................................................... 700A
Key ........................................................................ 10A
Horn ...................................................................... 10A
DC / DC Converter ................................................ 10A
Light ..................................................................... 10A
Option light ............................................................ 10A

Assembly Layout of Controller

9
Control Panel Layout

NOTE: Apply a small amount of D557047 Thermal Joint Compound on control panel plate and mating surface
prior to assembly. Communication cables assembly with power units and logic control unit uses the
micro screw driver(2.5*100mm)

Communication cable's assembly with Power Unit and Logic Control Unit uses Micro Screw Driver

(1) Logic Control Unit. Use a socket wrench (7mm) to hold bolts
(2) Left Drive Motor Power Unit. Use a hex bit socket (5mm) wrench (100mm) or L-wrench to hold bolts
(3) Pump Motor Power Unit
(4) Right Drive Motor Power Unit
(5) FUSE. Use a socket wrench (13mm) and a wrench (13mm) to hold bolts
(6) Line Contactor
(7) Bus Bar. Use a socket wrench (13mm) and a socket wrench (17mm) to hold bolts

10
Systems Operation
Glossary
NAME DESCRIPTION

Accelerator A device that converts mechanical movement into an 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.

11
NAME DESCRIPTION

Microprocessor A small computer chip preprogrammed to control the various electrical functions on a
lift truck.
Normal Condition Words used with a switch or relay. Their normal condition is their condition when they
are not controlled by the application of force, temperature, pressure, or electricity.
MOSFET A semiconductor component used in electric lift trucks as an electronic switch. A
MOSFET most often has three terminals, a GATE (G), a DRAIN (D), and a
SOURCE(S). A MOSFET is a voltage-controlled device and required only a small
input current. The switching speed is very high.
Ohm The unit of measurement of resistance. The amount of resistance that will let one volt
push only one ampere of current through it.
ON-Time The amount of time current flows through a transistor.
Open Circuit Wiring or components of a circuit that have no continuity.
Overload The presence of voltage or current which is greater than an electrical circuit or
component is designed to handle.
Plugging A portion of electrical braking where the generated current is directed back through
the armature.
Relay An electrical component consisting of an electromagnetic coil and a set of small
contact tips. Control current passes through the coil, building a magnetic field which
closes or opens the contact tips. When the contact tips are closed, low current can
flow in a separate isolated circuit.
Resistor A component made of a material that has a specific resistance to the flow of current.
Rotor Part that rotate of motor
Schematic A line drawing of an electrical or electronic assembly which uses symbols to show
individual components. It shows how the components, wires and connectors function
electrically.
Short Circuit An electrical connection between two or more components that is not desired.
Socket The female contact of a connector that slips over a male contact (pin) of another
connector.
Solid State Reference to semiconductor components or circuits that use semiconductor
components that have no moving parts, such as diodes and transistors.
Stator Fixed part in driving state of motor
Switch A component used to control an electric circuit. It can close or open a circuit.
Systems The electrical components, circuits, and connections that deliver power to perform
specific tasks.
Terminal An electrical connection point on an electrical component.
Thermal Sensor A sensor that activates at a set temperature.
Volt The unit of measurement of electromotive force. One volt is the force needed to
make one ampere of current flow through one ohm of resistance in a circuit.
Watt The unit of measurement of power. The amount of power used when one volt pushes
one ampere of current through a resistance of one ohm. The result of amperes
(current) multiplied by volts (voltage) is watts (power).
Wire A conductor used to provide a path for current to flow to and from electrical
components.
Wiring Diagram A drawing using visual representation of components the way they actually look. It is
used to show the locations of components and the connections between them.
Zener Diode A special diode used to regulate voltage or as an over-voltage (too high a voltage)
protector.

12
General Information
Advantage of AC motor Comparison between AC and DC
motor
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
4
studies about this matter. maintenance free maintenance to brushes

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


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

13
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 is 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.

14
Main ITC (Intelligent Torque Control) Software control algorithm is customized in order to
features best fit lift truck characteristics; you can set the
value of a wide range of parameters, in order to
Most important features of Intelligent Torque optimize system performance and to adjust the
Control system developed by DHIM the settings of main functions in compliance with users
following: needs.

1. Control unit: One panel assembly containing User can interact with control board making use of a
three power inverters for drive and pump and a software application (named EYE) developed by
control board; main board, wired directly to the DHIM, or with COMPACT display. In both cases, its
power modules, could manage up to 4 inverters. possible to obtain an exhaustive on line diagnostic
The presence of 2 DSP (Digital Signal for all lift truck functional parameters and also to
Processors), working in mutual redundant adjust them.
control, guarantees powerful software
performance: in case of such a system, You can upgrade control board internal software
managing both drive and pump motors, high connecting a PC via serial port (or via USB 1.x or
dynamic performance in vectorial torque control higher, inserting the appropriate serial port-USB
can be obtained. adapter); in fact, working with RS232
communication standard, EYE application permit to
2. Two asynchronous three-phase drive motors load and upgrade panel software in any working
equipped with magnetic sensors (64 impulses/ conditions, if only control board is correctly fed on .
rotation).

3. An asynchronous three-phase pump motor for


lifting equipped with magnetic sensor (64
impulses/ rotation).

4. Instrument Panel.

Instrument Panel

15
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

16
Installation and Wiring
General

1. A metallic container encloses control board (Fig.


1).

2. There are three power modules (see fig 2 for


single module) assembled to main board as
shown in Fig. 3 and Fig. 4.

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


Fig. 1: Logic control board
to interface control board to lift truck
electrical/electronic sub-devices. See Fig. 4 for
a view of K1- 68 ways connector.

4. Three 26 ways connectors (named C1 C2 C4)


permit to wire and control 3 power inverters. No
details are given about the pin-out of these
connectors t, because they are not user
accessible for maintenance or diagnostic
operations. Power modules shall be connected
also to battery supply (wire named +B and -B)
and to corresponding motor phases.

Fig. 2: Single power module

Working on electrical systems is potentially


dangerous; you should protect yourself against:
Uncontrolled operation: some conditions could
cause the motor to run out of control:
Disconnect the motor or jack up the vehicle and
get the drive wheels off the ground before
attempting any work on motor control circuitry.
High current arcs: batteries can supply very
high power, and arcs can occur if they are short
circuited. Always open the battery circuit
ground before working on motor control circuit.
Wear safety glasses and use properly insulated
Fig. 3: Power modules assembly with main contactor and
tools to prevent shorts. fuses
Lead acid batteries: charging or discharging
generates hydrogen gas, which can build up
and go around the batteries. Follow the battery
manufacturers safety

Fig. 4: Power modules assembly with control board mounted

17
Fig. 4: View of accessible terminals on 68 ways connector

18
K1 connector: list of all terminals

Pin
Use Name Function
number
K1 1 IN -Battery Negative supply voltage of control board
K1 2 OUT + 24 V supply
IN Lift pressure (optional) Proportional voltage signal (0-5V); you can connect a
K1 3 A pressure linear sensor, made by SME cod B00ID160
working correctly in 0250 bar pressure range
IN start switch for accelerator START signal
K1 4
D pedal N.O. with internal pull-up and Vmax(in)=24V
IN accelerator pedal 2 Proportional voltage signal (0-5V) or (0-12V) managed
K1 5
A potentiometer as accelerator pedal input
IN park brake switch Park brake signal
K1 6
D N.C., with internal pull-up and Vmax(in)=24V
IN seat switch Seat switch signal
K1 7
D N.O., with internal pull-up and Vmax(in)=24V
IN reverse drive direction switch reverse drive direction signal
K1 8
D N.O., with internal pull-up and Vmax(in)=24V
IN forward drive direction switch forward drive direction signal
K1 9
D N.O., with internal pull-up and Vmax(in)=24V
IN accelerator pedal 1 Proportional voltage signal (0-5V) or (0-12V) managed
K1 10
A potentiometer as accelerator pedal input
OUT + 12 V supply +12V supply voltage (self-protected electronic
K1 11
component) with: Idc (nominal) =500mA; Imax = 1Adc
IN/OUT LIN data line (Display I/0)
K1 12 Data line of LIN interface for COMPACT display
D
IN not used - Digital input, for an optional encoder, Vmax(in) =5V
K1 13
A/D - Analogue input (0-12V)
OUT + 5 V encoder supply +5V supply voltage (self-protected electronic component)
K1 14
with: Idc (nominal) =500mA; Imax = 1Adc
OUT GND Negative supply voltage for data type signals, with self
K1 15 protection against noises coming from DC power line;
Imax=500mA
IN PHASE B of left drive motor PHASE B signal of the sensor bearing mounted into the
K1 16
D encoder left drive motor; internal pull-up; Vin:(0 5V)
IN PHASE A of left drive PHASE A signal of the sensor bearing mounted into the
K1 17
D motor encoder left drive motor; internal pull-up; Vin:(0 5V)
K1 18 OUT + coil main breaker Positive command of contactor coil; Inom=1A; Imax = 5A
K1 19 OUT - coil main breaker Main breaker coil reference signal; Inom=1A; Imax = 5A
OUT not used Self-protected open collector power output, you can
K1 20 A apply it to an ON/OFF or proportional electrovalve coil;
Vmax =Vali; Inom=2A; Imax=6A

19
Pin
Use Name Function
number
OUT not used Self-protected open collector power output, you can
K1 21 D apply it to an ON/OFF or proportional electrovalve
coil; Vmax =Vali; Inom=2A; Imax=6A
K1 22 IN + battery Control board supply voltage; V = Vsupply
K1 23 IN + battery key input Supply voltage of key and coils ; Vkey=Vsupply
IN not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;
K1 24
A/D - Analogue input (0-12V)
IN not used Digital input , N.O., internal pull-up, Vmax(in)=24V
K1 25
D
IN not used Analogue input (0-12V)
K1 26
A
IN lift pressure Analogue input (0-5V)
K1 27
A
IN PHASE B of pump PHASE B signal of the sensor bearing mounted into
K1 28
D motor encoder the pump motor; internal pull-up; Vin:(0 5V)
IN PHASE A of pump PHASE A signal of the sensor bearing mounted into
K1 29
D motor encoder the pump motor; internal pull-up; Vin:(0 5V)
IN Not used; Digital input for an optional encoder, motor; internal
K1 30
D PHASE A of an optional encoder pull-up; Vmax(in)=5V;
IN/OUT Not used; - Digital input for an optional encoder, Vmax(in)=5V;
A/D PHASE B of an optional encoder - Open Collector power output, to command an
K1 31
ON/OFF electrovalve coil; Vmax =Vsupply; Inom=2A;
Imax=6A
IN Asynchronous RS232 RX input for asynchronous RS232 serial
K1 32
D serial RX input communication standard
IN PHASE A of left drive TX output for asynchronous RS232 serial
K1 33
D motor encoder communication standard
OUT + coil main breaker H line input for CAN (Controller Area Network )
K1 34 component; presence of internal termination
resistance
OUT - coil main breaker L line input for CAN component; presence of internal
K1 35
termination resistance
OUT not used PHASE B signal of the sensor bearing mounted into
K1 36
A the right drive motor; internal pull-up; Vin:(0 5V)
OUT not used PHASE A signal of the sensor bearing mounted into
K1 37
D the right drive motor; internal pull-up; Vin:(0 5V)
IN AUX 2 Digital input to activate pump motor auxiliary function
K1 38
AUX2; N.O., internal pull-up, Vmax(in)=24V
IN FANS Command (optional) Open Collector power output, to command fans (or
K1 39
other devices) Inom = 1A, Imax=3A; Vmax=60V;
IN not used Open Collector power output, to command an
K1 40 A/D ON/OFF
electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A

20
Pin
Use Name Function
number
IN not used Open Collector power output, to command an ON/OFF
K1 41
D electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
IN not used Open Collector power output, to command an ON/OFF
K1 42
A electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
IN not used Open Collector power output, to command an ON/OFF
K1 43
A electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
IN not used Open Collector power output, to command an ON/OFF
K1 44
D electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
IN not used PWM supply voltage for electrovalve coils (or similar
K1 45
D devices)
IN lift high 1 switch(optional) Voltage signal of lift critical high switch, N.O., internal
K1 46
D pull-up, Vmax(in)=24V
IN Not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;
K1 47
A/D - Analogue input (0-12V)

IN Pedal brake switch Activation signal for park brake, N.O., internal pull-up,
K1 48
D Vmax(in)=24V

IN Not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;


K1 49
A/D - Analogue input (0-12V)

IN lift lever potentiometer voltage Proportional voltage signal (0-12V), input of lift lever
K1 50
A potentiometer
IN Not used Proportional voltage signal (0-12V)
K1 51
A
IN Not used Proportional voltage signal (0-12V)
K1 52
A
OUT buzzer command Open Collector power output, to command buzzer
K1 53
D activation; Vmax =24V; Inom=30mA; Imax=100mA.
IN tilt switch Request of tilting, N.O., internal pull-up, Vmax(in)=24V
K1 54
D
IN lift high 2 switch(option) Voltage signal of lift critical high switch, N.O., internal
K1 55
D pull-up, Vmax(in)=24V
IN digital input for 3 / 4 wheels - Digital input to select a lift truck with 3 wheels (Closed )
D choice; or 4 wheels (Open);
K1 56
PHASE A of an optional - PHASE A signal for an optional encoder; internal pull
encoder up; Vin:(0 5V)
IN AUX1 Digital input to activate pump motor auxiliary function
K1 57
D AUX1; N.O., internal pull-up, Vmax(in)=24V
IN right drive motor thermal Analogue input (or digital as optional) used for right drive
K1 - 58
A/D sensor/ switch motor thermal sensor (0-5V); internal pull-up;
IN left drive motor thermal sensor/ Analogue input (or digital as optional) used for left drive
K1 59
A/D switch motor thermal sensor (0-5V); internal pull-up;
IN pump motor thermal sensor/ Analogue input (or digital as optional) used for pump
K1 - 60
A/D switch motor thermal sensor (0-5V)

21
Pin
Use Name Function
number
IN Not in use - Digital input , N.O., internal pull-up, Vmax(in)=5V;
K1 - 61
A/D - Analogue input (0-5V)
IN steering angle sensor voltage Proportional voltage signal (0-12V) or (0-5V), used as input
K1 62
A to steering sensor circuit
OUT Not used; Open Collector power output, to command an ON/OFF
K1 63
D Electrovalve (or alike) command electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
OUT Not used;
Open Collector power output, to command an ON/OFF
K1 64 D Electrovalve (or alike)
electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
command
OUT Not used; Open Collector power output, to command an ON/OFF
K1 65
D Electrovalve (or alike) electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
OUT Not used; Open Collector power output, to command an ON/OFF
K1 66
D Electrovalve (or alike) electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
OUT Not used Power output, to command a proportional electrovalve coil;
K1 67
A Vmax =Vsupply; Inom=2A; Imax=6A
OUT Not used; Open Collector power output, to command an ON/OFF
K1 68
D Electrovalve (or alike) electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A

NOTES:
D : digital signal, with boolean values (ON/OFF)
A : analogue signal, assuming values in
[Vground -Vmax] range
A/D : signal that could be both analogue and digital
NO : normally open
NC : normally close
IN : signal used as input
OUT : signal used as output

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

22
System Circuit

Power Circuit

If divide greatly composition of electric controller


system of this vehicles, is consisted of 1 Logic
control board, Power Unit (Left Drive, Right Drive,
Pump) 3, Line Contactor 1.

Each power unit controls each motor's speed, logic


control board vehicles situation and drivers select
receiving feedback vehicles control.

23
Actuation Circuit

This circuit supplies power to the Logic Control When the seat switch is closed, current will flow
Board and the Instrument Panel (Display). It must from the logic K1-7 through the seat switch to
be activated before power steering, hydraulics or controller negative. The logics then activates the
drive will operate. line contactor by allowing current to flow from K1-18
through the line contactor coil (+) and K1-19 the line
When the battery is connected and the key switch is contactor coil (-).
closed, current flows from battery positive through
the key fuse, key switch, and wire #23 to the logic With the line contactor tips closed the logics
control board (logic) contactor K1-23. continues its checks for any Run Time faults. If no
The logic connection to battery negative is at K1-1. faults are detected the display will indicate the
The logic circuits are powered up to accept voltage battery charge level, the power steering (IDLE)
inputs and create voltage outputs whenever the system operates, the pump and drive power circuits
battery is connected and the key is turned to ON. receive battery voltage and the logics receives
battery voltage.

24
Hydraulic Pump Motor Circuit

Only one hydraulic pump motor is used for all power


steering, lift, tilt and auxiliary hydraulic functions. To
activate the pump circuit, the seat switch, key switch
and line contactor must be closed first as explained
in the topic, Actuation Circuit.

Power Steering Circuit

The power steering speed of this vehicles operate


by speed (default 500 rpm) that specify in pump
motor calibration.

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 K1-50. The logics use
these changing voltages to determine what speed to
operate the pump motor. The logics then control 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.

25
Thermal protection circuit Accessory Circuits

Control Panel Horn Circuit

If the Power Units MOSFETs overheat, a thermal The horn will operate when the battery is connected
senders mounted in the MOSFET heatsink will give and the horn button is pushed. Current flows from
a voltage signal to logic. If the temperature is over battery positive through horn fuse, horn switch and
than preset value (100C), the Instrument Panel will horn, back to battery negative.
display a Run Time diagnostic symbol and E1, E2,
E3. The logics will decrease the speed of the drive
motors and the pump motor. The amount of current DC-DC Converter Circuit
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 (155C).
If reach in overheating temperature, the Instrument
Panel will display a Run Time diagnostic symbol
and E4, E5. To decrease the amount of current
allowed to flow through the drive motor, the logics
will reduce the speed. When the drive motor cools
off, the truck will return to normal operation. Drive
system acceleration performance and top travel
speed is affected by an overheated drive motor.
MOTOR TEMPERATURE will be stored for Drive
Motor overheating in memory.

The 12 volt output of the converter is protected


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

The positive of the 12 volt output is common to the


positive of the batter y voltage. The negative of the
12 volt output is pulsed to maintain a steady 12 volt
supply.

26
Testing and Adjusting Cell Voltage Test

With the truck powered up and the pump (Idle)


Preparation Tests and Check motor running, measure the voltage at each cell.
Normal voltage should be between 1.95V and 2.12V
Battery Tests per cell. If the voltage on each cell is below 1.95V
the battery must be charged or repaired before
A weak battery can cause or contribute to problems continuing to troubleshoot.
in the Logic Control Board and power circuits. Verify
the battery is good before investigating other NOTE: The indication between cells should not
possibilities. differ more than 0.05 volts. If it does, the
battery must have an equalizing charge or
1. Verify proper polarity at the battery connector
be repaired.
and the control panel. Positive cable should be
at the line fuse and negative at the negative on
control panel.
Hydrometer Test
2. If the lift truck is operational, perform a battery
load test. Test each cell of the battery with a hydrometer. If
the specific gravity indication is below 1.140, the
3. If the truck is not operational and the battery is battery must be charged. The battery is fully
suspected, perform a cell voltage or specific charged if the indication is 1.265 to 1.285.
gravity test.
NOTE: The indication between cells should not
differ more than 1.020 if it does; the battery
Battery Load Test needs an equalizing charge or needs to be
repaired.
1. Turn the range switch on the multimeter to read
battery voltage.

2. Connect the battery.

Battery Voltage Test.


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

3. Connect the multimeter leads between positive


(+) cable connection (1), and negative (-) cable
connection (2).

4. In a safe area, operate the hydraulic system,


(hold tilt lever to maximum position
momentarily) while reading the voltage
indicated on the multimeter.

5. If the indication is less than 45.6V (48V truck),


34.5V (36V truck), the battery needs to be
charged or repaired before continuing to
troubleshoot.

27
Battery Maintenance 6. Keep accurate battery records. Regular battery
readings should be taken with a battery tester or
NOTE: It is important that all batteries be charged voltmeter and a written record kept. Specific
and maintained according to the battery gravity and voltage of each cell should be
manufacturers instructions. checked and recorded at least once each month.
This inspection should be made after an
The care and maintenance of batteries is most equalizing charge. Readings should never be
important to maximize battery life and efficient truck taken directly after water has been added.
operation. Periodic inspection and service will Records of all battery maintenance should be
increase the life of batteries. Special attention made and filed so it will be known which
should be given to the rules that follow: batteries are being abused or wearing out.

1. Keep batteries clean at all times. Cleaning will Repairs should be made immediately otherwise the
prevent corrosion, current leakage and shorts to battery may become damaged. Batteries stored in a
chassis. Tighten all vent plugs; wash the battery discharged condition may be difficult to recharge
with water and a brush, then dry with an air due to sulfate formation.
hose. It may be necessary to use a baking soda
solution if water alone will not clean the top of
the battery. Visual Checks

2. Add enough water to cover the plates before 1. Verify all components and wires are in their
charging. This will ensure the proper chemical proper place. Check fuses, components,
reaction over the entire plate surface. After contactor tips, wires and connections. Verify
charging is complete, add water until it is about that they are not burned, broken or loose.
12.7 mm (.50 in) above the plates. Use distilled
water or water that has tested free from 2. Verify there is no mechanical binding or
minerals. interference in the contactor.

3. Charge the battery correctly. A battery should 3. Visually check the parking brake switch, the
be discharged to 80% of its capacity then fully hydraulic switches and accelerator linkage for
recharged. It should cool four to eight hours to adjustment or interference problems.
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 43C (110F) either while operating or
charging. Overcharging a battery will cause
over heating and warp the batter y plates.
Maximum battery life will result from maintaining
25C (77F) electrolyte temperature. Most of the
charging equipment is fully automatic but should
be checked periodically to assure proper
working order.

28
Resistance to Chassis Checks

Resistance between any point in the truck wiring


and the chassis should be a minimum of 10,000
ohms or more.

Many malfunctions are caused by shorts to chassis.


Usually, two shorts must exist before a malfunction
will occur. But, since batteries can have chassis
leakage, only one short to chassis in the truck wiring
can cause problems. To prevent problems because
of shorts, do the following:

1. Disconnect the battery and discharge the Power


Unit.

2. Randomly measure any component connection


or wiring connection in respect to the lift truck
chassis for a minimum resistance of 10,000
ohms. Any test point with low resistance must
have the short to chassis removed.

3. Always keep batteries clean to minimize current


leakage to the chassis.

4. Routinely clean the brush dust from the motors.

5. Be sure that all attachments, such as horns and


lights are designed for no chassis connection (a
two wire system).

29
Programmable Parameters
Adjustable Parameters Description

The possibility of interfacing by PC with the system


allows to have an exhaustive real time analysis of
the system working and of the condition of its
components; moreover, you can choose among a
wide range of parameters in order to reach the
optimum operating of the system in compliance with
your needs.

Adjustable parameters are listed next page. We


briefly explain whats the meaning of each
programmable parameter, and which is the effect of
its changes in lift truck performance.

30
Drive Motor

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 0 800 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 6 10
steering ramp 2
deceleration ramp while the driver is steering
at high speed.
Buzzer on If its 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 its 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
35 temperature of cooling Fan stops when the motors cools 0 60 155
motor's Fans down below 60 from set value(The
minimum of stop temperature is 25).
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 3,600 5,000
maximum speed
(no alarms present and turtle not active)
Maximum reverse lift truck speed with no
Reverse
43 speed limitation rpm 1,000 3,600 5,000
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 4,500 option
drive max speed "ON"
Steer limitation drive Maximum speed reference in the angle in
47 rpm 400 1,000 4,500
maximum speed which the internal wheel is mechanically still.
Acceleration Lift truck acceleration with accelerator pedal
48 rpm/s 400 1,100 2,000
ramp pressed
49 Inversion ramp Lift truck deceleration in inversion rpm/s 400 1,300 2,000
Lift truck deceleration with accelerator pedal
50 Release ramp rpm/s 40 900 2,000
released
Lift truck deceleration with pedal brake
51 Pedal brake ramp rpm/s 40 1,200 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 400 558 700
tires
High lift switch 2 Maximum travel speed when switch 1 and
54 rpm 0 1,000 4,500 option
drive max speed switch 2 was "ON"
Parameter that softens the drive inversion
Partial release
59 ramp if the traction motors are working with rpm/s 10 50 500
ramp
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.
96 Display brightness Display's brightness adjustment digit 0 5 8
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 digit
Enable = 1(Default)
the display

31
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.
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
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
20 Steering middle Steering voltage with wheels straight ahead mV 500 6,300 11,500
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 1,000 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 priority for LIFT + AUX1, TILT + AUX1.......), will be the highest OFF = 0 (Default)
27 digit
speed reference of every single command; if it's ON the reference ON = 1
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 bar10 0 0 2,200 option
38 Load pressure Load measurement bar10 0 0 2,200
Limitation
39 Start temperature of performance reduction 100 155
temperature
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 65 100
maximum current released
Lift maximum
63 Maximum lift speed rpm 1,000 2,100 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

32
High lift 1 switch Maximum pump motor speed with forks above the
69 rpm 0 1,500 3,500 option
lift max speed critical height
70 Hydro speed Pump motor speed when steering rpm 400 500 800
Pump motor speed with direction command lever
71 Hydro idle speed not in neutral, acceleration pressed and no pump rpm 200 300 500
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 3,500 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

33
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*10 752 773 829
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 10000
Maintenance time Disable = 0 (Default)
14 Maintenance time inserting enable digit
inserting enable Enable = 1

34
E-S-H Energetic Modes Parameters

Some parameters value depend on selected energetic mode: in following tables are listed parameter default
values for each operating mode (Economic, Standard and High)

In case of 48 V systems:

PARAMETER ECONOMIC MODE STANDARD MODE HIGH MODE


Maximum drive current 62 76 100
Maximum forward speed [rpm] 2300 3300 3600
Maximum reverse speed [rpm] 2300 3300 3600
Drive acceleration ramp [rpm/s] 700 900 1100
Aux max current 58 62 65
Drive inversion ramp [rpm/s] 600 900 1300
Drive release ramp [rpm/s] 600 850 1000
Lift maximum current 85 88 100
Maximum lift speed [rpm] 1350 1900 2100

35
Some Functions Management
Static Return to Off Buzzer Management

To ensure operator safety, when switching on the lift The buzzer is activated in the following cases:
truck, a number of inputs are analyzed; if one of 1. Alarm condition
these signals indicates a wrong start condition or 2. Switching your device on you find wrong start
any likely danger situation, main breaker is not conditions:
closed and all system modes are disabled. a. Accelerator pedal pressed or directional
(forward or reverse) switch inserted.
If the anomalous input assumes the correct value, b. One of pump motor command levers not
main breaker is closed and its now possible go on released.
with usual truck management. 3. Parking lever is pot pulling and no one is in the
seat.
The analyzed inputs are the followings:
1. Seat switch (the closing is checked)
2. Directional switch (the insertion of a selected B.D.I. Measure Management
direction is checked)
3. Accelerator (the system controls if the pedal is To measure battery voltage one of the following
pressed) conditions must be true:
1. Chat mode
2. Lift with drive and pump motors still
Pump Motor Modes 3. Drive motors still and pump motor working to its
minimum speed (idle speed)
Control of a command lever moving when
starting If this conditions are fulfilled for at least 2 seconds,
battery voltage begins to be evaluated, using a low
When switching on the key, in case a hydraulic pass filtering. After 15 seconds of voltage
command is active, the lift, lateral shift, tilt and processing, the filter output signal is uses to
auxiliary functions are disabled. evaluate the battery charge level.

Only when the activated lever and/or the requested If the battery is discharged for at least two
command assume the released position, operator consecutive sampling periods, low battery voltage
can return to the usual operative condition. alarm is signaled and following limitations are
activated:
Pump motor commands management switching on 1. Limitation of drive motor speed and maximum
the key, the motor works at minimum speed (idle torque
speed, adjustable by PC). 2. Limitation of maximum pump motor speed
3. Lift, tilt and auxiliary functions are disabled
If the operator moves a command lever or the
steering wheel, the speed takes on a value that can If the alarm is observed switching on the key, the
be adjusted, depending on the type of the active first received pump commands is keep active for 3
command and on the possible presence of seconds and then is disabled. Battery voltage must
limitations (caused by thermal or low battery alarms). exceed an adjustable limit value (Battery reset value,
see Chapter4) to return to normal operative
After the active command is switched off, motor condition after a low battery voltage alarm.
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)

36
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 control unit, exceeds following
from the least to the most serious one. levels: 106 V

If an alarm condition is detected by main board, If the controller detects such a fault, refer to
software control inhibits some lift truck functions, to following troubleshooting procedure:
guarantee operator safety. 1. Such an alarm can be caused also by the
Anomalous working conditions are indicated by presence of regeneration currents; when lift
different alarm levels, classified as follows, truck is on release or reverse braking ramp,
depending on their effects on the system: motors work as generators, and battery voltage
1. Main breaker is opened and both pump and can exceed overvoltage limit. In a case like that,
drive motors are stopped; buzzer and red led on the battery condition should be verified ( if the
the upper right corner of COMPACT display battery is new it is necessary to do some
signal the presence of such an alarm. charge-discharge cycles before reaching the
2. Pump and drive motors are stopped. rating declared by the constructor) or has a high
3. Drive motors speed is limited to 2000 rpm. internal resistance. If the case is the second
Moreover, in presence of such an alarm, first and it is not possible to change the battery, the
command given to pump motor is inhibited 3 solution may be to reduce the release and
seconds after activation, together with all pump reverse braking ramp.
motor functions (except hydro functions). 2. Incorrect wiring to battery positive or negative
4. Drive and pump motors speed is limited to 800 terminals.
rpm; buzzer signals the presence of such an 3. Verify if battery is still in good conditions.
alarm. 4. Replace the logic.
5. Drive motors speed is limited to 800; over
temperature alarms are signaled by. Buzzer Minimum battery voltage
activation.
6. Pump motor speed is limited to 800; buzzer 1. Eye alarm code: 2
signals the presence of such an alarm. 2. Display alarm code: F1
7. No effects on system performance. 3. Alarm level: 1
4. Alarm cause : battery voltage, measured by an
internal circuit, is lower than following levels : 46
NOTICE V
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.

37
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). are in good conditions;
2. Verify if the following 68 ways 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. K1-14 (5 V) a. K1-18 (positive terminal)
b. K1-15 (ground) b. K1-19 (negative terminal)
c. K1-10 (pedal input A) 4. Replace main breaker;
d. K1-5 (pedal input B) 5. Replace logic.
3. In case of correct wiring, replace the accelerator
itself.
4. Replace logic

38
Power module desaturation or Pump motor power module
overcurrent alarm overtemperature

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


8 for right drive motor power module 2. Display alarm code E3:
24 for pump motor power module 3. Alarm level: 6
25 for left drive motor power module 4. Alarm cause: the power module temperature
2. Display alarm code: (measured with a temperature probe), exceeds
F3 for right drive motor power module 100 C, or is inside [95 C, 100 C] range at
F4 for pump motor power module least 30s.
F5 for left drive motor power module
3. Alarm level: 1 In case of alarm follow this procedure:
4. Alarm cause: actual current exceeds limits 1. Alarm could be caused by ineffective
929A temperature dissipation. Verify thermal coupling
between power module block and aluminum
In case of alarm follow this procedure: plate, and between aluminum plate and truck
1. With such an alarm present when you turn on ballast. The presence of a correct amount of
lift truck, disconnect the power cable between thermal grease in the coupling is essential to
the malfunctioning power module and the ensure an efficient heat exchange;
corresponding motor (first, turn off the system, 2. Replace cable connecting the output CN4 of the
of course). logic to the pump power module;
3. If temperature readings seem too high in
If turning lift truck on again, alarm is not active, function of total time interval of lift truck using,
then: replace pump power module causing the alarm.
1. Replace the power module; You can read temperature measures using
Instrument Panel display or EYE
If turning lift truck on again, alarm is active, communication software.
then: 4. Replace logic.
1. Replace the power module;
2. Replace the motor.

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. Replace main breaker.
2. Replace cable connecting the CN1 output of the
logic with the corresponding power module;
3. Replace the power module connected with the
CN1output of logic.
4. Replace logic.

39
Capacitors too charged on start Drive motor overtemperature

1. Eye alarm code: 11 1. Eye alarm code: 13 for right drive motor
2. Display alarm code: A 19 for left drive motor
3. Alarm level: 1 2. Display alarm code: E4 for right drive motor
4. Alarm cause: when you turn on the system, E5 for left drive motor
capacitors are not completely discharged by 3. Alarm level: 5
pump motor. In fact, if you turn suddenly on the 4. Alarm cause: The measure of drive motor
lift truck, after a turning off, capacitors voltage temperature exceeds 155 C.
level is too high. You have to discharge them
before checking the presence of any fault (both In case of alarm, follow this procedure:
of capacitors and of logic) Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
In case of alarm follow this procedure: operating mode) you have to measure a
1. Verify the correctness of wiring from pump resistance of about 10 kohm between the two
motor and relative power module; wires of the temperature connector (execute the
2. Replace wire connecting CN4 with the measure at ambient temperature of 25C). If the
corresponding power module or if not possible measure is not correct it is necessary to replace
because the pump motor power module box the temperature connector;
integrates the outlet wire, substitute the power 2. Disconnect the temperature connector and
module box; check the wiring insulation between signal
3. Verify if main breaker has stuck closed wire an ground wire (towards logic);
terminals: in such a case replace it; 3. Replace logic.
4. Replace the wire connecting CN1 in logic to
right drive motor power module: a defective wire Presence of alarm with hot motors:
could give a wrong measure for capacitors 1. If temperature value (you can read it from
voltage; Instrument panel or via PC) seems correct,
5. Replace logic. verify if fans (if present) work properly; fault is
caused by an inefficient motor refreshing, or by
Low battery alarm operating out of nominal maximum ranges.

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 2 in Instrument user manual.

In case of low battery alarm, follow this


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

40
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 25C
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 3. Alarm level: 1
connector; 4. Alarm cause: improper communication between
2. Disconnect the temperature connector and DSPs present on logic, or/and defective logic.
check the wiring insulation between signal wire
and ground wire ( towards logic); In case of alarm follow this procedure:
3. Replace logic. 1. Using EYE program interface, try to program
control board flash memory;
Presence of alarm with hot motors: 2. Replace logic.
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.

Motor current offset alarm

1. Eye alarm code: 15 for right drive motor


16 for left drive motor
36 for pump motor
2. Display alarm code: F6 for right drive motor
F7 for left drive motor
F8 for pump motor
3. Alarm level: 1
4. Alarm cause: non-zero phase currents when
you turn lift truck on.

In case of motor current offset alarm, follow this


procedure:
1. Replace the cable connecting the
malfunctioning power module to logic.
2. Replace power module.
3. Replace logic.

41
Drive motor power module Serial communication alarm
overtemperature
1. Eye alarm code: 21
1. Eye alarm code: 20 for right drive motor 2. Display alarm code: F
22 for left drive motor 3. Alarm level: 1
2. Display alarm code: E1 for right drive motor 4. Alarm cause: error in serial communication
E2 for left drive motor between the two DSP; DSP present on main
3. Alarm level: 5 board make a mutual software control, to insure
4. Alarm cause: power module temperature, fast diagnosis of such a fault.
measured with a probe, exceed 100 C.
In case of alarm follow this procedure:
In case of alarm follow this procedure: 1. Program pumps and drive DSP again; maybe
1. Alarm could be caused by ineffective software present in flash memory was corrupted.
temperature dissipation; verify thermal coupling 2. Replace logic.
between power module block and aluminum
plate and between aluminum plate and truck Alarm on 5 V encoder voltage
ballast. The presence of the correct amount of
thermal grease in the coupling are essential to 1. Eye alarm code: 37
ensure a correct heat exchange; 2. Display alarm code: FH
2. Replace cable connecting the output CN1 ( for 3. Alarm level: 1
right drive motor) or CN2 ( for left drive motor) 4. Alarm cause: K1-14 terminal (5 V output)
of the logic to the corresponding power module; voltage is lower than 4.3 V.
3. If temperature readings seem too high in
function of total time interval of lift truck using, In case of alarm follow this procedure:
replace power module causing the alarm. You 1. Verify if 5 V output is grounded, cause an
can read temperature measures using incorrect encoder wiring.
Instrument Panel display or EYE 2. Verify if 5 V output is grounded, cause any
communication software. encoder malfunction. In that case, replace the
4. Replace logic. defective one.
3. Replace logic.

Alarm on 12 V output voltage

1. Eye alarm code: 38


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

In case of an alarm on 12 V output voltages,


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

42
Pump motor commands active on Drive motor shutdown temperature
start
1. Eye alarm code: 61 for right drive motor
1. Eye alarm code: 50 62 for left drive motor
2. Display alarm code: FL 2. Display alarm code: 61 for right drive motor
3. Alarm level: warning; while the fault condition is 62 for left drive motor
active, all pump motor functions (except hydro 3. Alarm level: warning; 1
functions) are inhibited. 4. Alarm cause: The measure of right drive motor
4. Alarm cause: you find a pump motor command temperature exceeds 165 C.
active when you turn your system on.
In case of alarm follow this procedure:
In case of alarm follow this procedure: 1. With a handheld multimeter (in resistance
1. Before starting to operate, turn off any active operating mode) you have to measure a
command (both levers and switches); resistance of about 10 kohm between the two
2. Be sure that lift, tilt and auxiliary command wires of the temperature connector (execute the
switches, are not active; measure at ambient temperature of 25C). If the
3. Replace logic. measure is not correct it is necessary to replace
the temperature connector;
Battery miss matching 2. Disconnect the temperature connector and
check the wiring insulation between signal wire
1. Eye alarm code: 60 an ground wire ( towards logic);
2. Display alarm code: 60 3. Replace logic.
3. Alarm level: warning; 7
4. Alarm cause: Battery is not suitable voltage to Presence of alarm with hot motors:
controller. 1. If temperature value (you can read it from
Instrument panel or via PC) seems correct,
In case of alarm follow this procedure: verify if fans (if present) work properly; fault is
1. Check battery voltage at the system. caused by an inefficient motor refreshing, or by
operating out of nominal maximum ranges.

Seat switch open on start

1. Eye alarm code: 63


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

In case of alarm follow this procedure:


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

43
Wrong start Encoder alarm

1. Eye alarm code: 64 1. Eye alarm code:


2. Eye alarm code: EE 74 (for right drive motor encoder)
3. Alarm level: warning; main breaker is opened 75 (for left drive motor encoder)
and pump and drive motors are stopped. 76 (for pump drive motor encoder)
4. Alarm cause: when you start working, you find 2. Display alarm code:
accelerator pedal pressed or a forward/ reverse Fc (for right drive motor encoder)
switch active. Fd (for left drive motor encoder)
76 (for pump drive motor encoder)
In case of alarm follow this procedure: 3. Alarm level: 1
1. Verify if a switch was active or the pedal 4. Alarm cause: an encoder channel is
pressed, when you turn on the lift truck; disconnected, and motor is working.
2. Verify if start, forward or reverse switches are
stuck close; In case of alarm follow this procedure:
3. Verify if pedal circuit voltage exceeds 1/3 its 1. Verify if the encoder is correctly connected to:
maximum range (measured in Volt); a. Motor itself
4. Replace logic. b. Ground : K1- 15 terminal
c. + 5 V: K1- 14 terminal
Pump motor shutdown temperature d. A channel:
K1- 37 terminal (for right drive motor
1. Eye alarm code: 65 encoder)
2. Display alarm code: 65 K1- 17 terminal (for left drive motor encoder)
3. Alarm level: warning; 1 K1- 29 terminal (for left drive motor encoder)
4. Alarm cause: The measure of pump motor e. B channel:
temperature exceeds 165 C. K1- 36 terminal (for right drive motor
encoder)
In case of alarm follow this procedure: K1- 16 terminal (for left drive motor encoder)
1. With a handheld multimeter in resistance K1- 28 terminal (for left drive motor
operating mode, you have to measure about encoder):
10kohm at ambient temperature of 25C 2. If correctly wired, replace the encoder;
between the two wires of the temperature 3. Replace logic.
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
2. Disconnect the temperature connector and
check the wiring insulation between signal wire
and ground wire ( towards logic);
3. Replace logic.

Presence of alarm with hot motors:


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

44
Alarm of motor thermal sensor CRC(Cyclic Redundancy Check) fault
alarm
1. Eye alarm code:
77 (for right drive motor thermal sensor) 1. Eye alarm code: 83
78 (for left drive motor thermal sensor) 2. Display alarm code: 83
79 (for pump motor thermal sensor). 3. Alarm level: 1
2. Display alarm code: 4. Alarm cause: Faulty eeprom or mismatching
77 (for right drive motor thermal sensor) software release.
78 (for left drive motor thermal sensor)
79 (for pump motor thermal sensor). In case of alarm follow this procedure:
3. Alarm level: 7 1. Restore eeprom with EYE application software,
4. Alarm cause: Temperature difference between using the RESTORE item present in main
any two of the 3 motors results greater than page
70 C 2. If alarm is still present, replace logic.

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


1. Verify if the wiring is correct;
restored
2. Replace the sensor;
3. Replace logic.
1. Eye alarm code: 84
2. Display alarm code: 84
Alarm of a power module temperature 3. Alarm level: warning
thermal sensor 4. Alarm cause: there was an eeprom restore,
caused by a CRC (Cyclic Redundancy Check)
1. Eye alarm code: alarm.
80 (for right drive motor power module sensor)
81 (for left drive motor power module thermal In case of alarm follow this procedure:
sensor) 1. Switch on the system and the turn it on again
82 (for pump motor power module thermal
sensor) Steering sensor alarm
2. Display alarm code:
80 (for right drive motor power module thermal 1. Eye alarm code: 91
sensor) 2. Display alarm code: F9
81 (for left 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)
3. Alarm level: 7 In case of a steering sensor alarm follow this
4. Alarm cause: Temperature difference between procedure:
any two of the 3 power modules is greater than 1. Verify correctness of wiring with :
70C. a. K1-11 (12 V),
b. K1-15 (ground)
In case of alarm follow this procedure: c. K1-10 (steering sensor input);
1. Check the wiring connecting logic and power 2. If correctly wired, replace steering sensor;
module; 3. Replace logic.
2. Replace the power module;
3. If alarm is still present, replace logic.

45
Capacitors pre-charge too slow

1. Eye alarm code: 98


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

In case of alarm follow this procedure:


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

Capacitors pre-charge timeout

1. Eye alarm code: 99


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

In case of alarm follow this procedure:


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

46
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="E2", The max speed of drive motor is reduced. 22
12 Display="E3", The max speed of pump motor is reduced. 10
13 Display="E4", The max speed of drive motor is reduced. 13
14 Display="E5", The max speed of drive motor is reduced. 19
15 Display="E6", The max speed of pump motor is reduced. 14
16 Display="EE", No lift truck operation 64
17 Display="EE(Flash)", No lift truck operation 63
Display="EL", The max speed and max torque of drive &pump motor is reduced
18 12
to minimum value
19 Display="F", No lift truck operation 5, 18, 21
20 Display="F0", No lift truck operation 1
21 Display="F1", No lift truck operation 2
22 Display="F2", No lift truck operation 3
23 Display="F3", No lift truck operation 8
24 Display="F4", No lift truck operation 24
25 Display="F5", No lift truck operation 25
26 Display="F6", No lift truck operation 15
27 Display="F7", No lift truck operation 16
28 Display="F8", No lift truck operation 36
29 Display="F9",The max speed of pump motor is reduced. 91
30 Display="FH", No lift truck operation 21,37
31 Display="Fc", No lift truck operation 74
32 Display="Fd", No lift truck operation 75
33 Display="FA", No lift truck operation 38
34 Display="FL", No lift truck operation 50
35 Display="A", No lift truck operation 6, 9, 11, 98, 99
36 Display="60", Lift truck operation 60

47
37 Display="61", No lift truck operation 61
38 Display="62", No lift truck operation 62
39 Display="65", No lift truck operation 65
40 Display="76", No lift truck operation 40
41 Display="77", Lift truck operation 77
42 Display="78", Lift truck operation 78
43 Display="79", Lift truck operation 79
44 Display="80", Lift truck operation 80
45 Display="81", Lift truck operation 81
46 Display="82", Lift truck operation 82
47 Display="83", No lift truck operation 83
48 Display="84", No lift truck operation 84
49 Display does work normal, Lift truck operation abnormal. -

48
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

Disconnect battery and check the horn


fuse for continuity.

Continuity No continuity

Check for shorts and


replace fuse.

Close key switch. Measure voltage on K1-23 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 K1-23.

49
PROBLEM 2

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


If only part of CVMS works.

POSSIBLE CAUSE

Open circuit from K1-11 to CVMS connector PIN 8;


Open circuit from K1-15 to CVMS connector PIN 7;
CVMS defect.

CHECKS

Make sure CVMS connector is connected to CVMS.

If connected If not connected

Connect multimeter positive lead to K1-11 Connect CVMS connector.


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

12 volts 0 volts

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

50
PROBLEM 3

Display portion of the CVMS seems random or wrong.


Lift truck operation normal.

POSSIBLE CAUSE

Connection defect; Wiring defect; Logics defect;


Display defect.

CHECKS

Check continuity from logics to CVMS connector

Continuity No continuity

Check for shorts to battery negative from Repair or replace open wire.
PIN 1 to PIN 8 on CVMS connector.

No shorts found Shorted

Replace logics. Repair or replace shorted wire.

51
PROBLEM 4

Direction switch circuit defect.

POSSIBLE CAUSE

Direction switch defect; Wiring to direction


switch defect;

CHECKS

Disconnect the battery.


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

Check OK Check failed

Check continuity from K1-15 to K1-8. 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 K1-15 and K1-8. between harness connector K1-15 and K1-9.
Repair any open/short circuit found. Repair any open/short circuit found.

Replace direction switch.

52
PROBLEM 5

Lift sensor circuit defect.

POSSIBLE CAUSE

Lift sensor not adjusted properly or defective;


Lift sensor wiring defect; Valve control card (board)
defect; Logics defect.

CHECKS

Retest lifts sensor circuit in self diagnostics.

Circuit passes Circuit fails


Diagnostics Diagnostics

Perform Problem 11, 12 Tilt Key switch ON.


or auxiliary circuit defect. 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
#15) 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 auxiliary switches and verify proper adjustment.
Refer to Valve Control Card Adjustments.

53
PROBLEM 6

Tilt switch circuit defect.

POSSIBLE CAUSE

Tilt switches defect; Wiring defect; Logics defect.

CHECKS

Disconnect K1 connector. Pull tilt lever to maximum.


Check continuity from K1-54 to K1-15.

Continuity No continuity

Replace logics. Check continuity of wire #54.

Continuity No continuity

Check continuity from K1-54 of wire #54 to Repair or replace wire.


Pin5 of valve board connector.

Continuity No continuity

Replace tilt switch. Repair or replace wire.

54
PROBLEM 7

Auxiliary switch circuit defect.

POSSIBLE CAUSE

Wiring defect; Auxiliary switch defect; Logics defect.

CHECKS

Disconnect K1 connector. Pull auxiliary lever to maximum.


Check continuity from K1-15 to K1-38 or K1-57.

Continuity No continuity

Replace logics. Check continuity of wire #38 or #57.

Continuity No continuity

Check continuity from K1-15 of wire #15 to Repair or replace wire.


Pin1 of valve board connector.

Continuity No continuity

Replace AUX switch. Repair or replace wire.

55
PROBLEM 8

Park brake switch circuit defect.

POSSIBLE CAUSE

Wiring defect; Park brake switch defect; Logics defect.

CHECKS

Disconnect K1 connector. Release park brake lever.


Check continuity from K1-6 to K1-15.

Continuity No continuity

Replace logics. Check continuity of wire #6.

Continuity No continuity

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


to terminal of park brake switch.

Continuity No continuity

Replace park brake switch. Repair or replace wire.

56
PROBLEM 9

Pedal brake switch circuit defect.

POSSIBLE CAUSE

Wiring defect; Pedal brake switch defect; Logics defect.

CHECKS

Disconnect K1 connector. Push down the brake pedal.


Check continuity from K1-15 to K1-48.

Continuity No continuity

Replace logics. Check continuity of wire #48.

Continuity No continuity

Check continuity from K1-15 of wire Repair or replace wire.


#15 to Pin2 of pedal brake switch.

Continuity No continuity

Replace park brake switch. Repair or replace wire.

57
PROBLEM 10

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

POSSIBLE CAUSE

Right drive power module over temperature.


Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

Check temperature of right If repeat occur, check right drive


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

Yes No

Replace right power module Replace logic board

58
PROBLEM 11

Display=E2
The max speed of drive motor is reduced.

POSSIBLE CAUSE

Left drive module over temperature.


Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

Check temperature of left If repeat occur, check left drive


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

Yes No

Replace left power module Replace logic board

59
PROBLEM 12

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

POSSIBLE CAUSE

Pump module over temperature.


Control board failed

CHECKS

Let the truck cool for 15 minutes.

Continuity Normal

Check temperature of pump If repeat occur, check pump motor


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

Yes No

Replace pump power module Replace logic board

60
PROBLEM 13

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 right drive


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

Yes No

Replace control board. Replace thermal sensor.

61
PROBLEM 14

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

POSSIBLE CAUSE

Left 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 left drive


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

Yes No

Replace control board. Replace thermal sensor.

62
PROBLEM 15

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

POSSIBLE CAUSE

Pump motor over temperature.


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 pump motor


resistance about 10kohm current draw or operating cycle for
between two wires of the excessive ramp climbing or
thermal sensor of pump towing
motor.
Yes No

Replace control board. Replace thermal sensor.

63
PROBLEM 16

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 releases.
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.

64
PROBLEM 17

Display=EE (Flashing)
No left truck operation

POSSIBLE CAUSE

No operator in seat; Seat switch defect;


Open wire.

CHECKS

Disconnect K1 connector Check continuity from wire #7 to


wire #15. Should be closed circuit when seat is pressed on
and open circuit when seat release.

No continuity Check OK

Disconnect seat switch connector. 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 #7 and #15.
Repair any open circuit found.

65
PROBLEM 18

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 75.7V

Voltage OK Voltage low

With key on, seat switch and main Check battery connection;
contactor closed, measure voltage Charge or replace battery
at BATT+ on controller.

Battery voltage

Replace logics

66
PROBLEM 19

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

67
PROBLEM 20

Display=F0,
Lift truck operation.

POSSIBLE CAUSE

Battery voltage exceeds 106V.


Failed logic

CHECKS

Disconnect battery, measure voltage at battery connector


terminal.

More than 106V Not

Battery discharge Replace logic board

68
PROBLEM 21

Display=F1
Lift truck operation.

POSSIBLE CAUSE

Battery voltage is lower than 46V.


Failed logic

CHECKS

Disconnect battery, measure voltage at battery connector


terminal.

Lower than 46V Not

Battery charge Replace logic board

69
PROBLEM 22

Display=F2
No lift truck operation.

POSSIBLE CAUSE

Accelerator sensor failure.


Accelerator connector disconnects. Failed logic.

CHECKS

Check Accelerator connector.

Connector Disconnector

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

70
PROBLEM 23

Display=F3
No lift truck operation.

POSSIBLE CAUSE

Right drive power module overcurrent.


(Actual current exceeds limit 783Apeak)
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 right drive motor

Measure the resistance between U, V, W terminals on the


right power module.

About 4.4 Mohm 0 ohm or open

Replace logic board Replace right power module

71
PROBLEM 24

Display=F4
No lift truck operation.

POSSIBLE CAUSE

Left drive power module overcurrent.


(Actual current exceeds limit 783Apeak)
Failed logic board or power module.

CHECKS

Key switch off and on again.

Display=F4 Drive operation normal

Measure the resistance between U, V, W terminals and


shell on the left motor

Open 0 ohm

Replace left drive motor

Measure the resistance between U, V, W terminals on the


left power module.

About 4.4 Mohm 0 ohm or open

Replace logic board Replace left power module

72
PROBLEM 25

Display=F5
No lift truck operation.

POSSIBLE CAUSE

Pump power module overcurrent.


(Actual current exceeds limit 783Apeak)
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 on the


pump power module.

About 4.4 Mohm 0 ohm or open

Replace logic board Replace pump power module

73
PROBLEM 26

Display=F6
No lift truck operation.

POSSIBLE CAUSE

Disconnect cable (CN1) from right power module to


right drive motor; Right power module defect.
Logic board defect.

CHECKS

Check the cable connecting from right power module


to right drive motor

Connection Disconnection

Connect cable (CN1)

Check current of right power module when you turn on the lift
truck. (You can read temperature measures
usingCOMPACT display or EYE software.)

Zero current Non zero current

Replace logic board Replace right power module.

74
PROBLEM 27

Display=F7
No lift truck operation.

POSSIBLE CAUSE

Disconnect cable (CN2) from left power module to left drive


motor; Left power module defect.
Logic board defect.

CHECKS

Check the cable connecting from left power module to left drive
motor.
Connection Disconnection

Connect cable (CN2)

Check current of left 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 left power module.

75
PROBLEM 28

Display=F8
No lift truck operation.

POSSIBLE CAUSE

Disconnect cable (CN4) 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 cable (CN4)

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

76
PROBLEM 29

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

POSSIBLE CAUSE

Steering angle sensor fault.


Wiring defect.

CHECKS

Check continuity from K-11(12V) to pin3. Check continuity from


K-15(GND) to pin1. Check continuity from K-62(out) to pin2.
Check the housing.

No continuity Continuity

Repair or replace wire Replace angle sensor

77
PROBLEM 30

Display=FH
No lift truck operation.

POSSIBLE CAUSE

5V Encoder not ok.


Voltage of K1-14 terminal is lower than 4.3V

CHECKS

Measure voltage from K1-14 terminal of encoder


to K1-15 (GND) terminal of encoder.

5 voltage Lower than 4.3 voltages

Replace logic board Replace defective one


(Right/left, pump encoder,
accelerator)

78
PROBLEM 31

Display=Fc
No lift truck operation.

POSSIBLE CAUSE

Right drive motor encoder defect.


An encoder channel is disconnected and motor is working.

CHECKS

Check right drive motor encoder connection.

If correct If not correct

Check continuity from K1-36 to Connect correctly encoder


encoder (pin 4) and from K1-37 connector
to encoder (pin 3).

If correct If no correct

Replace logic board Repair or replace wire

79
PROBLEM 32

Display=Fd
No lift truck operation.

POSSIBLE CAUSE

Left drive motor encoder fail.


An encoder channel is disconnected and motor is working.

CHECKS

Check left drive motor encoder connection.

If correct If not correct

Check continuity from K1-16 to Connect correctly encoder


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

If correct If no correct

Replace logic board Repair or replace wire

80
PROBLEM 33

Display=FA
Lift truck operation.

POSSIBLE CAUSE

12V output not ok.


Voltage of K1-11 terminal is lower than 10.5V.

CHECKS

Measure voltage from K1-11 to K1-15.

12 voltage Lower than 10.5 voltages

Replace logic board Replace defective device one


(Instrument, steering sensor,
Valve board)

81
PROBLEM 34

Display=FL
No lift truck operation.

POSSIBLE CAUSE

Valve control card defect, Lift setting fault.

CHECKS

Key switch on. Seat switch on.


Measure voltage at K1-50

Over minimum setting voltage No voltage

Resetting lift calibration. Replace logic board

Ok If not ok

Adjust valve board

Ok If not ok

Replace valve board

82
PROBLEM 35

Display=A
No lift truck operation

POSSIBLE CAUSE

Capacitor discharge; Main contactor fail, Logic board fail

CHECKS

Key switch off and on again. Key switches off and


measure resistance of the main contactor.

About 85~90 Other resistance

Check continuity from K-18 to Replace main contactor


main contactor terminal.

Check continuity from K-19 to


main contactor terminal.

Continuity No continuity

Check power fuse Repair or replace wire

Normal Open

Replace logic board Replace main fuse

83
PROBLEM 36

Display=60
Lift truck operation

POSSIBLE CAUSE

Battery misses matching;


Logic board fail

CHECKS

Check battery voltage at the each system.


(must use another voltage battery)

OK If not ok

Replace logic board Replace battery

84
PROBLEM 37

Display=61
No Lift truck operation.

POSSIBLE CAUSE

Blocking over temperature of right 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 right drive


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

YES NO

Replace control board. Replace thermal sensor.

85
PROBLEM 38

Display=62
No Lift truck operation

POSSIBLE CAUSE

Blocking over temperature of lift 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 left drive


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

YES NO

Replace control board. Replace thermal sensor.

86
PROBLEM 39

Display=65
No lift truck operation

POSSIBLE CAUSE

Blocking over temperature of pump 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 pump


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

YES NO

Replace control board. Replace thermal sensor.

87
PROBLEM 40

Display=76
No lift truck operation

POSSIBLE CAUSE

Pump motor encoder fail.


An encoder channel is disconnected and motor is working.

CHECKS

Check left drive motor encoder connection.

If correct If not correct

Check continuity from K1-28 to Connect correctly encoder


encoder (pin 4) and from K1-29 connector
to encoder (pin 3).

If correct If no correct

Replace logic board Repair or replace wire

88
PROBLEM 41

Display=77
Lift truck operation

POSSIBLE CAUSE

Thermal sensor wire of right drive motor open.


Logic board fail

CHECKS

Check continuity from K1-15 to thermal sensor pin1.


Check continuity from K1-58 to thermal sensor pin2.

Continuity No continuity

Replace thermal sensor. Repair or replace wire.

89
PROBLEM 42

Display=78
Lift truck operation

POSSIBLE CAUSE

Thermal sensor wire of right drive motor open.


Logic board fail

CHECKS

Check continuity from K1-15 to thermal sensor pin1.


Check continuity from K1-59 to thermal sensor pin2.

Continuity No continuity

Replace thermal sensor Repair or replace wire.

90
PROBLEM 43

Display=79
Lift truck operation

POSSIBLE CAUSE

Thermal sensor wire of right drive motor open.


Logic board fail

CHECKS

Check continuity from K1-15 to thermal sensor pin1.


Check continuity from K1-60 to thermal sensor pin2.

Continuity No continuity

Replace thermal sensor Repair or replace wire.

91
PROBLEM 44

Display=80
Lift truck operation

POSSIBLE CAUSE

Wrong right drive power modules thermal sensor.


Logic board fail

CHECKS

Check temperature of right drive power module.


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

Normal Abnormal

Replace logic board. Replace right drive power module

92
PROBLEM 45

Display=81
Lift truck operation

POSSIBLE CAUSE

Wrong left drive power module thermal sensor


Logic board fail

CHECKS

Check temperature of left drive power module.


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

Normal Abnormal

Replace logic board. Replace left drive power module

93
PROBLEM 46

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

94
PROBLEM 47

Display=83
No lift truck operation

POSSIBLE CAUSE

Faulty eeprom or mismatching software release.


Logic board fail

CHECKS

Restore eeprom with EYE application, Eye software install

Normal Still problem

Replace logic board.

95
PROBLEM 48

Display=84
No lift truck operation

POSSIBLE CAUSE

CRC alarm

CHECKS

System turns off/on again.


Eye software reinstalls.

Normal Still problem

Replace logic board.

96
PROBLEM 49

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: Right drive motor current,
18, 19, 20: Left drive motor current,
21, 22, 23: Pump motor current
2: Right drive motor rpm
4: Left drive motor rpm
9: Pump motor rpm
49: Right drive motor encoder channels
50: Left 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
OK If not ok

Replace defected motor

Check wiring for open circuit.


Wiring No. #14, #15, #36, #37 of right motor and #14,
#15, #16, #17 of left motor and # 14, #15, #28, #29 of
pump motor.

OK If not ok

Replace encoder

97
System Tests and Adjustments Hydrometer

Test Equipment Hydrometers are usually available from any battery


supplier. Battery maintenance is a crucial par t of
maintaining the electric vehicle. The ability to
measure specific gravity and adjust the battery
discharge indicator to match battery manufacturers
specifications is an important part in the total
maintenance of the electric vehicle.
There are various pieces of electric truck test
equipment that DOOSAN recommends for all
service personnel. 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
There are various pieces of electric truck test
equipment that DOOSAN recommends for all A digital multimeter that measures DC voltage,
service personnel. This equipment is available from resistance, and has a diode tester, is required. It is
a number of world wide manufactures and local recommended that a high quality meter that is drop
electronic suppliers. Contact your DOOSAN dealer protected, or comes with a drop proof case, be
or the factory for further recommendations. 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.

98
Electrical System Adjustment Lift Sensor

Parking Brake Switch 1. Disconnect the battery and discharge the head
capacitor.

The lift truck can move suddenly. Injury to


personnel or damage to the lift truck is possible. 1
Safely lift the drive wheels off the floor. Put 3
blocks of wood under the frame so both drive
wheels are free to turn. Keep away from drive
wheels that turn.

4
2

Lift Sensor Adjustment


(1) Lift Sensor (transducer) (2) Magnet. (3) Screw.
(4) Setscrew. (A) 1.0 mm (.039 in) Clearance.

NOTICE
Lift sensor may be damaged. Do not allow the
magnet (2) to make contact with the plastic
bracket when the lift lever is activated.
Parking Brake Switch Adjustment
(1) Switch. (2) Plate. (3) Bolts.
2. Loosen setscrew (4).
1. Close the seat switch and turn the key to ON.
3. Adjust screw (3) to make clearance (A) 1.0mm
2. Release the parking brake and put the truck in (.039 in) between lift sensor (1) and magnet (2)
forward. when the lift lever is activated fully (pulled all the
way back).
3. Reposition plate (2) so the switch (1) actuator is
against the bracket. Tighten bolts (3). 4. Tighten setscrew (4). Check lifts sensor circuit.
The valve control card may need adjusting.
4. Engage the parking brake and the park brake
symbol will be displayed. Repeat the procedure 5. Set lift sensor initial setting.
until adjustment is correct. Refer to Sensor Initial Setting.

99
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.

100
Instrument Panel
LCD Instrument panel shows information about
system main analogue and digital parameters,
as follows:
1. Truck speed
2. Park brake insertion
3. Steering angle
4. Seat switch closure
5. Maintenance period expiry
6. Low speed insertion
7. Battery charge level
8. Energetic operating mode

To find further technical data and useful information


about Compact display refer its own user manual.

We briefly mention two important functions:

Diagnostic Mode
This operating mode enables you to test main
analogical and digital signals managed by your
system.

Parameter Calibration
This procedure allows to adjust the main operating
parameters of the system.
You can enter calibration mode before working as
usual with your lift truck.
It is also possible to update the parameters with
default values.
(Notice this way you loose calibration values).

101
Instrument Panel Display Segments

The display gives the following information about


Monitoring Systems the operating state of the system:
Indicator (Compact Display)
Lift truck speed (expressed in kmh or
mph)
Handbrake active, indicated by the
warning symbol
Safety contact open, indicated both by
EE blinking message visualized in
timemeter area and by relative symbol.
With any directional switch active and safety
contact still open, lift truck cant be moved, even
after seat switch is closed; in such a case, after
safety contact is closed, the symbol disappears.

EE code disappears only after active directional


switch is turned off.

Time meter or, otherwise, milometer


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

Battery level, indicated by a 9


segments symbol.
In following Table 1, you can read the generic
relation between battery charge level and number
of visualized bars. See Table 2 in case of an 80V
system. Display signals with alarm code EL the
fact battery is completely discharged.

102
Relation between battery charge level and Table 3: Contraction for dot matrix display.
number of visualized bars Alarm Code

Table 1: Case of a generic system Display


Description Contraction
BATTERY CHARGE Code
DISPLAY INDICATION CONTACTOR
LEVEL 17 Main breaker fault
FAULT
No segments Discharged battery Battery/ power
1 flashing segment 10 % 60 module mismatch
BATT MISMATCH
1 segment 20 % Blocking
2 segments 30 % overtemperature of R-MOTOR
61
right motor SHUTDOWN
3 segments 40 % (over 165)
4 segments 50 % Blocking
L-MOTOR
5 segments 60 % 62 overtemperature of
SHUTDOWN
6 segments 70 % left motor(over 165)
Blocking
7 segments 80 % overtemperature of P-MOTOR
8 segments 90 % 65
pump motor SHUTDOWN
9 segments Full charged battery (over 165)
P-MOTOR
76 Pump motor Encoder
ENCODER.
Table 2: Case of an 80V system Wrong right traction R-M TEMP
77 motor thermal switch SENSOR
BATTERY CHARGE BATTERY VOLTAGE
LEVEL [V] Wrong left traction L-M TEMP
78 motor thermal switch SENSOR
Discharged battery Voltage < 75.7 V Wrong pump motor P-M TEMP
10 % 75.7 V 76.5 V 79 thermal probe SENSOR
20 % 76.5 V 77.3 V Wrong right traction
R-INV T
30 % 77.4 V 78.2 V 80 module thermal
probe
SENSOR
40 % 78.3 V 79.1 V Wrong left traction
50 % 79.2 V 80.0 V 81 module thermal
L-INV T
SENSOR
60 % 80.1 V 80.9 V probe
70 % 81.0 V 81.8 V Wrong pump module
82 thermal probe
P-INV T SENSOR
80 % 81.9 V 82.7 V 83 CRC fault CRC FAULT
90 % 82.8 V 83.6 V 84 Bank CRC restored CRC RESTORED
Full charged battery Voltage > 83.6 V Capacitors not
A charged : fast charge
FAST CHARGE
Trans.precharge in
A Short / Cap. Too TOO CHARGED
charged
Capacitors not
CAP SLOW
A charged :
CHARGE
slow charge
Capacitors not TIME OUT
A charged : time out CHARGE
Capacitors not CAP NOT
A charged CHARGED
Drive right module R-INV
E1 Overtemperature OVERTEMP
Drive left module L-INV
E2 Overtemperature OVERTEMP
Pump module P-INV
E3 Overtemperature OVERTEMP
Drive right motor R-MOTOR
E4 Overtemperature OVERTEMP
Drive left motor L-MOTOR
E5 Overtemperature OVERTEMP
Pump motor P-MOTOR
E6 Overtemperature OVERTEMP
EE Wrong start WRONG START
EE
(FLASI Seat switch SEAT SW OPEN
NG)
LOW BATT
EL Low battery voltage
VOLT
F Wrong Eeprom EEPROM FAULT

103
WD Timer/Enable WD TIMER NOTE: Percent values can be modified only with
F micro signals FAULT EYE Calibration E-S-H menu.
F Serial communication COMM FAULT
Maximum battery
F0 voltage
MAX BATT VOLT NOTE: Pressing PROGRAMMABLE WORKING
Minimum battery you can manage economic, standard or
F1 voltage
MIN BATT VOLT
high operating mode too.
F2 Pedal trimmer fault ACCEL FAULT
Drive right module R-INVERTER COMPACT display shows different symbols in
F3 Desat/overcurrent FAULT
Drive left module L-INVERTER function of selected energetic mode:
F4 Desat/overcurrent FAULT
F5 Pump module P-INVERTER - E-S-H management disabled: no symbol
Desat/overcurrent FAULT visualized.
Drive right motor R-MOTOR I - E-S-H management enabled: active
F6 current Offset OFFSET
Drive left motor L-MOTOR I mode is indicated by symbol.
F7 current Offset OFFSET
Pump motor current P-MOTOR I
F8 Offset OFFSET - PROGRAMMABLE WORKING management
STEER SENSOR enabled: in case you have chosen one of L1, L2
F9 Steer sensor fault
OUT
FH 5V encoders not ok 5V NOT OK or L3 operating modes, and lift truck is stopped,
Drive right motor R-MOTOR one of the segments of speed indicator symbol
Fc Encoder ENCODER (see Table 4) blinks to show selected energetic
Drive left motor L-MOTOR mode.
Fd Encoder ENCODER
FA 12V out not ok 12V NOT OK
Pump input on at the Table 4: selected energetic mode
FL start
PUMP SIGN ON
DISPLAY
VISUALIZATION OPERATING MODE
(from symbol left side)
Lift truck operation mode
1st segment L1 (Limit 1)
5th segment L2 (Limit 1)
Pressing E-S-H button, you can set
9th segment L3 (Limit 1)
energetic operating mode for your
system.
Otherwise symbol indicates, as usual,
This function is enabled using EYE menu named
selected operating mode.
Calibration ESH, to select desired operating
mode. In particular you can choose between E-S-
H NOTE: as usual, if lift truck is moving,
or PROGRAMMABLE WORKING : symbol indicates speed level

- Pressing E-S-H (economic, standard, high)


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

104
NOTE: if active mode is one of L1, L2 or L3 Seat Belt warning (Option) : red color
limitations and you change operating mode LED for 10 seconds.
(from PROGRAMMABLE WORKING to E-
S- H), software automatically sets
operating mode to economic one NOTE: Alarm LED is managed as follows:

Alarm message, indicated by an alpha-numerical - Display normally working: LED lights up


code in the display area where usually lift truck briefly switching on /off your system
speed appears. - Display not communicating with control
See Table 3 for the meaning of alarm codes. board: after 3 seconds from the moment
in which the communication stops, alarm
Over-temperature warning indicated by the LED brightens
warning light in case the temperature of - Display board microprocessor not
power transistors exceeds the limit and working: alarm LED brightens.
relative light blink.
If this light is on, there is possibility that cooling No Alarm, No Movement
fan is breakdown. Inspect cooling fan.
In case the truck does not move forward or
Hour meter separation point, usually blinking, reverse direction, check to see if the service
stops brake switch is activated.
In following cases:
- Seat switch open.
- Serial communication between display and
control unit not active
- Main breaker open

Turning your lift truck on, some alphanumeric


codes, visible for 3 seconds, appear where
usually is visualized speed indicator symbol;
those codes help to identify system in use (see
Table 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
SYSTEM IN USE CODE

BX (4WHEEL) C0

LED Indicators

On left side, COMPACT display has four LED


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

Alarm message; red color LED

Message of lamps; green color LED

Indicator lights activated; green color


LED(OPTION)

Low oil level of the brakes; red color


LED.

105
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 7:
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
Limitation 3 (L3) Economic (E)
exit this procedure pressing once ENTER key.
Moreover, ENTER key is used to confirm the new Table 7
value of the parameter in calibration procedure.
Notice: You can modify system operating modes
only after enabling their management with
UP key EYE 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
2. In calibration phase, you increase the numeric of 10 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.

106
Parameter Calibration The parameter number (blinking) appears on the
display area usually reserved to lift truck speed and
This chapter describes the way to adjust the main alarm codes, and its value is shown in the time-
operating parameters of the system. meter area.
You inhibit the access to this menu with EYE Moreover, appear a number of segments
submenu named Lift truck setup. proportional to the parameter value.
To calibrate your parameters, read following
instructions: If you see that the numeric data have been modified
in the time meter area, it means that the value of the
To enter calibration mode: chosen parameter has really been updated into
1. Switching on your system, press ENTER key control board memory.
until a blinking 0 (zero) appears.
2. Press UP key: the entry to the chosen Notice: Remember that parameter values can be
calibration mode is indicated by C; this symbol modified only by discrete increments.
persists until the first parameter will be selected. See Table 8 for the list of all adjustable
parameters and relative minimum available
Notice: If calibration procedure is not enabled variations.
using EYE Lift truck setup menu, UP key
pressure has no effect.

Notice: You can exit this operating mode only


switching off your system.

To execute the calibration:


1. Select parameter 10 using UP and DOWN keys,
and confirm your choice pressing ENTER key.
2. Use UP and DOWN keys to set at 4 the value of
this parameter, and confirm with ENTER key.
3. Repeat the above operations to fix parameter
17 value at 6 Notice: it doesnt matter if you first
modify parameter 10 and then 17, or vice versa.

Only after this procedure, you allow operator to


change the value of other parameters:
1. Select the parameter to change, using UP or
DOWN key; press ENTER to confirm.
2. Now adjust the value of the selected parameter
with UP and DOWN keys; confirm your choice
typing ENTER key.

107
No Parameter Unit Minimum Default Maximum Remark
5 Deceleration steering ramp 1 rpm/s 0 800 5,000
6 Deceleration steering ramp 2 rpm/s 0 6 10
9 Battery reset value V*10 752 773 829
10 First parameter for calibration enable
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
17 Second parameter for calibration enable
18 Steering anticlockwise mV 500 10,300 11,500
19 Steering clockwise mV 500 1,200 11,500
20 Steering middle mV 500 6,300 11,500
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 1,000 12,000
34 Middle lift mV 1,000 2,750 12,000
35 Starting temperature of motor's Fans 0 60 155
36 Weight of the load on the forks kg 0 0
Future
37 No load pressure bar10 0 0 2,200 option

38 Load pressure bar10 0 0 2,200


39 Limitation temperature 100
41 Drive maximum current % 20 100 100
42 Forward maximum speed rpm 1,000 3,600 5,000
43 Reverse maximum speed rpm 1,000 3,600 5,000
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 1,000 4,500
48 Acceleration ramp rpm/s 400 1,100 2,000
49 Inversion ramp rpm/s 400 1,300 2,000
50 Release ramp rpm/s 40 900 2,000
51 Pedal brake ramp rpm/s 40 1,200 2,000
52 Creep speed rpm/s 100 300 2,000
53 Diameter of drive tires mm 400 558 700

108
No Parameter Unit Minimum Default Maximum Remark
54 High lift switch 2 drive max speed rpm 0 1,000 4,500 Option
59 Partial release ramp rpm/s 10 50 500
61 Lift maximum current % 20 100 100
62 Auxiliary maximum current % 10 65 100
63 Lift maximum speed rpm 1,000 2,100 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 3,500 Option
70 Hydro speed rpm 400 500 800
71 Hydro idle speed rpm 200 300 500
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 3,500 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
High lift 1 switch auxiliary 2 function max
79 rpm 0 500 2,800 Option
speed
High lift 2 switch auxiliary 2 function max
80 rpm 0 500 2,800 Option
speed
High lift 1 switch auxiliary 3 function max
83 rpm 0 500 2,800 Option
speed
High lift 2 switch auxiliary 3 function max
84 rpm 0 500 2,800 Option
speed
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

109
Sensor Initial Setting Default Setting
In case that initial settings of sensors are not It is also possible to update the parameters with
performed accordingly, the machine performance default values.
can be lowered.
So, in the following cases, initial setting for each As for the procedure explained below, use UP,
sensor should be done to secure the correct DOWN and ENTER keys to set parameter 10 value
machine performance. to 5 and parameter 17 value to 2. Once more, the
order you adopt to change the two parameters is
- Replacing Logic not important.
- Updating flash memory (Update EEPROM) or The loading of default data is indicated by the
Resetting EEPROM symbols d S (default set);
- Replacing or adjusting Sensor
- Default Setting Notice: All parameters whose value is related to
selected energetic operating mode
STEERING SENSOR (parameter 13): (economic, standard, high, limitation 1,
Enter diagnostic mode to visualize steering sensor limitation 2, and limitation 3) are updated
voltage. with default values corresponding to the
Minimum value calibration: turn wheels completely active one.
on left and read sensor voltage value from display; Pressing E-S-H key on display, and
enter calibration mode and set parameter 19 to the selecting a different working mode, you
value measured. immediately change the value of all
parameters related. Such parameters, as
Maximum value calibration: turn wheels completely well as their default values, are listed in
on right and read sensor voltage value from display; Table 10 (*)
enter calibration mode and set parameter 18 to the
value measured.
Econom Standar Hige
Parameter
ic Mode d Mode Mode
Central value calibration: put wheels straight and
Maximum drive
read sensor voltage value from display; enter 62 76 100
current
calibration mode and set parameter 20 to the value
Maximum forward
measured. 2300 3300 3600
speed [rpm]
ACCELERATOR SENSOR (parameter 11): Maximum reverse
2300 3300 3600
Enter diagnostic mode to visualize speed sensor speed [rpm]
voltage. Drive acceleration
700 900 1100
Minimum value calibration: read from display sensor ramp [rpm/s]
voltage corresponding to start switch closure (when Aux max current 58 62 65
all segments dedicated to speed level visualization Lift maximum
85 88 100
are active); enter calibration mode and set current
parameter 23 to the value measured. Maximum lift speed
1350 1900 2100
[rpm]
Maximum value calibration: read sensor voltage Drive inversion ramp
600 900 1300
value from display, with pedal completely pressed; [rpm/s]
enter calibration mode and set parameter 24 to the Drive release ramp
600 850 1000
value measured. [rpm/s]
Table 10 (*) its values are actually implemented into the
LIFT LEVER SENSOR (parameter 5): software of BX20 48 V lift truck
Enter diagnostic mode to visualize lift lever voltage.
Minimum value calibration: read from display sensor Notice: Once default data have been loaded, if you
voltage with lift lever released; enter calibration further need to modify parameters value,
mode and set parameter 33 to the value read. you have to switch your system off, before
entering calibration mode again.
Maximum value calibration: read from display
sensor voltage with lift lever completely pressed; Notice: Parameter 94 is visualized only in case E-
enter calibration mode and set parameter 32 to the S-H management procedure is enabled
value measured. with relative EYE software calibration menu.
Central value calibration: enter calibration mode and
modify parameter 34.

110
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 analyze
using UP and DOWN keys (parameter number
increases using UP key and decreases with DOWN
key).

Here, in Table 11, you have a list of the parameters


you can analyze with their respective displaying
order:

111
List of diagnostic
Parameter No. Description Unit
1 Right traction motor speed [rpm]
2 Right traction motor speed reference [rpm]
3 Left traction motor speed [rpm]
4 Left traction motor speed reference [rpm]
5 Lift voltage [mV]
6 Battery voltage [V10]
7 Right traction motor power module temperature [C / F]
8 Pump motor power module temperature [C / 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]
14 Left traction motor power module temperature [C / F]
15 Right traction motor phase current U [A rms]
16 Right traction motor phase current V [A rms]
17 Right traction motor phase current W [A rms]
18 Left traction motor phase current U [A rms]
19 Left traction motor phase current V [A rms]
20 Left traction motor phase current W [A rms]
21 Pump motor phase current U [A rms]
22 Pump motor phase current V [A rms]
23 Pump motor phase current W [A rms]
24 Right traction motor temperature [C / F]
25 Left traction motor temperature [C / F]
26 Pump motor temperature [C / F]
27 Seat switch hour meter [h]
28 Drive motor hour meter [h]
29 Pump motor hour meter [h]
30 Seat switch [digit]
31 Park brake switch [digit]
32 Start switch [digit]
33 Reverse traction direction switch [digit]
34 Forward traction direction switch [digit]
35 Pedal brake switch [digit]
36 3 / 4 wheels selection switch [digit]
37 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]

112
46 24V out [digit] [digit]
47 Buzzer command [digit] [digit]
48 Fans command [digit] [digit]
49 Drive right motor encoder channels -
50 Drive left 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]

113
In diagnostic mode selected parameter is Accessing Stored Error Codes
visualized as follows:
1. In the area dedicated to speed and alarm The B18X series of remembers the last 10 error
signals, appears parameter number ( flashing) codes. This is case the truck has had an intermittent
2. Its actual value is displayed in the area reserved problem, but the operator cannot remember which
to the time meter. code appeared on the display. Also by analyzing the
contents of the last 10 error codes, it may be
In particular, if the selected parameter is: possible to determine what sort of application the
Analogue input: Instrument panel shows the truck has been working in.
parameter value, expressed in the unit of Table 11
The stored error codes are accessed at diagnostic
Digital input: if the command activated by the mode by using E-S-H button.
operator corresponds to the parameter selected, the
value of the quantity is visualized. 1. Access the diagnostic mode.

Other way the symbol E (error) appears, except 2. Press E-S-H button. And then, the stored error
in following case: code will be shown with SMU hours, if any.
1. Seat switch active, for any selected digital input.
3. By pressing UP or DOWN key, more error
To exit diagnostic mode, type ENTER key again. codes can be shown.

Notice: If an alarm occurs when diagnostic mode is 4. Pressing again E-S-H key, you return to
enabled, and the system is working as diagnostic mode.
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.

If the selected parameter is a temperature,


also thermal alarm symbol is visualized.

114
Eye Software Interface
EYE is a diagnostic software environment designed
to communicate with the forklift truck.

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


port. Connection between PC and Main harnesss
Serial Communication connector is characterized by
a 38, 4 kBaud/s Baud-rate.

User can communicate with lift truck during working


operations, and can analyze 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

115
To find further technical data and useful information about EYE software, refer its own user manual.

116
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

Serial port

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

117
Installation
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

118
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.

119
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

120
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

121
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 greyed menu is not accessible in that
moment); you can also access present sub panels with a further selection by a pop-up menu (Fig.9)

Fig.9: Submenu selection

122
Not Actual Software / Eeprom Crc Fault

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

Submenus

Print function is accessible from many of listed submenus: you can send active front panel image to printer or
save it on file; in that case destination directory is <EYE PATH>\EYE\ images.

BEWARE: if more than one window is in use, only the one relative to the inner submenu is active and all others
work in background.
If you select a non active window, you cant communicate\ interact with logic.

123
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.

124
Test

This pop-up menu includes of following subjects:


1. Drive (Fig.11)
2. Pump (Fig.12)
3. Battery (Fig.13)
4. Timers (Fig.14)

Drive (Traction)

Fig.11: Drive menu

Following items appear in Drive menu front panel:


1. Accelerator pedal voltage
2. Pedal brake pressure (in bar)
3. Drive motors phase currents: you can select current phase from pop-up menu
4. Both modules temperature: you can select measure unit between C and F.
Temperature above 60C is signaled by a red color; temperature above 90C 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

125
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 60C is signaled by a red color; temperature above 90C is signaled by a flashing display.
5. Request RPM and motor speed, with an arrow signaling 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. Electro valves 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

126
Battery

Fig.13: Battery menu

Following items appear in Battery menu front panel:


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

With Reset alarms menu, you can reset alarm list.

127
Timers

Fig.14: Timers menu

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

128
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 cant set a value out of fixed limits: the message OUT OF LIMIT signals a case like that.

By a pop-up menu, you can access following calibration functions:


1. Battery: Battery reset voltage calibration (Refer to page 125)
2. Timers: Timers calibration (Refer to page 126)
3. Steering: Steering sensor (Refer to page 127)
4. Pedal: Pedal accelerator calibration (Refer to page 128) (**)
5. Lift: Lift calibration (Refer to page 129)
6. ESH: E/S/H parameters calibration and limits (Refer to page 130)
7. Steering parameters: Steering parameters calibration (Refer to page 132)
8. Program service: Program service interval setting (Refer to page 133)
9. Drive motor: Drive motors parameters calibration (Refer to page 134)
10. Pump motor: Pump motors parameters calibration (Refer to page 135)
11. Critical height switches: Speed limits calibration in case of critical height (Refer to page 136)
12. Weight sensor: Weight sensor calibration (Refer to page 137) (*)
13. Cab lift: Cab lift speed calibration (Refer to page 138) (*)
14. Timer reset: Timers meters reset (Refer to page 139)
15. Truck setup: Some lift truck parameters setup (Refer to page 140) (*)
16. Backing mode: Slow mode calibration (Refer to page 141) (*)
17. Load eeprom default: EEPROM configuration (Refer to page 142)
18. Parameters image: Parameter store or Restore. (Refer to page 143)

(*): Optional menu


(**): Menu present in standard or optional version

129
Battery reset voltage calibration

Fig.15: Battery reset menu

In that menu front panel, you can find following data about battery reset voltage: description, actual value, new
value you want to set, measure unit, default value, minimum and maximum settable values.
You can execute following operations:

Load default value:


1. Press DEFAULT button ; NEW data field will be automatically updated with default value
2. Press SAVE button and confirm; OLD data field too will be updated

Change actual value:


1. Insert changed value in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial value is restored.

Discard changes:
1. Press CANCEL button; initial value will be restored in NEW data field
2. Press SAVE button and confirm; OLD data field too is restored with initial value

130
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

131
Steering sensor calibration

Fig.17: Steering calibration menu

There are following data about steering parameters: description, actual value, measure unit, default values,
minimum and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with steering sensor actual voltage.
You can execute following operations:

Load default value:


1. Press DEFAULT button; VALUE data fields will be automatically updated with default values

Change parameters value:


1. Select ANTICLOCK parameter
2. Turn steering completely anticlockwise
3. Press SAVE button and confirm
4. Select CLOCK parameter
5. Turn steering completely clockwise
6. Press SAVE button and confirm
7. Select MIDDLE parameter
8. Put wheels straight ahead
9. Press SAVE button and confirm

Discard changes:
1. Press CANCEL button; initial value will be restored in VALUE data fields

If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any
lift truck fault.

132
Accelerator pedal calibration

Standard version

Fig.18: Men di calibrazione del pedale

There are following data about accelerator parameters: description, actual value, measure unit, default values,
minimum and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with pedal sensor actual voltage.
You can execute following operations:

Load default value:


1. Press DEFAULT button; VALUE data field will be automatically updated with default value

Change parameters value:


1. Select MIN ACCELERATOR parameter
2. 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.

Optional version

There is a second pedal sensor.


Calibration procedure is like standard one, except that START led present (Fig.18) turns ON only after software
verifies that the voltages on both pedal sensors are equal to Vmin + 0.5 V voltage, obtained slowly pressing
accelerator pedal.

133
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.

134
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, and default values for E, S, and H operating mode, settable per cent values for
parameters in L1, L2, and 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.

135
Fig.21: Parameters externally changed

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

Fig.22: Percent parameters menu

In that menu front panel, there are data about L1, L2 and L3 parameters: description, measure unit, modifiable
values expressed in per cent, minimum and maximum settable values.
You can execute following operations:

Change actual value:


1. Insert new value
2. Confirm

If actually selected operating mode percent values are now modified, exiting to ESH calibration menu, user can
load new default values. Every parameter per cent value is referred to High mode data.

136
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

137
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

138
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.

139
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

140
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

141
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

142
Lift truck setup (Optional Menu)

Fig.31: Lift truck setup menu

In that menu front panel, you can find following data: parameters description, actual status (ON or OFF), new
status you want to set, and default status.
You can execute following operations:

Select default value:


1. Press DEFAULT button; NEW data fields will be automatically updated with default status
2. Press SAVE button and confirm; OLD data fields will be updated

Change actual value:


1. Insert changed status in NEW data field
2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is
signaled and NEW data field initial status is restored.

Discard changes:
1. Press CANCEL button; NEW data fields will be restored with initial status
2. Press SAVE button and confirm; OLD data fields are restored with initial status

143
Eeprom reset menu

That menu has two important functions:


1. In case of Eeprom alarm, you have to use complete EEPROM reset procedure.
2. If you have updated flash memory software, and you want to load default Eeprom configuration, you have to
use complete Eeprom reset; to maintain already calibrated values you can use partial EEPROM reset
procedure.

Pay attention that using complete reset procedure you loose already calibrated values.
Both procedures, in any case, dont modify timers value and alarm history.

Partial EEPROM reset:


1. Press PARTIAL LOAD EEPROM button
2. Give a confirmation to load default values

Fig. 33: Eeprom configuration menu

Complete EEPROM reset:


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

Fig. 34: Further confirmation

144
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

145
Data Logging

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

Fig. 36: Data logging menu

Data acquisition procedure is following:


1. Select Nmax, the number of variables you want to save
2. Select the variables whose value you want to record, with apposite pop-up menu
3. You can modify sampling period, expressed in seconds.
4. Pressing START button, saving procedure begins; in that phase you cant modify acquisition parameters

During acquisition procedure (Fig. 37), following data are visualized:


1. A led signals saving instant
2. A gauge scans time between 2 saving instants
3. Indication of number of saved frames
4. Flashing message SAVING

To stop saving procedure you can press START button, or simply exiting the menu.

146
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.

147
Flash

Fig. 38: Flash programming phase

To upgrade main controller software, with Flash menu (Fig. 36) follow these steps:
1. Disable all commands
2. Verify if C:\SOURCE_FILE directory exists (otherwise create it)
3. Source directory must contain only 2 source files
4. Select FLASH item from menu-bar
5. Give confirmation to start programming phase
6. In case of troubles with source files, (missing files, wrong version,) there will be an error message and flash
memory will not programmed.
7. After a synchronization phase, flash programming will start; a bar gives the percent indication of already
programmed memory.
8. In case of problems with serial communication, there will be an error message and flash programming phase
will be stopped.
9. After traction micro successful programming, begins pump micro programming phase (step 7 and 8)
10. A message will signal the end of programming phase, and its result; give confirmation to exit the menu.

See troubleshooting section in case of any error.

NOTE: If programming phase fails after synchronization, panel has to be programmed with correct software
before being used.

Enforce necessarily following item after Flash.


1. Click the total load EEPROM of LOAD EEPROM DEFAULT MENU
2. Re-set the lift, pedal, steering sensor

148
Troubleshooting of Eye Program
Generality Flash Programmation
Often you can solve problems reading error If panel programming phase fails, when you try
messages and following suggestions. to load source files:
1. Verify if c:\source_file directory exists
2. Verify if c:\source_file directory contains only 2
Software Installation source files
3. Be sure that source files are the ones provided
In case of failed EYE software installation, by DIs Homepage.
follow these steps:
1. Verify if your PC complies minimal requirements If you program memory successfully, but power
2. Be sure of having PC administrator rights module doesnt work correctly:
3. Close all active applications and disable 1. Be sure that source files are the ones provided
antivirus before installation by S.M.E
4. Verify installation, step by step
In case of transmission error:
In case of successful installation, if application 1. Verify system ground connections
has a runtime error: 2. Control serial connection cable: you must use a
1. Verify if your PC complies minimal requirements shielded one
2. Turn off PC and try again after turning it on 3. Verify if serial port works correctly
3. Uninstall and install again EYE software 4. Verify if there are any active commands

Serial Communication Other Problems

If application doesnt work and message not Application works slowly:


connected appears: 1. Verify if your PC complies minimal requirements
1. Verify system ground connections
2. Verify if logic works correctly Application doesnt work properly:
3. Control serial connection cable: you must use a 1. Verify if your PC complies minimal requirements
shielded one
4. Verify if serial port works correctly Text and objects on main panel are not centered:
5. Use Setup menu to verify serial port 1. Verify if your PC complies minimal requirements
configuration 2. Dont modify window size
6. Verify no other applications serial port
Monitor doesnt display correctly text and
objects
1. Verify if monitor refresh frequency is at least
75Hz
2. Verify if your PC complies minimal requirements

149
Appendix A: 48[V] 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 0 800 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 6 10
2 ramp while the driver is steering at high
speed.
Battery reset Minimum battery voltage necessary to reset
9 V*10 752 773 829
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 4,500
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
27 speed digit
command; if it's ON the reference speed of pump motor, ON = 1 (Default)
reference
in case of many simultaneous commands, will be the
lowest of those reference speed required by every single
command.
Buzzer on
If its ON, the buzzer will be alarmed when the direction OFF = 0 (Default)
30 forward digit
switch is moved to forward. ON = 1
direction
Buzzer on
If its ON, the buzzer will be alarmed when the direction OFF = 0 (Default)
31 reverse digit
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
35 temperature of cooling Fan stops when the motors cools 0 60 155
motor's Fans down below 60 from set value(The
minimum of stop temperature is 25).
Weight of the
36 Load measurement kg 0 0
load on the forks
future
No load
37 Load measurement bar10 0 0 2,200 option
pressure
38 Load pressure Load measurement bar10 0 0 2,200

150
Parameter Mini Def Maxi Re
Parameter Parameter Description Unit
No mum ault mum mark
Limitation
39 Start temperature of performance reduction 100 155
temperature
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 3,600 5,000
speed (no alarms present and turtle not active)
Reverse Maximum reverse lift truck speed with no
43 maximum speed limitation rpm 1,000 3,600 5,000
speed (no alarms present and turtle not active)
Drive limitation
Maximum lift truck speed with speed
44 maximum rpm 500 3,800 3,500
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 1,000 4,500
which the internal wheel is mechanically still.
speed
Acceleration Lift truck acceleration with accelerator pedal
48 rpm/s 400 1,100 2,000
ramp pressed
Inversion
49 Lift truck deceleration in inversion rpm/s 400 1,300 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 1,200 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 tire's diameter mm 400 558 600
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 50 500
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 65 100
released
current
Lift maximum
63 Maximum lift speed rpm 1,000 2,100 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 3,500 Option
above the critical height
speed
70 Hydro speed Pump motor speed when steering rpm 400 500 800
Pump motor speed with direction command
Hydro idle
71 lever not in neutral, acceleration pressed and rpm 200 300 500
speed
no pump command active

151
Parameter Mini Def Maxi Re
Parameter Parameter Description Unit
No mum ault mum mark
Pump
72 acceleration Lift acceleration rpm/s 1,000 7,000 10,000
ramp
Pump
Pump motor deceleration after the end of a
73 deceleration rpm 1000 7,000 10,000
command
ramp
High lift 2
Maximum lift speed when switch 1 and switch
74 switch lift max rpm 0 1,500 3,500 Option
2 was "ON"
speed
High lift 1
75 switch tilt max Maximum tilt speed when switch 1 was "ON" rpm 0 500 2,000 Option
speed
High lift 2
Maximum tilt speed when switch 1 and switch
76 switch tilt max rpm 0 500 2,000 Option
2 was "ON"
speed
High lift 1
Maximum auxiliary 1 speed when switch 1
77 switch auxiliary rpm 0 500 2,800 Option
was "ON"
1 max 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 Maximum auxiliary 2 speed when switch 1
79 rpm 0 500 2,800 Option
2 function max was "ON"
speed
High lift 2
switch auxiliary Maximum auxiliary 2 speed when switch 1
80 rpm 0 500 2,800 Option
2 function max and switch 2 was "ON"
speed
High lift 1
switch auxiliary Maximum auxiliary 3 speed when switch 1
83 rpm 0 500 2,800 Option
3 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 (Default)
95 British unit digit
in British unit, otherwise in international ones. British unit = 1
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)

152
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
Battery voltage, measured
Maximum charge-discharge cycles before reaching the
by a circuit inside logic,
1 F0 battery 1 rating declared by the constructor) or has a
exceeds following levels:
voltage high internal resistance.
106 V
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
Battery voltage, measured
Minimum alarm can sometimes be detected from the
by an internal circuit, is
2 F1 battery 1 controller; even in case of low battery charge
lower than following
voltage (<10%), high current rates (i.e. both pump and
levels : 46 V
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
Voltage measured on software and Instrument panel).
accelerator circuit exceeds 2. Verify if the following 68 ways connector
the value calculated terminals are correctly wired to their
Pedal
3 F2 2 averaging calibration and correspondent inputs in accelerator circuit:
trimmer fault
reachable voltages; - K1-11 (12 V)
moreover, start switch - K1-15 (ground)
seems to be open. - K1-10 (pedal input)
3. In case of correct wiring, replace the
accelerator itself.
4. Replace 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 6 to their correspondent inputs :
module is working with
(Capacitors - K1-18 (positive terminal)
main breaker open.
not - K1-19 (negative terminal)
Capacitors voltage
charged) 4. Replace main breaker;
decreases cause energy
5. Replace logic.
spent to keep motors in
motion.

153
EYE Error
Description Level Cause Troubleshooting
Code Code
right drive 1. With such an alarm present when you turn on
8 F3 motor power 1 lift truck, disconnect the power cable between
module the malfunctioning power module and the
pump motor corresponding motor (first, turn off the system,
24 F4 power 1 of course).
module If turning lift truck on again, alarm is not active,
then:
Actual current exceeds
1. Replace the cable connecting logic and
limits 929 A
power module.
left drive 2. Replace the power module;
25 F5 motor power 1 3. Replace logic.
module If turning lift truck on again, alarm is active,
then :
1. Replace the power module;
2. Replace the motor.
1. Replace main breaker.
power
Pre -charge capacitors 2. Replace cable connecting the CN1 output of
module
voltage increases too fast the logic with the corresponding power module;
9 A capacitors 1
when you turn the system 3. Replace the power module connected with the
pre -charge
on. CN1output of logic
too fast
4. Replace logic
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
The power module grease in the coupling is essential to ensure an
Pump motor
temperature (measured efficient heat exchange;
power
with a temperature 2. Replace cable connecting the output CN4 of
10 E3 module 6
connector), exceeds 100 the logic to the pump power module;
overtemper
C, or is inside [95 C, 100 3. If temperature readings seem too high in
ature
C] range at least 30 s. function of total time interval of lift truck using,
replace pump power module causing the
alarm.
You can read temperature measures using
Instrument panel or EYE communication
software.
4. Replace logic.
1. Verify the correctness of wiring from pump
When you turn on the
motor and relative power module;
system, capacitors are not
2. Replace wire connecting CN4 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 CN1 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 logic.

154
EYE Error
Description Level Cause Troubleshooting
Code Code
1. Measure battery voltage with a tester and, if
Low battery Battery voltage level is different from the value reported on Instrument
12 EL 3
alarm lower than minimum 75.7V panel, replace logic;
2. Otherwise recharge battery.
Presence of alarm with cold motors:
1. With a handheld multimeter (in resistance
operating mode) you have to measure a
Right drive resistance of about 10 kohm between the two
13 E4 motor over 5 wires of the temperature connector (execute
temperature the measure at ambient temperature of 25C) .
If the measure is not correct it is necessary to
replace the temperature connector;
The measure of drive 2. Disconnect the temperature connector and
motor temperature check the wiring insulation between signal
exceeds 155 C. wire an ground wire (towards logic);
3. Replace logic.

Left drive Presence of alarm with hot motors :


19 E5 motor over 5 1. If temperature value (you can read it from
temperature Instrument panel or via PC) seems correct,
verify if fans (if present) work properly; fault is
caused by an inefficient motor refreshing, or by
operating out of nominal maximum ranges.
Presence of alarm with cold motors:
1. With a handheld multimeter in resistance
operating mode, you have to measure about
10kohm at ambient temperature of 25C
between the two wires of the temperature
connector. If the measure is not correct it is
necessary to replace the temperature
connector;
Pump motor The measure of pump 2. Disconnect the temperature connector and
14 E6 over 6 motor temperature check the wiring insulation between signal
temperature exceeds 155 C . wire and ground wire ( towards logic);
3. replace logic.

Presence of alarm with hot motors:


1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
Right drive
motor
15 F6 1
current
offset alarm
1. Replace the wire connecting power module to
Left drive
Non-zero phase currents logic.
motor
16 F7 1 when you turn lift truck on. 2. Replace power module.
current
3. Replace logic.
offset alarm
Pump motor
36 F8 current 1
offset alarm
Main Overcurrent on main 1. Replace main breaker
17 17 1
breaker fault breaker coil. 2. If alarm is still present, replace logic
Improper communication
1. Using EYE program interface, try to program
Watchdog between DSPs present on
18 F 1 logic flash memory;
timer alarm logic, or/and defective
2. Replace logic.
logic.

155
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
Right drive power module
ensure a correct heat exchange;
motor power temperature, measured
2. Replace cable connecting the output CN1 of
20 E1 module 5 with a connector, exceed
the logic to the corresponding power module;
overtemper 100 C , or is inside [100
3. If temperature readings seem too high in
ature C] range at least 30 s.
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 logic.
Error in serial
communication between
1. 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.
ion alarm software control, to insure
2. Replace logic.
fast diagnosis of such a
fault.
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
Left drive power module
ensure a correct heat exchange;
motor power temperature, measured
2. Replace cable connecting the output CN2 of
22 E2 module 5 with a connector, exceed
the logic to the corresponding power module;
overtemper 100 C , or is inside [100
3. If temperature readings seem too high in
ature C] range at least 30 s.
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 logic.
1. Verify if 5 V output is grounded, cause an
incorrect encoder wiring.
Alarm on 5 logic K1-14 terminal (5 V
2. Verify if 5 V output is grounded, cause any
37 FH V encoder 1 output) voltage is lower
encoder malfunction. In that case, replace the
voltage than 4.3 V.
defective one.
3. Replace logic.
1. Verify if 12 V output is grounded, cause an
incorrect wiring to:
- Accelerator potentiometer
Alarm on 12 logic K1-12 terminal (12 V
- Steering sensor
38 FA V output 1 output) voltage is lower
- Buzzer
voltage than 10.5 V.
- Display
2. Replace defective device;
3. Replace 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 valve board.
Battery miss Battery is not suitable
60 60 1 Check battery voltage at the system.
matching voltage to controller.

156
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
Right drive resistance of about 10 kohm between the two
The measure of right drive
motor wires of the temperature connector ( execute
61 61 1 motor temperature
shutdown the measure at ambient temperature of 25C) .
exceeds 165 C.
temperature If the measure is not correct it is necessary to
replace the temperature connector;
2. Disconnect the temperature connector and
check the wiring insulation between signal
wire an ground wire ( towards logic);
3. Replace logic.
Left drive
The measure of left drive Presence of alarm with hot motors :
motor
62 62 1 motor temperature 1. If temperature value (you can read it from
shutdown
exceeds 165 C. Instrument panel or via PC) seems correct,
temperature
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 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 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 25C
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
temperature exceeds 165 C. wire and ground wire ( towards logic);
3. Replace logic.

Presence of alarm with hot motors:


1. If temperature value (you can read it from
display or via PC) seems correct, verify if fans
(if present) work properly; fault is caused by an
inefficient motor refreshing, or by operating out
of nominal maximum ranges.
1. Verify if the encoder is correctly connected to:
- Motor itself
Right drive - Ground : K1- 15 terminal
An encoder channel is
motor - + 5 V: K1- 14 terminal
74 Fc 1 disconnected, and motor
encoder - A channel: K1- 37 terminal
is working.
alarm - B channel: K1- 36 terminal
2. If correctly wired, replace the encoder;
3. Replace logic.

157
EYE Error
Description Level Cause Troubleshooting
Code Code
1. Verify if the encoder is correctly connected to:
- Motor itself
Left drive - Ground : K1- 15 terminal
An encoder channel is
motor - + 5 V: K1- 14 terminal
75 Fd 1 disconnected, and motor
encoder - A channel: K1- 17 terminal
is working.
alarm - B channel: K1- 16 terminal
2. If correctly wired, replace the encoder;
3. Replace logic.
1. Verify if the encoder is correctly connected to:
- Motor itself
- Ground : K1- 15 terminal
Pump motor An encoder channel is
- + 5 V: K1- 14 terminal
76 76 encoder 1 disconnected, and motor
- A channel: K1- 29 terminal
alarm is working.
- B channel: K1- 28 terminal
2. If correctly wired, replace the encoder;
3. Replace the logic.
Alarm of
right drive
77 77 motor
thermal
connector
Temperature difference
Alarm of left 1. Verify if the wiring is correct;
between any two of the 3
drive motor 7 2. Replace the connector;
78 78 motors results greater
thermal 3. Replace logic.
than 70 C.
connector
Alarm of
pump motor
79 79
thermal
connector
Alarm of
right drive
80 80 motor
module
connector
Temperature difference 1. Check the wiring connecting control unit and
Alarm of left
between any two of the 3 power module;
drive motor 7
81 81 power modules results 2. Replace the power module;
module
greater than 70 C. 3. If alarm is still present, replace logic.
connector
Alarm of
pump motor
82 82
module
connector
1. restore eeprom with EYE application software,
Faulty eeprom or using the RESTORE item present in main
CRC fault
83 83 1 mismatching software page
alarm
release. 2. If alarm is still present, replace logic.
CRC : Cyclic Redundancy Checking error.
There was an eeprom
Bank CRC
84 84 1 restore, caused by a CRC 1. Switch on the system and the turn it on again
restored
alarm.
1. verify correctness of wiring with :
- K1-11 (12 V),
Steering
Steer circuit voltage is out - K1-15 (ground)
91 F9 sensor 5
of nominal range. - K1-10 (steering sensor input);
alarm
2. if correctly wired, replace steering sensor;
3. Replace logic.
1. Check cable connecting the CN1 output of the
Pre-charge capacitor
Capacitors logic with the corresponding power module
voltage grows too slowly,
98 A pre-charge 1 2. Replace the power module connected with
when you turn on the
too slow CN1 output of the logic;
system.
3. Replace logic;

158
EYE Error
Description Level Cause Troubleshooting
Code Code
Pre-charge capacitors 1. Check cable connecting the CN1 output of the
Capacitors voltage does not reach the logic with the corresponding power module
99 A pre-charge 1 rated battery voltage 2. Replace the power module connected with
too slow within a limit time, when CN1 output of the logic;
you turn on the system. 3. Replace logic;

159
Appendix C: Contraction for dot matrix display.
C.1. Alarm Code

[Display Code] [Description] [Contraction]


17 Main breaker fault CONTACTOR FAULT
60 Battery/controller mismatch BATT MISMATCH
61 Right Motor Shutdown Temperature R-MOTOR SHUTDOWN
62 Left Motor Shutdown Temperature L-MOTOR SHUTDOWN
65 Pump Motor Shutdown Temperature P-MOTOR SHUTDOWN
76 Pump motor Encoder P-MOTOR ENCODER
77 Wrong right traction motor thermal switch R-M TEMP SENSOR
78 Wrong left traction motor thermal switch L-M TEMP SENSOR
79 Wrong pump motor thermal probe P-M TEMP SENSOR
80 Wrong right traction module thermal probe R-INV T SENSOR
81 Wrong left traction module thermal probe L-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 right module Overtemperature R-INV OVERTEMP
E2 Drive left module Overtemperature L-INV OVERTEMP
E3 Pump module Overtemperature P-INV OVERTEMP
E4 Drive right motor Overtemperature R-MOTOR OVERTEMP
E5 Drive left motor Overtemperature L-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 right module Desat/overcurrent R-INVERTER FAULT
F4 Drive left module Desat/overcurrent L-INVERTER FAULT
F5 Pump module Desat/overcurrent P-INVERTER FAULT
F6 Drive right motor current Offset R-MOTOR I OFFSET
F7 Drive left motor current Offset L-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 right motor Encoder R-MOTOR ENCODER
Fd Drive left motor Encoder L-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

160
C.2. 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
10 First parameter for calibration enable 1ST 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
17 Second parameter for calibration enable 2ND PASSWARD
18 Steering sensor value : wheels turned on the left WHEEL TURN LEFT
19 Steering sensor value : wheels turned on the right WHEEL TURN RIGHT
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
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 Pump max speed in limiting PUMP LIMIT MAX
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
75 High lift 1 switch tilt max speed HIGH1 TILT LIMIT

161
[Display Code] [Description] [Contraction]
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

162
C.3. Diagnostic Code

[Display Code] [Description] [Contraction]


1 Right traction motor speed RIGHT MOTOR SPD
2 Right traction motor speed reference R-MOTOR REF SPD
3 Left traction motor speed LEFT MOTOR SPD
4 Left traction motor speed reference L-MOTOR REF SPD
5 Lift lever voltage LIFT SENSOR OUT
6 Battery voltage BATT VOLTAGE
7 Right traction 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
14 Left traction motor power module temperature L-INVERTER TEMP
15 Right traction motor phase current R-MOTOR I-U
16 Right traction motor phase current R-MOTOR I-V
17 Right traction motor phase current R-MOTOR I-W
18 Left traction motor phase current L-MOTOR I-U
19 Left traction motor phase current L-MOTOR I-V
20 Left traction motor phase current L-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 Right traction motor temperature R-MOTOR TEMP
25 Left traction motor temperature L-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
36 3/4 wheels selection switch 3 OR 4 WHEEL
37 Auxiliary 1 switch AUX 1 OUTPUT
38 Auxiliary 2 switch AUX 2 OUTPUT
39 Auxiliary 3 switch AUX 3 OUTPUT
40 High lift switch HIGH LIFT SWITCH
41 Tilt switch TILT SWITCH OUT
42 High lift 2 switch HIGH LIFT 2 SWITCH
43 Main breaker command CONTACTOR
44 5V out 5V OUT

163
[Display Code] [Description] [Contraction]
45 12V out 12V OUT
46 24V out 24V OUT
47 Buzzer command BUZZER
48 Fans command FAN
49 Drive right motor encoder channels R-MOTOR ENCODER
50 Drive left motor encoder channels L-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

164
SB4208E01
Feb. 2012

Power Train
Specification
Systems Operation
Testing & Adjusting
Disassembly & Assembly

B22X-5, B25X-5, B30X-5, B35X-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.
Index
Specifications

General Tightening Torques.............................. 3


General tightening torque .............................. 3
for bolts, nuts and taperlock studs ................. 3

Drive Motor ....................................................... 5

Drive Axle ......................................................... 5


Safety regulation: .......................................... 5
Specification - Drive Axle ............................... 6

Wheel Mounting ................................................ 7


Drive Motor assembly procedure - general
description..................................................... 8
Transfer Gear Oil Refill .................................. 8
Brake ............................................................ 9
Brake disassembly procedure -general
description....................................................10

Systems Operation

General Information .........................................12

Drive Motor ......................................................12


Exploded view of transfer .............................14

Testing And Adjusting

Troubleshooting ...............................................15
Visual Checks ..............................................15

Checks During Operation .................................15


Drive Motor ..................................................15

Drive Motor ......................................................20


Thermal Sensor Tests ..................................20
In case the speed sensor is fixed to the motors
shield with two screws ..................................21
Motor and Transmission ...............................21

Disassemble and Assemble

Drive Axle ........................................................22


1
Gearbox disassembly -general description ..22
Disassembly of the Ring Gear (19) and of the
Wheel Hub (1) ..............................................22
2
Assembly of the Sun Pinion (40) ..................25
Assembling the Ring gear (19) and the Wheel
Hub (1) .........................................................26

Special Service Tools ......................................29

Power Train 1 Index


Power Train 2 Specifications
Specifications

General Tightening Torques

General tightening torque


for bolts, nuts and taperlock studs
The following charts give the
standard torque values for bolts,
nuts and taperlock studs of SAE
Grade 5 or better quality.
Exceptions are given in other thread
sections of the Service Manual size standard torque
where needed.
inches lbft Nm*
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 7/16 50 10 70 15
standard threads 1/2 75 10 100 15
(Conversions are approximate) 9/16 110 15 150 20
5/8 150 20 200 25
3/4 265 35 360 50
7/8 420 60 570 80
1 640 80 875 100
standard thread 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
1/2 60 3 80 4
bodies.
5/8 118 4 160 6
1 52 7 3
5 103 15 5
Use these torques for 3 203 30 5
studs with taperlock 7 305 40 10
threads. 1 405 55 10
9 60 10 80 15
5 7510 100 15
3 110 15 150 20
7 170 20 230 30
taperlock stud 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(Nm) is approximately the same as 0.1 mkg.

Power Train 3 Specifications


Metric fasteners
metric ISO thread

thread size torque


(mm) (Nm)* (lbft)
M6 12 4 93
M6 12 4 93
M8 25 7 185
[Usually, material strength identification on bolt M10 55 10 40 7
head is with numbers (i.e., 8.8, 10.9, etc.)] M12 95 15 70 10
M14 150 20 110 15
The chart on the right gives the torque for bolts and M16 220 30 160 20
nuts with Grade 8.8. M18 325 50 240 35
M20 450 70 330 50
NOTICE : Caution must be taken to avoid mixing M22 600 90 440 65
metric and standard (customary) fasteners. M24 775 100 570 75
Mismatched or incorrect fasteners can result in M27 1150 150 840 110
vehicle M30 1610 200 1175 150
damage or malfunction, or possible personal injury. M33 2000 275 1450 200
Original fasteners removed from the vehicle should M36 2700 400 2000 300
be saved for assembly when possible. If new ones
are required, caution must be taken to replace with ISO-International Standard Organization
one that is of same part no. and grade or better.
Hose clamps-worm drive band type

intitial assembly reassembly or


clamp
torque on new hose retightening torque
width
(Nm)* (lbft) (Nm)* (lbft)
15.9 mm (.625 inch) 7.5 0.5 65 5 4.50.5 40 5
13.5 mm (.531 inch) 4.5 0.5 40 5 3.00.5 2 5
7.9 mm (.312 inch) 0.9 0.2 8 2 0.70.2 6 2
*1 newton meter(Nm) is approximately the same as 0.1 mkg.

Power Train 4 Specifications


Drive Motor Drive Axle
(AC)
Safety regulation:

This handbook gives just an overall view of the


reduction gearbox and is addressed to skilled
workman with proper tools (properly equipped).
Detailed descriptions of disassembly and assembly
of gearbox are available in separate document.
During operations of maintenance, assembly and
disassembly use caution and proper safety
equipment in observance of the rule of law.

ATTENTION! Gearbox is made with heavy parts:


secure the parts and use proper lifting equipment.
Thermal switch

Warning temperature ........... 155 4C (311 10F) Drive axle is designed to be used mainly on 2.5 ~
3.5 ton-capacity lift trucks.

Drive axle is composed of two independent and


separate parts, and namely:
1) the reduction gear itself;
2) the brake cartridge, containing oillubricated brake
discs.

The patented technical solution of the separation


between the brake cartridge and the gearbox allows
to optimise the performance of the unit, because the
two chambers are separated and work with the
same oil but with two different oil levels that
automatically compensate it during the working
processing.

This system allows an excellent lubrication of the


brake disks and the reduction gear, so optimise:
a) the brake system life time
b) the thermal exchange
c) the system performance

Replacing brake disks requires that the brake


cartridge only need be disassembled, and not the
whole reduction gear.
It is possible to shift from the positive brake
mechanism (hydraulic or mechanical control) to the
negative brake mechanism (hydraulic release) by
partially replacing the brake cartridge.

Power Train 5 Specifications


Specification - Drive Axle
Brake fluid type Mineral*
One-wheel with braking system in single chamber: Max dynamic braking
hydraulic service brake (dynamic) and mechanical 85 bar
pressure
parking brake (static)
Max dynamic brake
150 bar
pressure allowable
Max axial load 4400 kg Oil volume for 3
3.2 cm
Electric motor dynamic braking
7-8 kW
power Chamber volume
5.6 cm3
with worn discs
Max input
5000* rpm
speed Lever stroke, never
15 mm
used discs
Ratio 24.2 Lever stroke, worn
21 mm
discs
Continuous Dynamic braking
torque torque at wheel (@ >3300 Nm
1900 Nm
allowable at 85 bar)
wheel
Force on lever /
Max. motor 1000N = 1700Nm
torque at wheel
acceleration 3000 Nm
torque at wheel

Tyre 23x9/10
dimensions 23x10/12

Gearbox oil
SAE 80W / API GL4**
type
Gearbox oil
1.2 ~ 1.3*** L
quantity
Gearbox oil
Ore
changing 1000
Hours
interval
Gearbox
57 kg
weight

*High speed (>3500 rpm) require VITON/FPM


seals on motor flange

**Recommended oil

*** Depending on the mounting angle

Power Train 6 Specifications


Wheel Mounting

(1) Nut. (2) Bolt.

(1) Torque for drive wheel mounting nut


........... 200 Nm (148 lbft)

(2) Torque for bolt that hold housing to frame


........... 240 Nm (177 lbft)

Service brake M10X1 Service brake drain valve

Parking brake

Power Train 7 Specifications


Drive Motor assembly procedure - Transfer Gear Oil Refill
general description
Fig 4
Oil-sealing of the inlet shaft is ensured by a single-
lip seal and an O-ring, housed in the motor flange.
The motor flange and the reduction gear arcoupled
(see fig.2) by means of five M10 screws, three are
60 mm-long and two are 85 mm long.
It is recommended to use the outer crown of screws
(1) and use-if required the inner crown of screws (2)
for further fixing of heavy motors or for fixing small
motors.

Fig 2 (13)

(12)

Assembly warnings
(12)
In order to connect the gearbox to the motor, move it
only along its axis. Absolutely avoid to connect it
sideways. You are recommended to secure the
gearbox and lift it until both the motor and the input (12) Gearbox oil refill plug, (12) Gearbox oil level plug,
axes match. (13) Gearbox oil drain plug
To facilitate the assembly drive in three studs into
the connecting screw holes and centre the gearbox For oil-filling operations, use the refill plug, the level
on them. Then remove the studs and replace them plug and the drain plug as shown on fig.4.
with the M10 screws. The oil level check is "overflow", meaning that the
correct oil level is reached when the oil starts
Detailed descriptions of disassembly-assembly of leaking off the plug.
motor are available in separate document supplied In any case, every reduction gearbox need to be
by the truck maker. filled with the following oil quantities: 1.2 ~ 1.3 litres.

Oil should be changed every 1000 working hours.

You are recommended to use oil type SAE 80W /


API GL4 as the following: MOBIL FLUID 424

Power Train 8 Specifications


Brake The brake is designed to guarantee that the wheel
maximum braking torque exceeds 3300 Nm under a
pressure of 85 bars or with a pull (cp version) of
Fig 5
approx. 2000N on the brake lever.
For parking brake purpouse the relation is 1000 N at
lever = 1700Nm at wheel (cp version).
The lever stroke (related to the cable connection
point) is 15 to 21 mm depending on brake disks
consumption (cp version).
From a mechanical point of view, the brake discs
can temporarily bear a pressure exceeding 200 bars
in total security;
tightness of gaskets on the brake inner piston is not
guaranteed when pressure exceeds 150 bars.
(50) Brake lever, (63) Brake piston
Piston gaskets* have been successfully tested with
mineral oil.
The brakes chamber employees the reduction gear
oil and it is always feed in the working processing.
During the installation of the reduction gear, it is
necessary to verify that the handbrakes draught
cable isnt in tension or that it doesnt reduce the
space between the brake disks. It would
compromise the correct working of the brake.
We suggest an installation of a brake pump type:
mini-servo with max operative pressure 85 bar. For
the normal use the operative pressure is from 50 to
70 bar.

It is necessary to check every 3000 working hours


that the stroke of the brake piston is not over 3.5
mm, otherwise it is necessary to replace the brake
discs. For the PMS701 cp version, in order to
estimate the worn of the discs, disconnect the brake
rod. Move the lever closer the brake piston, then pull
it strongly and measure the stroke of the lever: it has
not to be over 21 mm. In case the stroke exceed this
value, its suggested to replace the disc pack (see
fig. 5).

Fig 6

The M10x1 plug is used as connection to the


hydraulic service brake circuit (see fig 6).
The bleeder nipple located near the lever is used for
bleeding the braking circuit before it is started.

Power Train 9 Specifications


Brake disassembly procedure -general Replace of the Brake Discs
description
Fig 8

Fig 7

(66) Friction disc, (67) Steel disc, (68) Elastic spacer,


(69) Reaction disc, (71) Pins, (73) Studs
(12) Gearbox oil refill plug, (13) Gearbox oil drain plug, (53) 8
Screws, (54) Brake oil refill plug, (54) Brake oil drain plug
The brake discs unit is made of 6 steel discs (67)
and 5 friction discs (66), ordered in an alternate way
To service the brake its necessary to work remove (the first one and the last one must be smooth).
the gearbox from the truck. Secure the gearbox, Between every couple of steel discs four elastic
disconnect pipes and ropes and unscrew the 8 M16 spacers are inserted (68), one spacer on each
screws connecting the gearbox to the frame. locking pin (71) (see fig 8) Remove first the 2
Remove the gearbox from the truck and place it on a retaining rings (70) from the studs (73), then the
surface. discs pusher device (64+65) and the brake disc unit.
Unscrew the plugs (54) and drain the oil off, at least Pull the springs (72) out from the studs (73).
in part; unscrew the 8 screws (53) (see fig 7). Two of Remove the aluminium reaction disc (69).
the holes where the screws are located have a M10 Wash down the cartridge thoroughly, then to
thread:drive two M8 grubs in, in order to save the assemble the parts again follow next steps:
thread of the flange (33), then drive two M10 screws step1: insert the reaction disc (69)
in until the brake cartridge cover (55) is extracted. step2: insert steel disc (67), 4 elastic spacers (68)
one spacer on each locking pin (71), friction discs
Detailed description of disassembly-assembly of (66).
gearbox are available in separate document step3: repeat step2 for 4 times
step4: place last steel disc and the 2 springs (72)
in the studs (73).
step5: insert the discs pusher device (64+65) onto
the pins (73), then, pressing down all, place the 2
retaining rings (70) into the seat on the pins (73).

Power Train 10 Specifications


Fig 9a

Fig 9b

(33) Flange, (38) Spine, (53) 8 Screws, (71) Pins

Place the spacer-seal (56) on the flange (33) contact


surface. Insert the brake cartridge cover, centre on
its 2 pins (38) and on the 4 brake locking pins (71)
(see fig. 9a) and, using a rubber hammer, finetune
the cartridge position until it is completely inserted.
Now, insert the 8 screws (53) in their own holes (see
fig. 9b) and set them with the following torque
wrenches: (53) screw M8 cl. 10.9 33 Nm

Oil filling

Follow instructions on page 7 because the brakes


chamber employees the reduction gear oil.

Power Train 11 Specifications


Systems Operation Drive Motor
General Information (AC)

Power Flow The motor is protected from over temperature by a


(1) Final drive. (2) Drive motor. thermal sensor.
If motors temperature reaches in 155 4C (311
The power train for the B25X-5 MODEL Lift Trucks 10F), controller does overheat warning and
consist of two main components; drive motors (2) operates by lowest performance.
and final drives (1).
The drive motor is activated when the parking brake
Electric storage batteries are used as a power is released, the key and seat switch are closed, a
source for the drive motors (2). The drive motor direction is selected and the accelerator pedal is
turns final drive (1), which turn the drive wheels. depressed.

The drive motor powers the power transfer group


through input gear.

Power Train 12 Systems Operation


Fig 10

It is necessary to identify the model and the serial


number on the name-plate of the gearbox (see fig
10) while asking for spare parts.

Power Train 13 Systems Operation


Exploded view of transfer

Power Train 14 Systems Operation


WARNING
Testing And Adjusting
If an electrical failure or an overload of the
Troubleshooting motor is present, personnel must not breathe
the toxic fumes which are a product of the burnt
Visual Checks insulation. All power must be disconnected
from the motor before any inspection is made to
Make a visual inspection of the truck to check for find the failure. The area around the motor must
problems. Operate the truck in each direction. be well ventilated (air flow) and the motor is to
Make a note of the noises that are not normal and be cooled before any repair work is done.
find their source. If the operation is not correct, Water must not be used on any electrical
make reference to the Check List During Operation equipment because of the danger of electric
for "Problems" and "Probable Causes". shock. If a fire is present, disconnect the
electrical power and use a carbon dioxide
extinguisher to put the flame out.
Checks During Operation Do not operate the drive motors without a load,
as too much speed may cause damage to the
Drive Motor motor and injury to personnel.

Before an analysis is made of any electric drive <AC>


motor problem, always make reference to the
Troubleshooting section of the MicroController Problem 1 : Drive Motor Will Not Operate.
System Operation module.
probable Cause :
WARNING
1. Switch not closed (battery connector, key switch,
The lift truck can move suddenly. Battery seat switch, direction switch or parking brake
voltage and high amperage is present. Injury to switch) :
personnel or damage to the lift truck is possible. Close the switch. If it still does not operate test
Safely lift both drive wheels off the floor. Put for power to the control panel and power flow
wood blocks or jack stands of the correct through each switch with a voltmeter.
capacity under the frame so the drive wheels But the service brake switch should be opened.
are free to turn. During any test or operation
check, keep away from the drive wheels. 2. Bad connection. Fuse blown :
The Power unit will have to be discharged Check battery connections. Check connections
before any contact with the control panel is at battery connector. Check fuses, drive and
made. Disconnect the battery and discharge the logics. Replace fuse if blown.
Power unit. Rings, watches and other metallic Check the Drive motor and control panel for
objects should be removed from hands and possible reasons for a blown fuse. Some causes
arms when troubleshooting the MicroController are :
Control System. a. Operation under excessive MOSFET load, too
To prevent personal injury, never use air high current limit (C/L).
pressure that is more than 205 kPa (30 psi), and b. Possible short circuit in power unit.
wear protective clothing and a face shield.
3. Low battery voltage:
Check battery terminal voltage. If too low, charge
the battery.
NOTICE Check all the cells for one or more that have
To prevent damage to electrical components, make defects.
sure the air line is equipped with a water filter when Check the specific gravity of each cell. The
they are cleaned with air. 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.

Power Train 15 Testing And Adjusting


5. Static return to off circuit (S.R.O.) actuated: Problem 3 : Neither traction or hydraulic will
If the static return to off is activated, the control last
will not start again until the accelerator is through a complete normal work period.
released and the directional control lever is
returned to neutral. Probable Cause :

6. Speed sensor is breakdown. 1. Too small a battery equipped in the lift truck :
Use a larger battery for the complete work cycle
Problem 2 : Traction will not operate through a and normal work period.
normal work period, but hydraulic operation is
normal. 2. Battery not being fully charged or equalized
during the battery charging operation :
Probable Cause : Check the battery cells for an equalization
charge(a charge to make the specific gravity the
1. Brakes have a defect, cause a resistance(lack of same in all cells). Check the battery charger for
free movement). Heat increases, which causes defects.
the motor to stall :
Check the brake adjustment according to the 3. Battery change interval is too long or changed
procedures in Testing And Adjusting in the battery cooling time is too short. This decreases
Vehicle Systems module. the capacity and the ability of the battery :
Decrease the battery work duration before a
2. Too much heat in MicroController control panel change. Increase the battery cooling time after a
because: charge before it is put to use.
a. Extra heavy traction loads.
Decrease the duty cycle load. 4. Battery has one or more defective cells which
b. Faulty thermal sensor. results in less than the rated capacity and ability
See the MicroController System Operation of the battery :
module. Replace the battery.

These can cause MOSFETS to become defective, 5. Traction system draws (makes a consumption of)
control panel failure or drive fuse to go bad. 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.

Power Train 16 Testing And Adjusting


Problem 4 : Low resistance to ground [battery Problem 6 : Lift truck does not have enough
polarity either positive (+) or negative () or a power to position itself under a load. Lift truck
medium voltage is in direct contact with truck does not have enough power on ramps or
frame (body) or drive motor body]. towing trailers.

Probable Cause : Probable Cause:

1. Dirty battery, electrolyte on top of cells and is in 1. Unpolished or improperly positioned forks :
contact with the frame. Current flows through Install tapered and polished forks. Position forks
battery box, which places a voltage on the truck correctly for load being lifted.
frame :
Clean the battery with baking soda and water 2. Lift truck equipped with tires that have poor
solution. traction :
Install tires that have good traction per
2. Battery or control panel wire connections in recommendation from DOOSAN Inc.
contact with truck frame :
Make a continuity test and move the wire from 3. Lift truck work load is too heavy or the duty cycle
contact. too long :
Remove wires in sequence until the fault is Decrease the work load and/or duty cycle.
cleared.
The fault will be in the wire last disconnected. Problem 7 : Lift truck has slow acceleration.

3. Dirty motor : Probable Cause:


Remove metallic or carbon dust with air pressure.
1. Drive control overheated and the thermal switch
4. Wet motor : opens :
To dry the motor, heat it to 90C (194F).
NOTE: The thermal switch will warning if the
Problem 5 : Lift truck will not get to top speed. temperature is 155 4C (311 10F).

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 17 Testing And Adjusting


Transmission Problem 5 : Long brake pedal stroke.

Problem 1 : Abnormal movement of drive shaft Probable cause :


to axial direction.
1. Excessive lining wear :
Probable cause : Check the stroke of brake piston rod. Keep the
stroke within 3~5 mm by adding shim.
1. Lock nut loosening :
Check if lock nut and socket head bolt for 2. Failure of brake master cylinder :
stopping lock nut are loosened. Tighten lock nut Change the seals in the brake master cylinder.
and socket head bolt with Loctite No.277.
Problem 6 : Decreased oil level in brake oil
Problem 2 : Rattle noise during coasting and reservoir or leakage through brake piston rod.
cornering.
Probable cause :
Probable cause :
1. Damage on seals of brake piston rod :
1. Abnormal wear on tire tread : Change the quad ring, back up ring and wear
Change tires with new tires. rings on piston rod.
Rattle noise could be improved by change tires
left and right each other. 2. Scratch on brake piston bore :
Replace transmission housing cover with new
Problem 3 : Gear noise during driving. one.

Probable cause : Problem 7 : Noise during brake application.

1. Damaged tooth or excessive wear of bearing : Probable cause :


Check gears and bearings and change the
damaged gear and bearing of excessive wear. 1. Using wrong transmission oil specification :
Keep the oil drain interval and use specified oil. Check the transmission oil with specified one and
keep the drain interval.
Problem 4 : Leakage through air breather.
2. Insufficient soaking hour of friction discs. After a
Probable cause : few days, problem will disappear.

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.

Power Train 18 Testing And Adjusting


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.

Power Train 19 Testing And Adjusting


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 25C between the two
wires of the thermal sensor.

Power Train 20 Testing And Adjusting


In case the speed sensor is fixed to the Motor and Transmission
motors shield with two screws

(3) (1)

(2)

(3)

(1) (2)
(1) Socket head bolt. (2) Drive motor. (3) Transmission
1. Unscrew 2 M4 screws
1. Place the drive motor (2) carefully on the
2. Remove the installed sensor (1) transmission (3) and join the gearings of motor
spline and pinion gear carefully.
3. Position and push the new sensor into its housing
NOTE : When joining the splines, turn the motor
4. Verify if its completely inserted in its housing as, shaft carefully until the motor spline engages into
on the contrary, it could be damaged as soon as the pinion gear.
the screws are screwd
2. Turn motor so that bore pattern of transmission
5. Screw the two (2) M4 screws with a tightening lines up with that of motor.
torque of 1.2 Nm
3. Screw motor and transmission together with three
socket head bolts (1). Tighten the bolts to a
torque of 55 Nm (41 lbft).

Power Train 21 Testing And Adjusting


Disassemble and e = 27mm) on the centre of the M40 thread of the
hub, and carefully press it out. At this point slip off
Assemble the planet carrier (20) (see fig. 12b).
Unscrew the 10 screws (18) and pull out the ring
Drive Axle gear (19) (see fig. 12c).
Gearbox disassembly -general
description1
Fig 12a

Note : Detailed description of disassembly-


assembly of axle are available in separate
document

Numbers in brackets refer to the parts as


listed in the spare part list

Its possible to open the gearbox without


disassembling it from the truck. You have to drain
the oil from the reduction gearbox only, removing
the plugs (12 and 13 magnetic) 2 from the bottom
side (see fig 4 on page 9) but, in order to accelerate
the operation, remove the brake oil plugs (54) too
(see fig 7 on page 9).

Casing Removal (11)

Unscrew the 6 frame connecting screws M16 from


the bottom side of the casing following instruction on
page 9. Fig 12b
Unscrew the 3 screws (10) and the 4 screws (8)
from the casing (11) and remove the cover pulling it
along the wheel axis and inserting a tool in the 4
housing on the edge of the cover itself (see fig. 11).
Please, pay attention: the casing is heavy!

Fig 11

Fig 12c

(8) 4 Screws, (10) 3 Screws

Disassembly of the Ring Gear (19) and


of the Wheel Hub (1)

In order to pull out the planet gears (22) and their


bearings (23), remove the retaining ring (24) and (1) Wheel hub, (18) 10 Screws, (19) Ring gear, (20) Planet carrier,
use a special extractor (see fig. 12a). (22) Planet gears, (24) Retaining rings, (25) Ring nut
To unscrew the ring nut (25) a special tool is
required; this tool is described on page 28. To
remove the wheel hub (1) place a pipe (i = 17mm,

Power Train 22 Disassemble and Assemble


To disassembly the Sun Pinion and the Input Shaft
you have to remove the flange and the connected
motor from the truck. Secure the motor, then
unscrew the 2 screws M16 from the top of the flange.
Place the flange and the motor on a surface.
Unscrew the 5 M10 motor connecting screws and
separate it from the flange.

Disassembly of the Input Shaft (37)

Remove first the retaining ring (30) and helping


yourself with an extractor pull out the bearing (31)
and/or the helix pinion (32) (see fig. 13). Using a
rubber hammer take out the input shaft.

Disassembly of the Sun Pinion (40)

Attention, please: prior to this operation you have to


remove the cartridge and the brake disc unit
following the instructions on page 12 Remove the
retaining ring (26). To remove the Helix gear (27)
put a disc (i = 92mm, e = 130mm) on the cover
(looking from the brake side) and carefully press on
a pipe (i = 17mm, e = 27mm) placed on the sun
pinion (40) (looking from the gearbox side) (fig.14)

Fig 13

Fig 14

(26) Retaining ring, (27) Helix gear, (30) Retaining ring,


(31) Bearing, (32) Helix pinion, (40) Sun pinion

Power Train 23 Disassemble and Assemble


Disassembly of the Cover (42) Assembly of the Cover (42)2

Unscrews the 12 screws (43) (see fig. 15a). Remove Insert the O-ring (41) onto the housing on flange
the cover (42) pulling it along the axis. (33) (see fig. x16a).
Take out the O-ring (41) from the housing on the Place the cover (42) on the flange (33) and insert
flange (33) (see fig. 15b). the 12 screws in their own holes (see fig. 16b).
Set the screws with the following torque wrenche:
Fig 15a (43) screw M6 cl. 12.9 15 Nm

Fig 16a

Fig 15b

Fig 16b

(41) O-ring, (42) Cover, (43) 12 Screws


(41) O-ring, (42) Cover, (43) 12 Screws

Assembly of the Reduction Gear -general


description1-

After the worn-out parts have been replaced, to


assemble the unit again follow the disassembling
process steps in reverse order.

Power Train 24 Disassemble and Assemble


Assembly of the Sun Pinion (40)2 Fig 17c

Key the bearing (29) in its own slot on the flange


(33), locking it with the retaining ring (28) (fig. 17a),
insert the sun pinion (40) (fig. 17b) using a press
and pushing on the inner ring of the bearing; place
the feather key (39) into its own slot and insert the
helix gear (27) on the sun pinion (40) (fig. 17c).
To easy keying operations, you may heat the helix
gear (27) to maximum 100-120C. Insert the
retaining ring (26).

Fig 17a

(26) Retaining ring, (27) Helix gear, (28) Retaining ring,


(29) Bearing, (33) Flange, (40) Sun pinion

Fig 17b

Power Train 25 Disassemble and Assemble


Assembling the Ring gear (19) and the Fig 19a
Wheel Hub (1)

Insert the cup (outer ring) of the conical bearings (5)


and (15) in their front and rear housings on the
casing (11); insert the cone (inner ring) of bearing
(5) onto the hub (1) possibly heating it up to 100-
120C-. Insert the seal ring (4) into its housing in the
hub.
Insert the needle shell (3) in its own slot in the hub
(1) (fig. 18).
Introduce the pre-assembled hub into the casing,
insert the spacer (6) into the shaft and then place
the cone of the bearing (15), pressure-keying it in.
Fig 19b
Fig 18

Fig 19c

(1) Wheel hub, (3) Needle cage, (4) Seal ring, (5) Conical bearing

Insert the ring-gear carrier disc (17) into the ring


gear (19) and fix it introducing the retaining ring (16)
in its housing (fig. 19a).
Place the disc in the casing (11) centring it on the Fig 19d
two pins (14) and then tighten its 10 screws (18)
with a 80Nm torque wrench setting (fig. 19b) Heat
the planet carrier (20) up to 120C, then place it onto
the wheel hub spline (1) and press it down until the
group is packclosed; tighten the ring nut (25) with an
dynamometric key set at 500 Nm torque wrench, (fig.
19c) then lay the outer edge low.
Insert the planet gears pre-mounted with their
bearings (22+23+21+21) on the 3 axes of the planet
carrier (20), then lock them with the retaining rings
(24), one for each planet gear (fig. 19d)

(14) Pin housings, (16) Spring, (17) Ring-gear carrier disc,


(18) 10 Screws (19) Ring gear, (20) Planet carrier,
(22+23+21+21) Pre-mounted planet gears, (24) Retaining ring

Power Train 26 Disassemble and Assemble


Assembling the Input Shaft (37)
Fig 20c

Key the bearing (34) onto the input shaft (37), insert
it into the housing in the flange (33) and lock all with
the retaining ring (35) (fig. 20a), then place the
feather key (36) into its own slot on the shaft, insert
the helix pinion (32), the needle cage (31) and finally
lock all with the retaining ring (30) (fig. 20b).

Assembly of the Cover (33)

Lay a coat of sealant on the housing contact surface


(11) and key the pre-mounted flange (33) onto the
housing centring it on the 3 pins (14) (fig. 20c) and,
Fig 20d
using a rubber hammer, seal it all.
Insert the 4 screws (8) and the 3 screws (10) into
their own seats and tighten them at: (8) M8x35 cl.
10.9 33 Nm (10) M8x20 cl. 12.9 40 Nm

torque wrench setting (fig. 20d).

Fig 20a

(10) 3 Screws, (14) Pins, (34) Bearing, (35) Retaining ring,


(37) Input shaft, (40) Retaining ring, (41) Needle cage,
(42) Helix pinion, (42) Helix pinion

Now is possible to assemble the brake disc unit


Fig 20b paying attention to respect the steps on page 13.
Place the spacer-seal (56) on the cover contact
surface. Insert the brake cartridge cover (55),
centring it on the 2 pins (38) and, using a rubber
hammer, fine-tune the cartridge position until it is
completely inserted.
Now, insert the 8 screws in their own holes (see fig.
21) and set them with the following torque wrenche:
(53) screw M8 cl. 10.9 33 Nm

Power Train 27 Disassemble and Assemble


Oil filling

Follow with great attention instructions on page 7.

Power Train 28 Disassemble and Assemble


Special Service Tools
General specifications for the tool needed to open (see page 21) and close (see page 25) the ring nut (25).

Ref. No Tool Name Illustration Remark

1 Nut Installer DOOSAN Tool

Power Train 29 Disassemble and Assemble


SB4209E00
Oct. 2006

Vehicle System
Specification
Systems Operation
Testing & Adjusting

B22X-5, B25X-5, B30X-5, B35X-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 prod uct 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.
Index Brake System ..................................................30
Electric Motors.................................................31
Hydraulic System.............................................33
System operation Relief Valve Pressure Check............................33
Flow Control Valve Adjustment ........................34
Hydraulic Operation .............................................. 3 Standard Lift Cylinder Air Removal...................35
Hydraulic Schematic.......................................... 3
Basic Oil Flow ................................................... 4 Mast and Carriage...............................................36
Mast Adjustment ..............................................36
Control Valve ........................................................ 5 Carriage Adjustment ........................................41
External Configuration ....................................... 5
Hydraulic Circuit ................................................ 6 Chain Adjustments ..............................................42
Neutral position of lift spool at solenoid-off (or, Chain Adjustment Check..................................42
key-off).............................................................. 7 Chain Wear Test..............................................43
Neutral position of lift spool at solenoid-on (or, Carriage and Mast Height Adjustment..............44
key-on).............................................................. 7 Forks Parallel Check........................................44
Shifting lift spool outside for lifting...................... 8 Tilt Cylinder Alignment .....................................45
Shifting lift spool inside for lowering ................... 8 Tilt Cylinder Length Check ...............................45
Shifting tilt spool inside for tilting forward ........... 9 Drift Test..........................................................46
Shifting tilt spool outside for tilting backward ...... 9
Shifting aux. spool outside............................... 10
Steering System..................................................47
Shifting aux. spool inside ................................. 10
Steer Wheel Bearing Adjustment .....................47
Section for control of pressure and flow ........... 11
Steering Axle Stop Adjustment.........................47
Adjusting flow control for tilt and auxiliary......... 11
Steering Knuckle Bearing Preload Adjustment .48
Steering System Pressure Check.....................48
Lift Cylinders and Mast........................................ 12
Standard Lift.................................................... 12
Brake System......................................................50
Full Free Triple Lift Mast .................................. 13
Brake System Air Removal ..............................50
Pedal Adjustment.............................................51
Hydraulic Steering system................................... 15 Parking Brake Test ..........................................52
Hydraulic Schematic........................................ 15 Parking Brake Adjustment................................52
Steering Cylinder............................................. 16
Steering Gear.................................................. 17
Electric Motors ....................................................53
Oil Flow........................................................... 19
Hydraulic Pump Motor .....................................53

Brake System ..................................................... 20


Master Cylinder ............................................... 20
Oil Cooled Disc Brakes.................................... 20 Specifications
Oil Cooled Disc Brakes.................................... 21
Parking Brake.................................................. 21 Hydraulic Control Valve .......................................55
Hydraulic Pump Motor ..................................... 22 Hydraulic Pumps..............................................55
Encorder Hydraulic pump motor ................... 22 Lift Cylinders....................................................56
Full Free Triple Lift and Full Free Lift Primary...56
Full Free Triple Lift And Full Free Lift Secondary
........................................................................56
Testing and Adjusting

Troubleshooting .................................................. 23
Visual Checks ................................................. 23
Hydraulic System and Mast ............................. 23
Hydraulic Oil Temperature (Too Hot) ............... 24
Mast and Carriage........................................... 24
Hydraulic Pump............................................... 26
Hydraulic Control Valve ................................... 27
Lift and Tilt Cylinders ....................................... 28
Steering System.............................................. 28

Vehicle Systems 1 System Operation


Tilt Cylinders ..................................................... 57
Mast................................................................ 58
Carriage .......................................................... 58
Lift Relay Group - Standard Lift........................ 59
Lift Relay Group - Full Free Lift........................ 60
Lift Relay Group - Full Free Triple Lift .............. 61
Lift and Tilt Mounting Group............................. 62
Steering Wheel................................................ 63
Priority Valve................................................... 63
Steering Gear.................................................. 64
Steer Axle and Wheel...................................... 65
Steer Tire Installation....................................... 65

Vehicle Systems 2 Index


System operation
Hydraulic Operation
Hydraulic Schematic

FFT mast STD mast


3
8 1
5

10 4

7
6

15
11
17
19
Steering system

12

Motor

18

20
13 14
16

Basic Hydraulic Actuator System Schematic


(1) Lift cylinder-secondary (2) Flow protector-primary (3) Lift cylinder-primary (4) Flow protector
(5) Side shift cylinder (6) Control valve (7) Solenoid valve for lift lock (8) Tilt cylinder (9) Relief valve-auxiliary (10) Gage port
(11) Relief valve-main (12) Hydraulic pump (13) Tank (14) Filter-return (15) Priority valve (16) Filter-suction
(17) Needle valve (18) Electric motor (19) Hydraulic line (20) Hydraulic line

Vehicle Systems 3 Index


Basic Oil Flow Flow protector (2) & (4) integrated to lift cylinder acts
as a kind of fuse valve if the line between control
valve (flow regulator) and flow protector is
The hydraulic system has a tank (13) which holds a
disconnected when the lift cylinder is raised or
fluid for a hydraulic pump (12). A hydraulic pump
lowered. This prevents the sudden fall of mast or
sends a pressurized fluid to the hydraulic actuator
carriage if a hydraulic line is broken.
system and hydraulic steering system. A pump fluid
flows from hydraulic pump (12) to priority valve (15),
The tilt backward & forward speed, side shift
where the fluid divides. Some fluid goes to the
cylinder speed are controlled by adjustable flow
hydraulic steering system at first. The remained fluid
control kit in control valve.
goes to the control valve (6) through hydraulic line
There is a counter-balance valve (or, tilt lock valve)
(19).
in tilt spool to prevent the cavitation (development of
air pocket) in tilt cylinder.
The levers of control valve move spools in control
valve. The movement of spool makes a fluid for a lift
cylinder (1), (3) and/or tilt cylinder (8) and/or side
shift cylinder (5).
The return hydraulic fluid from each cylinder flows
through control valve, hydraulic line (20) and a filter-
return (14), and back to a hydraulic tank.

There is a safety lift lock function on lift block which


disables a lowering of carriage or mast if the lift lever
is shifted intentionally or unintentionally for lowering
when operator leaves a seat for more than 3
seconds or a start key is off. The solenoid valve (7)
for lift lock is electrically connected to the electric on-
off switch beneath a seat. When the operator leaves
a seat for more than 3 seconds or a start key is off,
the solenoid valve is off. This leads to block the flow
passage for lowering. Once the operator sits on a
seat or a start key is on, the solenoid valve is
engaged and immediately lowering works normally.

On some cases that lowering doesnt work normally,


the needle valve (17) should be loosened about half
counterclockwise turn, which makes it possible to
lower the mast or carriage when lift spool is shifted
for lowering. After lowering the mast or carriage to
the ground absolutely and a start key off, start to
inspect the possible causes. The detailed trouble
shooting guide will be shown in TESTING and
ADJUSTING.

The relief valve-main (11) releases the excessive


pressure to the hydraulic tank when the pressure in
the lift circuit goes higher than the setting pressure
shown at CONTROL VALVE SECTION of
SPECIFICATION. The relief valve-auxiliary (9)
releases the excessive pressure to the hydraulic
tank when the pressure in tilt circuit and auxiliary
circuit goes higher than the setting pressure shown
at CONTROL VALVE SECTION of SPECIFICATION.

The lowering speed of lift cylinders is controlled by


the flow regulator valve integrated into lift spool.

Vehicle Systems 4 System Operation


Control Valve

External Configuration

Gage port
LIFT
TILT
AUX 1

AUX 2 Lift lock solenoid valve

T port

P port

To tank

Needle Valve
From priority valve

Auxiliary relief valve Main relief valve

External configuration of control valve

Vehicle Systems 5 System Operation


Hydraulic Circuit

Vehicle Systems 6 System Operation


Neutral position of lift spool at solenoid-off (or, key-off)

Lift cylinder

The above figure shows a neutral position of lift spool when a start key is off. When the solenoid valve is off, it
blocks the fluid passage of lift cylinder to tank. And also, lift lock blocks the fluid passage of lift cylinder to tank.

Neutral position of lift spool at solenoid-on (or, key-on)

Lift cylinder

The above figure shows the neutral position of lift spool when the start key is on. Solenoid valve is engaged.

Vehicle Systems 7 System Operation


Shifting lift spool outside for lifting

Lift cylinder

When shifting the lift spool outside, the fluid goes through a load check valve, spool and lift lock to lift cylinder.
Lift cylinder is raised.

Shifting lift spool inside for lowering

Lift cylinder

Flow regulator valve

When shifting the lift spool inside, the fluid of lift cylinder passes to tank. The fluid goes through lift lock, lift
spool, flow regular valve and tank. Lift cylinder is lowered. The flow regulator valve permits a consistent
lowering speed of lift cylinder regardless of load.

Vehicle Systems 8 System Operation


Shifting tilt spool inside for tilting forward

Tilt cylinder

Tank line

Tilt Lock valve Parallel Line

When shifting the tilt spool inside, the fluid passage from pump to tilt cylinder is made. Pump fluid goes
through a load check valve & tilt spool to a head side of tilt cylinder. At the same time, the fluid at the rod side
of tilt cylinder goes through the tilt lock to tank. The tilt cylinder is moved forward.

Shifting tilt spool outside for tilting backward

Tilt cylinder

When shifting the tilt spool outside, the fluid passage from pump to tilt cylinder is made. Pump fluid goes through a
load check valve & tilt spool to a rod side of tilt cylinder. At the same time, the fluid at the head side of tilt cylinder
goes through spool to tank. The tilt cylinder is moved backward.

Vehicle Systems 9 System Operation


Shifting aux. spool outside

Shifting aux. spool inside

Vehicle Systems 10 System Operation


Section for control of pressure and flow

Auxiliary relief valve

The main relief valve limits the max. lifting pressure. The auxiliary relief valve limits the max. tilting and
auxiliary system relief pressure. The hydrostator will bypass the remaining flow back to tank according to the
control flow of flow control valve in tilt and auxiliary section.

Adjusting flow control for tilt and auxiliary

Adjusting. Plug
Released state of Flow Control valve

Tightening State of Flow Control Valve

In tilt and auxiliary section, there is a flow control valve to adjust the flow of pump to each cylinder.
If the control flow is increased to speed up each actuator, rotate adjustment screw clockwise carefully while
checking its speed, vise versa

Vehicle Systems 11 System Operation


Lift Cylinders and Mast
Standard Lift

(A)

Standard Lift Mast (Typical Example)


(A)Free lift period.

The rods of Standard Lift Cylinders (1) and (2) are Standard Lift Mast At Full Extension (Typical Example)
moved up by oil under pressure and go back to their (1) Lift cylinder (2) Lift cylinder.
original position by gravity.

The combination of the single-acting hydraulic lift The inner mast and carriage will continue to move
cylinders with other mechanical lifting components up until they are in the extended position. If the
will operate as follows: control valve lift lever is held in the lift position with
the mast fully extended, the pressure relief valve in
When the control valve lift lever is pulled back, the the control valve will release the extra pressure until
hydraulic oil under pressure, pushes against the the lift lever is released. The oil flows through the
rods at the bottom of the lift cylinders. The inner relief valve and the control valve into the hydraulic
tank. The carriage and inner mast will be stationary
mast crossbar, which is connected to the top of the
at this full height until the lift lever is moved to the
cylinder rods, begins to move up. At this time, the lowered position.
carriage also starts to move up because it is
connected to the inner mast through the lift chains When the lift lever is moved forward, the oil under
arrangement. From the start of the lift cycle until the pressure is released in the lift cylinders. Gravity and
top of the inner mast becomes equal height to the the weight of a load will cause the carriage to move
top of the outer mast, the carriage and mast are in down at a 2 to 1 ratio and the inner mast to move
their free lift period (A). down at 1 to 1 ratio with the rods of the lift cylinders
until the carriage and mast are completely lowered.
The inner mast moves at a 1 to 1 ratio and the
carriage moves at a 2 to 1 ratio with the rods of the The flow regulator valve installed into the lift spool of
lift cylinders. control valve permits 54 to 66 liter/min (14 to 17
GPM) of fluid flow back to the hydraulic tank through
the control valve.

The lift cylinders also have excess flow protectors.


These flow protectors act as a lowering flow control
valve if an oil line is broken between them and the
flow regulator located near the base of the lift
cylinders.

The carriage and inner mast move up and down


smoothly on load bearings (rollers). Stability of the
mast and carriage is controlled by bearing size and
shims behind the bearings (rollers).

Vehicle Systems 12 System Operation


Full Free Triple Lift Mast

3
4

3
5
6

Full Free Triple Lift Mast At Free Lift (Typical Example)


Full Free Triple Lift Mast (Typical Example)
(3) Primary lift cylinder.
(3) Primary lift cylinder. (4) Crosshead. (5) Intermediate mast.
(6) Inner mast.

When the movement of the primary cylinder is


On trucks equipped with a Full Free Lift or Full Free completed, pressure oil then works against the
Triple Lift Mast, the carriage can move the full length pistons in secondary cylinders (7). The movement of
of inner mast (6) before any increase in height of the secondary cylinders (7) starts the movement of the
inner mast. This is possible because primary lift inner mast on the Full Free Lift models or
cylinder (3) moves the carriage only. intermediate mast (5) and inner mast (6) on the Full
Free Triple lift models. The inner mast moves at a 2
The carriage is lifted when the lift control lever is to 1 ratio and the intermediate mast moves at a 1 to
pulled back. Oil under pressure flows from the 1 ratio with the rods of secondary cylinders (7) until
control valve into the base of primary lift cylinder (3) they reach the top of their travel.
and secondary lift cylinders (7). Since the primary lift
cylinder has the larger diameter for the oil to work At this position, the pressure relief valve in the
against, the primary lift cylinder moves up first. The control valve will open if the lift control lever is held
carriage moves up with the primary lift cylinder, with back and release the extra pressure until the lift
the assistance of crosshead (4) and the lift chains, control lever is released. The oil flows through the
until the carriage reaches the top of inner mast (6). relief valve and the control valve and then into the
From the start of the lift cycle until the carriage hydraulic tank. The carriage will be stationary at this
reaches the top of the inner mast, the mast is in its full height until the lift control lever is moved to the
free lift period. During this lift cycle, the carriage lowered position.
moves up at a 2 to 1 ratio with the rod movement of
primary lift cylinder (3).

Vehicle Systems 13 System Operation


4
6

Full Free Triple Lift Mast In The Extended Position


(Typical Example)
(3) Primary lift cylinder. (5) Intermediate mast. (6) Inner mast.
(7) Secondary cylinder.

The oil under pressure in the primary and secondary


cylinders is released when the lift control lever is
moved forward. Gravity and the weight of a load will
cause the cylinders to move back into their housings.
The secondary cylinders move completely back into
their housings before the primary cylinder starts to
move down.

The flow regulator valve installed into the lift spool of


control valve permits 54 to 66 lifter/min (14 to 17
GPM) of fluid flow back to the hydraulic tank through
the control valve.

The Full Free Lift and Full Free Triple Lift Masts also
have excess flow protectors connected to the
primary lift cylinder and in the inlet of the secondary
lift cylinders. They will act as a lowering flow control
valve if an oil line is broken between any of them
and the flow regulator valve located near the base of
the lift cylinders.

The carriage and inner mast move up and down


smoothly on load bearings (rollers). Stability of the
mast and carriage is controlled by bearing size and
shims behind the bearings (rollers).

Vehicle Systems 14 System Operation


Hydraulic Steering system

Hydraulic Schematic

Steering system schematic


(1) Steering unit (2) Hydraulic line (3) Hydraulic line (4) Hydraulic line (5) Hydraulic line (6) Power steering cylinder
(7) Load sensing line (8) Electric motor (9) Hydraulic line (10) Hydraulic pump (11) Tank (12) Priority valve
(13) Suction filter (14) Filter-return

The steering system uses the hydraulic fluid for hydraulic line (4) steering unit, a hydraulic line (2)
operation. The system has priority valve (12) which into the tank (11).
sends the fluid to steering unit (1) as needed before
the requirement for mast operation are filled. During the left turn, pilot pressure is again increased
The fluid is pulled from a tank (11) to a hydraulic in load sensing line (7) which moves the spool of
pump (10). Pump supplies a fluid to a priority valve priority valve to the right. A fluid flows through a
(12). hydraulic line (9) to a steering unit. From the
When the steering unit (1) is in the neutral position, steering unit, the fluid flows through a hydraulic line
pilot pressure in load sensing line (7) is reduced and (4) to a power steering cylinder (6) to make a left
the spool of priority valve is moved to the left. Then, turn. The return fluid flows through a hydraulic line
the fluid flows to control valve. (5), steering unit, hydraulic line (2) to the tank.

During the right turn, pilot pressure is increased in A check valve is installed into the port of steering
load sensing line (7) and the spool of priority valve is unit connected to hydraulic line (9) to prevent a fluid
moved to the right. Then, the fluid flows through back to priority valve right after a turn is made.
hydraulic line (9) to the steering unit. From the Relief valve in priority valve will open if steering
steering unit, the fluid flows through a hydraulic line pressure goes above 9,500 (+500,-0) kpa or 1,380
(5) for the right turn. The return fluid flows through a (+70,0) psi.

Vehicle Systems 15 System Operation


Steering Cylinder

Steering cylinder (1) gives power assistance through


the use of pressure oil at either end of the cylinder.

The steering cylinder is double ended and the body


of the cylinder is mounted stationary to the steer
axle. The rod assemblies at both ends of the
cylinder which allows the cylinder to move the link
assemblies.

Vehicle Systems 16 System Operation


Steering Gear

Steering Gear
(1) Spool (2) Sleeve (3) Outlet (to tank) (4) Inlet (for pump oil) (5) Internal pump gear (6) External pump gear
(7) Centering springs (8) Pin (9) Left turn port (10) Right turn port (11) Body
(12) Drive (A) Control section (B) Metering sectio

Vehicle Systems 17 System Operation


Lift trucks use the load sensing, closed center (oil Oil from the priority valve goes through inlet (4) into
flow to steering gear only when needed) steering the control section of the steering gear. When the
gear. steering wheel is turned, the control section sends
the oil to and from the metering section and also to
All lift truck hydraulic lines serve a dual purpose in and from the steering cylinder.
that they serve both the steering and cylinder
hydraulics through the use of a priority valve. The The metering section is a small hydraulic pump. It
priority valve sends oil to the steering gear before controls (meters) the oil that goes to the steering
the needs of the cylinder hydraulics are met. cylinder. As the steering wheel is turned faster, there
is an increase in the flow of oil to the steering
The steering gear has two main sections: control cylinder. This increased flow causes the main valve
section (A), and pump or metering section (B). spool to move farther. As the spool moves farther,
These two sections work together to send oil to the more oil can flow from the priority valve or power
steering cylinder. steering pump to the steering cylinder, and a faster
turn is made.

Vehicle Systems 18 System Operation


Oil Flow

The oil from the priority valve flows through inlet (4).
When the steering wheel is stationary (NEUTRAL)
the oil is stopped by spool (1). The oil can not flow
through the steering gear to the steering cylinder
until the steering wheel is turned.

The steering wheel is connected to spool (1) by a


shaft assembly and splines. When the steering
wheel is turned, spool (1) turns a small amount until
springs (7) are compressed. Then, sleeve (2) starts
to turn. As long as the steering wheel is turned, the
spool and sleeve both turn as a unit, but they turn a
few degrees apart.
When the spool and sleeve are a few degrees apart,
oil passages are opened between them. This lets
the pump oil from inlet (4) flow through passages in
body (11) to the metering section.
When the steering wheel is turned, pin (8) turns with
the sleeve and causes drive (12) to turn also. The
drive causes a rotation of gear (5) inside gear (6).
This rotation of the gear sends a controlled
(metered) flow of pilot oil back through body (11). Pump Gears In Metering Section
This oil flows to port (9) or (10) and then to the (5) Internal pump gear. (6) External pump gear. (8) Pin.
steering cylinder. Port (9) or (10), that is not used for (12) Drive.
pressure oil to the steering cylinder, is used for
return oil from the other end of the steering cylinder.
If the steering wheel rotation is stopped, springs (7)
will move sleeve (2) back in alignment with spool (1)
(NEUTRAL position). This will close passages
between the metering section and control section
and the steering gear will be in the NEUTRAL
position.

When a start key is off, the steering gear can be


manually operated. The control section will work as
a pump. The oil that is returned from the steering
cylinder is not returned to the tank. The suction of
the control section will open an internal check valve
and let return oil from the steering cylinder go to the
inlet side of the control section. During power
operation, supply pressure keeps the check valve
closed.

Vehicle Systems 19 System Operation


Brake System Oil Cooled Disc Brakes

Master Cylinder

2
(2) Service brake bleeder, (3) Brake piston, (4) Hydraulic service
brake inlet, (5) Brake oil refill plug, (6) Gearbox oil drain plug,
Brake reservoir and Master Cylinder
(12) Gearbox oil refill plug
(1) Brake reservoir, (2) Master cylinder

Brake fluid from remote reservoir (1) to replenish


master cylinder (2). The master cylinder has a piston,
which pushes brake liquid into the brake lines. The
reservoir, located on the cowl, is connected to inlet
of master cylinder. The supply lines keep master
cylinder (2) filled so no air enters the system.
Reservoir (1) supplies brake liquid to the system.
When the brake pedal is first pushed, the piston
moves into the master cylinder and pushes brake
liquid through outlet into the brake lines.
Wheel Brakes
(7) Steel disc, (8) Friction disc, (9) Elastic spacer,
(10) Reaction disc, (11) Studs, (12) Pins, (13) Support disc

The liquid pushed through outlet goes through the


brake lines to the brake inlet (4). When hydraulic
pressure is supplied to the brake piston (3),
The brake piston (3) pushes the brake piston (4) and
then the reaction plate (10) is moved to the function
disc. By above procedure, the wet disc brake is
actuated by the force from brake piston (3).

Vehicle Systems 20 System Operation


Oil Cooled Disc Brakes Parking Brake

When the brake pedal is pushed, the master


cylinder pushes brake liquid through the master
cylinder outlet, the brake lines, to inlet (4) of disc
brake assembly. Liquid flows through inlet (4),
passage and pushes on brake piston (3) and then
piston (3) pushes actuator body (10). Actuator body 4
(10) pushes against brake disc (3) and reaction
plate (4). Reaction plate (10) pushes steel disc (7),
friction disc (8) and support disc (12), so reaction
plate (10) is pushed. Reaction plate (10) pushes
steel plate (7) and friction disc (8) to stop any
movement of the lift truck. The reaction plates (10)
are splined to the shaft and the steel plate (7) are to
stop the drive shaft in order to hold the truck drive.

When the brake pedal is released, the brake liquid


3
pressure is released and brake piston (1) return to
their original position by the elastie plate (9). The
retractions of elastic plate (9) gives the regular
running clearance needed between plates and discs.
This action will retract disk pusher and will release
the brakes on the lift truck. As elastic plate retracts, (4) Lever. (3) Cable assembly.
brake liquid is returned to the master cylinder. The
disk pusher automatically is sided outward by elastic
plate as the discs wear. The new location then
becomes the beginning at rest position of the disc
pusher.

This will maintain the proper clearances of the discs


and reaction plates.

Parking Brake uses the wet disc brake system same


with service brake.

The parking brake control is actuated with the brake


lever(1) and is released with the brake lever(1). The
brake lever(1) is mounted on the brake cover and is
connected by cable assembly(3) to the parking
lever(4).

When the parking lever(4) is pulled, cable


assembly(3) pull the brake lever(1). The brake
pistion(2) pushed by the brake lever(1) and then it
pushes elastic plate, so all lift truck movement is
stopped.

The brakes are designed to hold the truck positively


for sure parking using parking lever (4) and cables
(3).

When parking lever(4) is depressed, the cable(3) is


released and brake piston(2) is returned.

Vehicle Systems 21 System Operation


Hydraulic Pump Motor

Thermal switch

Warning temperature .............. 155 4(31110)

Encorder Hydraulic pump motor


In case the speed sensor is fixed to the motors
shield with two screws

1. unscrew 2 M4 screws
2. remove the installed sensor
3. position and push the new sensor into its housing
4. verify if its completely inserted in its housing as,
on the contrary, it could be damaged as soon as
the screws are screwed
5. screw the two (2) M4 screws with a tightening
torque of 1.2Nm

Vehicle Systems 22 System Operation


Testing and Adjusting 3. Check all oil lines and connections for damage or
leaks.

Troubleshooting 4. Check all the lift chains and the mast and carriage
welds for wear or damage.
Troubleshooting can be difficult. A list of possible
problems and corrections are on the pages that Hydraulic System and Mast
follow.
During a diagnosis of the hydraulic system,
This list of problems and corrections will only give an remember that correct oil flow and pressure are
indication of where a problem can be and what necessary for correct operation. The output of the
repairs are needed. Normally, more or other repair pump (oil flow) increases with an increase in motor
work is needed beyond the recommendations on the speed (rpm) and decreases when motor speed
list. Remember that a problem is not necessarily (rpm) is decreased. Oil pressure is caused by
caused only by one part, but by the relation of one resistance to the flow of oil.
part with other parts. This list can not give all
possible problems and corrections. The serviceman Visual checks and measurements are the first step
must find the problem and its source, then make the when troubleshooting a possible problem. Then do
necessary repairs. the Operation Checks and finally, do instrument
tests with pressure gauges.
The pressure Gauge Kit or the Tetragauge Group
can be used to make the pressure tests of the Use the Pressure Gauge Kit, a stop watch, a
hydraulic system. Before any test is made, visually magnet, a thermometer and a mm (inch) ruler for
inspect the complete hydraulic system for leakage of basic test measurements.
oil and for parts that have damage.
1. The pre ssure of the oil required to
open the relief valve. Relief valve pressures that
WARNING are too low will cause a decrease in the lift and
the tilt characteristics of the lift truck. Pressures
To prevent personal injury when testing and that are too high will cause a decrease in the life
adjusting the hydraulic system, move the of hoses and components.
machine to a smooth horizontal location and
lower the mast and carriage to the ground, make 2. Drift rates in the cylinders. Cylinder drift is caused
sure they are blocked correctly to keep them
from a fall that is not expected. Move away from by a leakage past cylinder pistons, O-ring seals in
machines and personnel that are at work. There the control valve, check valves that do not seat
must be only one operator. Keep all other correctly or poor adjustment or fit in the control
personnel away from the machine or where the valve spools.
operator can see the other personnel. Before
any hydraulic pressure plug, line or component 3. Cycle times in the lift and tilt circuits: Cycle times
is removed, make sure all hydraulic pressure is
released. that are too long are the result of leakage, pump
wear and/or pump speed (rpm).

Performance Test
Visual Checks
The performance tests can be used to find leakage
in the system. They can also be used to find a bad
A visual inspection of the hydraulic system and its valve or pump. The speed of rod movement when
components is the first step when a diagnosis of a the cylinders move can be used to check the
problem is made. Lower the carriage to the floor and condition of the cylinders and the pump.
follow these inspections; Lift, lower, tilt forward and tilt back the forks several
times.
1. Measure the oil level. Look for air bubbles in the
oil tank. 1. Watch the cylinders as they are extended and
retracted. Movement must be smooth and regular.
2. Remove the filter element and look for particles
removed from the oil by the filter element. A 2. Listen for noise from the pump.
magnet will separate ferrous particles from
nonferrous particles (piston rings, O-ring seals, 3. Listen for the sound of the relief valve. It must not
etc.). open except when the cylinders are fully
extended or retracted, when the forks are empty.

Vehicle Systems 23 Testing And Adjusting


Hydraulic Oil Temperature (Too Hot) Probable Mechanical Cause:

1. The mast is not in alignment with the other lifting


When the temperature of the hydraulic oil gets over
components and does not move freely.
98.8C (210F), polyurethane seals in the system
start to fail. High oil temperature causes seal failure
2. Not enough lubricant on the parts of the mast that
to become more rapid. There are many reasons why
move.
the temperature of the oil will get this hot.
3. The carriage or mast rollers (bearings) are worn
1. Hydraulic pump is badly worn.
and do not move (seized).
2. Heavy hydraulic loads that cause the relief valve
Problem: Lift cylinder extends too slowly.
to open.
Probable Hydraulic Cause:
3. The setting on the relief valve is too low.
1. Not enough oil supply to lift cylinder.
4. Too many restrictions in the system.
2. Defective lift cylinder seals.
5. Hydraulic oil level in the tank is too low.

6. High Pressure oil leak in one or more circuits.


Probable Mechanical Cause:
7. Very dirty oil.
1. The mast is not in alignment with the other lifting
components and does not move freely.
8. Air in the hydraulic oil.
2. Not enough lubricant on the parts of the mast that
NOTE: If the problem is because of air in the oil, it
move.
must be corrected before the system will
operate at normal temperatures. There are
3. The carriage or mast rollers (bearings) are worn
two things that cause air in the oil (aeration).
and do not move (seized).
These are:

a. Return oil to the tank goes in above the level of


Problem: Mast does not move smoothly.
the oil in the tank.
Probable Hydraulic Cause:
b. Air leaks in the oil suction line between the pump
and the tank.
1. Air in the hydraulic system.
Mast and Carriage 2. Relief valve sticks or defective.

Problem: The hydraulic system will not lift the


load. Probable Mechanical Cause:

Probable Hydraulic Cause: 1. Not enough lubricant on the parts of the mast that
move.
1. There is an air leak, which lets air into the
hydraulic system on the inlet side of the hydraulic 2. Load rollers (bearings) defective or not adjusted
pump. correctly.

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).

Vehicle Systems 24 Testing And Adjusting


Problem: Mast will not lower completely or will Probable Hydraulic cause
not lower at all.
1. Damaged or contaminated lift poppet (lift lock).
WARNING Probable Mechanical Cause
First of all, the needle valve in control valve as
seen in a picture below should be loosened 1. Damaged or bent lift cylinder.
about half counterclockwise turn, which makes
it possible to lower the mast or carriage safely 2. Load roller (bearing) defective or not adjusted
when lift spool is shifted for lowering. After correctly.
lowering the mast or carriage to the ground
absolutely and a start key off, the possible
causes needs to be inspected. If mast or 3. Not enough lubricant on the sliding parts of mast.
carriage wont lower by loosening a needle valve,
its cause would be a mechanical problem or a
hydraulic problem rather than an electrical Problem: Safety lift lock doesnt work
problem. After the related problems are
completely fixed, the needle valve should be re-
tightened in a clockwise turn. If not so, the Safety lift lock function: Once the operator leaves a
safety lift lock doesnt work properly. seat more than 3 seconds or a start key is off, the lift
cylinder doesnt lower even though lift lever is pulled
for lowering. If the operator is seated or, a key is on,
the lowering will normally work immediately.

Probable Electric Cause

1. The electric switch (on-off) below a seat is


damaged.

2. The electric parts (relay and controller) related to


a solenoid valve in lift section of control valve is
damaged

Probable Hydraulic cause


Needle valve(with Hex size 10mm)
1. Damaged or contaminated lift poppet (lift lock).

2. Needle valve is loosened.

Problem: The mast does not tilt correctly or


moves too slowly.

Probable Hydraulic Cause:

1. There is an air leak, which lets air into the


hydraulic system on the inlet side of the hydraulic
pump.
Probable Electric Cause
2. The relief valve opens at low oil pressure.
1. Not to supply the electric power to solenoid valve
3. The hydraulic pump has too much wear.
in lift section of control valve.
4. The internal valve of the tilt spool is stuck.
2. A broken solenoid valve in lift section of control
valve.
5. Control valve tilt spool has a restriction.

Vehicle Systems 25 Specifications


Probable Mechanical Cause: Hydraulic Pump
1. Damage or failure of the piston rods on the tilt
Problem: Noise in the pump.
cylinders.
Probable Cause:
Problem: The carriage will not lower correctly.
1. The oil level is low.
Probable Hydraulic Cause:
2. The oil is thick (viscosity too high).
1. There are restrictions in the lift line.
3. The pump inlet line has a restriction in it.
2. The lift spool in the control valve has a restriction
caused by foreign material and does not operate
4. Worn parts in the pump.
freely.
5. Oil is dirty.
3. The lift cylinder flow control valve has a restriction.
6. Air leaks into the inlet line.
4. Lift cylinders excess flow protectors have a
restriction.
Problem: The oil temperature is too high.
5. Air in the hydraulic system.
Probable Cause:
Probable Mechanical Cause:
1. The oil level is low.
1. The mast is not in alignment with the other lifting
2. There is a restriction in an oil passage.
components and does not move freely.
3. The relief valve setting is too low.
2. Carriage chains need an adjustment.
4. The oil is too thin.
3. Not enough lubricant on the part of the mast that
moves.
5. There is air leakage in the system.
4. The carriage or mast rollers (bearings) are worn
6. The pump has too much wear.
and do not move (seized).
7. The system operates at too high a pressure.
Problem: The lift or tilt cylinders do not hold
their position with the valve control levers in
a. Relief valve setting too high.
neutral position.
b. Attachment components cause a restriction
during movement.
Probable Cause:
c. Restrictions in flow control valve, check valve
and in oil lines.
1. The valve spools do not hold their positions
because the springs for the valve spools are
weak or broken.

2. Control valve leakage caused by worn valve


spools.

3. The check valve or flow control valves in the


control valve are bad.

4. Leakage of the cylinder lines or piston seals.

5. There is foreign material in the control valve.

Vehicle Systems 26 Testing And Adjusting


Problem: Leakage at the pump shaft seal. Hydraulic Control Valve
Probable Cause:
Problem: The control spools do not move freely.
1. The shaft seal is worn.
Probable Cause:
2. The inner parts of the pump body are worn.
1. The temperature of the oil is too high.
3. Operation with too low oil level in tank causes
2. There is foreign material in the fluid.
suction on the seal.
3. The fitting connections in the valve body are too
4. Seal cut on shoulder of pump or keyway during
tight.
installation.
4. The fastening bolts of the valve assembly do not
5. Seal lips are dry and hardened from heat.
have the correct torque and have twisted the
body.
Problem: There is failure of the pump to deliver
fluid.
5. Linkage of the lift and tilt levers does not operate
smoothly.
Probable Cause:
6. Bent lift or tilt spools.
1. Low level of the oil in the tank.
7. Damage to the return springs of the spools.
2. There is a restriction in the pump inlet line.
8. The hydraulic oil is not at normal temperature for
3. There is air leakage in the pump inlet line.
operation.
a. Loose bolts.
Problem: Control valve spools have leakage
b. Defects in suction line.
around the seals.
4. The viscosity of the oil is wrong.
Probable Cause:
5. The pump has too much wear.
1. There is foreign material under the seal.
6. Failure of the pump shaft.
2. The valve spools are worn.
7. The bolts of the pump do not have the correct
3. The seal plates are loose.
torque.
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.

Vehicle Systems 27 Specifications


Problem: Spools do not return to neutral. Problem: The tilt cylinder rods show wear.

Probable Cause: Probable Cause:

1. The springs are broken. 1. The cylinders are not in correct alignment.

2. The spool is bent. 2. Oil is dirty.

3. The system or valve has foreign particles in it. Problem: Foreign material behind the wiper
rings causing scratches on the cylinder rod.
4. The control linkage is not in alignment.
Probable Cause:
5. The fastening bolts of the valve have too much
torque. 1. The wiper rings shoe wear and do not remove dirt
and foreign material.
Problem: No motion or slow, then a too sudden
action of the hydraulic system.
Steering System
Probable Cause:
Problem: Too much force needed to turn
1. The relief valve is not correctly set, or will not
steering wheel.
move in base and/or is worn.
Probable Cause:
2. There is air in the system.
1. Priority valve (if equipped) releases pressure oil at
3. Dirt or foreign particles between relief valve
a low setting.
control poppet and its seat.
2. Pump oil pressure is low, worn pump.
4. Valve body has a crack inside.
3. Steering gear covers are too tight.
5. Spool not moved to a full stroke.
4. Steering column not aligned with steering gear.
Lift and Tilt Cylinders 5. Priority valve spool is held in one position.

Problem: Leakage around the cylinder rod. 6. Steering gear without lubrication.

Probable Cause: 7. Low fluid level in the hydraulic supply tank.

1. Cylinder head (bearing) seals are worn. Problem: Steering wheel does not return to
center position correctly.
2. Cylinder rod is worn, scratched or bent.
Probable Cause:
Problem: There is leakage of oil inside the
cylinder or loss of lift or tilt power. 1. Steering gear covers are too tight.

Probable Cause: 2. Steering column is not in correct alignment.

1. The piston seals are worn and let oil go through. 3. Valve spool in the steering gear has a restriction.

2. Cylinder has damage. 4. Priority valve check valve permits lift and tilt
hydraulic oil to affect steering hydraulic circuit.

Vehicle Systems 28 Testing And Adjusting


Problem: Oil leakage at the pump. Problem: Lift truck does not turn when steering
wheel is slowly turned.
Probable Cause:
Probable Cause:
1. Loose hose connections.
1. The oil level of the tank is low.
2. Bad shaft seal.
2. There is air in the steering system.
Problem: Low oil pressure.
3. The pump operation is not correct.
Probable Cause:
4. Dirt in the steering system.
1. Low oil level.
5. Steering gear operation is not correct.
2. Priority valve (if equipped) relief valve spring
weak. 6. Steering cylinder has worn parts.

3. Relief valve (priority valve) will not move from the 7. Restriction in the steer axle linkage.
open position.
Problem: The temperature of oil is too hot.
4. Oil leakage inside or outside of the system.
Probable Cause:
5. Bad pump.
1. The viscosity of the oil is wrong.
Problem: Pump makes noise and the steering
cylinder rod does not move smoothly. 2. Air is mixed with the oil.

Probable Cause: 3. The relief valve is set too high (priority valve).

1. Air in the steering hydraulic circuit. 4. There is a restriction in the return line circuit.

2. The pump has too 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.

Vehicle Systems 29 Specifications


Brake System Problem: Hard pedal.

Probable Cause:
NOTE: If excessive force is applied to the brake
pedal, the pedal can be forced to the end of 1. Mechanical resistance at pedal or disc assembly.
the stroke. This is normal and should not be
interpreted as a problem. 2. Restriction in the brake line.

3. Defective master cylinder.


Problem: Pedal resistance is not solid (spongy) 4. Brake discs look like glass (glazed) or are worn.
(under normal pedal pressure).

Probable Cause: Problem: Both brake disc assemblies will not


release all the way (drag).
1. Leakage or low brake fluid or oil level.
Probable Cause:
2. Air in the brake hydraulic system.
1. Brake disc assemblies defective (pistons stuck).
3. Master cylinder is loose.
2. Brake disc uneven (out of flat).
4. Master cylinder has the leakage internally. 3. Restriction in the brake line.
Problem: Pedal gradually goes to the floor 4. Defective master cylinder.
(under normal pedal pressure).

Probable Cause:
Problem: Brakes will not make application after
1. Leakage or low brake fluid or oil level. being bled.

2. Defective master cylinder. Probable Cause:

1. Leak in hydraulic line or connection.


Problem: Extra (excessive) pedal travel (under
normal pedal pressure). 2. Damaged cup seal or boot in the master cylinder.

Probable Cause:
Problem: Brake oil low in master cylinder
1. Pedal adjustment is not correct. reservoir, fluid must be added frequently.

2. Leakage or low brake fluid or oil level. Probable Cause:


3. Air in the brake hydraulic system. 1. Leak in hydraulic line or connection.
4. Defective master cylinder. 2. Damaged ring seal in the master cylinder.

3. Leak in the disc assemblies.


Problem: Brake will not make application.

Probable Cause: Parking Brakes


1. Leakage or low brake fluid or oil level. Problem: Brake will not make application.
2. Air in the brake hydraulic system. Probable Cause :
3. Linkage is not in correct adjustment or is bent. 1. Parking brake assembly out.

4. Defective master cylinder. 2. Parking brake control cable out of adjustment.

5. Bent plates or discs. 3. Worn brake band.

Vehicle Systems 30 Testing And Adjusting


Electric Motors (AC)

Problem 1 : Hydraulic pump motor will not


Before an analysis is made of any electric motor
operate.
problem, always make reference to the
troubleshooting section of MicroController Control
Probable Cause :
System module.
1. Bad connections or fuses.
WARNING Check battery connections.
Check the key fuse.
Check the hydraulic pump motor for possible
If an electrical failure or an overload of the motor reasons for a bad fuse.
is present, personnel must not breathe the toxic Some causes are:
fumes which are a product of the burnt a) Operation with too high hydraulic pressures.
insulation. b) Operation with too much current draw.
All power must be disconnected from the motor c) Possible short circuit in power(Inverter) unit.
before any inspection is made to find the failure.
The area around the motor must be well 2. Key switch, seat switch or line contactor not
ventilated(air flow) and the motor is to be cooled closed.
before any repair work is done. Water must not Close the seat and key switch. Use a
be multimeter(VOM) to check power flow thru the
used on any electrical equipment because of the seat switch, key switch, line contactor coil and line
danger of electrical shock. If a fire is present, contactor. The key switch, seat switch and line
disconnect the electrical power and use a contacor must be closed for the power steering
carbon function to operate.
dioxide extinguisher to put the flame out. The key switch, seat switch, control valve switch
and the line contactor must be closed for the
Do not operate the drive motor without a load as hydraulic pump motor to operate.
too much speed may cause damage to the motor
3. Not enough voltage. High resistance in battery
and injury to personnel.
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
NOTICE maximum density difference from the highest to
Never use air pressure that is more than 30 psi(205 lowest cell must not be more than .020 SG
kPa) and make sure the air line is equipped with a (specific gravity).
water filter. 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.

Problem 2 : Battery will not last a complete


normal work period.

Probable cause :

1. Too small a battery installed in the lift truck.


Study and question the use of the lift truck in its
complete working conditions, select and purchase
appropriate capacity of battery regarding work hours.

Vehicle Systems 31 Specifications


2. Battery not being fully charged or equalized Problem 4 : Lift truck has slow hydraulic speeds.
during the battery charging operation.
Check the battery cells for an equalization charge Probable Cause :
(a charge to make the specific gravity the same in
all cells). 1. Hydraulic pump motor overheated.
Check the battery charger for defects. In case motors temperature reaches in 155C
controller does overheat warning and reduce the
3. Battery Discharge Indicator (BDI) lift interrupter performance.
circuit which protects the battery, shuts off the
hydraulic motor circuit too soon. 2. Pump motor power module circuit overheated.
See Battery Discharge Indicator Operation In case power units tenperature reaches in
Adjustment and Troubleshooting in the 100C controller does overheat warning and
MicroController Control System module. reduce the performance.

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.

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.

Vehicle Systems 32 Testing And Adjusting


Hydraulic System RELIEF PRESSUES
Auxiliary
Relief Valve Pressure Check main relief pressure
MODEL MAST
pressure- lift - tilt,
Use the Pressure Gauge Kit to check the relief valve attachment
pressure. psi kpa psi kpa
B20S-5
STD/FF/ 2,400 16,600
BC20S-5
WARNING B20X-5
FFT (+75,-0) (+500,-0)

Hydraulic oil under pressure can remain in the STD/FF/ 2,640 18,260
hydraulic system after the engine and pump B22X-5
FFT (+75,-0) (+500,-0)
have been stopped. Personal injury can be
B25S-5
caused if this pressure is not released before STD/FF/ 2,800 19,300 2,250 15,500
BC25S-5
any work is done on the hydraulic system. To FFT (+75,-0) (+500,-0) 50 350
B25X-5
prevent the possible injury, lower the carriage to
B30S-5
the ground, turn the key switch off and move the STD/FF/ 3,000 20,700
BC30/32-5
control levers to make sure all hydraulic FFT (+75,-0) (+500,-0)
B30X-5
pressure is released before any fitting, plug,
hose or component is loosened, tightened, B32S-5 STD/FF/ 3,420 23,500

removed or adjusted. Always move the lift truck B35X-5 FFT (+75,-0) ( +500,-0)

to a clean and level location away from the travel


of other machines. Be sure that other people are With the key off, remove the plug (1) and connect
not near the machine when the engine is running the 28,000 kpa (4,000 psi) gauge to the nipple
and tests or adjustments are made. assembly.

Lift Relief Valve Check and Adjustment

1. Turn the key switch on and activate the hydraulics


until the hydraulic oil is at the normal operating
1 temperature.

2. With the motor at fast rpm under unload condition,


hold the lift control lever in the lift up position and
watch the gauge. The gauge indication is the
pressure that opens the relief valve at the end of
lift cylinder stroke.

3. The correct pressure setting is shown in the chart.


Pressure Tap Location
(1) Plug
4. If an adjustment to the relief valve setting is
necessary, loosen locknut (3).

Relief Valve Adjustment


(3) Locknut. (4) Stud

Vehicle Systems 33 Specifications


5. Turn stud (4) clockwise to increase or
counterclockwise to decrease the pressure
setting of the relief valve.

6. Tighten the locknut and check the pressure


setting again for correct adjustment.

Tilt and Sideshifter Relief Valve Check and


Adjustment

1. Turn the key switch on and activate the hydraulics


until the hydraulic oil is at the normal operating
temperature. Put the carriage in the full sideshift 1. Remove the nut from the slotted tie-stud of main
position. hydraulic valve.

2. With the motor at fast rpm, hold the sideshift 2. Remove the slotted tie-stud from the valve.
position and watch the gauge. The gauge
indication is the pressure that opens the relief 3. Use Hex Wrench (6mm or 1/4 inch), turn the flow
valve. control adjuster clockwise to increase the flow
or counterclockwise to decrease the flow.
3. The correct pressure setting is shown in the chart.
4. Assemble the tie stud in the valve. Torque the
4. If an adjustment to the relief valve setting is stud to 40.5 2.5 Nm (360 24 lbin)
necessary, loosen locknut (5).
5. Reinstall the nut.

WARNING
Hydraulic oil, under pressure, can remain in the
hydraulic system after the motor and pump have
5 been stopped. Personal injury can be caused if
this pressure is not released before any work is
6 done on the hydraulic system. To prevent
possible injury, lower the carriage to the ground,
turn the key switch off and move the control
levers to make sure all hydraulic pressure is
released before any fitting, plug, hose or
Relief Valve Adjustment component is loosened, tightened, removed or
(5) Locknut. (6) Stud
adjusted. Always move the lift truck to a clean
and level location away from the travel of other
5. Turn stud (6) clockwise to increase or
machines. Be sure that other personnel are not
counterclockwise to decrease the pressure
near the machine when the engine is running
setting of the relief valve.
and tests or adjustments are made.
6. Tighten the locknut and check the pressure stting
again for correct adjustment.

Flow Control Valve Adjustment

The tilt and first attachment speeds can be adjusted


at the control valves. They can be adjusted by
turning the plug in the hydraulic control valve body.
The lift speed can not be adjusted.
Do the procedure that follows to change the flow
control assembly.

Vehicle Systems 34 Testing And Adjusting


Standard Lift Cylinder Air Removal 5. Locate the setscrew on each lift cylinder. Slowly
open secondary cylinder(s) setscrews no more
After the standard lift cylinder has been than one turn. The weight of the carriage will
disassembled and then assembled again, it may be force air and hydraulic oil out of the cylinders
necessary to remove the air (bleed) from the through the setscrews. Close the setscrews
cylinder. before all the pressure is out of the cylinders. This
will prevent air from entering through the
1. With no load, lift and lower the mast and carriage setscrews.
through one complete cycle.
6. Repeat Steps 4 and 5 until there are no air
2. With the forks on the floor, check the oil level in bubbles at the setscrews.
the hydraulic tank. Add oil (if necessary) to bring
the oil level to the full mark.
7. After all the air is removed, tighten the setscrews
3. With no load, lift and lower the mast and carriage to a torque of 5 to 7 Nm (45 to 60 lbin).
again through four complete cycles.
8. Fill the hydraulic tank to the full mark.

WARNING 9. Lift and lower the mast and carriage again


The oil will have high pressure present. To through one complete cycle. If the mast does not
prevent personal injury, do not remove the bleed operate smoothly, repeat Steps 3 through 9.
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
loosened.

4. Lift the forks high enough to put a load on all


stages of the lift cylinders.

Setscrew Locations (Standard Cylinders)

NOTE: The Standard Lift mast has two secondary


cylinders and no primary cylinders. The Full
Free and Full Free Triple Lift mast has one
primary and two secondary cylinders.

Vehicle Systems 35 Specifications


Mast and Carriage Mast And Carriage Bearings
Part No. Bearing Size Bearing O.D.*
Mast Adjustment D581814 Under Size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.135 in)
NOTE: The Standard, Full Free Lift and Full Free
Triple Lift mast load bearings are all adjusted D581816 Over Size 110.7 mm (4.358 in)
the same way. The mast shown in the
following illustrations is the Full Free Triple * Permissible tolerance 0.08mm (.003in)
Lift mast.

To make the mast clearance adjustments, mast


must be removed from the lift truck.

Carriage, chain and lift cylinder must be removed


from the mast for easy adjustments.

Use the procedure that follows to adjust the load


bearings.

A. Lower Bearing Adjustment of Intermediate


Mast

2. Find narrowest point by ruler on the stationary


mast in the area where the bearings make
contact at 475 mm (18.7 in) channel lap.

Mast Adjustment Lower Bearings


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

1. Select lower bearings (3) and (4) from the chart to


obtain minimum clearance (B) between bearing
and channel leg for full channel length. Use same
bearing on left and right side.

Vehicle Systems 36 Testing And Adjusting


Mast Adjustment Lower Bearings
(A) Zero clearance. (B) Minimum clearance.
(C) Zero clearance. (3) Bearing. (4) Bearing.
3. Install 1 mm shim to each bearing of intermediate (5) Shims. (6) Shims.
lower and stationary upper basically. Lifting by
crane, insert intermediate mast into stationary
mast from the upper side.

NOTE: When installing shims (5) behind bearing (4),


make sure the amount of shim is divided
equally when positioned behind each bearing
(4).

4. Make sure whether intermediate mast lower


bearings are properly shimmed in the stationary
mast by rolling up and down and moving
intermediate mast to right and left. If clearance
between both masts can be detected, pull out the
intermediate mast from the stationary mast with
crane and add shim 0.5 mm or 1 mm to both
intermediate lower bearings.

Vehicle Systems 37 Specifications


B. Upper Bearing Adjustment of Stationary
Mast

5. 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 do not move 1. Lifting by crane, and pull out intermediate mast
rolling up and down, there might be excessive from stationary mast. Install 1 mm shim to each
shim. Pull out the intermediate mast from the bearing of stationary mast upper basically.
stationary mast and remove shim 0.5 mm to both Bearing should be selected D581814 under size
intermediate lower bearings. Repeat same bearing.
procedure of aboves until properly shimmed.
There is to be contact zero clearance (C)
between intermediate lower bearings and
stationary channel at approximately 475 mm
(18.7 in) channel lap.

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.

Vehicle Systems 38 Testing And Adjusting


C. Upper Pad Adjustment

2. Make sure whether stationary mast upper


bearings are properly shimmed by rolling up and
down and moving intermediate mast to right and
left. If clearance between both masts can be
detected, pull out the intermediate mast from the
stationary mast with crane and add shim 0.5 mm
or 1 mm to both stationary upper bearings.

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.

3. 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 do not
move rolling up and down, there might be
excessive shim. Pull out the intermediate mast
from the stationary mast and remove shim 0.5
mm to both stationary upper bearings. Repeat
same procedure of aboves until properly
shimmed. There is to be contact zero clearance
(C) between stationary upper bearings and the 1. Install shims (8) behind each pad (7) until there is
widest point of intermediate mast to be checked 0.80 mm (.031 in) maximum clearance (E)
before. between the pads and the inner and intermediate
masts with the masts at full extension. Lifting by
crane, and pull out intermediate mast from
stationary mast and insert the shims behind each
pad. In case of standard and full free mast, the
pads of stationary upper can be easily extruded
by pulling down the inner mast from the bottom of
stationary mast.

Vehicle Systems 39 Specifications


D. Lower Bearing Adjustment of Inner Mast Mast And Carriage Bearings
Part No. Bearing Size Bearing O.D.*
D581814 Under Size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.135 in)
D581816 Over Size 110.7 mm (4.358 in)

* Permissible tolerance 0.08mm (.003in)

2. Find narrowest point by ruler on the intermediate


Mast Adjustment Lower Bearings
mast in the area where the inner lower bearings
(A) Zero clearance. (B) Minimum clearance. make contact full length of intermediate mast
(C) Zero clearance. (3) Bearing. (4) Bearing. (5) Shims. excluding minimum channel lap 475 mm (18.7 in).
(6) Shims.

1. Select lower bearings (3) and (4) from the chart to


obtain minimum clearance (B) between bearing
and channel leg for full channel length. Use same
bearing on left and right side.

3. Install 1 mm shim to each bearing of inner lower


and intermediate upper basically. Lifting by crane,
insert inner mast into intermediate mast from
the upper side.

Vehicle Systems 40 Testing And Adjusting


Carriage Adjustment

NOTE: The standard, Full Free Lift and Full Free


Triple Lift carriage load bearings are all
adjusted the same way. The Full Free Triple
Lift carriage is shown in the following
illustrations.

To make the carriage clearance adjustments,


carriage must be removed from the mast.

Use the procedure that follows to adjust carriage


load bearings.

Mast Adjustment Lower Bearings


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

4. Make sure whether inner mast lower bearings are


properly shimmed in the intermediate mast by
rolling up and down and moving inner mast to
right and left. If clearance between both masts
can be detected, pull down the inner mast from
the bottom of intermediate mast. Inner lower
bearings can be easily extruded. Add shim 0.5
mm or 1 mm to both inner lower bearings. If inner
mast is stuck and do not move rolling up and
down, there might be excessive shim. Pull out
the inner mast from the intermediate mast and
remove shim 0.5 mm to both inner lower bearings.
Repeat same procedure of aboves until properly
shimmed. There is to be contact zero clearance
Carriage Adjustment
(C) between inner lower bearings and (3) Upper bearings. (4) Shims. (6) Screw.
intermediate channel at narrowest point. (7) Middle bearings. (8) Lower bearings.
(A) Zero clearance. (C) Minimum clearance.
E. Upper Bearing Adjustment of intermediate
Mast
1. Select lower bearings from the chart to obtain
Follow same procedure with above B. minimum clearance (C) between bearings and
channel leg for full channel length. Use same
bearing in all six locations.
F. Upper Pad Adjustment of Intermediate Mast

Follow same procedure with above C.

Vehicle Systems 41 Specifications


Mast And Carriage Bearings
Part No. Bearing Size Bearing O.D.*
D581814 Under Size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.135 in)
D581816 Over Size 110.7 mm (4.358 in)

* Permissible tolerance 0.08mm (.003in)

5. Tighten screw (5) that holds the top bearings to


the carriage to a torque of 347 Nm (255 lbft)

Chain Adjustments
Chain Adjustment Check

2. Find narrowest point by ruler on the inner mast in


the area where the bearings make contact.

3. Install enough shims (4) that have been divided


into two equal groups behind bearings (3). At
installation, there is to be contact [zero clearance
(A)] between the bearings and the narrowest
point of inner mast.

4. Do step 2 through 3 for other sets of bearings.


Chain Adjustment Check

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.

Vehicle Systems 42 Testing And Adjusting


Chain Adjustment Chain Wear Test
If the tension is not the same on both chains, do the
Chain wear test is a measurement of wear of the
procedure that follows:
chain links and pins. Do the steps that follow to
check chain wear.
WARNING
1. Lift the mast and carriage enough to put tension
Personal injury can be caused by sudden on the lift chains.
movement of the mast and carriage. Blocks
must be used to prevent the mast and carriage
from any movement while the adjustments are 2. Measure precisely ten links of chain distance at
made. Keep hands and feet clear of any parts the center of pins in millimeter.
that can move.
3. Calculate chain wear rate.

New one pitch = 19.05 mm (2~3 Ton)


25.4mm(3.3~Light 3.5 Ton. 6500lb)

Chain wear rate (%)

= Actual measurement - 190.5 x 100 (10 Links)


190.5

1 or = Actual measurement - 254 x 100 (10 Links)


254

WARNING
Inner Lift Chains
(1) Chain anchor nuts. Do not put a lift truck into service if the chain
wear indication is 2% or more. A reading of 2%
or more could cause damage or injury to
persons.
1. Lift the mast and carriage and put blocks under
the mast and carriage to release the tension from
the lift chains.
4. If the chain wear indication is 2% or more, replace
2. Make adjustments to chain anchor nuts (1) for the lift chain.
equal tension of the mast and carriage chains.

3. Put LOCTITE NO.242 Thread Lock on the


threads of the locknuts after the adjustment is
completed.

Outer Lift Chains


(2) Chain anchor bolts.

Vehicle Systems 43 Specifications


Carriage and Mast Height Adjustment Forks Parallel Check

1. Move the mast either forward or backward so it is 1. Lift the mast and operate the tilt control lever, until
in the vertical position. the top surface of the forks is parallel with the
floor. Place two straight bars, that are the same
2. Lower the carriage completely. 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 put one fork, one third back from the
tip, under a fixture that will not move. Then
operate the tilt control with caution until the rear of
the truck just lifts off of the floor. Follow the same
procedure with the second fork, and then check
the forks again as in Step 1.

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.

5. The measurement (A) must be as follows: Forks Parallel Check


STD............................................................. Zero (Typical Example)
FFL & FFTL .............. 41 1.5 mm (1.61 .06 in)

NOTE: On Standard Lift models the bearing must be


even (flush) with the inner mast.
If the above measurements are not correct,
make adjustments to the chains to get the
correct measurement. See Chain
Adjustments in TESTING AND ADJUSTING.

Vehicle Systems 44 Testing And Adjusting


Tilt Cylinder Alignment Tilt Cylinder Length Check

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 Cylinder Length Check

1. Tilt the mast to full forward position. Measure the


extended length of the cylinder rods from the
cylinder housing to the mast. The difference of
length between the two cylinder rods must be
within 3.18 mm (.125 in) of each other.

Tilt Angle Check (Typical Example)


Tilt Cylinders With Tilt Back Limiting Group

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.

Tilt Cylinder Adjustment


(1) Pivot eye. (2) Bolt. (3) Rod. (4) Shims. (5) Spacer.
(6) Head.

1. With the mast at full forward tilt, loosen bolt (2).

2. Slide spacer (5) back so rod (3) can be turned


into or out of pivot eye (1) to obtain the correct
length or angle.

Vehicle Systems 45 Specifications


Drift Test For Lift System
WARNING
Tilt cylinder pivot eyes can loosen if the torque 1. Put a rated capacity load on the forks of the lift
on the pivot eye clamping bolt is not tight truck. Operate the lift truck through a complete lift
enough. This will let the tilt cylinder rod turn in and tilt cycle until the oil is at normal temperature
the tilt cylinder eye. The cylinder rod may then of operation, 45 to 55C.
twist our of the pivot eye and the tilt cylinder will
be out of alignment or may let the mast fall and
cause personal injury or 2. Put the mast in a vertical position.
Raise a rated capacity load to a sufficient height
damage. When the rod lengths are made even,
the tilt angle differences or the mast alignment to test the lift cylinders.
will no longer be a problem.
3. Measure any drift of the carriage for a ten minute
period. Drift for all models shall not exceed 100.0
mm (4.00 in).
3. Tighten bolt (2) and the nut to a torque of 95 15
Nm (70 10 lbft). Drift Test For The Tilt System
4. With mast at full back tilt, install shims (4) as 1. Put a rated capacity load on the forks on the lift
required to permit no gap between spacer (5) and truck. Operate the lift truck through a complete lift
head (6). Shim so mast does not twist at full tilt and tilt cycle until the oil is at normal temperature
back. for operation, 45 to 55C.

2. Put the mast in a vertical position. Raise a rated


Drift Test capacity load to a height of 2.5 meters (8.2 ft). In
the case of trucks with less than 2.5 meters (8.2
Drift is movement of the mast or carriage that is the ft) height extension, raise the load to the trucks
result of hydraulic leakage in the cylinders or control maximum height.
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.
Tilt Drift Check.
2. Lift the mast approximately 762 mm (30 in). Use
wood blocks and clamps to hold the mast in this
position. 3. The tilt drift is measured as the charge in the tilt
cylinder stroke. Measure any drift of the mast for
3. Check the mast hinge bolts to make sure they are ten minute period.
tight. Drift for shall not exceed 35.5 mm (1.40 in).

4. Remove the blocks and clamps and lower the


mast.

Vehicle Systems 46 Testing And Adjusting


Steering System Steering Axle Stop Adjustment

Steer Wheel Bearing Adjustment

Bearing Adjustment
(1) Nut. (2) Lock

1. Tighten nut (1) slowly to 135 Nm (100 lbft)


while the wheels is rotated in both directions put
the bearings into position.

2. Loosen nut (1) completely. Tighten nut (1) again


Steer Angle
to 50 5 Nm (37 4 lbft) .
(1) Bolt. (2) Nut. (3) Bolt. (4) Nut. (5) Bolts. (A) 80 angle

3. Bend lock (2) over nut (1) to hold the nut in


position.
Use the procedure that follows to make an
adjustment to the steer axle turning angle.

1. Adjust the cylinder rod extension so it is equal on


both sides of the axle.

2. Loosen nuts (2) and (4) on both sides of the steer


axle.

3. Turn the steer wheel one direction until the steer


cylinder rod extension measures 94mm(3.7 in) for
B Models and 80mm(3.2in) for BC Models more
than the straight ahead measurement.

4. Adjust stop bolt (1) on one side and stop bolt (3)
on the other.

5. Tighten nut (2) on one side and nut (4) on the


other side. Turn the steer wheel the opposite
direction and do the same procedure for the
opposite stop bolts. This will give a maximum
cramp angle of 80.

Vehicle Systems 47 Specifications


Steering Knuckle Bearing Preload Steering System Pressure Check
Adjustment
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 Kit to check the
steering hydraulic system and its relief pressure
setting.

1
2

(1) Hydraulic Steering Gear


(2) Pressure gage plug (M10 x P1).

Steering Knuckle Bearing Preload Adjustment WARNING


(6) Steering link. (7) Shims. (8) Cover. (9) Bolts.
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
1. During assembly of the steering knuckle, install components are disconnected, make sure all
the upper bearing cup, cone and seal. hydraulic pressure is released in the steering
system. Move the steer wheels to the left and
2. Install lower bearing group cover (8) without right and then to the straight forward direction.
shims. Tighten two opposed cover bolts (9) to a
torque of 5.6 Nm (50 lbin) .
Check steering system relief pressure as
3. Measure the clearance between cover (8) and the follows:
axle beam at each bolt with a feeler gauge.
1. Turn the engine off.
4. Take an average of the measurements found in
Step 3. Select shims (7) equal in thickness to the 2. Remove plug (1) from elbow. Install pressure-
average clearance. checking adapter (4) and connect pressure-tube
(5) and pressure gage (6). Pressure gage (6) has
a range of 2,800 kpa (4,000 psi).
5. Remove the bearing group and install shims (7),
cover (8) and bolts (9). Tighten bolts (9) to a 3. Move the seat to the normal position for operation,
torque of 55 6 Nm (40 5 lbft) . turn the key switch to the ON position and
activate the hydraulic controls until the oil is at a
6. With steering links (6) disconnected from the temperature for normal operation.
steering cylinder, check knuckle for 4.5 to 6.8 N
m(40 to 60 lbin) of rolling torque. Add or remove 4. Turn the steer wheels to the left or right against
shims from cover (8) to obtain the proper rolling the stops and make a note of the indication on the
torque. pressure gauge.

7. Connect links (6) to the steering cylinder. Tighten


cylinder mounting bolts (5) to a torque of 460 60
Nm (340 40 lbft) .

Vehicle Systems 48 Testing And Adjusting


5. The indication on the pressure gauge must be the 7. If the steering gear and the priority valve are
priority valve relief setting of 9,500 (+500,0) kpa working properly, the steering cylinder is defective
or 1,380 (+70,0) psi. If the indication is correct and must be repaired.
and a problem exists, then there is possibly a
mechanical failure in the steering system.
8. Correct the problem and check steering relief
6. If the indication is not correct, then there is valve pressure again.
steering hydraulic failure in the components.

(4) Pressure-checking adapter (5) Pressure-tube


(6) Pressure gauge

NOTICE

Do not let Valve be closed for more than 3 or 4


seconds or, damage can be caused to the steering
system components.

a. With the motor running, turn the steer wheels in


any directions and read the indication on
pressure gauge (6).

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 or its components must be
replaced.

Vehicle Systems 49 Specifications


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.

Reservoir Location
(1) Reservoir.

1. Fill reservoir (1) with the correct fluid to 12.7mm


(.50 in) from the filler cap. See the Operation And
Maintenance Manual for the correct brake fluid.

2
1

Bleed Screw Location


(Standard Lift Truck)
(1) Brake oil inlet, (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.

Vehicle Systems 50 Testing And Adjusting


3. Do step 2 again as many times as necessary until
the brake fluid is free of air.

4. (If equipped): Use the procedure in Steps 2 and 3


again, except this time use the other bleed screw
(not shown).

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


the level explained in Step 1.

Pedal Adjustment

The brake pedal must have enough free play to let


the master cylinder piston return to the release
positon and open the relief outlet.

Hydraulic pressure in the brake lines goes back


through the relief opening and releases the brakes.
If there is no pedal free play, the pressure can not
go back through the relief opening, and the brakes
will tighten and not release.

If there is too much free play, the brake pedal will


below even with the correct brake adjustment.

The master cylinder push rod must be adjusted so


the brake pedal has 3.0 to 8.0 mm (.118 .315 in)
of free play from the pedals stop to the push rod
contact point with the master cylinder piston.

If the pedal free play adjustment is not correct, do


the procedure that follows :

Location of Master Cylinder


(1) Boot. (2) Rod. (3) Nut.

NOTE: On some trucks the rubber boot may have to


be moved to expose the adjustment nuts.

1. Loosen nut (3).

2. Adjust rod (2) until there is the correct amount of


free play.

3. Hold rod (2) and tighten nut (3).

Vehicle Systems 51 Specifications


Parking Brake Test not to be over 21 mm. In case the stroke exceed this
value, its suggested to replace the disc pack (see
1. Drive the lift truck with a rated load up a 15%
fig. 5).
incline.

WARNING
To prevent personal injury, the operator must be
ready to use the service brake if the parking
brake is not adjusted correctly and the lift truck
starts to move.

2. Half way up the incline, stop the lift truck with the
service brakes. Make an application of the
parking brake.
3. If the parking brake has the correct adjustment,
the lift truck will be held in this position.
4. If the parking brake does not hold, do the steps in
Parking Brake Adjustment.

Parking Brake Adjustment

Parking Brake
(1) Control brake lever. (2) Brake piston.

1. Put the parking brake in the OFF position.

The brakes chamber employees the reduction gear


oil and it is always feed in the working processing.
During the installation of the reduction gear, it is
necessary to verify that the handbrakes draught
cable isnt in tension or that it doesnt reduce the
space between the brake disks. It would
compromise the correct working of the brake.

It is necessary to check every 3000 working hours


that the stroke of the brake piston is not over 3.5
mm, otherwise it is necessary to replace the brake
discs. For the PMS701 cp version, in order to
estimate the worn of the discs, disconnect the brake
rod. Move the lever closer the brake piston, then pull
it strongly and measure the stroke of the lever: it has

Vehicle Systems 52 Testing And Adjusting


Electric Motors
Hydraulic Pump Motor

The motor is protected from over temperature by a


thermal sensor. If motors temperature reaches in
1554 (31110) 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 53 Testing And Adjusting


Replace Motors Speed Sensors In case the speed sensor is fixed to the motors
shield with two screws
In case the speed sensor is fixed to the motors
shield with four screws and lateral flanges

1. unscrew 2 M4 screws

1. remove the fastener which locks the cable to the 2. remove the installed sensor
motors endbell
3. position and push the new sensor into its housing
2. unscrew the four M6 screws
4. verify if its completely inserted in its housing as,
3. remove two lateral locking flanges on the contrary, it could be damaged as soon as
the screws are screwed
4. remove the installed sensor
5. screw the two (2) M4 screws with a tightening
5. position the new sensor in its housing in the torque of 1.2Nm
endbell

6. fix the fastener which locks the cable to the


endbell

7. position and mount the locking flanges

8. screw the 4 M6 screws with a tightening torque of


6.5Nm

Vehicle Systems 54 Testing And Adjusting


Specifications (1) Torque for bolts that hold control valve sections
together ................40.5 2.5 Nm (360 24 lbin).

Hydraulic Control Valve (2) Adjust main system relief valve pressure for lift
as shown above. See Relief Valve Pressure
Check in Testing And Adjusting

(3) Adjust secondary relief valve pressure for tilt and


sideshift as shown above. See Relief Valve
Pressure Check in Testing And Adjusting.

(4) Torque for plug....29.5 1.5 Nm ( 264 12 lbin) .

(5) Torque for plug........101 5 Nm ( 894 42 lbin) .

(6) Adjust tilt and sideshift flow rate by using 1/4 inch
hex-wrench if required. See Flow Control Valve
Adjustment in Testing And Adjusting.

(7) Torque for plug.....55.5 2.5 Nm ( 492 24 lbin).

(8) Torque for plug.......... 79 4 Nm ( 696 36 lbin).

(9) Torque for screws..... 5.4 2.7 Nm (48 24 lbin).

RELIEF PRESSUES
Auxiliary
MODEL MAST main relief pressure
pressure- lift - tilt,
attachment
psi kpa psi kpa
B20S-5
STD/FF/ 2,400 16,600
BC20S-5
FFT (+75,-0) (+500,-0)
B20X-5

STD/FF/ 2,640 18,260


B22X-5
FFT (+75,-0) (+500,-0)
B25S-5
STD/FF/ 2,800 19,300 2,250 15,500
BC25S-5
FFT (+75,-0) (+500,-0) 50 350
B25X-5
B30S-5
STD/FF/ 3,000 20,700
BC30/32-5
FFT (+75,-0) (+500,-0)
B30X-5
B32S-5 STD/FF/ 3,420 23,500
B35X-5 FFT (+75,-0) ( +500,-0)

Hydraulic Pumps

Rotation is clockwise when seen from drive end.

Type of pump: Gear

Displacement : 33 cc/rev

Vehicle Systems 55 Specifications


Lift Cylinders Full Free Triple Lift and Full Free Lift
Primary
Standard

(1) Put Thread Lock on the last three threads of


bearing.
NOTE: All seals to be lubricated with hydraulic oil.
(1) Put pipe sealant on the lost three threads of
bearing.
Full Free Triple Lift And Full Free Lift
(2) Torque for setscrews 6 1 Nm ( 53 9 lbin) Secondary

NOTE: All seals to be lubricated with hydraulic oil.

(1) Put Thread Lock on the last three threads of


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

Vehicle Systems 56 Specifications


Tilt Cylinders

IDCS189S

TILT CYLINDER CHART


Tilt Gp Part Forward Tilt Backward Tilt Cyl.Stroke (x) Cyl. Closed
Model
No. Angle* Angle* mm(in) (z) mm(in)
A215207 3 3 43.5 (1.71) 525.0 (20.67)
A215203 6 3 65.0 (2.56) 525.0 (20.67)
B22X-5 A215206 3 5 58.0 (2.28) 510.3 (20.08)
B25X-5 A215202 6 5 79.5 (3.13) 510.3 (20.08)
B30X-5 A215209 10 5 107.0 (4.21) 510.3 (20.08)
B35X-5 A215205 3 8 81.0 (3.19) 487.8 (19.21)
A285307 6 9 113.7 (4.48) 477.5 (18.80)
A285308 3 9 91.5 (3.60) 477.5 (18.80)

* Permissible tolerance of 1/2


(1) Adjust pivot eye to dimension (Z) with cylinder closed.
(2) Torque for bolt................... 95 15 Nm ( 70 10 lbft)
(3) Torque for head............. 270 30 N m ( 200 22 lbft)
(4) Torque for piston nut ..... 270 30 N m ( 200 22 lbft)

Vehicle Systems 57 Specifications


Mast Carriage

(1) With mast at 475 mm (18.7 in) channel lap,


equally shim both sides until contact (A) is made
(zero clearance) between bearings and mast
uprights.

(2) With mast at full extension, shim behind pads


until there is clearance (B) between the mast (1) Select bearings from the chart to obtain minimum
clearance (C) between bearings and channel leg
uprights and the pads of 0.80 mm (.031 in) for full channel length. Must use same bearing at
all six locations.
(3) Select lower bearings from the chart to obtain
minimum clearance (c) between bearing and (2) Equally shim both sides until contact (A) is made
channel leg for full channel length. Must use (zero clearance) between bearings and inner
mast at narrowest point.
same bearing on left and right side.
(3) Shim bolt as needed to obtain a 6.0 to 9.0 mm
(See Mast Adjustment in Testing And Adjusting). (.236 to .354 in) overlap (B) between bolt (3) and
the carriage stop on the inner upright.
(See Carriage Adjustment in Testing and
MAST BEARING CHART Adjusting.)
108.60 mm
D581814 Undersize (4) Torque for screw ......34 7 Nm (360 24 lbin)
(4.276 in)
109.60 mm
D581815 Standard CARRIAGE BEARING CHART
(4.315 in)
110.70 mm Part No. Bearing Size Bearing OD*
D581816 Oversize
(4.358 in)
108.60 mm
D581814 Undersize
* Permissible tolerance of 0.08 mm (.003 in). (4.276 in)
109.60 mm
D581815 Standard
(4.315 in)
110.70 mm
D581816 Oversize
(4.358 in)

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

Vehicle Systems 58 Specifications


Lift Relay Group - Standard Lift
WARNING
Do not put a lift truck into service if the chain
wear indication is 2% or more. A reading of 2%
or more could cause damage or injury to
persons.

(1) Put LOCTITE NO. 242 Thread Lock on the


threads of the relay group locknuts after
adjustment of the lift chains is completed.

(2) Maximum chain wea..................... Less than 2%


(See Chain Wear Test in TESTING AND
ADJUSTING).

(3) Distance from bottom of inner mast to bottom of


lower bearing on carriage must be even (flush)
with the inner mast.

Vehicle Systems 59 Specifications


Lift Relay Group - Full Free Lift
WARNING
Do not put a lift truck into service if the chain
wear indication is 2% or more. A reading of 2%
or more could cause damage or injury to
persons.

(1) Tighten bolts until contact is made with guard.

(2) Put LOCTITE NO. 242 Thread Lock on the


threads of the relay group locknuts after
adjustment of the lift chains is completed.

(3) Maximum chain wear Less than 2% (See Chain


Wear Test in TESTING AND ADJUSTING).

(4) Distance from bottom of inner mast to bottom of


lower bearing on carriage must be 41 1.5 mm
(1.61 0.6 in).
Bottom of inner mast must be even (flush) with
bottom of stationary mast. Adjust inner first.

Vehicle Systems 60 Specifications


Lift Relay Group - Full Free Triple Lift
WARNING
Do not put a lift truck into service if the chain
wear indication is 2% or more. A Reading of 2%
or more could cause damage or injury to
persons.

(1) Maximum chain wear Less than 2% (See Chain


Wear in TESTING AND ADJUSTING).

(2) Put LOCTITE NO. 242 Thread Lock on the


threads of the relay group locknuts after
adjustment of the lift chains is completed.

(3) Tighten bolts until contact is made with guide


assembly.

(4) Distance from bottom of inner mast to bottom of


lower bearing on carriage must be 41 1.5 mm
(1.61 0.6 in).
Bottom of inner mast be even (flush) with bottom
of stationary mast. Adjust inner mast first.

Vehicle Systems 61 Specifications


Lift and Tilt Mounting Group (1) (Standard Mast or Full Free Triple Lift mast
Only):
With chains adjusted for equal tension, run mast
to full lift. If mast does not kick (move) to one side,
no shims are needed. If mast does kick (move) to
one side, disconnect cylinder from the bar on that
side. Add shim, connect cylinder, adjust chains
and run mast to full lift to check for kick. Repeat
process if necessary. The total shim pack must
not be more than three shims maximum.

(2) Tilt cylinder installation shown for M40D thru


MC60d models.

(3) Bearing split to be located at angle (d) 45 5

(4) Install bearing outer race to a depth of (G)


................................ 4.5 0.8 mm (.177 .031 in).

(5) (Full Free Lift Mast Only):


Tighten nuts until U-bolts is firm against cylinder,
do not apply standard torque.

(6) (Full Free Lift Mast Only):


With chains adjusted for equal tension run mast
to full lift. If mast does not kick (move) to one side,
no shims are needed. If mast does kick (move) to
one side, hold lift cylinder tube on that side and
loosen bearing 1/4 turn and check mast again.
Loosen bearing until kicking (movement) stops or
gap (H) reaches 3.0 mm (.12 in) (approximately
1.5 turns)), whichever is less. Insert shims (8)
under bearing (it may be necessary to loosen
bearing an additional amount of turns to install
shims). Tighten bearing again.

Vehicle Systems 62 Specifications


Steering Wheel Priority Valve

(1) Torque for steering wheel nut......... 75 to 88 Nm Flow ...................................................Load sensing


( 55 to 65 lbft)
Relief valve (no adjustment) opens at:
............................. 7,600 350 kPa (1,100 50 psi)

Vehicle Systems 63 Specifications


Steering Gear

(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 Nm (125 25 lbin)
Tighten to a final torque of
.............................. 28.2 2.8 Nm (250 25 lbin)

(5) Torque for plug .......................11.3 Nm (100 lbin)


Plug to be flush (even) with or below mounting
surface.

Vehicle Systems 64 Specifications


Steer Axle and Wheel (9) tapered Roller Bearing Axles Only:
Torque for bolts that hold cover
..........................................55 6 Nm (40 5 lbin)

(10) Add or remove shims under cover until torque


required to turn knuckle assembly is.4.5 to
6.8 Nm (40 to 60 lbin) See Steering Knuckle
Bearing Preload Adjustment in Testing And
Adjusting section.

Steer Tire Installation

NOTE: Steer axles with tapered roller bearings


shown.

(1) Do the steps that follow for steer wheel bearing


adjustment.
a. tighten nut (1) slowly to 135 Nm (100 lbft) while
turning the wheel.
b. Loosen nut 91) completely. Tighten it again to
..................................... 50 5 Nm (37 4 lbft)
c. Bend lock (2) over nut (1).

(3) torque for bolt that holds pin


.................................... 11 1 Nm (100 9 lbft)

(4), (6) Loosen nuts (5) and (7) on both sides. Adjust
bolts to get steering knuckle turning angle (A) of
78 to 80 See Steering Axle Stop Adjustment in
Testing And Adjusting section. WARNING
The solid softer or pneumatic steer tire must be
(8) Tapered Roller Bearing Axles Only: installed as shown. Failure to do so will
Torque for bolts that hold steer cylinder to axle decrease machine stability.
beam .................... 300 40 Nm (220 30 lbft)

Install the soled softer or pneumatic tire so that the


edge of the tire is even with the outside edge of the
wheel.
Tighten the cushion tire wheel mounting bolts (1) to
a torque of ......................95 15 Nm (70 10 lbft)

Vehicle Systems 65 Specifications


SB4210E00
Oct.2006

Vehicle System
Disassembly & Assembly

B22X-5, B25X-5, B30X-5, B35X-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 Tilt Cylinders .......................................................35
Remove & Install Tilt Cylinders .......................35
Disassemble & Assemble Tilt Cylinders ..........36
Disassembly And Assembly
Steering Cylinder.................................................39
Disassemble Steering Cylinder .......................39
Hydraulic Control Valve Switch Group................... 5
Assemble Steering Cylinder............................40
Remove And Install Hydraulic Control Valve
Switch Group ................................................... 5
Hydraulic Control Valve .......................................41
Remove & Install Hydraulic Control Valve.......41
Hydraulic Pump Motor........................................... 5
Disassemble Hydraulic Control Valve .............41
Remove And Install Hydraulic Pump Motor....... 5
Assemble Hydraulic Control Valve..................43
Remove And Install............................................... 6
Steering Unit .......................................................45
Encoder Hydraulic Pump Motor..................... 6
Disassemble Steering Unit .............................45
Forks .................................................................... 7 Assemble Steering Unit ..................................49
Remove & Install Forks .................................... 7
Steering Wheel....................................................55
Backrest ............................................................... 7 Remove And Install Steering Wheel................55
Remove & Install Backrest ............................... 7 Steering Column .................................................55
Remove Steering Column...............................55
Carriage................................................................ 7
Remove & Install Carriage ............................... 7 Steer Axle ...........................................................57
Disassemble Carriage.................................... 10 Remove Steer Axle ........................................57
Assemble Carriage ........................................ 10 Install Steer Axle ............................................57

Mast ................................................................... 13 Master Cylinder ...................................................58


Remove & Install Mast ................................... 13 Remove And Install Master Cylinder ...............58
Disassemble Mast.......................................... 14
Accelerator Control Switch ..................................59
Assemble Mast .............................................. 18
Remove And Install Accelerator Control Switch
Standard Lift Cylinders........................................ 26 ......................................................................59
Disassemble Standard Lift Cylinders .............. 26
Drive Motor and Drive Axle Assembly..................60
Assemble Standard Lift Cylinders................... 28
Remove And Install Drive Motor and Drive Axle
Secondary Lift Cylinders ..................................... 29 Assembly .......................................................60
Disassemble Secondary Lift Cylinders ........... 29
Control Panel ......................................................61
Assemble Secondary Lift Cylinders ................ 31
Remove And install Control Panel ..................61
Primary Lift Cylinder............................................ 32
Counterweight .....................................................62
Remove & Install Primary Lift Cylinder............ 32
Remove And Install Counterweight .................62
Disassemble Primary Lift Cylinders ................ 33
Assemble Primary Lift Cylinders..................... 34

Vehicle Systems 3 Index


Disassembly And Hydraulic Pump Motor
Assembly
Remove And Install Hydraulic Pump
Hydraulic Control Valve Switch Motor
Group
Remove And Install Hydraulic Control
Valve Switch Group

1. Remove the battery. Mark the wires and cables


for proper installation. Disconnect three electric
wires (unshown) and three electric cables (10)
from the hydraulic pump motor.

2. Remove two bolts (3) and hydraulic pump (1)


1. Remove the cover over the hydraulic control
from the pump motor. Remove the pump
valve. Disconnect connector (1).
coupling if necessary. Pull the pump away from
the motor, but keep the pump above the level of
2. Remove two screws (2) and board assembly (3).
the hydraulic tank to prevent oil leakage from the
pump.
3. Remove two screws (4) for each micro switches
(5).
3. Remove four nuts (5) and washers (6).
4. Remove micro switches (5) and sensor (6).
4. Support pump motor (7) with hoist and remove
pump motor (7) from truck. Remove two bracket
5. Install the hydraulic control valve switch group in
(8, 9) from the motor if necessary.
the reverse order of removal.
5. Install the pump motor in the reverse order of
removal.

Vehicle Systems 5 Disassembly & Assembly


Remove And Install
Encoder Hydraulic Pump Motor

In case the speed sensor is fixed to the motors


shield with two screws

(3)

(1) (2)

1. unscrew M4 screws (2)

2. remove the installed sensor (1)

3. position and push the new sensor into its housing

4. verify if its completely inserted in its housing as,


on the contrary, it could be damaged as soon as
the screws are screwed

5. screw the two (2) M4 screws with a tightening


torque of 1.2 Nm

Vehicle Systems 6 Disassembly & Assembly


Forks Backrest
Remove & Install Forks Remove & Install Backrest

Start By:

a. Remove forks.

1
2

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


that fasten the backrest to the carriage.

2. Remove backrest (1). Backrest (1) weighs 40kg


(90lb).

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


removal.

End By:
1. Lift fork pin (1).
a. Install forks.
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
carriage.
Remove & Install Carriage
4. Remove the fork. The weight of the fork is 50 kg
(110 lb). Tools Needed A

5. Repeat steps 1 through 4 for the remaining fork. Retaining Ring Pliers 1

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


Start By:
7. Put the forks in position. Lower both fork pins (1)
to lock the forks in position. a. Remove forks.

b. Remove backrest.

Vehicle Systems 7 Disassembly & Assembly


NOTE : For purposes of reassembly, identify and
mark all hydraulic lines and connectors
before removing or disconnecting.

3. Remove four bolts (8) from the chain guard/hose


support assembly (6). Set the hoses aside, clear
of the primary cylinder and cross head.

10

1. Raise carriage (1). Position a wooden block as


shown. Lower carriage (1) onto the wooden block.

2. Disconnect two hydraulic lines (4) from side


shifter cylinder (2). Plug and cap all openings to
prevent contamination and debris from entering 9
system.

4. Remove two bolts (10) from the hose mounting


WARNING
bracket. Set the hoses aside. Remove two nuts
(9) from the chain anchors. Set the chains aside,
To prevent personal injury be sure pressure in
the hydraulic system has been released before clear of the mast.
disconnecting any hydraulic lines. Slowly
loosen the cap of the hydraulic tank to release
any pressure in the tank. Be cautious of hot
hydraulic oil when any lines are disconnected in
the hydraulic system.

Vehicle Systems 8 Disassembly & Assembly


Typical Example
10. Install cross head (12) and retaining ring (11).

5. Use tool (A) to remove retainer ring (11) from the


cross head shaft.
10
6. Remove cross head (12) from the shaft.

11. Put the chains in position over cross head (12).


Install nuts (9) onto the chain anchors.
Install bolts (10) onto the hose mounting bracket.

7. Raise the inner mast to pull out carriage as


shown.

8. Remove carriage from bottom of inner mast (15).


Carriage (14) weighs 116kg (255 lb).

NOTE : Use the following steps to install the


carriage. 12. Install chain guard/hose support assembly (6)
and four bolts (8).
9. Raise the inner mast to put in the carriage onto
the mast, and lower the inner mast to cover
carriage (1) bearing fully.

Vehicle Systems 9 Disassembly & Assembly


13. Connect two hydraulic line (4) in their original 2. Remove four lower roller bearings (3) and the
positions. shims from the carriage.

End By:

a. Install backrest.

b. Install forks.

Disassemble Carriage

Start By:

a. Remove carriage.
3. Remove screw (5) and washer (4). Remove top
roller bearings (6) and the shims.

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,


Typical Example carriage must be removed from the mast.

Use the procedure that follows to adjust carriage


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

Vehicle Systems 10 Disassembly & Assembly


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

3. Install enough shims (4) that have been divided


into two equal groups behind bearings (3). At
installation, there is to be contact [zero clearance
(A)] between the bearings and the narrowest
point of inner mast.

4. Do step 2 through 3 for other sets of bearings (8),


(9).

Carriage Adjustment
(3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Middle bearings. (8) Lower bearings. (A) Zero clearance.
(B) 6.0 to 9.0 mm. (.236 to .354 in) clearance.
(C) Minimum clearance.

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 six locations.

Mast And Carriage Bearings


Part No. Bearing Size Bearing O.D.*
D581814 Under Size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.135 in)
D581816 Over Size 110.7 mm (4.358 in)

* Permissible tolerance 0.08 mm (.003in)

5. Tighten screw (5) that holds the top bearings to


the carriage to a torque of 34 7 Nm (25 5
lbft)

Vehicle Systems 11 Disassembly & Assembly


6. Position chains (6) on the carriage. Install pins
(7) and the rolt pins.

End By:

a. Install carriage, raise the inner mast and insert


the carriage from the bottom of inner mast.

Vehicle Systems 12 Disassembly & Assembly


Mast
4
Remove & Install Mast

Start By: 5

a. remove forks 6

b. drain the hydraulic oil to tank


7

3. Disconnect two hydraulic lines (4).

WARNING
Tilt cylinders (7) can drop when pin (6) is
removed. To avoid component damage or
personal injury, support tilt cylinder (7) while
removing pin (6).

4. Remove bolt (5) from each side of mast


1. Support mast assembly (2) with a hoist and two assembly (2).
straps as shown.
5. Remove pin (6) from the tilt cylinders on each
side of the mast assembly (2).

NOTICE
6. Tilt forward mast assembly (2) about 8 with the
Place identification marks on all hydraulic hoist.
connectors and hoses to assure proper installation. Remove bolts (8) from each side of the base of
Plug and cap all hydraulic connectors and hoses to mast assembly (2).
avoid debris and contamination from entering the
system.

2. Disconnect hose (3).

Vehicle Systems 13 Disassembly & Assembly


Disassemble Mast

WARNING Start By:

Loose the tension of straps to be connected a. Remove primary lift cylinder.


with hoist when mast assembly(2) is tilted
forward. If straps are too tight, mast assembly b. Remove side shift cylinder.
(2) could be got off when bolts(8) are removed.
c. Remove mast.

7. Use the hoist to remove mast assembly(2) from NOTE : The following disassembly and assembly
the machine. procedure is for a full free triple lift mast.

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

End By:

a. Install forks.

b. Fill hydraulic oil to tank*.


1
* Refer to the Operation And Maintenance Manual
for further information.

(Typical example)

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


clamps.

Vehicle Systems 14 Disassembly & Assembly


3

2. Remove hose sheave (3). 5. Remove top cylinder retainer bolt (6) from each
side of the mast.
3. Remove chain nut (4) from the top of the mast
(each side).

4. Disconnect and remove chains (5) from the


bottom of the mast.

6. Remove cylinder retainer brackets (8) from each


cylinder.

Vehicle Systems 15 Disassembly & Assembly


7. Fasten a nylon strap and hoist to secondary 10. Check the condition of bearings (12) located in
cylinder (9) as shown. Remove secondary each of the mast mounting bores.
cylinders (9). Each cylinder weighs 50 kg (110 lb). Replace the seals and bearings (12) with new if
worn or damaged. Seal lips should be forward
outside.

(Typical example)

8. Check the condition of bearings (10) located in 11. Fasten nylon straps and hoist to inner channel
each of the tilt cylinder pin bores. Replace (13). Remove inner channel (13). The weight of
bearings (10) with new if worn or damaged. the inner channel is 150kg (330 lb).

9. Remove mast mounting pins (11) from the mast 12. Remove rollers (14) and the shims from the
mounting bores. inner channel mast.

Vehicle Systems 16 Disassembly & Assembly


13. Fasten nylon straps and a hoist to the
intermediate mast channel (15). Remove mast
channel (15). The intermediate mast channel
weighs 168kg (370 lb).

14. Remove rollers (16) and the shims from the


intermediate mast channel.

15. Remove nylon pads (17) and the shims.

16. Remove rollers (18) and the shims from the


stationary mast channel.

17. Remove nylon pads (19) and the shims.

Vehicle Systems 17 Disassembly & Assembly


Assemble Mast

NOTE : The standard, Full Free Lift and Full Free


Triple Lift mast load bearings are all
adjusted the same way. The mast shown in
the following illustrations is the Full Free
Triple Lift mast.

1. Make sure all parts are clean and free of dirt and
foreign material.

2. Check all parts for damage, use new parts for


replacement.
4. Find narrowest point by ruler on the staionary
mast in the area where the bearings make
A. Lower Bearing Adjustment of Intermediate
contact at 475 mm (18.7 in) channel lap.
Mast
NOTE : When installing shims (2) behind bearings
(1), make sure the amount of shim is
divided equally when positioned behind
each bearing (1).

5. Install the correct amount of shim (2) behind


rollers until contact (zero clearance) is made
between the rollers.

Mast Adjustment Lower Bearings


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

3. Select lower bearings (3) and (4) from the chart


to obtain minimum clearance (B) between
bearing and channel leg for full channel length.
Must use same bearing on left and right side.

Mast And Carriage Bearings


Part No. Bearing Size Bearing O.D.*
D581814 Under Size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.135 in)
D581816 Over Size 110.7 mm (4.358 in)
* Permissible tolerance 0.08 mm (.003 in)

Vehicle Systems 18 Disassembly & Assembly


NOTICE

When the correct amount of shim has been


installed behind rollers (1) there will be contact
(zero clearance) between the rollers and the inner
mast at most narrow point of mast (refer to step 4)

Mast Adjustment Lower Bearings


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

6. Install 1 mm shim to each bearing of intermediate


lower and stationary upper basically. Lifting by
crane, insert intermediate mast into stationary
mast from the upper side.
7. Make sure whether intermediate mast lower
NOTE : When installing shims (5) behind bearings bearings are properly shimmed in the stationary
(4), make sure the amount of shim is mast by rolling up and down and moving
divided equally when positioned behind intermediate mast to right and left. If clearance
each bearing (4). 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.

Vehicle Systems 19 Disassembly & Assembly


8. 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 staionary
mast. If intermediate mast is stuck and do not
move 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 aboves until properly
shimmed. There is to be contact zero clearance
(C) between intermediate lower bearings and Mast Adjustment Upper Bearings
stationary channel at approximately 475 mm (D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
(18.7 in) channel lap.

B. Upper Bearing Adjustment of Stationary Mast

10. Make sure whether stationary mast upper


bearings are properly shimmed by rolling up
and down and moving intermediate mast to right
9. Lifting by crane, and pull out intermediate mast
and left. If clearance between both masts can
from stationary mast. Install 1 mm shim to each
be detected, pull out the intermediate mast from
bearing of stationary mast upper basically.
the stationary mast with crane and add shim 0.5
Bearing should be selected D581814 under size
mm or 1 mm to both stationary upper bearings.
bearing.

Vehicle Systems 20 Disassembly & Assembly


C. Upper Pad Adjustment

11. 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 staionary mast. If intermediate
mast is stuck and do not move 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 staionary
upper bearings. Repeat same procedure of
aboves until properly shimmed. There is to be
contact zero clearance (C) between staionary
upper bearings and the widest point of
intermediate mast to be checked before.
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.

12. Install shims (8) behind each pad (7) until there
is 0.80 mm (.031 in) maximum clearance (E)
between the pads and the inner and
intermediate masts with the masts at full
extension. Lifting by crane, and pull out
intermediate mast from stationary mast and
insert the shims behind each pad. In case of
standard and full free mast, the pads of
stationary upper can be easily extruded by
pulling down the inner mast from the bottom of
stationary mast.

Vehicle Systems 21 Disassembly & Assembly


D. Lower Bearing Adjustment of Inner Mast

14. 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 475 mm (18.7 in).

Mast Adjustment Lower Bearings


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

13. Select lower bearings (3) and (4) from the chart
to obtain minimum clearance (B) between
15. Install 1 mm shim to each bearing of inner lower
bearing and channel leg for full channel length.
and intermediate upper basically. Lifting by
Must use same bearing on left and right side.
crane, insert inner mast into intermediate mast
from the upper side.
Mast And Carriage Bearings
Part No. Bearing Size Bearing O.D.*
D581814 Under Size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.135 in)
D581816 Over Size 110.7 mm (4.358 in)

* Permissible tolerance 0.08mm (.003in)

Vehicle Systems 22 Disassembly & 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.

17. If the seals and bearings were removed from


the mast mounting blocks, install new ones.
Mast Adjustment Lower Bearings
(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.

16. Make sure whether inner mast lower bearings


are properly shimmed in the intermediate mast
by rolling up and down and moving inner mast
to right and left. If clearance between both
masts can be detected, pull down the inner
mast from the bottom of intermediate mast.
Inner lower bearings can be easily extruded.
Add shim 0.5 mm or 1 mm to both inner lower
bearings. If inner mast is stuck and do not move
rolling up and down, there might be excessive
shim. Pull out the inner mast from the 18. Put a small amount of clean grease on
intermediate mast and remove shim 0.5 mm to mounting pins (11). Install mounting pins (11)
both inner lower bearings. Repeat same into mast mounting blocks.
procedure of aboves until properly shimmed.
There is to be contact zero clearance (C)
between inner lower bearings and intermediate
channel at narrowest point.

Vehicle Systems 23 Disassembly & Assembly


19. If the bearings were removed from the tilt 22. Install top retainer bolts (14) for the secondary
cylinder pin bores, install new ones. cylinders.

20. Fasten a hoist and nylon strap to secondary


cylinder (12). Install secondary cylinders (12)
into the stationary mast.

23. Install hydraulic steel tube to each secondary


cylinder. When install the steel tube, assembling
angle should be kept as shown in above figure.

21. Install secondary cylinder mounting brackets


(13) over the secondary cylinders.

24. Connect chains (16) at the bottom of the mast.

Vehicle Systems 24 Disassembly & Assembly


25. Connect chains (16) at the chain bracket of
stationary mast upper.

26. Install sheave (18) of lift hose.

28. Install carriage assembly from the bottom of


inner mast.

19

27. Install the lift hose support bracket (19) and


hoses.

29. Install cross head (21) to primary lift cylinder.

Vehicle Systems 25 Disassembly & Assembly


Standard Lift Cylinders
Disassemble Standard Lift Cylinders

Start By:

a. Remove standard lift cylinders.

30. Install carriage chains to primary lift cylinder.

1. Put standard lift cylinder (1) in position on vise


(A).

31. Install hydraulic hose (22) of side shifter to side


shifter cylinder (23).

2. Loosen set screw (2) with wrench (B).

32. Install mast to lift truck.

Vehicle Systems 26 Disassembly & Assembly


3. Remove bearing (3) with wrench (C). 6. Remove O-ring seal (6) and back-up ring (7)
from the bearing.

4. Remove rod (4) from the cylinder body.


7. Remove wiper seal (8) and seal (9) from the
bearing.

5. Remove split rings (5) from the cylinder rod.

Vehicle Systems 27 Disassembly & Assembly


Assemble Standard Lift Cylinders

4. Install split rings (5) on the cylinder rod.

1. Install seal (1) in the bearing.

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

5. Install cylinder rod (6) in the cylinder body.

NOTE : Install back-up ring (4) with the curved side


contacting the O-ring seal.

3. Install O-ring seal (3) and back up ring (4) into


the bearing.

6. Install bearing (7) on the cylinder rod and tighten


using wrench (C).

Vehicle Systems 28 Disassembly & Assembly


Secondary Lift Cylinders
Disassemble Secondary Lift Cylinders

Tools Needed A B
Hydraulic Cylinder Repair Stand 1
Wrench Assembly 1

Start By:

a. Remove standard lift cylinders.


7. Tighten setscrew (8) with wrench (B) to a torque
of 6 1 Nm (53 9 lbin).

End By:

a. Install standard lift cylinders.

1. Put standard lift cylinder (1) in position on tool (A).

2. Remove bearing (2) with tool (B).

Vehicle Systems 29 Disassembly & Assembly


3. Remove rod (4) from the cylinder body. 7. Remove slyd ring (11), wear ring (12) and O-ring
(13) from the bearing.

4. Remove stop ring (4) from the cylinder rod.


8. Remove wiper seal (14) and retaining ring (15)
5. Remove wear ring (5), U-packing (6) and backup from the bearing.
ring (7).
9. Remove U-packing (16).

6. Remove retaining ring (8), spacer (9) and check


valve (10).

Vehicle Systems 30 Disassembly & Assembly


Assemble Secondary Lift Cylinders

5. Install stop rings (10) on the cylinder rod.

6. Install wear ring (11), U-packing (12) and backup


1. Install U-packing (1) in the bearing.
ring (13).
2. Install wiper seal (2) and retaining ring (3). Install
the seal with the lip toward the outside.

7. Install cylinder rod (14) in the cylinder body.

3. Install O-ring (4), wear ring (5) and slyd ring (6) in
the bearing.

8. Install bearing (15) on the cylinder rod and


tighten using tool (B).

End By :
4. Install check valve (7), retaining ring (8) and
spacer (9).
a. Install secondary lift cylinders *

* Refer to the topic Assemble Mast in this module.

Vehicle Systems 31 Disassembly & Assembly


Primary Lift Cylinder
Remove & Install Primary Lift Cylinder

Start By:

a. Remove carriage.

WARNING
To prevent personal injury, move the control
levers backward and forward to release any 3. Pull the cylinder out far enough to disconnect
pressure in hydraulic system. Slowly loosen the elbow (2). Remove primary lift cylinder (3).
cap of the hydraulic tank to release any Weight is 27 kg (60 lb).
pressure in the tank. Be cautious of hot
hydraulic oil when any lines are disconnected in NOTE : The following steps are for the installation
the hydraulic system. of the primary lift cylinder.

4. Put primary lift cylinder (3) in position on the


mast.

5. Connect elbow (2).

6. Install bolts (1).

End By:

a. Install carriage.

1. Fasten nylon straps and hoist to the primary lift


cylinder.

2. Remove bolts (1).

Vehicle Systems 32 Disassembly & Assembly


Disassemble Primary Lift Cylinders

Tools Needed A B
Hydraulic Cylinder Repair Stand 1
Wrench Assembly 1

Start By:

a. Remove primary lift cylinder.

4. Remove piston seal (4).

1. Remove flow protector valve (1) from the cylinder


body.

5. Remove retaining ring (5), and check valve (6).

2. Remove bearing (2) with tool (A).

3. Remove rod (3) from the cylinder body. 6. Remove O-ring (7).

Vehicle Systems 33 Disassembly & Assembly


7. Remove wiper seal (8) and retaining ring (9) and 3. Install O-ring seal (4).
U-packing (10) from the rod cover.

Assemble Primary Lift Cylinders

Tools Needed A B
Hydraulic Cylinder Repair Stand 1
Wrench Assembly 1

4. Install check valve (5), retaining ring (6).

1. Install U-packing (1) in the rod cover.

2. Install wiper seal (2) and retaining ring (3). Install


the seal with the lip toward the outside.
5. Install wear ring (7), piston seal (8) on the
cylinder rod.

Vehicle Systems 34 Disassembly & Assembly


6. Install cylinder rod (9) in the cylinder body.

7. Install rod cover (10) on the cylinder body. Use WARNING


tool (A) to tighten bearing.
To prevent personal injury, move the control
levers backward and forward to release any
pressure in hydraulic system. Slowly loosen the
cap of the hydraulic tank to release any
pressure in the tank. Be cautious of hot
hydraulic oil when any lines are disconnected in
the hydraulic system.

1. Disconnect elbow (2). Remove retainer bolt (3)


and pin (1).

8. Install flow protector valve (11) on the cylinder


body.

End By:

a. Install primary lift cylinder.

Tilt Cylinders
Remove & Install Tilt Cylinders
2. Remove retainer bolt (6) from pin (5). Remove
NOTE : The procedure for removing and installing pin (5).
the tilt cylinders is the same for both
cylinders. 3. Remove tilt cylinder (4).

4. Install the tilt cylinder in the reverse order of


removal.
WARNING
If both tilt cylinders are removed at the same
time the mast can fall. To avoid possible
personal injury, make sure the mast is securely
held in place or supported by a hoist before
removing the tilt cylinders.

Vehicle Systems 35 Disassembly & Assembly


Disassemble & Assemble Tilt Cylinders 4. Remove piston and seal assembly (4) from the
cylinder rod.

Tools Needed A 5. Remove head assembly (5).


Spanner Wrench 1

Start By:

a. Remove tilt cylinder.

6. Remove spacer (6) from the cylinder rod.

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


Remove cylinder rod (7) and shims (8).

1. Use tool (A) to remove head (1) from the cylinder


body.

NOTICE

Use extra care not to damage the highly finished


surface of the cylinder rod and the bore of the
cylinder body during disassembly and assembly of
the tilt cylinder.

2. Remove rod assembly (2) from the cylinder body. 8. Remove seal assembly (10) and O-ring seal (9)
from the piston.

3. Remove nut (3) from the cylinder rod.

Vehicle Systems 36 Disassembly & Assembly


9. Remove seal (11) from the spacer. 12. Install seal (14) in the head. Position the lip of
the seal toward the inside of the head.

13. Install seal (15).

14. Install seal (16) in the cylinder head. Position


the lip of seal (16) toward the outside of the
cylinder head.

10. Remove O-ring seal (12) and back-up ring (13)


from the head.

NOTE : The curved side of back up ring (13) should


contact O-ring seal (12).

15. Install O-ring seal (12) and back-up ring (13).


Make sure the curved side of back-up ring (13)
is in contact with O-ring seal (12).

11. Remove seals (14), (15), and (16) from the


head.

NOTE : Use the following steps to assemble the tilt


cylinder.

Vehicle Systems 37 Disassembly & Assembly


16. Install seal (11) in the spacer. 20. Install head assembly (5) on the cylinder rod.

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

22. Install nut (3). Tighten nut (3) to a torque of 270


30 Nm (200 22 lbft).

17. Install spacer (6).

18. Install shims (8) and rod eye (2). Tighten the
bolt on rod eye (2) to a torque of 95 15 Nm
(70 11 lbft). 23. Install the rod assembly in the cylinder body.

19. Install seals (10) and O-ring seal (9) on the


piston.

Vehicle Systems 38 Disassembly & Assembly


Steering Cylinder
Disassemble Steering Cylinder

Start By :

a. Remove steering cylinder.

4. Remove piston seal (3) and wear ring (4).

1. Put location marks on end caps (1) as to their


position on the steering cylinder tube.

2. Remove end caps (1) from the steering cylinder.

3. Remove cylinder tube (2) from the rod assembly.


5. Disassemble each rod cover as follows.

a. Remove retaining ring (5) and dust wiper (6).


b. Remove U-packing (7).
c. Remove O-ring (8) and back up ring (9).
d. Remove DU-bush (10).

Vehicle Systems 39 Disassembly & Assembly


Assemble Steering Cylinder

3. Install cylinder tube (2) on the rod assembly.

1. Assemble each rod cover as follows;


4. Install rod covers (1) on cylinder tube (2).
a. Install DU-bush (10).
b. Install back up ring (9) and O-ring (8)
End By:
c. Install u-packing (7).
d. Install dust wiper (6) and retaining ring (5).
a. Install the steering cylinder.

2. Install piston seal (3) and wear ring (4).

Vehicle Systems 40 Disassembly & Assembly


Hydraulic Control Valve Disassemble Hydraulic Control Valve

Remove & Install Hydraulic Control Start By:

Valve a. Remove hydraulic control valve.

WARNING
Hydraulic oil under pressure can remain in the
hydraulic system after the engine and pump
have been stopped. Personal injury can result if
the pressure is not released before any work is
done to the hydraulic system. To prevent
possible personal injury, turn the engine off and
move the control levers to make sure the
hydraulic pressure is released before any fitting,
plug, hose or component is loosened, tightened,
removed or adjusted. Always move the lift truck
to a clean and level location away from the
travel of other machines. NOTE : For purposes of assembly, put identification
marks on all valve sections such as L, T, A1
or A2. Also, to avoid the entrance of dirts or
1. Drain the hydraulic tank. any contaminants from the outside,
plugging on all openings are required.

NOTE : For purposes of reassembly, put


identification marks on all lines, tubes and
hoses before any disconnections are made.

2. Disconnect seven hydraulic lines from control


valve.

3. Support control valve. Remove two bolts and


control valve.

4. Install the control valve in the reverse order of


removal. 1. If required, take apart solenoid valve (1) and
plunger (3) by eliminating the nut (2).
5. Fill the hydraulic tank to the correct level with
fluid. Refer to the Operation And Maintenance
Manual for further information.

Vehicle Systems 41 Disassembly & Assembly


4

2. Remove bolts (4) to separate the valve sections. 4. Remove O-ring seals (7) from the valve body. Be
careful not to miss the small spring and ball.

8 9 10
6
5

3. Remove screw (5) and return cap (6) from the


valve. Then, remove the spool downward - cap 5. Disassemble the relief valve composed with relief
side - from the valve body. plug (8), spring (9) and poppet (10).

Vehicle Systems 42 Disassembly & Assembly


11

6. If required, disassemble lift lock valve (11) from


the lift block.
4
5
Assemble Hydraulic Control Valve

1. Make sure all valve parts are clean and free of


dirt.

3. Install O-ring seals (4) to the valve body. Be sure


that a small ball (4) and spring (5) are installed.

2
3

2. Assemble the spool (1), return cap (2) and screw


(3) to the valve section. The spool should be free 6
from any dent and nick. In case of the leakage
from either cap side or spool side, change the
seals with the new ones.
4. If lift lock valve (6) had been removed, assemble
it on the right place. The taper section and
perimeter of body should be free from the dent,
nick and any contaminent.

Vehicle Systems 43 Disassembly & Assembly


11 10 9

7. Assemble the relief valve composed with poppet


(9), spring (10) and relief plug (11). The poppet
should be checked in advance to be free from
the dent or contaminant.

8. Until the repaired valve is mounted on the lift


truck, be sure to plug all openings. Some proper
protection againt the rust is required if any.
7

5. Install and tighten the tie rods (7). The proper


torque and sequence are required. After
completing the assembly, inspect if the spools
can be moved smoothly by hand. Otherwise, try
to adjust the valve blocks concentrically after
loosening the bolts.

6. Assemble the solenoid valve on the lift section. In


advance, inspect if the o-rings (8) were damaged.

Vehicle Systems 44 Disassembly & Assembly


Steering Unit
Disassemble Steering Unit

Cleanliness is extremely important when repairing a


steering unit. Work in a clean area. Before
disconnecting lines, clean port area of unit
thoroughly.
Use a wire brush to remove foreign material and
debris from around exterior joints of the unit.

Althouh not all drawings show the unit in a vise, we


recommend that you keep the unit in the vise during
disassembly. Follow the clamping procedures
explained throughout the manual.

2. Remove 5/16 inch cap screws and washers if


applicable (7 each).

3. Remove end cap.

4. Remove seal from end cap.

1. Clamp unit in vise, meter end up. Clamp lightly


on edges of mounting area. Use protective
material on vise jaws. Housing distortion could
result if jaws are overtightened.

5. Remove meter. Be careful not to drop star.

6. Remove seal from meter.

7. Remove drive spacer(s).

Vehicle Systems 45 Disassembly & Assembly


8. Remove drive. 11. Remove housing from vise. Place housing on a
clean soft cloth to protect surface finish. Use a
9. Remove spacer plate. thin bladed screwdriver to pry retaining ring
from housing.
10. Remove seal from housing.

12. Rotate spool and sleeve until pin is horizontal.


Push spool and sleeve assembly forward with
your thumbs just far enough to free gland
bushing from housing. Remove bushing.

Vehicle Systems 46 Disassembly & Assembly


13. Remove quad ring seal from seal gland bushing. 16. Remove spool and sleeve assembly from 14
hole end of housing.
14. Use a thin bladed screwdriver to pry dust seal
from seal gland bushing. Do not damage ATTENTION : Do not bind spool and sleeve in
bushing. ousting. Rotate spool and sleeve
assembly slowly when removing from
housing.

17. Push pin from spool and sleeve assembly.

15. Remove 2 bearing races and the needle thrust


bearing from spool and sleeve assembly.

Vehicle Systems 47 Disassembly & Assembly


18. Push spool partially from control end of sleeve, 21. Remove set screw from housing.
then remove 4 centering springs from spool
carefully by hand. 22. Screw a #10-24 machine screw into end of
check ball seat. Then by pulling on screw, with
19. Push spool back through and out of sleeve. a pliers, lift seat out of housing.
Rotate spool slowly when removing from sleeve.
23. Remove 2 seals from check valve seat.
20. Remove seal from housing.
24. Tip housing to remove check ball and check ball
retainer.

Vehicle Systems 48 Disassembly & Assembly


Assemble Steering Unit

Check all mating surfaces. Replace any parts that


have scratches or burrs that could cause leakage.
Clean all metal parts in clean solvent. Blow dry with
air. Do not wipe dry with cloth or paper towel
because lint or other matter can get into the
hydraulic system and cause damage. Do not use a
coarse grit or try to file or grind these parts.

NOTE : Lubricate all seals with clean petroleum


jelly such as Vaseline.

Do not use excessive libricant on seals for meter


section.
Refer to parts listings covering your steering unit
when ordering replacement parts. A good service
policy is to replace all old seals with new seals.

1. Use a needle nose pliers to lower check ball


retainer into check valve hole of housing. Make
sure retainer is straight (not tilted on edge) in
housing.

2. Install check ball in housing

3. Lubricate 9.3 mm [.36 in.] ID seal and 7.7 mm


[.30 in.] ID seal. Install seals on check ball seat
as shown.

4. Lubricate check ball seat and seals thoroughly


before installing seat in housing. When installing
seat do not twist or damage seals. Install check
ball seat in housing, insert open end of seat first.
Push check ball seat to shoulder of hole.

5. Install set screw. Use a 1/4 inch hex key to


torque set screw to 11 Nm [100 lbin]. To
prevent interference make sure top of set screw
in slightly below housing mounting surface.

Vehicle Systems 49 Disassembly & Assembly


6. Assemble spool and sleeve carefully so that the 7. Bring spring slots of both parts in line and stand
spring slots line up at the same end. Rotate parts on end of bench. Insert spring installation
spool while sliding parts together. Some spool tool through spring slots of both parts. Tool is.
and sleeve sets have identification marks, align Position 2 pairs of centering springs on bench so
these marks. Test for free rotation. Spool should that extended edge is down and arched center
rotate smoothly in sleeve with finger tip force section is together. In this position, insert one
applied at splined end. end of entire spring set into spring installation
tool, with spring notches facing sleeve.

8. Compress extended end of centering spring set


and push into spool sleeve assembly
withdrawing installation tool at the same time.

9. Center the spring set in the parts so that they


push down evenly and flush with the upper
surface of the spool and sleeve.

10. Install pin through spool and sleeve assembly


until pin becomecs flush at both sides of sleeve.

Vehicle Systems 50 Disassembly & Assembly


11. Position the spool and sleeve assembly so that
the splined end of the spool enters the 14 hole
end of housing first.
12. Place housing on clean lint free cloth. Install
ATTENTION : Be extremely careful that the parts 47,5 mm [1.86 in.] ID seal in housing.
do not tilt out of position while inserting. Push parts
gently into place with slight rotating action, keep pin 13. Install 2 bearing reces and the needle thrust
nearly horizontal. Bring the spool assembly entirely bearing in the order shown.
within the housing bore until the parts are flush at
the meter end or 14 hole end of housing. 14. Install 25 mm [1 in.] ID dust seal in seal gland
Do not pull the spool assembly beyond this point to bushing, flat or smooth side must face down
prevent the cross pin from dropping into the towards bushing.
discharge groove of the housing. With the spool
assembly in this flush position, check for free 15. Install the quad ring seal in seal gland bushing.
rotation within the housing by turning with light Smooth seal in place with your finger. Do not
finger tip force at the splined end. use any seal that falls freely into pocket of
bushing.

Vehicle Systems 51 Disassembly & Assembly


16. Install seal gland bushing over the spool end 18. Clamp housing in vise. Clamp lightly on edges
with a twisting motion. Tap the bushing in place of mounting area. Do not over tighten jaws.
with a rubber hammer. Make sure the bushing
is flush against the bearing race. NOTE : Check to insure that the spool and sleeve
are flush or slightly below the 14 hole
surface of the housing.

ATTENTION : Clean the upper surface of the


housing by wiping with the palm of clean hand.
Clean each of the flat surfaces of the meter section
parts in a similar way when ready for reassembly.
Do not use cloth of paper to clean surfaces.

17. Install retaining ring in housing. After installing


ring, tap on ring end or pry with screwdriver
around entire circumference of ring to properly
seat ring in groove.
19. Install 73.5 mm [2.89 in.] ID seal in housing.

20. Install spacer plate. Align bolt holes in spacer


plate with tapped holes in housing.

Vehicle Systems 52 Disassembly & Assembly


21. Rotate spool and sleeve assembly until pin is
parrallel with port face. Install drive, make sure
you engage drive with pin, To assure proper
alignment, mark drive as shown. Note
relationship between slotted end fo drive to
splined end of drive when marking.
23. With seal side of meter toward spacer plate,
align star valleys on drive. Note the parallel
relationship of reference lines A, B, C, and D.
Align bolt holes without disengaging meter from
drive.

22. Install 73.5 mm [2.89 in.] ID seal in spacer plate


or gerotor (meter).

Vehicle Systems 53 Disassembly & Assembly


24. Install drive spacer (s) when used, in meter.

25. Install 73.5 mm [2.89 in.] ID seal in gerotor


(meter) or end cap, see notes.

26. Install end cap on gerotor, align holes.

Actual Spacer
Displacement 27. Install 7 dry cap screws in end cap. Pretighten
cm/r(in/r) Length mm[in.] screws to 11 to 17 Nm [100 to 150 lbin] then
45[2.8] None torque screws to specifications.
60[3.6] None
75[4.5] None
95[5.9] 3.56[.140]
120[7.3] 6.10[.240]
145[8.9] 10.29[.405]
160[9.7] 12.19[.480]
185[11.3] 15.62[.615]
230[14.1] 21.97[.865]
295[17.9] 28.45[1.120]
370[22.6] 41.15[1.620]
460[28.2] 53.67[2.113]
590[35.9] 66.37[2.613]
740[45.1] 91.77[3.613]

Vehicle Systems 54 Disassembly & 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 Nm (60 5 lbft).

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

EHCD127C

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

Vehicle Systems 55 Disassembly & Assembly


8

7
15

18

14 17

EHCD128C

4. Remove two bolts (7), washers and bracket with 7. Remove screw (14) and handle (15).
a directional switch (8) from the support Loosen nut (17) and remove gas cylinder (18).
assembly.
8. Install the steering column in the reverse order of
5. Disconnect four hoses (9) from the steering gear. 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 56 Disassembly & Assembly


Steer Axle
Remove Steer Axle

WARNING
Be sure the pressure in the hydraulic system is
released before any lines or hoses are
disconnected.

6. Remove bolts (2) and mounting caps (3) from the


steer axle.

1. Put the lift truck in position on wood block or by


use hoist.

2. Put identification marks on hoses (1); then 7. Remove steer axle (4). Weight of the steer axle
disconnect them. is 200 kg (440 lb).

Install Steer Axle

3. Put a floor jack in position under the steer axle.

4. Loosen axle mounting bolts (2) until


approximately two bolt threads are left in the 1. Put steer axle (4) in position with a floor jack.
mounting bosses.

5. Lower the steer axle onto the bolt heads with the
floor jack. disconnect the hydraulic lines from the
steering cylinder.

Vehicle Systems 57 Disassembly & Assembly


Master Cylinder
Remove And Install Master Cylinder

4
1
5

NOTE : Install bolts (2) with approximately two bolt 2 3 2


threads into the mounting bosses.

2. Install bolts (2) and caps (3) in the mounting


bosses.
1. Remove the floor plates from the lift truck. Drain
3. Connect the hydraulic lines to the steering the brake fluid from the brake reservoir.
cylinder. Disconnect hose (1) and line (4) from master
cylinder (5).
4. Raise the steer axle with the floor jack, then
tighten bolts (2). 2. Remove the cotter pin, washer and pin (3) from
the clevis and brake pedal.

3. Remove two bolts (2), the washers and master


cylinder (5) from the lift truck.

NOTE: The following steps are for installation of the


master cylinder.

4. Put the master cylinder in position, and install the


two washers and bolts (2).

5. Install pin (3) through the master cylinder clevis


and brake pedal. Install the washer and cotter pin.

5. Connect hoses (1) to the steering lines. 6. Connect brake line (4) and hose (1) to the master
cylinder. Fill the brake reservoir with brake fluid.
See the Operation And Maintenance Manual.

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


the pedal free travel. See Brake System Air
Removal And Pedal Adjustment in Testing And
Adjusting.

Vehicle Systems 58 Disassembly & Assembly


Accelerator Control Switch
Remove And Install Accelerator Control
Switch

4. Disconnect accelerator connector (4) from main


1 harness.

1. Remove the floormat (1).

5. Remove three screws (5).

6. Install the accelerator assembly in the reverse


order of removal.

2. Remove rear floor plate (2).

3. Remove front floor plate (3).

Vehicle Systems 59 Disassembly & Assembly


Drive Motor and Drive Axle
Assembly
Remove And Install Drive Motor and
Drive Axle Assembly

Start By;

a. Remove mast.

b. Remove floor mat and floor plate.


4. Remove conveyor assembly (7) from the drive
1. Disconnect the battery. Disconnect three cables motor.
and thermal switch connector from drive motor.
5. Remove eight bolts (5, 6) from lift truck.
Remove drive motor and drive axle assembly by
drawing out from frame by handcart.

6. Remove five bolts (3, 4) from drive axle.


Remove drive motor from drive axle.

NOTE: The following steps are for installation of the


drive motor and drive axle.
1
7. Install drive motor to drive axle.
Oil-sealing of the inlet shaft is ensured by a
single-lip seal and an O-ring, housed in the motor
flange. The motor flange and the drive axle are
2. Remove parking cable (1) from brake lever which coupled by means of five M10 screws, three are
is located at drive axle. 60 mm-long (4) and two are 85 mm long (3).

WARNING
In order to connect the gearbox to the motor,
move it only along its axis. Absolutely avoid to
connect it sideways. You are recommended to
secure the gearbox and lift it until both the
motor and the input axes match. To facilitate
the assembly drive in three studs into the
2 connecting screw holes and centre the gearbox
on them. Then remove the studs and replace
them with the M10 screws.
3. Support hydraulic hoses away from the transaxle
so they do not interfere during removal. Support
lift truck with hoist. Remove tire assembly.
Disconnect brake line (2).

Vehicle Systems 60 Disassembly & Assembly


8. Install and tighten five bolts (3, 4) to 55 Nm. Control Panel
9. Support lift truck with hoist. Put the drive motor
and drive axle in position with handcart. Install Remove And install Control Panel
the bolts (5, 6) and tighten them to 240 40
Nm (444 30 lbft).
WARNING
10. Install conveyor assembly to drive motor.
Battery voltage and high ampere are present.
11. Connect brake line (1) and install tire assembly. Injury to personnel is possible. The power unit
must be discharged before any contact with the
12. Connect parking cable to brake lever at which is control panel is made. Disconnect the battery
located at drive axle. and discharge the power unit.
13. Connect three cables and thermal switch
connector to drive motor and connect battery. 1. Remove the rear door.
Fill the brake reservoir to correct level. See the
Operation And Maintenance Manual. Bleed the
brakes. See brake System Air Removal in
Testing And Adjusting.

End By;

a. Install mast.

b. Install floor mat and floor plate.

2. Disconnect the main connector and the


communication cables, harness.

3. Remove the motors cables and battery cables

4. Loosen bolts of the logic and remove the logic.

5. Loosen seven bolts of the control panel.

6. Remove control panel assembly from the lift


truck.

7. Install the control panel in the reverse order of


removal.

Vehicle Systems 61 Disassembly & Assembly


Counterweight
Remove And Install Counterweight

WARNING
Battery voltage and high amperage are present.
Injury to personnel is possible. Disconnect
battery from truck and also discharge high
voltages between B+ and B- with 150ohm,
24watt resistor before attempting to service this
truck.

1. Remove the protector cover from the


counterweight. Disconnect the battery and
discharge high voltages between B+ and B-.

2. Disconnect positive battery cable and negative


battery cable from the control panel.

3. Install tooling in the two holes at the top of the


counterweight. Attach a hoist. The approximate
weight of the counterweight is as follows:
B22X-5 ................................................... 770 kg
B25X-5, B30X-5................................... 1,050 kg
B35X-5 ................................................ 1,480 kg

4. Remove three bolts and the counterweight.

NOTE: The following steps are for installation of the


counterweight.

5. Put the counterweight in position on the lift truck


and install three bolts.

7. Install the protector cover on the counterweight.

Vehicle Systems 62 Disassembly & Assembly


SB4204E00
Oct. 2006

Hydraulic Schematic
B20S-5, B25S-5, B30S-5, B32S-5
BC20S-5, BC25S-5, BC30S-5, BC32S-5
BC25SE-5
B22X-5, B25X-5, B30X-5, B35X-5
Relief pressure of Control valve
2
Bar psi Kpa Kgf/cm

2.0 Ton 166 (+5, 0) 2,400 (+75, 0) 16,600 (+500, 0) 169 (+5,0)

2.2 Ton 180 (+5, 0) 2,640 (+75, 0) 18,260 (+500, 0) 186 (+5,0)

2.5 Ton 193 (+5, 0) 2,800 (+75, 0) 19,300 (+500, 0) 196 (+5,0)
Main
3.0 Ton 207 (+5, 0) 3,000 (+75, 0) 20,700 (+500, 0) 211 (+5,0)

3.2 Ton 235 (+5, 0) 3,420 (+75, 0) 23,500 (+500, 0) 240 (+5,0)

3.5 Ton 235 (+5, 0) 3,420 (+75, 0) 23,500 (+500, 0) 240 (+5,0)

Aux. 155 (+5, 0) 2,250 (50) 15,500 (350) 158 (+/-4)


SB4212E01
May. 2008

Electric Schematic
B22X-5, B25X-5, B30X-5, B35X-5 (AC 80V)
WIRING SCHEMATIC - ELECTRIC
MODEL : B22X-5, B25X-5, B30X-5, B35X-5 (AC 80V)

A524000-04
ELECTRIC SCHEMATIC
OPTION LIGHT
SB2347E01

Operation &
Maintenance Manual
LIFT TRUCKS
B22X-5, B25X-5, B30X-5, B35X-5

Original Instruction

0911
Table of Contents

Table of Contents
Information Section Maintenance Section
Foreword ............................................................... 2 Inspection, Maintenance and Repair of Lift Truck
Forks ................................................................... 70
Tire Inflation Information...................................... 74
Safety Section Torque Specifications.......................................... 75
Lubricant Specifications ...................................... 77
Important Safety Information.................................. 4 Battery Discharge Indicator ................................. 79
Safety .................................................................... 5 Battery................................................................. 80
Warning Signs and Labels ..................................... 5 Cold Storage Applications ................................... 82
General Hazard Information................................. 10 Lubricant Viscosities and Refill Capacities .......... 84
Lift Chains............................................................ 11 Maintenance Intervals ......................................... 85
Operation Information .......................................... 11 When Required ................................................... 87
Maintenance Information ..................................... 13 Every 10 Service Hours or Daily.......................... 95
Operator Restraint System (If Equipped) ............. 16 First 50 - 100 Service Hours or 3 Months .......... 101
Avoiding Lift Truck Tipover .................................. 21 Every 250 Service Hours or Monthly ................. 102
Safety Rules ........................................................ 23 Every 500 Service Hours or 3 Months ............... 106
How to Survive in a Tipover (If Operator Restraint Every 1000 Service Hours or 6 Months ............. 111
System Equipped) ............................................... 29 Every 2000 Service Hours or Yearly.................. 116

General Section Environment Section


Declaration of Conformity .................................... 30 Environment Protection ..................................... 122
Specifications....................................................... 31
Noise and Vibration ............................................. 33
Capacity Chart - With Side Shifter ....................... 34 Index Section
Capacity Chart - With Side Shifter (Integrated) .... 35
Capacity Chart - With Side Shifter (Hook on) ....... 36 Index ................................................................. 123
Serial Number...................................................... 37
Operators Warning and Identification Plate......... 38

Operation Section
Operators Station and Monitoring Systems......... 40
Lift Truck Controls................................................ 47
Before Operating the Lift Truck ............................ 51
Lift Truck Operation ............................................. 54
Mono-Ped Control System (Option) ..................... 57
Finger Tip (Option)............................................... 58
Operating Techniques.......................................... 61
Parking the Lift Truck ........................................... 64
Lift Fork Adjustment ............................................. 66
Storage Information ............................................. 67
Transportation Hints ............................................ 68
Towing Information .............................................. 69

1
Information Section

Foreword Safety
The Safety Section lists basic safety precautions. In
Literature Information addition, this section identifies the text and
locations of warning signs and labels used on the
This manual should be stored in the operator's lift truck. Read and understand the basic
compartment in the literature holder or seat back precautions listed in the Safety Section before
literature storage area. operating or performing 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
Some photographs or illustrations in this publication maintenance information for the DOOSAN operator
show details or attachments that can be different restraint system. Read, study and keep it handy.
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 Your DOOSAN truck comes equipped with an
lift truck which are not included in this publication. operator restraint system. Should it become
Read, study and keep this manual with the lift truck. necessary to replace the seat for any reason, it
should only be replaced with another DOOSAN
Whenever a question arises regarding your lift truck, operator restraint system.
or this publication, please consult your DOOSAN
dealer for the latest available information.
Photographs or illustrations guide the operator
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 Note that DOOSAN INDUSTRIAL VEHICLE BG is
operator and a refresher for the experienced one. ISO 14001 certified which is harmonized with ISO
This section includes a discussion of gauges, 9001. Periodic ENVIRONMENTAL AUDITS &
switches, lift truck controls, attachment controls, ENVIRONMENTAL PERFORMANCE
transportation and towing information. EVALUATIONS have been made by internal and
Photographs and illustrations guide the operator external inspection entities. LIFECYCLE ANALYSIS
through correct procedures of checking, starting, has also been made through out the total product
operating and stopping the lift truck. life.
ENVIRONMENT MANAGEMENT SYSTEM
Operating techniques outlined in this publication are includes DESIGN FOR ENVIRONMENT from the
basic. Skill and techniques develop as the operator initial stage of the design. ENVIRONMENT
gains knowledge of the lift truck and its capabilities. MANAGEMENT SYSTEM considers environmental
laws & regulations, reduction or elimination of
resource consumption as well as environmental
Maintenance emission or pollution from industrial activities,
energy saving, environment friendly product
design(lower noise, vibration, emission, smoke,
The Maintenance Section is a guide to equipment
heavy metal free, ozone depleting substance free,
care. The illustrated, step-by-step instructions are
etc.), recycling, material cost reduction, and even
grouped by servicing intervals. Items without
environmentally oriented education for the
specific intervals are listed under "When Required"
employee.
topics. Items in the "Maintenance Intervals" chart
are referenced to detailed instructions that follow.

Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.

Under extremely severe, dusty or wet operating


conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" chart might
be necessary.

Perform service on items at multiples of the original


requirement. For example, at "Every 500 Service
Hours or 3 Months", also service those items listed
under "Every 250 Service Hours or Monthly" and
"Every 10 Service Hours or Daily".

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 There are several specific safety signs on your lift
representative of some, but not all rules and truck. Their exact location and description of the
regulations noted under the Occupational Safety hazard are reviewed in this section. Please take the
and Health Act (OSHA) and are paraphrased time to familiarize yourself with these safety signs.
without representation that the OSHA rules and
regulations have been reproduced verbatim. Make sure that you can read all warning and
instruction labels. Clean or replace these labels if
Please refer to 1910. 178 in Federal Register Vol. you cannot read the words or see the pictures.
37, No. 202, the National Fire Protection Association When cleaning the labels use a cloth, water and
No. 505 (NFPA), American National Standard, ANSI soap. Do not use solvent, gasoline, etc.
B56. 1 Safety Standard for Low lift and High Lift
Trucks and subsequent revisions for a complete list You must replace a label if it is damaged, missing or
of OSHA rules and regulations as to the safe cannot be read. If a label is on a part that is replaced,
operation of powered industrial lift trucks. Since make sure a new label is installed on the replaced
regulations vary from country to country outside in part. See your dealer for new labels.
U.S.A., operate this lift truck in accordance with local
regulations.
Training Required To Operate or Service
DOOSAN lift trucks are manufactured according to Warning
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.

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,


Located on the right side of the steering wheel.
defective or in any way unsafe. Report all defects
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and WARNING
authorized to do so.
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


directional control or shift lever in neutral. Set
parking/secondary brake. Turn "ON - OFF"
WARNING switch off. Chock wheels if machine is on incline.
Disconnect battery when storing electric
Only trained and authorized personnel may machines.
operate this machine. For safe operation, read
and follow the operation and maintenance 18. Observe safety rules when handling fuel for
Manual furnished with this lift truck and observe engine powered machine and when changing
the following warnings : batteries for electric machines.
19. The emergency switch uses in emergency really.
1. Before starting machine. Check all controls and When you use often emergency switch by key
warning devices for proper operation. switch, you can cause fatal mistake to your
machine.
2. Refer to machine identification plate for
allowable machine capacity. Do not overload. 20. If user operates continuously pushing work or
Operate machines equipped with attachments both brake pedal and accelerator pedal were
as partially loaded machines when not handling depressed at the same time, main electric parts
a load. were able to damage.

3. Put directional control or shift lever in neutral


before "ON-OFF" switch is turned on.
4. Start, turn and brake smoothly. Slow down for
turns, slippery or uneven surfaces. Extremely
poor surfaces should be repaired. Avoid running
over loose objects or holes in the roadway
surfaces. Use extreme caution when turning on
inclines.

5. Travel with load as low as possible and tilted


back. If load interferes with visibility, travel with
load trailing.
6. On grade operations travel with load up grade.

7. Watch out for pedestrians and obstructions.


Check overhead clearances.
8. Do not permit riders on forks or machine at any
time.

9. Do not allow anyone to stand or pass under the


elevated portion of any machine.
10. Be sure operating surface can safely support
machine.

11. Operate machine and attachments only from


operator's position.
12. Do not handle unstable or loosely stacked loads.
13. Use minimum tilt when picking up or depositing
a load.
14. Use extreme care when handling long, high, or
wide loads.
15. Forks should be completely under load and
spread apart as far as load permits.
16. Machine should be 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.

Overhead Guard Must Be In Place


Located on the mast. Warning

WARNING
No Standing On Forks Warning, No
Standing Under Forks Warning Operation without this device in place may be
hazardous. This guard conforms to A.N.S.I.B56.1
WARNING and F.E.M. Section IV. This design has been
tested with an impact of appropriate value.
Do not stand or ride on the forks. Do not stand
or ride on a load or pallet on the forks. Do not
stand or walk under the forks.

IB9O004P

Located on the Overhead Guard.

Located on the lift cylinder.

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


Warning
AC

WARNING

Disconnect battery from truck and also


discharge high voltages from capacitor banks
with a 150 ohm, 25 watt Resistor before
attempting to service this truck.(B+, B-)

Seat Switch Warning

WARNING

Install any seat to this seat frame. Switch must


shut off all power when operator is not seated.

9
Safety Section

General Hazard Information Do not raise loads any higher than necessary and
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
Attach a "Do Not Operate" or similar warning tag to and intended actions and have moved clear of the
start switch or controls before servicing or repairing lift truck and/or load.
the lift truck.
Do not drive lift truck up to anyone standing in front
Do not start or service the lift truck when a "DO NOT of an object.
OPERATE" or similar warning tag is attached to the
start switch or controls. Obey all traffic rules and warning signs.
Wear a hard hat, protective glasses and other Keep hands, feet and head inside the operator
protective equipment as required by job conditions. station. Do not hold onto the overhead guard while
operating the lift truck. Do not climb on any part of
Know the width of your attachments so proper the mast or overhead guard or permit others to do
clearance can be maintained when operating near so.
fences, boundary obstacles, etc.
Do not allow unauthorized personnel to ride on the
Do not wear loose clothing or jewelry that can catch forks or any other part of the lift truck, at any time.
on controls or other parts of the lift truck.
When working in a building or dock, observe floor
Keep the lift truck, especially the deck and steps, load limits and overhead clearances.
free of foreign material such as debris, oil tools and
other items which are not part of the lift truck. Inhaling Freon gas through a lit cigarette or other
smoking method or inhaling fumes released from a
Secure all loose items such as lunch boxes, tools flame contacting Freon can cause bodily harm or
and other items which are not part of the lift truck. death. Do not smoke when servicing air conditioners
or wherever Freon gas may be present.
Know the appropriate work-site hand signals and
who gives them. Accept signals from one person Never put maintenance fluids into glass containers.
only. Use all cleaning solutions with care.
Always use the overhead guard. The overhead Do not use steam, solvent, or high pressure to clean
guard is intended to protect the lift truck operator electrical components.
from overhead obstructions and from falling objects.
Report all needed repairs.
A truck that is used for handing small objects or
uneven loads must be fitted with a load backrest.

If the lift truck must be operated without the


overhead guard in place due to low overhead
clearance, use extreme care. Make sure there is no
possibility of falling objects from any adjacent
storage or work area. Make sure the load is stable
and fully supported by the carriage and the load
backrest extension (if equipped).

10
Safety Section

Lift Chains Operation Information

Mounting and Dismounting


Mount and dismount the lift truck carefully.

Clean your shoes and wipe your hands before


mounting.

Use both hands face the lift truck when mounting


and dismounting.

Use the handgrips for mounting and dismounting.

Inspect the part of the chain that is normally Do not try to climb on or off the lift truck when
operated over the crosshead roller. When the chain carrying tools or supplies.
bends over the roller, the movement of the parts
against each other causes wear. Do not use any controls as handholds when entering
or leaving the operator's station.
Inspect to be sure that chain link pins do not extend
outside of the bore hole. Never get on or off a moving lift truck. Never jump
off the lift truck.
If any single link pin is extended beyond its
connecting corresponding link, it should be Keep hands and steering wheel free of slippery
suspected of being broken inside of its bore hole. material.

Inspect the chain anchor and the anchor links for


wear. Before Starting the Lift Truck
Do not change any factory set adjustment values Perform a walk-around inspection daily and at the
(including engine rpm setting) unless you have both start of each shift. Refer to the topic "Walk-around
authorization and training. Especially Safety Inspection" in "Every 10 Service Hours or Daily"
equipment and switches may not be removed or section of this manual.
adjusted incorrectly. Repairs, adjustments and
maintenances that are not correct can make a Adjust the seat so that full brake pedal travel can be
dangerous operating condition. obtained with the operator's back against the seat
back.
For any checkup, repair, adjustments, maintenance
and all other work concerning your forklift truck, Make sure the lift truck is equipped with a lighting
please contact your DOOSAN dealer. We would like system as required by conditions.
to draw your attention to the fact that any secondary
damages due to improper handling, insufficient Make sure all hydraulic controls are in the HOLD
maintenance, wrong repairs or the use of other than position.
original DOOSAN spare parts waive any liability by
DOOSAN. 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.

11
Safety Section

Make sure the lift truck horn, lights, backup alarm (if Operating the Lift Truck
equipped) and all other devices are working properly.
Always keep the lift truck under control.
Check for proper operation of mast and attachments.
Pay particular attention to unusual noises or erratic Obey all traffic rules and warning signs.
movement which might indicate a problem. Never leave the lift truck with the engine operating,
or with the parking brake disengaged.
Make sure service and parking brakes, steering, and
directional controls are operational. Operate the engine only in a well ventilated area.
Lower the mast, with or without load, before turning
Make sure all personnel are clear of lift truck and or traveling. Tip over could result. Watch out for
travel path. overhead obstructions.

Refer to the topic "Lift Truck Operation" in the Always observe floor load limits and overhead
"Operation Section" of this manual for specific clearance.
starting instructions.
Start, turn, and brake smoothly. Slow down for turns,
grades, slippery or uneven surfaces.
Starting the Lift Truck
Use special care when operating on grades. Do not
angle across or turn on grades. Do not use a lift
truck on slippery grades. Travel with forks
downgrade when unloaded. Travel with load
upgrade.

Do not overload, or handle offset, unstable, or


loosely stacked loads. Refer to load capacity plate
on the lift truck. Use extreme caution when handling
suspended, long, high or wide load.

Tilt an elevated load forward only when directly over


unloading area and with load as low as possible.

Do not start the engine or move any of the controls if


there is a "DO NOT OPERATE" or similar warning Do not stunt ride or indulge in horseplay.
tag attached to the start switch or controls.
Always look and keep a clear view of the path of
travel.
Before Operating the Lift Truck Travel in reverse if load or attachment obstructs
Test brakes, steering controls, horn and other visibility. Use extreme caution if visibility is
devices for proper operation. Report any faulty obstructed.
performance. Do not operate lift truck until repaired.
Stay in designated travel path, clear of dock edges,
Learn how your lift truck operates. Know its safety ditches, other drop-
devices. Know how the attachments work. Before offs and surfaces which cannot safely support the lift
moving the lift truck, look around. Start, turn and truck.
brake smoothly.
Slow down and use extra care through doorways,
An operator must constantly observe his lift truck for intersections and other location where visibility is
proper operation. reduced.

Slow down for cross aisles, turns, ramps, dips,


uneven or slippery surfaces and in congested areas
and avoid pedestrians, other vehicles, obstruction,
pot holes and other hazards or objects in the path of
travel.

12
Safety Section

Always use overhead guards except where Maintenance Information


operation conditions do not permit. Do not operate
lift truck in high stacking areas without overhead
Perform all maintenance unless otherwise specified
guards.
as follows :
When stacking, watch for falling objects. Use load
z Park the lift truck in authorized areas only.
backrest extension and overhead guard.
z Park the lift truck level, with the forks lowered
Refer to the topic "Operation Techniques" in the
and the mast tilted forward until the fork tips
"Operation Section" of this manual.
touch the floor.

z Place the control lever in neutral.


Loading or Unloading Trucks/Trailers
Do not operate lift trucks on trucks or trailers which z Engage the parking brake.
are not designed or intended for that purpose. Be
certain truck or trailer brakes are applied and wheel z Remove the start switch key and turn the
chocks in place (or be certain unit is locked to the disconnect switch OFF (if equipped).
loading dock) before entering onto trucks or trailers.
z Block the drive wheels when parking on an
If trailer is not coupled to tractor, make sure the incline.
trailer landing gear is properly secured in place. On
some trailers, extra supports may be needed to
prevent upending or corner dipping. Pressure Air
Be certain dock plates are in good condition and Pressure air can cause personal injury. When using
properly placed and secured. Do not exceed the pressure air for cleaning, wear a protective face
rated capacity of dock boards or bridge plates. shield, protective clothing and protective shoes.

The maximum air pressure must be below 205 kPa


Lift Truck Parking (30 psi) for cleaning purposes.

When leaving the operator station, park the lift truck


in authorized areas only. Do not block traffic. Fluid Penetration
z Park the lift truck level, with the forks lowered
Always use a board or cardboard when checking for
and the mast tilted forward until the fork tips
a leak. Escaping fluid under pressure, even a
touch the floor.
pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid is
z Move the direction control lever to NEUTRAL. injected into your skin, it must be treated by a doctor
familiar with this type of injury immediately.
z Engage the parking brake.

z Turn the key switch off and remove the key. Crushing or Cutting Prevention
z Turn the disconnect switch to OFF (if equipped). Support equipment and attachments properly when
working beneath them. Do not depend on hydraulic
z Block the drive wheels when parking on an cylinders to hold it up. Any attachment can fall if a
incline. 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 Burn Prevention
will throw or cut any object or tool that falls or is
pushed into them. Oils

Do not use a kinked or frayed wire rope cable. Wear Hot oil and components can cause personal injury.
gloves when handling the wire rope cable. Do not allow hot oil or components to contact the
skin.
Retainer pins, when struck with force, can fly out At operation temperature, the hydraulic tank is hot
and injure nearby persons. Make sure the area is and can be under pressure.
clear of people when driving retainer pins.
Remove the hydraulic tank filter cap only after the
Wear protective glasses when striking a retainer pin engine has been stopped and the filter cap is cool
to avoid injury to your eyes. enough to remove with your bare hand.

Chips or other debris can fly off objects when struck. Remove the hydraulic tank filter cap slowly to relieve
Make sure no one can be injured by flying debris pressure.
before striking any object.
Relieve all pressure in air, oil fuel or cooling systems
before any lines, fittings or related items are
Falling Objects Protective Structure (FOPS) disconnected or removed.

This is an attached guard located above the


operator's compartment and secured to the lift truck. Batteries

To avoid possible weakening of the Falling Objects Only trained and designated personnel should
Protective Structure (FOPS), consult a DOOSAN inspect, recharge or exchange batteries.
dealer before altering, by adding weight to, welding
on, or cutting or drilling holes into the structure. Always wear protective glasses when working with
batteries.
The overhead guard is not intended to protect
against every possible impact. The overhead guard Service, exchange and handle batteries only in
may not protect against some objects penetrating authorized areas when proper safety and ventilation
into the operator's station from the sides or ends of facilities are provided.
the lift truck.
Do not smoke, or expose battery to sparks or flame
The lift truck is equipped with an overhead guard when checking, charging or servicing battery. Keep
and FOPS as standard. If there is a possibility of chains and metallic tools away from top of battery.
overhead objects falling through the guard, the
guard must be equipped with smaller holes or a Batteries give off flammable fumes which can
Plexiglas cover. explode.

Any altering done that is not specifically authorized Highly explosive gases are especially hazardous
by DOOSAN invalidates DOOSANs FOPS toward the end of the charging period as the battery
certification. The protection offered by this FOPS will approaches a full charge condition.
be impaired if it has been subjected to structural
damage. Structural damage can be caused by an Electrolyte is an acid and can cause personal injury
overturn accident, by falling objects, etc. if it contacts skin or eyes.

Do not mount any item such as fire extinguishers, Service batteries in accordance with battery
first aid kits and lights by welding brackets to or manufacture instructions.
drilling holes in any FOPS structure. See your
DOOSAN dealer for mounting guidelines. Refer to the topic "Batteries" in the "Maintenance
Section" of this manual.

14
Safety Section

Fire or Explosion Prevention z Outer covering chafed or cut and wire


reinforcing exposed.
All fuels, most lubricants and some coolant mixtures
are flammable. z Outer covering ballooning locally.
Do not smoke in areas where batteries are charged,
or where flammable materials are stored. z Evidence of kinking or crushing of the flexible
part of hose.
Clean and tighten all electrical connections. Check
daily for loose or frayed electrical wires. Have all z Armoring embedded in the outer cover.
loose or frayed electrical wires tightened, repaired or
replaced before operating the lift truck.
z End fittings displaced.
Keep all fuels and lubricants stored in properly
marked containers and away from all unauthorized
persons. Make sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbing
Store all oily rags or other flammable material in a against other parts, and excessive heat during
protective container, in a safe place. operation.

Do not weld or flame cut on pipes or tubes that


contain flammable fluids. Clean them thoroughly Tire Information
with nonflammable solvent before welding or flame Explosions of air-inflated tires have resulted from
cutting on them. heat-induced gas combustion inside the tires. The
heat, generated by welding or heating rim
Remove all flammable materials such as fuel, oil components, external fire, or excessive use of
and other debris before they accumulate on the lift brakes can cause gaseous combustion.
truck.
A tire explosion is much more violent than a blowout.
Do not expose the lift truck to flames, burning brush, The explosion can propel the tire, rim and axle
etc., if at all possible. components as far as 500 m (1500 ft) or more from
the lift truck. Both the force of the explosion and the
Do not operate in areas where explosive gases exist flying debris can cause personal injury or death, and
or are suspected. property damage.

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, Do not approach a warm tire closer than the outside
tubes and hoses. Leaks can cause fires. Contact of the area represented by the shaded area in the
your DOOSAN dealer for repair or replacement. above drawing.

Check lines, tubes and hoses carefully. Do not use Dry nitrogen (N2) gas is recommended for inflation
your bare hand to check for leaks. Use a board or of tires. If the tires were originally inflated with air,
cardboard to check for leaks. See Fluid Penetration nitrogen is still preferred for adjusting the pressure.
in the Safety Section for more details. Tighten all Nitrogen mixes properly with air.
connections to the recommended torque. Replace if
any of the following conditions are found.

z End fittings damaged or leaking.

15
Safety Section

Nitrogen inflated tires reduce the potential of a tire Operator Restraint System (If
explosion, because nitrogen does not support
combustion. Also, nitrogen helps prevent oxidation Equipped)
and the resulting deterioration of rubber and
corrosion of rim components. Warning Signs and Labels
Proper nitrogen inflation equipment and training in Your DOOSAN lift truck has the following tipover
its use are necessary to avoid over inflation. A tire warning decals.
blowout or rim failure can result from improper or
misused equipment. Make sure that you can read all safety signs. Clean
or replace these if you cannot read the words or see
Stand behind the tread and use a self-attaching the pictures. When cleaning the labels use a cloth,
chuck when inflation a tire. water and soap. Do not use solvent, gasoline, etc.
You must replace a label if it is damaged, missing or
Servicing, changing tires and rims can be dangerous cannot be read. If a label is on a part that is replaced,
and should be done only by trained personnel using make sure a new label is installed on the replaced
proper tools and procedures. If correct procedures part. See you DOOSAN Lift Truck dealer for new
are not followed while servicing tires and rims, the labels.
assemblies could burst with explosive force and
cause serious personal injury or death. Follow The most effective method of preventing serious
carefully the specific information provided by your injury or death to yourself or others is to familiarize
tire or rim servicing personnel or dealer. yourself with the proper operation of the lift truck, to
be alert, and to avoid actions or conditions which
can result in an accident.

WARNING

Tipover can occur if the truck is improperly


operated. In the event of tipover, injury or death
could result.

16
Safety Section

WARNING
Do NOT place your hand or fingers under the
seat. Injury may occur as the seat moves up and
down.

The "Survive in tipover" warning is located on the


overhead guard. It shows the proper use of the
operator restraint system.

Seat Adjustment

Move the lever, slide the seat to the desired position,


and release the lever.

Adjust the seat before operating the lift truck. After


adjusting, set the seat to make sure it is properly
locked. DO NOT adjust the seat while the truck is in
motion.

17
Safety Section

If Optional Suspension Seat Equipped Weight adjustment

Forward and Backward Adujstment Pull the weight adjustment lever upwards and move
right or left side.
The seat can be adjusted by pushing the lever on Adjust to drivers weight in 7 steps (50 ~ 110 kg)
the right side of seat.

NOTICE

Do not place your hand or fingers under the seat.


Injury may occur as the seat moves up and down.
Forward and Backward
Adujstment

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.

18
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


1. If the seat belt is torn, if pulling motion is z Worn or damaged hardware including anchor
interrupted during extension of the belt, or if the points
belt cannot be inserted into the buckle properly, z Buckle or retractor malfunction
replace the seat belt assembly. z Loose stitching

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 1. Grip the plate (connector) of the belt and pull the
DOOSAN operator restraint system. Should it belt from the retractor. Then insert the plate into
become necessary to replace the seat for any the slot of the buckle until a snap is heard. Pull
reason, it should only be replaced with another
DOOSAN operator restraint system. on the belt to confirm it is latched.

2. Make sure the belt is not twisted.

19
Safety Section

Hold the plate of the belt and allow the belt to slowly
WARNING 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.

20
Safety Section

Avoiding Lift Truck Tipover Stability and Center of Gravity

Lift Truck Stability

The stability of the lift truck is determined by the


location of its CG; or, if the truck is loaded, the
combined CG of the truck and load. The lift truck
Counterbalanced lift truck design is based on the has moving parts and, therefore, has a CG that
balance of two weights on opposite sides of a moves. The CG moves forward or backward as the
fulcrum (the front axle). The load on the forks must mast is tilted forward or backward. The CG moves
be balanced by the weight of the lift truck. up or down as the mast moves up or down. The CG
The location of the center of gravity of both the truck and, therefore, the stability of the loaded lift truck,
and the load is also a factor. This basic principle is are affected by a number of factors such as:
used for picking up a load. The ability of the lift truck z the size, weight, shape and position of the load
to handle a load is discussed in terms of center of
gravity and both forward and sideways stability. z the height to which the load is lifted

z the amount of forward or backward tilt


Center of Gravity (CG)
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

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.
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.

21
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


portion should be placed closer to the
backrest and centered on the forks.
For the lift truck to be stable (not tip over forward or
to the side), the CG must stay within the area of the
lift truck stability base a triangular area between
the front wheels and the pivot of the steer wheels. If NOTICE
the CG moves forward of the front axle, the lift truck
1. Capacity/Nameplates originally attached to
will tip forward. If the CG moves outside of the line
forklifts sold by DOOSAN shall not be removed,
on either side of the stability base, the lift truck will
altered or replaced without DOOSANs approval.
tip to the side.
2. DOOSAN assumes no responsibility for lift trucks
placed in service without a valid DOOSAN
WARNING Nameplate.
3. If necessary to change your specification,
Dynamic forces (braking, acceleration, turning) contact your DOOSAN lift truck dealer.
also affect stability and can produce tipover
even when the CG is within the stability triangle.

Capacity Load (Weight and Load Center)

The capacity load of the lift truck is shown on the


capacity/nameplate riveted to the truck. It is
determined by the weight and load center. The load
center is determined by the location of the CG of the
load.

The load center shown on the nameplate is the


horizontal distance from the front face of the forks,
or the load face of an attachment, to the CG of the
load. The location of the CG in the vertical direction
is the same as the horizontal dimension.

22
Safety Section

Safety Rules

Do not operate a lift truck unless you are in the


operators seat. Keep hands and feet inside the
operators compartment. Do not put any part of the
body outside of the operators compartment. Never
Only properly trained and authorized personnel
put any part of body into the mast structure or
should operate forklift trucks. Wear a hard hat and
between the mast and the truck
safety shoes when operating a lift truck. Do not wear
loose clothing.

Do not start, stop, turn or change direction suddenly


or at high speed. Sudden movement can cause the
Inspect and check the condition of your forklift truck
lift truck to tip over. Slow the speed of your truck and
using the operator's check list before starting work.
use the horn near corners, exits, entrances, and
Immediately report to your supervisor any obvious
near people.
defects or required repairs.

Never operate a lift truck with wet hands or shoes.


Do not operate your truck in unauthorized areas. Never hold any controls with grease on your hands.
Know your forklift truck and think safety. Your hands or feet will slide off of the controls and
Do not compromise safety. cause an accident.
Follow all safety rules and read all warning signs.

23
Safety Section

Do not raise anyone on the forks of your lift truck Do not overload. Always handle loads within the
unless using an approved safety cage. Do not let rated capacity shown on the capacity plate.
other people ride on the truck. Lift trucks are Do not add extra counterweight to the truck. An
designed to carry loads, not people. overload can cause the truck to roll over and cause
injury to personnel and damage to the lift truck.

Do not operate your truck without the load backrest


extension and overhead guard. Keep the load Do not drive on soft ground.
against the backrest with the mast tilted backward. Observe all signs, especially those on maximum
permitted floor loadings, elevator capacities and
clearance heights.
Handle loads carefully and check them closely for
stability and balance.

Do not lift or move loads that are not safe. Do not


pick up an off center load. Such a load increases the
possibility of a tipover to the side. Make sure loads
are correctly stacked and positioned across both
forks. Always use the proper size pallet. Position the Do not drive on slippery surfaces.
forks as wide as possible under the load. Position Sand, gravel, ice or mud can cause a tipover.
loads evenly on the forks for proper balance. Do not If unavoidable, slow down.
lift a load with one fork.

24
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.

Do not jump off if your truck starts to tip over.


Look out for overhead obstructions when raising or Stay in your seat to survive.
stacking loads. Do not travel with a raised load. Do
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.

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.

25
Safety Section

Do not stack or turn on ramps. Do not drive in forward direction when loads restrict
Do not attempt to pick-up or deposit a load unless your visibility. Operate your lift truck in reverse to
the lift truck is level. Do not turn on or drive across improve visibility except when moving up a ramp.
an incline.

Be careful when operating a lift truck near the edge


Do not go over rough terrain. If unavoidable, slow of a loading dock or ramp. Maintain a safe distance
down. from the edge of docks, ramps and platforms.
Cross railroad tracks slowly and diagonally Always watch tail swing.
whenever possible. A railroad crossing can give a The truck can fall over the edge and cause injury or
loaded forklift truck a real jolt. For smoother crossing, death.
cross the railroad diagonally so one wheel crosses
at a time.

Do not operate on bridge plates unless they can


support the weight of the truck and load. Make sure
that they are correctly positioned. Put blocks on the
Avoid running over loose objects. Look in the
vehicle you enter to keep it from moving.
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.

26
Safety Section

Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully
Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in
make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and
Never overtake other vehicles. 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.

27
Safety Section

Forklift trucks are not cars. They often have small There are many special attachments available to
tires, no suspension, and are very heavy. replace the forks on a lift truck.
The forklift's center of gravity will also change when All carry safety implications and special training in
carrying loads. their operation is highly recommended.
Avoid uneven bumps, pot holes and other hazards
whenever possible.

The counterweight draw bar should not be used for


towing the forklift or for towing another forklift.
Carrying a load suspended on a chain or a cable Towing is only advised in emergencies, by trained
may unbalance a truck. operators and at low speed, no faster than 2 km/h,
Take extra care around pedestrians with a to a convenient location for repair.
suspended load as it may sway or even strike them.

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.

28
Safety Section

How to Survive in a Tipover (If


Operator Restraint System
Equipped)

WARNING

In the event of a tipover, the risk of serious


injury or death will be reduced if the operator is
using the operator restraint system and follows
the instructions provided.

Brace your feet and keep them within the operator's


compartment.

Always use operator restraint system.

Lean away from the direction of fall.

Dont jump.

Lean forward

Hold on tight.

29
General Section

Declaration of Conformity

We,

Manufacturer
Doosan Infracore Co., Ltd.
7-11, Hwasu-dong, 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 Infracore Europe S.A., Mr. K. S. Yoon
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 : B25X-5 Series

Model Name : B22X-5, B25X-5, B30X-5, B35X-5

30
General Section

Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center kg
4 Load center distance mm
5 Power type electric,diesel,gas,Lp-gas
6 Operator type stand-on, rider seated
7 Tire P=pneumatic,E=elastic,C=cushion,V=rubber
8 Wheels(x=driven) 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 lengthXwidthXthickness mm
13 fork spacing (minimumXmaximum) mm
14 Tilt of mast forward/backward deg
15 length to fork face mm
16 width mm
17 Overall mast lowered height mm
18 dimensions mast extended height mm
19 overhead guard height mm
20 seat height 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 mm
23a Aisle width with pallets 800X1200 mm
PERFORMANCE
24 travel,loaded/unloaded 80V km/h
25 Speeds lift,loaded/unloaded 80V mm/s
26 lowering,loaded/unloaded mm/s
28 Max. Drawbar pull loaded/unloaded (5 min. rating) kg.f
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 front/rear kg
34 without load front/rear kg
CHASSIS
35 number of front/rear
36 Tires Size front
37 rear
38 Wheelbase mm
39 Tread front/rear mm
40 Ground loaded at the lowest point mm
at center of
41 clearance mm
wheelbase
42 Service brake
43 Parking brake
DRIVE
44 Type
45 Battery Voltage/capacity(5 hours) V/AH
46 Weight (minimun) kg
47 Electric motor Drive motor (1 HR Rating) 80V kw
48 Hydraulic motor (20% Duty) 80V kw
54 Speed control with electric drive Type
57 Relief pressure system/attachment /
58 Noise level Leq dB(A)

31
General Section

100mm 23 100mm
MIN.AISLE-90 STACK
DOOSAN DOOSAN DOOSAN DOOSAN 1 21

B22X-5 B25X-5 B30X-5 B35X-5 2

INERSECTON RIGHT
ANGLE AISLE
2200 2500 3000 3500 3

13

16
39
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 P,E 7
2x/2 2x/2 2x/2 2x/2 8

3230 3230 3230 3230 9


1414
140 140 140 140 10
CLASSII CLASSII CLASSII CLASSII 11
45X100X1050 45X100X1050 45X125X1050 45X125X1050 12

18
200X1040 200X1040 200X1040 200X1040 13
6/9 6/9 6/9 6/9 14

9
17

19
2360 2360 2505 2600 15 4

20
1245 1245 1245 1245 16 40

10
2165 2165 2200 2200 17 22 38
15
3990 3990 3990 3990 18
2155 2155 2155 2155 19
1070 1070 1070 1070 20
1980 1980 2100 2180 21
500 500 508 508 22
3680 3680 3808 3888 23
3480 3480 3608 3688 23a

16/16 16/16 16/16 16/16 24


500/550 480/550 420/550 380/550 25
490/460 490/460 490/460 500/460 26
1955/1905 1955/1900 1922/1880 1701/1685 28
27/41 24/39 24/31 19/31 30
full power full power full power full power 31

4588 4755 5282 5630 32


6001/787 6353/902 7312/970 8056/1074 33
2371/2217 2224/2531 2511/2771 2455/3175 34

2/2 2/2 2/2 2/2 35


23X10-12 23X10-12 23X10X12 23X10X12 36
18X7-8 18X7-8 18X7-8 18X7-8 37
1535 1535 1679 1679 38
998/998 998/998 998/998 998/998 39
130 130 130 130 40
140 140 140 140 41
HYD HYD HYD HYD 42
HAND HAND HAND HAND 43

DIN43536A DIN43536A DIN43536A DIN43536A 44


80/500 80/500 80/600 80/600 45
1560 1560 1870 1870 46
7.5X2 7.5X2 7.5X2 7.5X2 47
21 21 21 21 48
AC AC AC AC 54
158 158 158 158 57
58

32
General Section

Noise and Vibration


Noise at operator ear
(measured by PREN 12053)
unit:dB(A)
Noise Level[unit:Db(A)]
Model
Sound Pressure Level at operators
Ear(Leq)
B22X-5
PREN 12053
B25X-5
B30X-5
66.9
B35X-5

* Test Model : B35X-5

33
General Section

Capacity Chart
MODEL STD, FFL FFT

A A

B C B
B22X-5

A. 2030 3600 mm MAST A. 3900 4730 mm MAST C. 6010mm MAST


B. 4960 mm MAST B. 5560 mm MAST

A A
B
C B
C

D
B25X-5

A. 2030 - 3600mm MAST C. 4960mm MAST A. 3900mm MAST D. 5560mm MAST


B. 4350 mm MAST B. 4290mm MAST E. 6010mm MAST
C. 4730mm MAST

A A

B B
C
B30X-5

A. 2030 - 3600mm MAST A. 3900-4290 MAST D. 6010mm MAST


B. 4960 mm MAST B. 4730mm MAST
C. 5560mm MAST

A
A
B
B
C
C
D
B35X-5

E
F

A. 1800 - 3495mm MAST C. 4805mm MAST A. 3555mm MAST D. 4820mm MAST


B. 4205mm MAST B. 3960mm MAST E. 5205mm MAST
C. 4380mm MAST F. 5655mm MAST

34
General Section

Capacity Chart - With Side Shifter (Integrated)


MODEL STD, FFL FFT

A A
B
C B D C
B22X-5

A. 2030 3600 mm MAST C. 4960mm MAST A. 3900 mm MAST D. 5560mm MAST


B. 4350 mm MAST B. 4290 mm MAST E. 6010mm MAST
C. 4730mm MAST

A
A
B B
C C
D
B25X-5

A. 2030 - 3600mm MAST C. 4960mm MAST A. 3900mm MAST D. 5560mm MAST


B. 4350 mm MAST B. 4290mm MAST E. 6010mm MAST
C. 4730mm MAST

A A B
C
C B D
E
B30X-5

A. 2030 - 3600mm MAST C. 4960mm MAST A. 3900mm MAST D. 5560mm MAST


B. 4350 mm MAST B. 4290mm MAST E. 6010mm MAST
C. 4730mm MAST

A A
B B
C

C E D

F
B35X-5

A. 1800 3495 mm MAST C. 4805 mm MAST A. 3555 mm MAST D. 4820mm MAST


B. 4205 mm MAST B. 3960 mm MAST E. 5205mm MAST
C. 4380mm MAST F. 5655mm MAST

35
General Section

Capacity Chart - With Side Shifter (Hook on)


MODEL STD, FF FFT

A A
B
C B D C
B22X-5

A. 2030 3600 mm MAST C. 4960mm MAST A. 3900 mm MAST D. 5560mm MAST


B. 4350 mm MAST B. 4290 mm MAST E. 6010mm MAST
C. 4730mm MAST

A
A
B B
C C
D
B25X-5

A. 2030 - 3600mm MAST C. 4960mm MAST A. 3900mm MAST D. 5560mm MAST


B. 4350 mm MAST B. 4290mm MAST E. 6010mm MAST
C. 4730mm MAST

A A B
C
C B D
E
B30X-5

A. 2030 - 3600mm MAST C. 4960mm MAST A. 3900mm MAST D. 5560mm MAST


B. 4350mm MAST B. 4290mm MAST E. 6010mm MAST
C. 4730mm MAST

A A
B B
C

C E D

F
B35X-5

A. 1800 3495 mm MAST C. 4805 mm MAST A. 3555mm MAST D. 4820mm MAST


B. 4205 mm MAST B. 3960mm MAST E. 5205mm MAST
C. 4380mm MAST F. 5655mm MAST

36
General Section

Serial Number
Serial Numbers Locations
For quick reference, record the serial numbers in
the space provide below the illustration
photographs.

Lift Truck Serial Number

37
General Section

Operators Warning and Identification Plate


Familiarize yourself with the information on the ldentification, Lift Capacity and Attachment Plates. Do not
exceed allowable lift truck working capacity load ratings.

Operators Warning Plate Identification, Lift Capacity and


Attachment Plate
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 operators seat on Before attempting to lift any load, ensure that the
the battery cover. weight and load center combination is within the
capacity of the lift truck as shown on the capacity
rating plate. To determine the load center measure
the distance from the face of the carriage to the
gravitational center of the load.

The rated capacity on the plate refers to the


capacity of the lift truck as it left the factory.
Subsequent changes of any form to the equipment
or battery can alter the lift trucks rating.

The rated capacity of the lift truck applies to


operating conditions where the lift truck is on level
ground. The capacity of the lift truck is reduced on
inclines.

Below are abbreviations that may appear on the


Identification, Lift Capacity and Attachment Plate
and their meanings.

38
General Section

Mast Abbreviations HFP - Hydraulic Fork Positioner, Non Sideshift.

The identification plate indicates the type of mast CR - Crane Arm or Crane Boom.
installed on the lift truck when it left the factory. The
type of mast is indicated by an abbreviation. TH - Tire Handler.

STD - Standard Mast(single inner member, low CTH - Container Top Handler.
free lift).
CSH - Container Side Handler
FF - Full Free Mast (single inner member,
high free lift with primary cylinder). LP - Load Push Device, Non Sideshift.

FFT - Triple Lift Mast (two inner members, LPP - Load Push-Pull Device, Non Sideshift.
high free lift with primary cylinder).
C -General Clamp (other than Bale, Carton
QUAD - Quadruple(Quad) Mast(three inner or Roll).
members, high free lift with primary
cylinder). BC - Bale Clamp.

SPEC - Special Mast, such as non-telescopic or CC - Carton Clamp.


double mast, not within the other
classifications. RC - Roll Clamp.

NOTE: When only a mast-type is listed on the LS - Load Stabilizer.


identification plate, a standard carriage and
forks are used. LH - Log Handler.

Attachment Abbreviations (includes PWH - Pulp Wood Handler.


Special Forks)
SS-ST - Sideshift-Side Tilt Carriage.
SC - Special Carriage-increased width, height
or outreach.

SSS - Shaft-type Sideshift Carriage.

HSS - Hook-type Sideshift Carriage(ITA).

ISS - Integral type Sideshift Carriage.

ISFP - Integral Shifting type Fork Positioner.

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

39
Operation Section

Operators Station and Monitoring Systems


Read and understand the Safety, Operation and Maintenance sections before operating the lift truck.

Key Switch Seat Switch

The key switch is located on the right side of the the seat switch is located under the operators seat.
steering column.
OPEN - When the operators seat is in the
OFF - Turn the key switch to OFF (1) to up position the electrical circuits are
disconnect the electrical circuits. disconnected.

ON - Turn the key switch the ON (2) to CLOSE - When the operators seat is in
connect the electrical circuits. If the key the down position(operator seated) the
switch is left in the ON position when the electrical circuits are connected.
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
The power steering pump motor is activated when is closed.
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.

40
Operation Section

Monitoring Systems Display Segments


Indicator(Compact Display) The display gives the following information about
the operating state of the system:
Lift truck speed (expressed in kmh or
mph)
Handbrake active, indicated by the
warning symbol
Safety contact open, indicated both by
EE blinking message visualized in
timemeter area and by relative symbol.
With any directional switch active and safety
contact still open, lift truck cant be moved, even
after seat switch is closed; in such a case, after
safety contact is closed, the symbol disappears.

EE code disappears only after active directional


switch is turned off.

Time meter or, otherwise, milometer


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

Battery level, indicated by a 9


segments symbol.
In following Table 1, you can read the generic
relation between battery charge level and number
of visualized bars . See Table 2 in case of a 80V
system. Display signals with alarm code EL the fact
battery is completely discharged.

41
Operation Section

Relation between battery charge level and Table 3 : Contraction for dot matrix display.
number of visualized bars Alarm Code

Table 1 : Case of a generic system Display


Description Contraction
DISPLAY BATTERY CHARGE Code
INDICATION LEVEL CONTACTOR
17 Main breaker fault
FAULT
No segments Discharged battery Battery/inverter
1 flashing segment 10 % 60 BATT MISMATCH
mismatch
1 segment 20 % Blocking
R-MOTOR
2 segments 30 % 61 overtemperature of
SHUTDOWN
right moter(over 165)
3 segments 40 % Blocking
4 segments 50 % L-MOTOR
62 overtemperature of left
SHUTDOWN
5 segments 60 % moter(over 165)
6 segments 70 % Blocking
overtemperature of P-MOTOR
7 segments 80 % 65
pump moter(over SHUTDOWN
8 segments 90 % 165)
9 segments Full charged battery 76 Pump motor Encoder
P-MOTOR
ENCODER.
Wrong right traction R-M TEMP
Table 2 : Case of a 80V system 77
motor thermal switch SENSOR
BATTERY CHARGE BATTERY VOLTAGE Wrong left traction L-M TEMP
78
LEVEL [V] motor thermal switch SENSOR
Wrong pump motor P-M TEMP
Discharged battery Voltage < 75.7 V 79
thermal probe SENSOR
10 % 75.7 V 76.5 V Wrong right traction
80 R-INV T SENSOR
20 % 76.5 V 77.3 V module thermal probe
30 % 77.4 V 78.2 V Wrong left traction
81 L-INV T SENSOR
module thermal probe
40 % 78.3 V 79.1 V
Wrong pump module
50 % 79.2 V 80.0 V 82 P-INV T SENSOR
thermal probe
60 % 80.1 V 80.9 V 83 CRC fault CRC FAULT
70 % 81.0 V 81.8 V 84 Bank CRC restored CRC RESTORED
80 % 81.9 V 82.7 V Capacitors not
A FAST CHARGE
charged : fast charge
90 % 82.8 V 83.6 V Trans.precharge in
Full charged battery Voltage > 83.6 V A Short / Cap. Too TOO CHARGED
charged
Capacitors not
CAP SLOW
A charged :
CHARGE
slow charge
Capacitors not TIME OUT
A
charged : time out CHARGE
Capacitors not CAP NOT
A
charged CHARGED
Drive right module R-INV
E1
Overtemperature OVERTEMP
Drive left module L-INV
E2
Overtemperature OVERTEMP
Pump module P-INV
E3
Overtemperature OVERTEMP
Drive right motor R-MOTOR
E4
Overtemperature OVERTEMP
Drive left motor L-MOTOR
E5
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 Wrong Eeprom EEPROM FAULT
WD Timer/Enable WD TIMER
F
micro signals FAULT

42
Operation Section

F Serial communication COMM FAULT NOTE: Percent values can be modified only with
Maximum battery EYE Calibration E-S-H menu.
F0 MAX BATT VOLT
voltage
Minimum battery
F1 MIN BATT VOLT NOTE: Pressing PROGRAMMABLE WORKING
voltage
F2 Pedal trimmer fault ACCEL FAULT you can manage economic, standard or
F3
Drive right module R-INVERTER high operating mode too.
Desat/overcurrent FAULT
Drive left module L-INVERTER
F4 COMPACT display shows different symbols in
Desat/overcurrent FAULT
Pump module P-INVERTER function of selected energetic mode:
F5
Desat/overcurrent FAULT
F6
Drive right motor R-MOTOR I - E-S-H management disabled: no symbol
current Offset OFFSET visualised.
Drive left motor L-MOTOR I - E-S-H management enabled: active
F7
current Offset OFFSET
Pump motor current P-MOTOR I mode is indicated by symbol.
F8
Offset OFFSET
STEER SENSOR
F9 Steer sensor fault
OUT - PROGRAMMABLE WORKING management
FA 5V encoders not ok 5V NOT OK enabled: in case you have chosen one of L1, L2
Drive right motor R-MOTOR
Fc
Encoder ENCODER
or L3 operating modes, and lift truck is stopped,
Drive left motor L-MOTOR one of the segments of speed indicator symbol
Fd
Encoder ENCODER (see Table 4 ) blinks to show selected energetic
FE 24V out 24V NOT OK mode.
FH 12V out not ok 12V NOT OK
Pump input on at the
FL PUMP SIGN ON
start Table 4 : selected energetic mode
DISPLAY
VISUALISATION OPERATING MODE
Lift truck operation mode (from symbol left side)
1st segment L1 (Limit 1)
Pressing E-S-H button, you can set 5st segment L2 (Limit 1)
energetic operating mode for your 9st segment L3 (Limit 1)
system.

This function is enabled using EYE menu named Otherwise symbol indicates, as usual,
Calibration ESH, to select desired operating selected operating mode.
mode. In particular you can choose between E-S-H
or PROGRAMMABLE WORKING :
NOTE: as usual, if lift truck is moving,
symbol indicates speed level
- Pressing E-S-H (economic, standard, high) button,
you change energetic mode and update related
parameters with a value, corresponding to
selected operating mode, that operator cant
modify.
- Pressing PROGRAMMABLE WORKING you can
manage 3 further options (limit 1, limit 2, and limit
3). You can set parameters value, that are
expressed in per cent of high energetic mode;
changing active limitation (among L1, L2 or L3),
related per cent data are used to calculate actual
parameters value.

43
Operation Section

NOTE: if active mode is one of L1, L2 or L3 Seat Belt warning (Option) : red color
limitations and you change operating mode LED for 10 seconds.
(from PROGRAMMABLE WORKING to E-
S- H), software automatically sets operating
mode to economic one NOTE: Alarm LED is managed as follows:

Alarm message, indicated by an alpha-numerical - Display normally working: LED lights up


code in the display area where usually lift truck briefly switching on /off your system
speed appears. - Display not communicating with control
See Table 3 for the meaning of alarm codes. board: after 3 seconds from the moment in
which the communication stops, alarm
Over-temperature warning, indicated by the LED brightens
warning light In case the temperature of - Display board microprocessor not working:
power transistors exceeds the limit and alarm LED brightens.
relative light blink.
If this light is on, there is possibility that cooling fan No Alarm, No Movement
is breakdown. Inspect cooling fan.
In case the truck does not move forward or reverse
Hour meter separation point, usually blinking, stops direction, check to see if the service brake switch is
in following cases: activated.
- Seat switch open.
- Serial communication between display and control
unit not active
- Main breaker open

Turning your lift truck on, some alphanumeric codes,


visible for 3 seconds, appear where usually is
visualized speed indicator symbol; those codes
help to identify system in use (see Table 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
SYSTEM IN USE CODE

BX (4WHEEL) C0

LED Indicators

On left side, COMPACT display has four LED


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

Alarm message; red color LED

Message of lamps; green color LED

Indicator lights activated; green color


LED(OPTION)

Low oil level of the brakes; red colour LED.

44
Operation Section

Front and Rear Floodlights Switch Tilt Steering Column

Located on the right side of the instrument panel,


Located on the lower front of the steering column.
below the display panel.
To adjust the steering column, raise the handle(1)
OFF - Push down on the left side of the
and move the steering column to the desired
switch to turn both front and rear flood
position. Release the handle and the steering
lights off.
column will remain in the desired position.
Front Floodlights - Push down on the
right side of the switch, to the first position, Seat Adjustment
to turn the front floodlights on.
Adjust the seat at the beginning of each shift or
Front and Rear Floodlights - Push down when changing operators.
on the right side of the switch, to the
second position, to turn both the front and Adjust the seat to allow full travel of all pedals with
rear floodlights on. The rear floodlights are optional. the operator seated against the seat back.

Horn Button The seat must be adjusted with the operator seated.

Located in the center of the steering wheel. Move the lever to adjust the seat forward or
Push in on the horn button to sound the backward. Release the lever. Move the seat slightly
horn. to lock it.

45
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. If
use often this button by the key switch, the electric
system can make a problem. So, this button uses in
emergency certainly).

ON - Pull the emergency switch button to


connect the electrical circuit.

46
Operation Section

Lift Truck Controls


Parking Brake Service Brake Pedal

NOTICE

Do not engage the parking brake while the lift truck


is moving unless an emergency arises. The use of
the parking brake as a service brake in regular
operation will cause severe damage to the parking
brake system.

Service Brake - The service brake pedal is located


on the floor of the operators compartment.

Depress the service brake pedal to slow or


stop the lift truck. Drive circuit will be
interrupted while the pedal is depressed.

Release the service brake pedal to allow


the lift truck to move.

Parking Brake - The parking brake lever


is located on the left side of the cowl.

Parking Brake Engaged - Pull the


parking brake lever (1) up, which will
engage the interlock switch that shuts off
power to the drive motor.

Parking Brake Disengaged - Push the


parking brake lever (2) down to release
the parking brake.

47
Operation Section

Accelerator Pedal Directional Control Lever


NOTICE

The service brake and accelerator pedals should


not be used at the same time, except for
emergency situations. Use of both the brake and
accelerator pedals at the same time may cause the
drive motor to overheat.

Forward(1) - Push the lever forward.


The lift truck will move forward.

Neutral(2) - 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.
Accelerator Pedal - The accelerator pedal is The lift truck will not move until accelerator pedal is
located on the floor of the operators compartment. released and lever is returned to NEUTRAL.

NOTE: Wait Mode of Operation-This condition will


Push down the pedal to increase travel speed.
go into effect when the following occurs.
The seat switch is closed, key switch is on
If the accelerator pedal is depressed before the key and the directional control lever is left in
switch is turned to the ON position, the lift truck will NEUTRAL for more than five seconds, with
not move until the pedal is released and depressed no operator input to any control.
again.
The line contactor will open and the power steering
Release the pedal to decrease travel speed. motor will turn off to conserve energy. The lift truck
will remain in this mode until the operator moves
Film For function of pedals (if equipped) the directional control lever, pushes on the
accelerator pedal and/or moves any control valve
lever.

Reverse(3) - 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.

This plate shows the function of the brake and


accelerator pedals.

48
Operation Section

When the operator raises off the seat (seat switch Tilt Control Lever
opens) while the lift truck is in motion, the drive
motor will lose power. When this occurs, release
the accelerator, close the seat switch (operator
seated), move the directional control lever to
NEUTRAL and then to desired direction of travel.
Push down on the accelerator.

Lift Control Lever

The forks tilt control is located at the operators


right side front. The tilt control lever is the lever at
the center.

Tilt Forward(1) - Push the lever forward


smoothly to tilt the forks forward.

The forks lift control is located at the operators Hold(2) - Release the tilt lever. The lever
right side front. The lift control lever is the lever at will return to the center(hold) position and
the left. the forks will remain in the position they
are in.
Lower(1) - Push the lever forward
smoothly to lower the lift forks. Tilt Back(3) - Pull the lever back smoothly
to tilt the forks back.
Hold(2) - Release the lift lever. The lever
will return to the center(hold) position and
the forks will remain in the position they NOTE: To prevent a sudden change of position of
are in. the load, operate all lift, tilt and attachment
controls smoothly. Never tilt an elevated
Raise(3) - Pull the lever back smoothly to load forward past vertical.
raise the lift forks.

NOTE: To prevent a sudden change of position of


the load, operate all lift, tilt and attachment
controls smoothly.

49
Operation Section

Sideshift Attachment Control


(If Equipped)

The sideshift attachment control is located at the


operators right side front. The sideshift attachment
control lever is the lever at the right.

Sideshift Left(1) - Push the lever forward


smoothly to shift the carriage to the left.

Sideshift Hold(2) - Release the sideshif


attachment lever. The lever will return to
the center(hold) position and sideshifting
action will stop.

Sideshift Right(3) - 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.

50
Operation Section

Before Operating the Lift Truck

Walk-Around Inspection
8
For your own safety and maximum service life of
the lift truck, make a thorough walk-around 7
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 9
attachments.
6

3
6. Inspect the tires and wheels for proper inflation,
2 cuts, gouges, foreign objects and loose or
missing nuts.

7. Inspect the overhead guard for damage, loose


or missing mounting bolts.
1
8. Inspect the hydraulic system for leaks, worn
hoses or damaged lines.

1. Inspect the operators 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.

4 5
10

10. Inspect the battery compartment for loose


connections, frayed cables and properly
secured battery restraint.

Batteries give off flammable fumes that can


4. Inspect the mast and lift chains for wear, broken explode.
links, pins and loose rollers. Do not smoke when observing the battery
electrolyte levels.
5. Inspect the carriage, forks or attachments for Electrolyte is an acid and can cause personal
wear, damage and loose or missing bolts. injury if it contacts skin or eyes.
Always wear protective glasses when working
with batteries.

51
Operation Section

11. Disconnect the battery. Tilt the steering column 15. Adjust the steering wheel to comfortable
to the full upright position and move the seat position. Grasp the steering wheel and raise the
fully rearward. handle to release the steering column. PULL
the steering column BACK or PUSH
12. Raise the seat and cover assembly and latch FORWARD to obtain the most comfortable
the cover to the cowl. 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
connect the battery to the lift truck.

Personal injury may occur from accidents


caused by improper seat adjustment. Always
adjust the operators seat before operating the
lift truck.

Seat adjustment must be done at the beginning


of each shift and when operators change.

16. With the seat switch closed and the directional


lever in NEUTRAL, turn the key switch ON.
Observe the battery discharge indicator.

14. Position the seat by operating the lever and


moving the seat forward or backward to a
comfortable position. 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.

52
Operation Section

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.

53
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 operators 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.

54
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.

55
Operation Section

Electrical Braking (Plugging)

2. Hold the accelerator pedal down until the lift


truck nearly comes to a complete stop. Release
To slow, stop or change direction when traveling in the accelerator pedal.
either direction, move the directional control lever
(1) to the opposite direction while keeping the 3. Push down on the service brake pedal to bring
accelerator pedal (2) depressed. the lift truck to a complete stop and hold it.

The Micro-controller senses that the motors are 4. If a change of direction is desired, continue to
turning opposite to the lift truck and immediately push down on the accelerator pedal until the
goes into the plugging mode. desired travel speed in the opposite direction is
obtained.
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.

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.

1. Move the directional control lever to the


opposite direction of lift truck travel.

56
Operation Section

Steering Knob (If Equipped) Mono-Ped Control System


There is a steering knob available for inclusion with (Option)
new truck deliveries. This option is solely intended
for slow travel situations when two handed steering
is not possible due to hydraulic operations.

Forward-Push the left side (2) of the pedal


WARNING for FORWARD direction travel.
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 Neutral-The lift truck should not move
easy rotation of the steering wheel, but if a when the Mono-Ped pedal is released..
steering knob is improperly used (e.g., rotating
the steering wheel quickly while the truck is in
motion), this can contribute to truck instability Reverse-Push the right side (1) of the
and a tip over. A steering knob is intended for pedal for REVERSE direction travel.
slow travel maneuverability ONLY.

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

57
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


return to the center(hold) position and the
forks will remain in the position they are in.
Lower - Push the knob forward smoothly
to lower the lift forks. Tilt Back - Pull the knob back smoothly to
tilt the lift forks back.
Hold - Release the lift knob. The knob will
return to the center(hold) position and the NOTE: To prevent a sudden change of position of
forks will remain in the position they are in. the load, operate all lift, tilt and attachment
knobs smoothly.
Raise - Pull the knob back smoothly to
raise the lift forks.

NOTE: To prevent a sudden change of position of


the load, operate all lift, tilt and attachment
knobs smoothly.

58
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.

59
Operation Section

Adjustment of Armrest Up and Down Adjustment

2
2

To move the armrest down, turn the knob(2)


By using 2 knobs, adjust the position of the armrest counterclockwise.
to give the operator the best comfortable position of
arm.

knob #1 - Forward and backward adjustment

knob #2 - Clockwise and Counterclockwise rotation


adjustment

Forward and Backward Adjustment

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

60
Operation Section

Operating Techniques
NOTE: The photographs and line art used in the following Operating Techniques, are typical examples and
may not apply 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, forks spaced evenly between
pallet stringers and as far apart as 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.

61
Operation Section

Traveling With or Without a load Lift Truck Turning


When traveling with and without a load, travel with
the fork as low as possible, while still maintaining
good floor clearance height.

1. When turning sharp corners, keep close to the


inside corner. Begin the turn when the inside
drive wheel meets the corner.
1. Carry the load as low as possible, while still
maintaining ground clearance.

2. When turning in narrow aisles, keep as far from


the stockpile as possible when making a turn
2. Travel with the load uphill on upgrades and into the aisle. Allow for counterweight swing.
downgrades.

3. For better vision, travel in reverse with bulky


loads.

62
Operation Section

Unloading Lift Truck Lifting Drums or Round Objects

1. Move the lift truck into the unloading position. 1. Block drums or round objects. Tilt mast forward
and slide fork tips along the floor to get under
2. Tilt the mast forward only when directly over the the load.
unloading area.

Do not tilt the mast forward with the load unless


directly over the unloading area, even if the
power is off.

2. Tilt the mast back slightly until the load is


cradled on the forks before lifting.

3. Lift the load to the travel position.

3. Deposit the load and back away carefully to


disengage the forks.

4. Lower the carriage and forks to either travel


position or park position.

63
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.

When leaving the operators station, park the lift


3. Engage the parking brake.
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 floor.

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.

64
Operation Section

6. Disconnect the battery.

7. Block the wheels if parking on an incline.

Packing Alarm Warning (If


Equipped)
When leaving the operators station without
engaging the parking brake, a warning buzzer will
sound.

65
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.

66
Operation Section

Storage Information
Before Storage
To place the machine in storage for an extended
period of time, the following measures must be
taken 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 metal


surface(hydraulic piston rods.)

4. Cover batteries after removing terminals, or


remove them from the machine and store
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 mixed water.

2. Wipe off grease from hydraulic cylinder piston


rod.

3. Measure specific gravity and check that battery


is charged.

4. Drive at low speed to make sure inside of


transfer is well oiled.

67
Operation Section

Transportation Hints
Shipping 6. Disconnect the battery.

Check travel route for overpass clearances. Make 7. Block the tires and secure the lift truck with
sure there is adequate clearance if the lift truck tiedowns.
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.

68
Operation Section

Towing Information
The different situation requirements cannot be
given, as minimal towing lift truck capacity is
Personal injury or death could result when required on smooth level surfaces to maximum on
towing a disabled lift truck incorrectly. inclines or poor surface conditions.

Block the lift truck wheels to prevent movement Consult your DOOSAN Lift Truck dealer for
before releasing the brakes. The lift truck can towing a disabled lift truck.
roll free if it is not blocked.

Follow the recommendations below to properly


perform the towing procedure.

These towing instructions are for moving a disabled


lift truck a short distance, at low speed, no faster
than 2 km/h(1.2 mph), to a convenient location for
repair.These instructions are for emergencies only.
Always haul the lift truck if long distance moving is
required.

Shield must be provided on the towing lift truck to


protect the operator if the tow line or bar should 1. Release the parking brake.
break.

Do not allow riders on the lift truck being towed NOTICE


unless the operator can control the steering and/or
braking. Release the parking brake to prevent excessive
wear and damage to the parking brake system.
Before towing, make sure the tow line or bar is in
good condition and has enough strength for the
towing situation involved. Use a towing line or bar 2. Check that the service brake pedal is released.
with a strength of at least 1.5 times the gross
weight of the towing lift truck for a disabled lift truck 3. Key switch is in the OFF position.
stuck in the mud or when towing on a grade.
4. Disconnect the battery.
Keep the tow line angle to a minimum. Do not
exceed a 30 angle from the straight ahead
5. Fasten the tow bar to the lift truck.
position.
Connect the tow line as low as possible on the lift
truck that is being towed. 6. Remove the wheel blocks. Tow the lift truck
slowly. Do not tow any faster than 2 km/h (1.2
Quick lift truck movement could overload the tow mph).
line or bar and cause it to break. Gradual and
smooth lift truck movement will work better.

Normally, the towing lift truck should be as large as Be sure all necessary repairs and adjustments
the disabled lift truck. Satisfy yourself that the have been made before a lift truck that has been
towing lift truck has enough brake capacity, weight towed to a service area is put back into
and power, to control both lift trucks for the grade operation.
and the distance involved.

To provide sufficient control and braking when


moving a disabled lift truck downhill, a larger towing
lift truck or additional lift trucks connected to the
rear could be required. This will prevent
uncontrolled rolling.

69
Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks

The following provides practical guidelines for Forks should be properly sized to the weight and
inspection, maintenance and repair of lift truck forks. length of the loads, and to the size of the machine
It also provides general information on the design on which they are used. The general practice is to
and application of forks and the common cause of use a fork size such that the combined rated
fork failures. capacity of the number of forks used is equal to or
greater than the Standard(or rated) Capacity of
Lift truck forks can be dangerously weakened by the lift truck.
repair or modification. They can also be damaged
by the cumulative effects of age, abrasion, The individual load rating, in most cases, will be
corrosion, overloading and misuse. stamped on the fork in a readily visible area.
Generally on the top or side of the fork shank.
A fork failure during use can cause damage to the
equipment and the load. A fork failure can also z A fork rated at 1500 pounds at 24 inch load
cause serious injury. center will be stamped 1500B24.

A good fork inspection and maintenance program z A fork rated at 2000 kg at 600 mm load center will
along with the proper application can be very be stamped 2000B600.
effective in preventing sudden on the job failures.
The manufacturer identification and year and date
Repairs and modifications should be done only by of manufacture is also usually shown.
the fork manufacturer or a qualified technician
knowledgeable of the material used and the Some countries have standards or regulations
required welding and heat treatment process. which apply specifically to the inspection and repair
of forks.
Users should evaluate the economics of returning
the forks to the manufacturer for repairs or Users may also refer to the International
purchasing new forks. This will vary depending on Organization
many factors including the size and type of fork. For Standardization - ISO Technical Report 5057 -
Inspection and Repair of Fork Arms and ISO
Standard 2330 - Fork Arms-Technical
Characteristics and Testing.

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.

70
Maintenance Section

Causes of Fork Failure z Repetitive Overloading

Repetitive cycling of loads which exceeds the


Improper Modification or Repair
fatigue strength of the material can lead to fatigue
failure. The overload could be caused by loads in
Fork failure can occur as a result of a field
excess of the rated fork capacity and by use of the
modification involving welding, flame cutting or
forks tips as pry bars. Also, by handling loads in a
other similar processes which affect the heat
manner which causes the fork tips to spread and
treatment and reduces the strength of the fork.
the forks to twist laterally about their mountings.
In most cases, specific processes and techniques
z Wear
are also required to achieve proper welding of the
particular alloy steels involved. Critical areas most
Forks are constantly subjected to abrasion as they
likely to be affected by improper processing are the
slide on floors and loads. The thickness of the fork
heel section, the mounting components and the fork
blade is gradually reduced to the point where it may
tip.
not be capable of handling the load for which it was
designed.
Bent or Twisted Forks
z Stress Risers
Forks can be bent out of shape by extreme
overloading, glancing blows against walls or other Scratches, nicks and corrosion are points of high
solid objects or using the fork tip as a pry bar. stress concentration where cracks can develop.
These cracks can progress under repetitive loading
Bent or twisted forks are much more likely to break in a typical mode of fatigue failure.
and cause damage or injury. They should be
removed from service immediately.
Overloading
Fatigue Extreme overloading can cause permanent bending
or immediate failure of the forks. Using forks of less
Parts which are subjected to repeated or fluctuating capacity than the load or lift truck when lifting loads
loads can fail after a large number of loading cycles and using forks in a manner for which they were not
even though the maximum stress was below the designed are some common causes of overloading.
static strength of the part.

The first sign of a fatigue failure is usually a crack


which starts in an area of high stress concentration
This is usually in the heel section or on the fork
mounting.

As the crack progresses under repetitive load


cycling, the load bearing cross section of the
remaining metal is decreased in size until it
becomes insufficient to support the load and
complete failure occurs.

Fatigue failure is the most common mode of fork


failure. It is also one which can be anticipated and
prevented by recognizing the conditions which lead
up to the failure and by removing the fork service
prior to failing.

71
Maintenance Section

Fork Inspection First Installation


1. Inspect forks to ensure they are the correct size
for the truck on which they will be used. Make
sure they are the correct length and type for the
loads to be handled.

If the forks have been previously used, perform


the12 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
Establish a daily and 12 month inspection routine 4, in the 2000 Service Hours or 1 Year in
by keeping a record for the forks on each lift truck. Maintenance Intervals

Initial information should include the machine serial 3. Make sure positioning lock is in place and
number on each the forks are used, the fork working Lock forks in position before using
manufacturer, type, original section size, original truck. See Forks, Step 7, in the 2000 Service
length and capacity. Also list any special Hours or 1 Year in Maintenance Intervals.
characteristics specified in the fork design.

Record the date and results of each inspection, Daily Inspection-Before First Use
making sure the following information is included.
and at Each Preventive
z Actual wear conditions, such as percent of Maintenance Inspection
original blade thickness remaining.
1. Visually inspect forks for cracks, especially in
z Any damage, failure or deformation which might the heel section, around the mounting brackets,
impair the use of the truck. and all weld areas. Inspect for broken or jagged
fork tips, bent or twisted blades and shanks.
z Note any repairs or maintenance.
2. Make sure positioning lock is in place and
An ongoing record of this information will help in working. Lock the forks in position before using
identifying proper inspection intervals for each the truck. See 2000 Service Hours or 1 Year
operation, in identifying and solving problem areas in Maintenance Intervals.
and in anticipating time for replacement of the forks.
3. Remove all defective forks from service.

72
Maintenance Section

12 Months Inspection 4. A fork should be load tested before being


returned to service on completion of repairs
Forks should be inspected, at a minimum, every 12 authorized and done in accordance with the
months. If the truck is being used in a multi-shift or manufacturers recommendations.
heavy duty operation, they should be checked
every six months. See Forks in the Maintenance Most manufacturers and standards require the
Section of this manual. repaired fork to be tested with a load 2.5 times
the specified capacity and at the load center
marked on the fork arm.
Maintenance and Repair With the fork restrained in the same manner as
its mounting on the lift truck, apply the test load
1. Repair forks only in accordance with the twice, gradually and without shock. Maintain the
manufacturers recomendations. test for 30 seconds each time.
Most repairs or modifications should be done Check the fork arm before and after the second
only by the original manufacturer of the forks or application of the test load. It shall not show any
an expert knowledgeable of the materials, permanent deformation.
design, welding and heat treatment process.
Consult the fork manufacturer for further
2. The following repairs or modifications SHOULD information as may be applicable to the specific
NOT be attempted. fork involved.
z Flame cutting holes or cutouts in fork blades. Testing is not required for repairs to the
positioning lock or the markings.
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.

73
Maintenance Section

Tire Inflation Information

Tire Inflation Tire Shipping Pressure


The inflation pressures shown in the following chart
are cold inflation shipping pressures for tires on
DOOSAN lift trucks.

Shipping
Ply Rating or
Size preeeure
Strength Index
kPa psi
B22/25/30/35X-5
18X7-8 Steer 16 1000 145
St
23X10-12Drive 16 930 135

The operating inflation pressure is based on the


weight of a ready-to-work lift truck without
attachments, at rated payload, and in average
Personal injury or death could result when tires operating conditions. Pressures for each application
are inflated incorrectly. may vary and should always be obtained youre
your tire supplier.
Use a self-attaching inflation chuck and stand
behind the tread when inflating a tire.
Adjusted Inflation Pressures
Proper inflation equipment, and training in
using the equipment, are necessary to avoid
A tire inflation in a warm shop area, 18C to 21C
overinflation. A tire blowout or rim failure can
(65F to 70F), will be underinflated if the lift truck
result from improper or misused equipment.
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.

74
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-Worm Drive Band Type Torques for Bolts and Nuts With
Standard Threads
NOTICE
Thread Size Standard Bolt & Nut Torque

The following chart gives the torques for initial Inch Nm1 lbin
installation of hose clamps on new hoses and for 1/4 124 93
reassembly or retightening of hose clamps on 5/16 257 185
existing hose. 3/8 457 335
7/16 7015 5011
1/2 10015 7511
Initial Installation
9/16 15020 11015
Clamp Width Torque on New Hose
5/8 20025 15018
Nm1 lbin
3/4 36050 27037
16 mm (.625 inch) 7.50.5 655
7/8 57080 42060
13.5 mm (.531 inch) 4.50.5 405
1 875100 64075
8 mm (.312 inch) 0.90.2 82
1 1/8 1100150 820110
Reassembly or
Clamp Width Retightening Torque 1 1/4 1350175 1000130

Nm
1
lbin 1 3/8 1600200 1180150

16 mm (.625 inch) 4.50.5 405 1 1/2 2000275 1480200


1
13.5 mm (.531 inch) 3.00.5 255 1 Newton meter (Nm) is approximately the same
8 mm (.312 inch) 0.70.2 62 as 0.1 kgm.
1
1 Newton meter (Nm) is approximately the same
as 0.1 kgm.

75
Maintenance Section

Torques for Taperlock studs Torque for Metric Fasteners


Standard Taperlock Stud
Thread Size NOTICE
Torque
Inch 1
Nm lbin
Be very careful never to mix metric with U.S.
1/4 83 62 customary (standard) fasteners. Mismatched or
5/16 175 134 incorrect fasteners will cause lift truck damage or
3/8 35 5 264 malfunction and may even result in personal injury.
7/16 4510 337
Original fasteners removed from the lift truck should
1/2 6510 487
be saved for reassembly whenever possible. If new
5/8 11020 8015 fasteners are needed, they must be of the same
3/4 17030 12522 size and grade as the ones that are being replaced.
7/8 26040 19030
1 40060 30045 The material strength identification is usually shown
on the bolt head by numbers.(8.8, 10.9, etc.) The
1 1/8 50070 37050
following chart gives standard torques for bolts and
1 1/4 65080 48060 nuts with Grade 8.8.
1 3/8 75090 55065
1 1/2 870100 64075
1
NOTE: Metric hardware must be replaced with
1 Newton meter (Nm) is approximately the same metric hardware. Check parts book for
as0.1 kgm. proper replacement.

METRIC ISO2 THREAD


Thread Size Standard Torque
Metric Nm1 lbin
M6 124 93
M8 257 185
M10 5510 417
M12 9515 7011
M14 15020 11015
M16 22030 16022
M20 45070 33050
M24 775100 57075
M30 1600200 1180150
M36 2700400 2000300
1
1 Newton meter (Nm) is approximately the same
as 0.1 kgm.
2
ISO-International Standard Organization.

76
Maintenance Section

Lubricant Specifications

Lubricant Information Hydraulic Oils (HYDO)


Some classifications and abbreviations we use in
this section follow S.A.E. (Society of automotive
Engineers) J754 nomenclature and others follow
S.A.E. J183.

All MIL specifications are U.S.A. Military.

Recommended oil viscosities are given in


theLubricant Viscosities chart later in this section
of the manual.

Greases are classified according to the National


Lubricating Grease Institute (NLGI) based on ASTM
D217-68 worked Penetration characteristics which The following commercial classifications can be
give a defined consistency numbel. used in the hydraulic system.

z ISO 6743/4 HM
Chain and Linkage Oils z AFNOR NFE 48-603 HM
DIN 51524 TEIL 2 H-LP
(DEO or EO)
z
z HAGGLUNDS DENISON HFO-HF2
z CINCINNATI 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
Use following engine oils are recommended for use system components. The following hydraulic Oil is
on chains and linkages. recommended in most hydraulic and hydrostatic
systems.
z European oil specification CCMC D3.
Make-up oil added to the hydraulic tanks must mix
z API Specification CD, CD/SF, CE with the oil already in the systems. Use only
petroleum products unless the systems are
z Military specifications MIL-L-2104D or E 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.

77
Maintenance Section

Drive Axle Oil Brake Fluid


NOTE: Failure to follow the recommendation will
cause shortened life due to excessive gear
wear.

The API GL- 4 specification or SAE 80W oils could


be used.

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 Located on the left site of the cowl.
improver and therefore, are not
recommended for transmission and drive Use heavy duty hydraulic brake fluid certified by the
train compartments. oil supplier to meet ISO 6743/4 HM VG 10 latest
revision.

TOTAL Azolla ZS 10
Lubricating Grease(MPGA)
AGIP Acer 10
Use Multipurpose Molybdenum Grease (MPGM) for
all lubrication points. If MPGM grease can not be
used, a multipurpose type grease which contains BP Energol HP 10 HLP 10
3% to 5% molybdenum disulfide can be used.
CALTEX Spindurn 10
NLGI NO.2 grade is suitable for most temperatures.
Use NLGI No.1 or No.0 grade for extremely low ELF Spinelf 10
temperature.
ESSO Nuto H 10 Spinesso 10

FINA Hydran 10

MOBIL Velocite oil No. 6 Velocite oil E

Tllvs oil C10


SHELL
Morlina 10

78
Maintenance Section

Battery Discharge Indicator

The battery discharge indicator should be observed of the full charge as indicated by their specific
frequently before and during operation. gravity.
This specification varies with different battery
manufacturers. See the manufacturers
specifications for specific gravity at 80% discharge.
If information is not available from the battery
supplier, use 1.140 specific gravity level.

A fully charged battery will cause a 9 segments to


be displayed on the LCD display. As the battery is
discharged, the LCD display will count down, 9, 8, 7,
and etc., until EL is displayed. When the battery
reaches 80% discharge level, the Micro-Controller
will cause the LCD display to continuously index
through the entire range (1 through 9 segments ) to
signal that the battery is discharged and lift interrupt
is imminent.

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%

79
Maintenance Section

Battery

The lift truck operator must not start his shift with a
battery that has been taken off a charger too soon.
When using pressure air for cleaning purposes, Batteries are designed to be charged and allowed
wear a protective face shield and protective to cool and stabilize. A battery should never be
clothing. Maximum air pressure must be below disconnected from a charger until the charge cycle
207 kPa (30 psi). has been completed.

Do not smoke near batteries that are being Low battery operation must be prevented.
stored or when checking the electrolyte level. Operation with a low battery may cause damage to
the battery.
Electrolyte is an acid solution and can cause Low battery operation will cause higher than normal
personal injury. Avoid contact with skin and current in the electrical system. This can damage
eyes. contactor tips or shorten motor brush life.

Batteries that have been fully charged should have


Maximum life and performance of lift truck batteries a tag attached for identification.
is dependent on the operator, battery charging,
maintenance and service. A battery should be recharged in 8 to 12 hours after
being discharged, depending on the charger type,
Most dirt and dust picked up by the battery can then allowed to cool and stabilize 4 to 8 hours.
usually be blown off with low pressure compressed Repeated undercharging must be prevented
air. because it can damage the battery.

However, if cells are overfilled and electrolyte A battery requires an equalizing charge at least
collects on the covers, the top of the battery will once every 20 normal charge/discharge cycles.
stay wet. This helps correct and prevent unequal cell specific
gravity (SG) readings. An equalizing charge is a
If necessary, clean the top of the battery with a cycle charge with modification, given usually at an
solution of baking soda and hot water. 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
NOTICE rate. It is usually given when the specific gravity
(SG) of electrolyte has a variation of more than 20
Vent caps must be tight to prevent soda solution points (.020) from cell to cell, after a regular cycle
from entering battery cells. charge.

A cycle charge will completely recharge the


To make the solution, add 0.5 kg (1 lb) of baking battery. The typical cycle charge for a fully
soda to 4 liters (1 gallon) of water. Use a brush discharged battery usually is an eight-hour charge.
having flexible bristles. Apply the soda solution to The battery must be recharged before it has been
the top of the battery until the cleaning action of the discharged over 80% of the rated capacity of the
soda stops. battery. The work shift of the lift truck can be
planned so the battery will not be discharged more
After cleaning action has stopped, rinse batteries than 80%.
thoroughly with water. Dry the batteries with low air
pressure.

80
Maintenance Section

A battery should never be left in a discharged state


because of sulfate formation. This reduces battery NOTICE
life drastically. To extend life always recharge the
DISPOSAL OF OLD BATTERY
battery without delay after it has been discharged.
Careless disposal of a battery can harm the
Repeated over discharging of the battery will
environment and can be dangerous to persons.
damage the cells, which will shorten battery life and
Always dispose of a battery to an authorized
increase operating cost. Battery life(number of
personnel only.
cycles) decreases as the depth of discharge
increases. The estimated life of the battery
Do not attempt to open or dismantle a battery or a
discharged to 80% will be approximately twice as
cell.
long as if it were discharged 100%.

The batterys maximum temperature is critical. The


electrolyte temperature should never exceed 43C
(110F) either while operating or charging. If higher
temperatures are maintained through use or abuse,
reduced battery service life can be expected.

Battery condition is important for a long life. The


elecrolyte level should be maintained at the
recommended levels and the battery should be kept
clean and dry. Washing down batteries at different
time periods will reduce the chance of grounds
caused by electrolyte spills and corrosion. If done
often enough, just washing with water alone will
eliminate the need for using baking soda. If not, a
solution of baking soda and water must be used to
wash battery at different time periods.

Add water at regular intervals. Enough water should


be added to bring the electrolyte approximately
13.0 mm (.50 inch) above the plates. This is a
simple matter with the use of an automatic cell filler,
which shows a light when the correct level has
been reached. Water should always be added
before charging to be sure thorough mixing with
acid when gassing occurs near the end of charging
period. Use distilled water or have the water supply
analyzed.

Charge batteries correctly. It is important that all


batteries should be charged according to the
manufacturers instructions. Most of the charging
equipment is fully automatic and should be checked
periodically. Never operate the lift truck with a fully
discharged battery because this will damage the
battery.

When 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.

81
Maintenance Section

Cold Storage Applications

When an electric lift truck is operated in cold Hydraulic System


storage applications, at temperatures as low as -
20C (-4F), the battery capacity is decreased.
Operation at cold temperatures can also cause
mechanical failures, short circuits and too much
wear due to the formation of ice crystals.

The direct cause of these problems is the extreme


changes in temperature in combination with
humidity in the air which can result in condensation.

To protect the electric lift trucks components and


decrease the effects of the cold temperature,
perform the following items before you put the lift
truck to work in cold storage applications.
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.
a. 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
b. 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.
c. Do not store a discharged battery at below
freezing temperature.

Observe the battery discharge indicator frequently

82
Maintenance Section

3. Put MPGM grease on the chains at one-week


intervals.

4. Check chains very carefully for wear on the link


plate edges, caused when they run over the
sheaves. Check the chains regularly for
cracked links, loss of shape in the holes, and
corrosion.

83
Maintenance Section

Lubricant Viscosities and Refill Capacities

Lubricant Viscosities Refill Capacities


LUBRICANT VISCOSITIES REFILL CAPACITIES-(APPROXIMATE)
FOR AMBIENT (OUTSIDE) TEMPERATURES Compartment or Imperial
Liters U.S. Gal
Compartment Oil C F System Gal
or System Viscosities Min Max Min Max Hydraulic & Power
Hydraulic 32 8.3 7.0
ISO VG 22 -30 +20 -22 +68 Steering System
and Power
ISO VG 32 -20 +30 -4 +86 1.2(Right) 0.4(Right) 0.32(Right)
Steering Drive Axle Housing
ISO VG 46 -10 +40 +14 +104 1.2(Left) 0.4(Left) 0.32(Left)
System
ISO VG 68 0 +50 +32 +122 Brake Reservoir 0.6 0.16 0.13
ISO 6743/4 HM

*Drive Axle API SAE


-20 +80 -4 +176
Housing GL-4 80W

*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.

84
Maintenance Section

Maintenance Intervals
Every 250 Service Hours or Monthly
NOTICE
Hydraulic Return Filter - Change ....................... 102
Never exceed the Maintenance Intervals specified Brake System - Check Oil Level ........................ 102
in the manual. Defects and/or damage to the Parking Brake - Test.......................................... 102
important functional components may be resulted in. Hydraulic and Power Steering System - Check . 103
Steer Angle Switches - Check, Clean................ 104
Mast Carriage, Chains and Attachments - Inspect,
Adjust, Lubricate................................................ 104
NOTICE

All maintenance and repair, except every 10 service Every 500 Service Hours or 3 Months
hours or daily, on the lift truck must be performed
by qualified and authorized personnel only. Drive Axle Oil - Change ..................................... 106
Cylinder Rod Extension - Adjust ........................ 107
Crosshead Rollers - Check................................ 107
Mast Hinge Pins - Lubricate .............................. 108
NOTICE Steering - Lubricate ........................................... 108
Overhead Guard - Inspect ................................. 108
Careless disposal of waste oil can harm the Control Panel - Clean, Inspect........................... 109
environment and can be dangerous to persons. Directional Lever - Check .................................. 110
Always dispose of waste oil to an authorized
personnel only.
Every 1000 Service Hours or 6 Months

Drive & Pump Motor - Clean, Inspect ................ 111


When Required Tires and Wheels - Inspect, Check.................... 113
Lift Chains - Test, Check, Adjust ....................... 114
Self Diagnostics - Test ......................................... 87
Compact Display Keys......................................... 87
Run Time Diagnostic ........................................... 88 Every 2000 Service Hours or Yearly
Carriage Roller Extrusion Adjust ....................... 91
Fuses - Replace................................................... 93 Hydraulic , Power Steering System ................... 116
Seat - Lubricate ................................................... 93 Steer Wheel Bearings - Reassemble................. 117
Wheel Bolts - Check for Tightness....................... 94 Fork - Inspect .................................................... 119
Drive Axle Gear Boxes......................................... 94 Environment Protection ..................................... 122

Every 10 Service Hours or Daily

Walk - Around Inspection - Inspect ...................... 95


Mast Channels - Lubricate ................................... 96
Battery - Check, Exchange, Change.................... 97
Indicator - Check.................................................. 99
Tires and Wheels - Inspect ................................ 100
Back - up Alarm (If Equipped) - Test.................. 100

First 50 - 100 Service Hours or 3 Months

Drive Axle - Change Oil ..................................... 101

85
Maintenance Section

Quick Reference to Maintenance Schedule EVERY

1000 Service Hours or 6 Months

1500 Service Hours or 9 Months


50-100 Service Hours or a Week

500 Service Hours or 3 Months


250 Service Hours or a Month

2000 Service Hours or a Year


10 Service Hours or a Day
ITEMS PAGE

When Required
Back - up Alarm (If Equipped) Test 100 O
Check, Exchange,
Battery 97 O
Change
Brake System Check Oil Level 102 O
Carriage Roller Extrusion Adjust 91 O
Compact Display Keys Clean, Inspect 87 O
Control Panel 109 O
Crosshead Rollers Check 107 O
Cylinder Rod Extension Adjust 107 O
Directional Lever Check 110 O
Drive & Pump Motor Clean, Inspect 111 O
Drive Axle Change Oil 101 O
Drive Axle Gear Boxes Change 94 O
Drive Axle Oil 106 O
Fork Inspect 119 O
Fuses Replace 93 O
Hydraulic , Power Steering System 116 O
Hydraulic and Power Steering System Check 103 O
Hydraulic Return Filter Change 102 O
Indicator Check 99 O
Lift Chains Test, Check, Adjust 114 O
Inspect, Adjust,
Mast Carriage, Chains and Attachments 104 O
Lubricate
Mast Channels Lubricate 97 O
Mast Hinge Pins Lubricate 108 O
Overhead Guard Inspect 108 O
Parking Brake Test 102 O
Run Time Diagnostic 88 O
Seat Lubricate 93 O
Self Diagnostics Test 87 O
Steer Angle Switches Check, Clean 104 O
Steer Wheel Bearings Reassemble 117 O
Steering Lubricate 108 O
Tires and Wheels Inspect 100 O
Tires and Wheels Inspect, Check 113 O
Walk - Around Inspection Inspect 95 O
Wheel Bolts Check for Tightness 94 O

86
Maintenance Section

When Required
You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any aperation or maintenance procedures.

Self Diagnostics - Test Compact Display Keys


Test Circuits and Components

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 2. During usual operations, this key, pressed for 3
and the mast tilted forward until the fork tips consecutive s, allows you to access merely to
touch the floor. diagnostic mode.

2. Block the drive wheels. Remember that if the display is operating in


diagnostic mode during typical operations, you can
3. Release the parking brake. exit this procedure pressing once ENTER key.

4. Move the directional control lever to NEUTRAL.

5. Move the key switch to OFF.

87
Maintenance Section

Moreover, ENTER key is used to confirm the new Run Time Diagnostic
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


value of the parameter displayed.

TURTLE key

Remember that pressing this key you can toggle This operating mode enables you to test main
between slow running and normal working condition analog and digital signals managed by your system.
(if the lift truck is already in speed limitation mode).
Enter diagnostic mode if you are switching on your
DOWN key lift truck:

1. Pressing of this key, in calibration and 1. Press ENTER key (for 3 consecutive s) until the
diagnostic mode, you decrease the number of symbol 0 lights up.
the parameter displayed.
2. Press DOWN key to enter diagnostic mode; the
2. In calibration phase, you decrease the numeric symbol d is visualized and it persists until the
value of the parameter displayed. first parameter has been selected.

3. "3. way of shifting from the visualization of "time Enter diagnostic mode if you are working as usual
meter" and "odometer": you can do it by with your lift truck:
pressing the "DOWN ARROW" button of
Compact display for 1 second in succession 1. Press ENTER key (for 3 consecutive s) until
during normal working of the display. symbol d appears; it will persist as long as the
first parameter has been selected.
E-S-H key
After diagnostic operation mode has been
enabled, you can choose the parameter you
With this key, you can modify the device operating
want to analyse using UP and DOWN keys
condition, in a circular sequence, as described in
(parameter number increases using UP key and
Table 7 :
decreases with DOWN key)

WORKING Here, in Table 11, you have a list of the


CURRENT WORKING
CONDITION AFTER parameters you can analyze with their
CONDITION
THE KEY PRESSURE respective displaying order :DOWN key).
Economic (E) Standard (S)
Standard (S) High (H)
High (H) Limitation 1 (L1))
Limitation 1 (L1) Limitation 2 (L2)
Limitation 2 (L2) Limitation 3 (L3)
Limitation 3 (L3) Economic (E)
Table 7

NOTE: You can modify system operating modes


only after enabling their management with
EYE applicative software

88
Maintenance Section

PARAMETER NUMBER PARAMETER DESCRIPTION

1 Right traction motor speed [rpm]

2 Right traction motor speed reference [rpm]


3 Left traction motor speed [rpm]

4 Left traction motor speed reference [rpm]

5 Lift voltage [mV]

6 Battery voltage [V10]

7 Right traction motor power module temperature [C / F]

8 Pump motor power module temperature [C / 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]

14 Left traction motor power module temperature [C / F]


15 Right traction motor phase current U [A rms]

16 Right traction motor phase current V [A rms]

17 Right traction motor phase current W [A rms]

18 Left traction motor phase current U [A rms]

19 Left traction motor phase current V [A rms]

20 Left traction motor phase current W [A rms]

21 Pump motor phase current U [A rms]

22 Pump motor phase current V [A rms]

23 Pump motor phase current W [A rms]

24 Right traction motor temperature [C / F]

25 Left traction motor temperature [C / F]

26 Pump motor temperature [C / F]


27 Seat switch hour meter [h]

28 Drive motor hour meter [h]

29 Pump motor hour meter [h]

30 Seat switch[digit]

31 Park brake switch [digit]

32 Start switch [digit]

33 Reverse traction direction switch [digit]

34 Forward traction direction switch [digit]

35 Pedal brake switch [digit]

89
Maintenance Section

36 3 / 4 wheels selection 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]

45 12V out [digit]

46 24V out [digit]

47 Buzzer command [digit]

48 Fans command [digit]

49 Drive right motor encoder channels

50 Drive left motor encoder channels


51 Drive pump motor encoder channels

52 Lift pressure [bar 10]

53 Pressure sensor voltage [mV]

54 Weight of the load on the forks [kg]

Table 11 : List of accessible parameters in diagnostic mode (from 1th to 54th).

90
Maintenance Section

In diagnostic mode selected parameter is visualized Carriage Roller Extrusion Adjust


as follows:
1. Set the mast vertical.
- In the area dedicated to speed and alarm
signals, appears parameter number( flashing) 2. Lower the carriage completely.
- Its actual value is displayed in the area reserved 3. On full free lift and full free triple lift models, the
to the time meter. bottom of the inner mast must be flush with the
bottom of the stationary mast.
In particular, if the selected parameter is:

Analogue input: COMPACT display shows the


parameter value, expressed in the
unit of Table 11

Digital input: if the command activated by the


operator corresponds to the
parameter selected, the value of the
quantity is visualized.
Other way the symbol e (error)
appears, except in following case:

- Seat switch active, for any selected


digital input.. 4. Measure the distance from the bottom of the
inner upright to the bottom of carriage bearing.
To exit diagnostic mode, type ENTER key again.
5. The measurement (A) must be as follows in
NOTE: If an alarm occurs when diagnostic mode is Chart below..
enabled, and the system is working as
usual, display returns automatically to its
typical visualization mode. However you Height of carriage roller extrusion (A)
can enter diagnostic mode again, pressing STD mast FF mast FFT mast
ENTER key (for 3 consecutives), until the -6 8 8
last parameter displayed before exiting is
visualized.

If the selected parameter is a temperature, also


thermal alarm symbol is visualized.

91
Maintenance Section

Power Modules Discharge


2. Open the hood.

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.
3. Before touching any electrical components, the
power modules must be discharged. Put a 90
ohm, 30 watt resistor in position between the
terminals of the power modules 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.

The power modules is located in the control panel


at the rear of the lift truck.

1. Disconnect the battery..

92
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
DC/DC converter- 10 amps
Lights(1) - 10 amps
Lights(2) - 10 amps
FAN - 10amps
Key Switch - 10amps

Main Fuse - 700 amps

93
Maintenance Section

Wheel Bolts - Check for Tightness Drive Axle Gear Boxes


Steer Wheels NOTE: If there is a leak from drive axle, the oil level
should be measured as follows.

Measure Lubricant Level

Typical example

1. Inspect tightness of wheel nuts in a sequence


opposite each other 140 Nm (105 abaft).
1. Park the lift truck on a level surface. Raise the
carriage high enough to gain access to the
Drive Wheels
housing level/fill plugs.

2. Use blocking to secure the carriage in this


position.

Typical example

2. Inspect tightness of wheel nuts in a sequence


opposite each other to 25020 Nm (187.5 lbft).
3. Remove the housing level checking plugs.
Maintain lubricant level to the bottom of the plug
opening. Install the level checking plugs.

4. Remove blocking. Lower the carriage.

94
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 aperation or maintenance procedures.

Walk - Around Inspection -


Inspect

6. Inspect the tires, valve stems and wheels for


cuts, gouges, foreign objects and loose or
missing nuts. Refer to Tires and Wheels in
Every 10 Service Hours or Daily section, if
repairs or replacement is necessary.
1. Inspect the operators compartment for loose
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.

7. Inspect the overhead guard for damage, loose


or missing mounting bolts.

4. Inspect the mast and lift chains for wear, broken


links, pins and loose rollers.

5. Inspect the carriage, forks or attachments for


wear, damage and loose or missing bolts.

8. Inspect the hydraulic system for leaks, worn


hoses or damaged lines.

95
Maintenance Section

9. Inspect the drive axle housing and the ground 12. Move the directional lever to NEUTRAL.
for oil leaks. Refer to Drive Axle in Every
1000 Service Hours or 6 Months section, if an
oil leak is found.

13. Turn the key switch to ON.

10. Adjust the operators seat.

Check the LCD display for battery discharge status.


A fully charged battery will be displayed on the LCD
display.
11. Adjust the steering wheel to a comfortable
position. 14. Check the operation of parking brake, service
brake, controls and other devices that may be
equipped on your lift truck.

15. Check the operation of parking brake, service


brake, controls and other devices that may be
equipped on your lift truck.

96
Maintenance Section

Mast Channels - Lubricate Battery - Check, Exchange,


Change
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.

97
Maintenance Section

Check Electrolyte 3. Check the specific gravity of the battery. If the


specific gravity reading is below 1.150, the
1. Inspect the battery compartment for loose battery must be charged.
connections, frayed cables and properly
secured battery restraint. NOTICE

2. Clean the top of the battery. If necessary, clean The battery should not be used if a difference in
the top of the battery with a solution of baking specific gravity between two cells is greater
soda and hot water. 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.
NOTICE

Vent caps must be tight to prevent soda solution 4. Check the electrolyte level of all cells. Maintain
from entering battery cells. the electrolyte level about 13 mm (.50 inch)
above the plates. Add water as needed. Use
A clean battery top is essential to avoid conductive only distilled water. Water is always added after
paths on higher voltage batteries. a battery is charged.

5. Lower the seat and battery cover. To closed


To make the solution, add 0.5 kg (1 lb) of baking position and secure with the latch on the front of
soda to 4 liters (1 gallon) of water. Use a brush the cover.
having flexible bristles. Apply the soda solution to
the top of the battery until the cleaning action of the 6. Connect the battery.
soda stops.
After cleaning action has stopped, rinse batteries
thoroughly with water. Dry the batteries with low air
Battery Exchanging
pressure.
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


position and secure with the latch on the front of
the cover.

9. Adjust the seat position.

98
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


access. 3. Move the directional control lever to the
2. Connect the battery to the charger and charge NEUTRAL position.
the battery. Observe safety warnings for
charging batteries.
4. Close the seat switch.
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.

99
Maintenance Section

Tires and Wheels - Inspect

Inflate the tires, if necessary. See Tire Inflation


Inspect tires and valve stems for wear, cuts, Information section of this manual.
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 With the key switch on, apply the service brake and
parts. Do not, under any circumstances, attempt to move the directional control lever into REVERSE.
rework, weld, heat or braze any rim components.
The alarm should start to sound immediately. It will
Check Inflation Pressure (If equipped with continue to sound until the directional control lever
pneumatic tires) is moved to NEUTRAL or FORWARD.

Measure the tire air pressure on each tire.

100
Maintenance Section

First 50 - 100 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 aperation or maintenance procedures.

Drive Axle - Change Oil


After the first 50~100 hour of operation,
subseguently after every 500 hours or 3 months.

5. Fill the drive axle housing with oil through air -


breather plug hole, the accurate amount of oil is
defined by the opening of level checking plug.

6. Maintain the oil level.


Park the lift truck level, with the parking brake
engaged and directional control lever in NEUTRAL. 7. Screw the level checking plug and air
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. Unscrew oil air - breather (Oil filling plug) ,


level checking plug and remove the drain
plug . Allow the oil to drain.

4. Clean and install the drain plugs.

101
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 aperation or maintenance procedures.

Hydraulic Return Filter - Change Brake System - Check Oil Level

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.

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 ca.

Parking Brake - Test


1. Loosen the bolts of the hydraulic tank top plate
assembly. 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.

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.

102
Maintenance Section

Hydraulic and Power Steering


System - Check

2. Halfway up the incline, stop the lift truck by


applying the service brakes.

1. Operate the lift truck for a few minutes to warm


the oil.

2. Park the lift truck level, with the forks lowered,


mast tilted back (all cylinders retracted), parking
brake engaged, directional control lever in
NEUTRAL, and the key switch to OFF.

3. Open the hood.

4. Remove the dipstick.


3. Engage the parking brake.
5. Maintain the oil level to the full mark on the
4. Release the service brake. dipstick.

If the parking brake has the correct adjustment, the 6. Install the dipstick.
lift truck will be held in place.
7. Install the access cover.
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.

103
Maintenance Section

Steer Angle Switches - Check, Mast Carriage, Chains and


Clean Attachments - Inspect, Adjust,
Lubricate

1. Clean steer angle switches with 205 kpa (30


psi) maximum air pressure until dust is removed. 1. Operate the lift, tilt and attachment controls.
Listen for unusual noises. These may indicate a
2. Check the operation of steer angle switches need for repair.
and the tightness of bracket Adjustment if
needed.

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.

104
Maintenance Section

5. Raise and lower the carriage a few times to


work lubricant into the chain links.

NOTICE

Lubricate chains more frequently than normal


where the atmosphere can cause corrosion to
components, or when lift truck must work in rapid lift
cycles.

6. Inspect the chain anchors and individual links


for wear, loose pins or cracked leaves.

NOTE: Have all repairs and adjustments made as


required.

105
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 aperation or maintenance procedures.

Drive Axle Oil - Change


See topic, Drive Axle Oil - Change in First 50 -
100 Service Hours .

Tilt Cylinders

Lubricate-Pivot Eyebolts

3. Check the pivot eye pins for loose retainer bolts


and wear.

1. Remove floor plates.

4. Lubricate the mast pivot eyes, one fitting on


each side of the mast.

2. Lubricate pivot eyebolts, one fitting on each tilt


cylinder.

5. Check the mast pivot eye pins for loose retainer


bolts and wear.

106
Maintenance Section

Cylinder Rod Extension - Adjust Crosshead Rollers - Check


Check Operation

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.

1. Tilt the mast to the full forward position.

Typical example

2. Check for damaged crosshead rollers, guards


and retainer rings.

2. Measure the extended length of the cylinder


rods from the cylinder housing to the pivot eye.
The cylinder rods must be within 3.18 mm (.125
inch) of each other..

3. To adjust the cylinder rod extension, loosen bolt.

4. Turn the cylinder rod in or out of pivot eye to


obtain the proper adjustment. Turning the rod
into pivot eye shortens the stroke. Turning the
rod out of pivot eye lengthens the stroke.

5. Tighten bolt to a torque of 9515 Nm (7010


lbft). Check the cylinder rods again for even
travel.

6. With the mast at the tilt back position, install


shims as required to permit no gap between
pivot eye and spacer, so the mast does not
twist at full tilt back position.

107
Maintenance Section

Mast Hinge Pins - Lubricate Steering - Lubricate


Lubricate two fittings Lubricate one fitting

1. Lower the forks and tilt the mast forward. Lubricate fitting on steer axle.

Overhead Guard - Inspect

2. Lubricate the mast hinge pins. One fitting on


each side of the mast. Total of two fittings.

Lubricate more frequently than normal where the Look for any loose or damaged bolts. Replace
ground minute particles prevent smooth working. damaged bolts or missing bolts with original
equipment part only. Retighten bolts to a torque of
9010 Nm (67.510 lbft).

Check the overhead guard for bent or cracked


sections. Repair if needed.

108
Maintenance Section

Control Panel - Clean, Inspect


Park the lift truck level, with the forks lowered, Pressurized air can cause personal injury.
parking brake engaged, directional control lever in
NEUTRAL, and the key switch to OFF. When using pressurized air for cleaning, wear a
protective face shield, protective clothing and
Disconnect the battery. protective shoes.

The maximum air pressure must be below 205


kPa (30 psi) for cleaning purposes.

1. Open the hood.

Battery voltage and high amperage are present. 3. Clean the control panel with 205 kPa (30 psi)
maximum air pressure, until dust is removed
The power modules must be discharged before from the control panel.
any contact with the control panel is made.
4. Inspect all wiring for loose connections, frayed
Personal injury could result if it has not been cables and loose mounting bolts.
discharged properly.
5. Inspect the fuses for looseness, corrosion and
broken connections.
2. Discharge the head capacitor. See power
modules in When Required section of this
manual.

6. Close the hood cover and connect the battery.

109
Maintenance Section

Directional Lever - Check

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.

110
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 aperation or maintenance procedures.

Drive & 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
1. Disconnect the battery. wheels are just off the ground.

2. Block the steer wheels. 6. Put stands under the frame. Remove the
tension on the lift chains.
3. Remove the battery. See topic, Battery in
Every 10 Service Hours or Daily section of 7. Remove the battery.
this manual.
8. Remove the floor plate.

NOTICE

Do not move directional lever from one direction to


the other when the drive wheels are off the ground
and rotating.

Damage can be caused to the control panel.

111
Maintenance Section

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.

9. Blow off the drive motor end shield with 205


kPa (30 psi) maximum air pressure, until dust is
removed from the motor.

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.

112
Maintenance Section

Tires and Wheels - Inspect, Check

Servicing and changing tires and rims can be


dangerous and should be done only by trained
personnel using proper tools and procedures. If
correct procedures are not followed while
servicing tires and rims, the assemblies could
burst with explosive force and cause serious
physical injury or death. Follow carefully the
specific information provided by your tire
serving man or dealer.
Do NOT inflate a tire that has been run while flat or
underinflated, without first checking to make sure
the locking ring on the wheel is not damaged and is
in position.

When tires are changed be sure to clean all rim


parts, and if necessary, repaint to stop detrimental
effects of corrosion.
Sand blasting is recommended for removal of rust.

Check all components carefully and replace any


cracked, badly worn, damaged and severely rusted
or corroded parts with new parts of the same size
and type. If there is any doubt, replace with new
parts. Do not, under any circumstances, attempt to
Inspect tires for wear, cuts, gouges and foreign rework, weld, heat or braze any rim components.
objects. Look for bent rims and correct seating of
locking ring.

If equipped with pneumatic tires, check tires for


proper inflation. See topic, Tire Inflation 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 1. Install drive wheel. Install two nuts opposite
ratings when pneumatic tires are used to replace each other (180).
solid (cushion) tires.
2. Install the remaining nuts. Tighten all nuts in a
crisscross sequence opposite each other (180)
to 250 Nm (187 lbft).

3. Reverse the lifting procedure for the front of the


lift truck and lower it to the ground.

113
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 (%)


Typical example for carriage equal tension
= ( Actual measurement - Pitch** X 10
Pitch** X 10 )x100
If the tension is not the same on both chains, take
1) FOR STO,FF,FFT MAST(2~Light 3.5 ton) for the procedure as follows.
2~3 ton truck (4000~6500b)
25.4 (1 in) for 3.3~Light 3.5 ton truck(7000b) NOTE: If carriage height is not correct, make
2) FOR QUAD MAST (for 2.5 ton) adjustments by following procedures.
19.05 (0.75 in) for inner mast chain.
25.4 (1 in) for carriage and qute mast chain.

**Chain Pitch = 15.88 mm(0.63 in)

114
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, QUAD 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, QUAD 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 tension. If not equal, repeat the same
check equal chain tension. If not equal, repeat procedure as step 1 through step 3.
the same procedure as step 1 through step 3.
5. Put LOCTITE No. 242 tread lock on the threads
5. Put LOCTITE No. 242 Tread lock on the of the anchor nuts(3),(4) after the adjustment is
threads of the anchor nuts(1),(2) after the completed.
adjustment is completed.

115
Maintenance Section

Every 2000 Service Hours or Yearly


You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any aperation or maintenance procedures.

Hydraulic , Power Steering


System
Change Oil and Filter Element

3. Remove an discard the hydraulic filter.

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.

4. Remove the breather / dipstick and the strainer.


Wash them in clean, nonflammable solvent and
dry them.

5. Install the strainer. Fill the hydraulic tank. See


Refill Capacities. Install the dipstick.

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.
2. Remove the hydraulic tank drain plug. Allow the
oil to drain. Clean and install the plug.

116
Maintenance Section

Steer Wheel Bearings -


Reassemble
Park the lift truck level with the forks lowered,
parking brake engaged, and directional control
lever in NEUTRAL.

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


breather / dipstick. Add oil if necessary.F.
1. Lift the steer wheels off the ground. Place
11. Remove the inner bearing. Clean and lubricate stands or blocking under the frame and steer
the steering knuckle. Repack both the inner and axle to support the lift truck.
outer bearing cones.
2. Remove the hub cap which is pressed into the
12. Install the inner bearing. Lubricate the seal and wheel hub.
install the wheel assembly on the knuckle.

13. Install the outer wheel bearing and the outer


washer. Install the lockwasher and locknut.

3. Straighten the lockwasher tangs.

14. Tighten the locknut to 135 Nm, while turning


wheel hub to seat the bearing.

15. Loosen the locknut. Retorque it to 505 Nm.


Bend the lockwasher tang to secure locknut.

16. Install the hub cap.

17. Raise the lift truck and remove the blocking


Lower the lift truck to the ground.

117
Maintenance Section

4. Remove the locknut, lockwasher and flat 7. While rotating the wheel, tighten the locknut to
washer. Remove the outer wheel bearing. 34 Nm (24 lbft). Loosen the nut completely.
Tighten the nut again to a torque of 113 Nm
(82 lbft) and lock within this range. Install the
cover.

8. Raise the lift truck and remove the blocking.


Lower the lift truck to the floor.

5. Remove the wheel assembly. Examine the


wheel for damage and wear. Replace the wheel
if necessary.

6. Install the steer wheel. Put two nuts opposite


each other (180). Tighten both. Install all
remaining nuts. Tighten all nuts in a crisscross
sequence opposite each other (180) to a
torque of 140 Nm (105 lbft).

118
Maintenance Section

Fork - Inspect

2. Check the angle between the upper face of the


blade and the front face of the shank. The fork
Forks should be inspected, at a minimum, every 12 should be withdrawn from service if angle (C)
months. If the truck is being used in a multi-shift or exceeds 93 degrees or deviates by more than 3
heavy duty operation, they should be checked degrees from an original angle other than 90
every six months. degrees, as may be found in some special
appli- cation forks.
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.
3. Check the straightness of the upper face of
Inspectors should be trained and qualified in blade (D) and the front face of shank (E) with a
accordance with The American Society for Non straight edge.
Destructive Testing, Level II Qualifications.
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").

119
Maintenance Section

4. Check the difference in height of one fork tip to 6. Check the fork mountings (K) for wear, crushing
the other when mounted on the fork carrier. A and other local deformation, which can cause
difference in fork tip height can result in uneven excessive side to side wobble of the forks.
support of the load and cause problems with Excessive clearance on hook type forks may
entering loads. allow them to fall from the carrier. Forks which
show visible signs of such damage should be
The maximum recommended difference in fork removed from service.
tip elevation (F) is 6.5 mm (0.25") for pallet
forks and 3 mm (0.125") for fully tapered forks. 7. Check the positioning lock and other fork
The maximum allowable difference in fork tip retention devices to make sure they are in place
eleva- tion between the two or more forks is 3 and working.
percent of blade length (L).
Hook type forks use a spring loaded pin (M),
Replace one or both forks when the difference located in the top hook, to engage notches in
in fork tip height exceeds the maximum the top carriage bar to hold the fork in place.
allowable difference. Contact your local
DOOSAN Lift Truck Dealer for further When adjusting the fork spacing, the forks are
information. prevented from sliding off the end of the
carriage by stop blocks. These stop blocks are
at both ends of the carriage and in the path of
the bottom fork hook. The load backrest
extension may be used in place of the stop
blocks in some cases.

Shaft mounted forks may use set collars or


spac- ers on the shaft to either side of the fork.
They may also use U bolts, pins, or similar
devices which engage the fork through the top
structure of the carriage.

5. Check the fork blade (J) and shank (H) for wear
with special attention to the heel (G). The fork
should be withdrawn from service if the
thickness is reduced to 90 percent or less of the
original thickness.

Fork blade length may also be reduced by wear,


especially on tapered forks and platens.
Remove the forks from service when the blade
length is no longer adequate for the intended
loads.

120
Maintenance Section

8. Check fork markings (N) for legibility. Renew 9. a. Lift the mast and operate the tilt control lever,
markings as required to retain legibility. until the top surface of the forks is parallel
with the floor. Place two straight bars that are
the same width as the carriage, accross 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
completer 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
procedure with the second fork. Repeat Step
a.

121
Environment Protection 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.

122
Index Section

Index Crosshead Rollers - Check................................ 107


Crushing or Cutting Prevention ........................... 13
Cylinder Rod Extension - Adjust ........................ 107
#
12 Months Inspection........................................... 73
D
Daily Inspection-Before First Use and at Each
Preventive Maintenance Inspection..................... 72
A
Declaration of Conformity .................................... 30
Directional Control Lever ..................................... 48
AC ......................................................................... 9
Directional Lever - Check .................................. 110
Accelerator Pedal ................................................ 48
Display Segments ............................................... 41
Adjusted Inflation Pressures ................................ 74
DOWN key .......................................................... 88
Adjustment of Armrest ......................................... 60
Drive & Pump Motor - Clean, Inspect ................ 111
After Storage........................................................ 67
Drive Axle - Change Oil ..................................... 101
Attachment Abbreviations (includes Special Forks)
Drive Axle Gear Boxes ........................................ 94
............................................................................ 39
Drive Axle Oil - Change ..................................... 106
Avoiding Lift Truck Tipover .................................. 21
Drive Axle Oil ...................................................... 78
Drive Wheels ....................................................... 94
During Storage .................................................... 67
B
Back - up Alarm (If Equipped) - Test.................. 100
Battery - Check, Exchange, Change.................... 97
E
Battery Access..................................................... 97
E-S-H key............................................................ 88
Battery Charging.................................................. 99
Electrical Braking (Plugging) ............................... 56
Battery Discharge Indicator.................................. 79
Emergency Switch (If Equipped) ......................... 46
Battery Disconnect Before Servicing Warning ....... 9
Emergency Switch............................................... 59
Battery Exchanging.............................................. 98
ENTER key ......................................................... 87
Battery Restraint Warning...................................... 8
Environment Management .................................... 3
Battery ............................................................ 80,82
Environment Protection ..................................... 122
Before Operating the Lift Truck ....................... 12,51
Every 10 Service Hours or Daily.......................... 95
Before Starting the Lift Truck ............................... 11
Every 1000 Service Hours or 6 Months ............. 111
Before Storage..................................................... 67
Every 2000 Service Hours or Yearly.................. 116
Bent or Twisted Forks .......................................... 71
Every 250 Service Hours or Monthly ................. 102
Better Battery Performance ................................. 53
Every 500 Service Hours or 3 Months ............... 106
Brake Fluid .......................................................... 78
Brake System - Check Oil Level ........................ 102
Burn Prevention ................................................... 14
F
Fatigue ................................................................ 71
C
Film For function of pedals (if equipped) ............. 48
Finger Tip (Option) .............................................. 58
Capacity Chart - With Side Shifter (Hook on) ....... 36
Fire or Explosion Prevention ............................... 15
Capacity Chart - With Side Shifter (Integrated) .... 35
First 50 - 100 Service Hours or 3 Months .......... 101
Capacity Chart ..................................................... 34
First Installation ................................................... 72
Carriage Roller Extrusion Adjust ....................... 91
Fluid Penetration ................................................. 13
Causes of Fork Failure......................................... 71
Foreword ............................................................... 2
Center of Gravity (CG) ......................................... 21
Fork - Inspect .................................................... 119
Chain and Linkage Oils (DEO or EO) .................. 77
Fork Inspection.................................................... 72
Change Oil and Filter Element ........................... 116
Forward and Backward Adjustment..................... 60
Check Electrolyte................................................. 98
Front and Rear Floodlights Switch....................... 45
Check for Equal Tension.................................... 114
Function of Knobs ............................................... 58
Check Operation................................................ 107
Fuses - Replace .................................................. 93
Cold Storage Applications.................................... 82
Compact Display Keys......................................... 87
Control Panel - Clean, Inspect ........................... 109

123
Index Section

G Lifting the Load.................................................... 61


Literature Information ............................................ 2
General Hazard Information................................. 10 Load Backrest Must Be In Place Warning ............. 7
General Warnings to Operator ............................... 6 Loading or Unloading Trucks/Trailers.................. 13
Lubricant Information........................................... 77
Lubricant Specifications ...................................... 77
H Lubricant Viscosities and Refill Capacities .......... 84
Lubricant Viscosities............................................ 84
Hand Placement Warning ...................................... 7 Lubricate one fitting ........................................... 108
Hook-on type Fork ............................................... 66 Lubricate two fittings.......................................... 108
Horn Button ......................................................... 45 Lubricating Grease(MPGA) ................................. 78
How to Survive in a Tipover (If Operator Restraint
System Equipped) ............................................... 29
Hydraulic , Power Steering System.................... 116 M
Hydraulic and Power Steering System - Check ... 103
Hydraulic Oils (HYDO) ......................................... 77 Machine Lifting and Tiedown Information ............ 68
Hydraulic Return Filter - Change........................ 102 Maintenance and Repair ..................................... 73
Hydraulic System................................................. 82 Maintenance Information ..................................... 13
Maintenance Intervals ...................................... 3,85
Maintenance.......................................................... 3
I Mast Abbreviations.............................................. 39
Mast Carriage, Chains and Attachments - Inspect,
Identification, Lift Capacity and Attachment Plate .... 38 Adjust, Lubricate................................................ 104
If Optional Suspension Seat Equipped ................ 18 Mast Channels - Lubricate................................... 97
Important Safety Information.................................. 4 Mast Hinge Pins - Lubricate .............................. 108
Improper Modification or Repair........................... 71 Measure Lubricant Level ..................................... 94
Inching into Loads................................................ 61 Monitoring Systems............................................. 41
Index.................................................................. 123 Mono-Ped Control System (Option)..................... 57
Indicator - Check.................................................. 99 Mounting and Dismounting.................................. 11
Indicator(Compact Display).................................. 41
Inspection, Maintenance and Repair of Lift Truck
Forks.................................................................... 70 N
No Alarm, No Movement ..................................... 44
K No Riders Warning ................................................ 8
No Standing On Forks Warning, No Standing Under
Key Switch........................................................... 40 Forks Warning....................................................... 7
Noise and Vibration ............................................. 33
Noise at operator ear (measured by PREN 12053)
L ............................................................................ 33

LED Indicators ..................................................... 44


Lift Chain Adjustment......................................... 114 O
Lift Chain Wear Test .......................................... 114
Lift Chains - Test, Check, Adjust........................ 114 Operating Techniques ......................................... 61
Lift Chains....................................................... 11,82 Operating the Lift Truck....................................... 12
Lift Control knob................................................... 58 Operation Information.......................................... 11
Lift Control Lever ................................................. 49 Operation .............................................................. 3
Lift Fork Adjustment ............................................. 66 Operator Restraint System (If Equipped).......... 2,16
Lift Truck Capacity Rating.................................... 38 Operators Station and Monitoring Systems ........ 40
Lift Truck Controls................................................ 47 Operators Warning and Identification Plate ........ 38
Lift Truck Operation ............................................. 54 Operators Warning Plate .................................... 38
Lift Truck Parking................................................. 13 Overhead Guard - Inspect ................................. 108
Lift Truck Stability Base ....................................... 22 Overhead Guard Must Be In Place Warning.......... 7
Lift Truck Stability ................................................ 21 Overloading......................................................... 71
Lift Truck Turning................................................. 62
Lifting Drums or Round Objects ........................... 63

124
Index Section

P Torque for Standard Bolts, Nuts and Taperlock


Studs ................................................................... 75
Packing Alarm Warning (If Equipped) .................. 65 Torque for Standard Hose Clamps-Worm Drive
Parking Brake - Test .......................................... 102 Band Type........................................................... 75
Parking Brake Warning .......................................... 8 Torque Specifications.......................................... 75
Parking Brake ...................................................... 47 Torques for Bolts and Nuts With Standard Threads
Parking the Lift Truck ........................................... 64 ............................................................................ 75
Pressure Air ......................................................... 13 Torques for Taperlock studs................................ 76
Towing Information.............................................. 69
Training Required To Operate or Service Warning.... 5
R Transportation Hints ............................................ 68
Traveling With or Without a load ......................... 62
Refill Capacities ................................................... 84 TURTLE key........................................................ 88
Run Time Diagnostic ........................................... 88

U
S
Unloading Lift Truck ............................................ 63
Safety Rules ........................................................ 23 Up and Down Adjustment.................................... 60
Safety ................................................................. 2,5 UP key................................................................. 88
Seat - Lubricate ................................................... 93
Seat Adjustment ............................................. 17,45
Seat Switch Warning ............................................. 9 W
Seat Switch.......................................................... 40
Self Diagnostics - Test ......................................... 87 Walk-Around Inspection ...................................... 51
Serial Number...................................................... 37 Walk - Around Inspection - Inspect...................... 95
Serial Numbers Locations.................................... 37 Warning Lamp..................................................... 59
Service Brake Pedal ............................................ 47 Warning Signs and Labels................................ 5,16
Shipping............................................................... 68 Wheel Bolts - Check for Tightness ...................... 94
Sideshift Attachment Control (If Equipped) .......... 50 When Required .............................................. 85,87
Sideshift Attachment Control ............................... 59
Specifications....................................................... 31
Stability and Center of Gravity ............................. 21
Starting the Lift Truck........................................... 12
Steer Angle Switches - Check, Clean ................ 104
Steer Wheel Bearings - Reassemble ................. 117
Steer Wheels ....................................................... 94
Steering - Lubricate ........................................... 108
Steering Knob (If Equipped)................................. 57
Storage Information ............................................. 67

T
Table of Contents .................................................. 1
Test Circuits and Components............................. 87
Tilt Control knob................................................... 58
Tilt Control Lever ................................................. 49
Tilt Cylinders ...................................................... 106
Tilt Steering Column ............................................ 45
Tire Inflation Information ...................................... 74
Tire Inflation ......................................................... 74
Tire Shipping Pressure ........................................ 74
Tires and Wheels - Inspect ................................ 100
Tires and Wheels - Inspect, Check .................... 113
Torque for Metric Fasteners................................. 76

125

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