Академический Документы
Профессиональный Документы
Культура Документы
form SB4197E
sb4206e01
Feb. 2012
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.
POWER TRAIN
VEHICLE SYSTEM
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.
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.
1 of 7
STANDARD TORQUE FOR INCH FASTENERS
2 of 7
O-RING FACE SEAL FITTINGS
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).
2
1 IDAS003B
4 of 7
37 FLARED AND STRAIGHT THREAD O-RING FITTINGS
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
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
7 of 7
SB4207E01
Oct.2006
MicroController
Control System
Specification
System Operation
Testing & Adjusting
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 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
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
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
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
13
AC and DC Motors Difference Explanation
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).
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
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 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
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
Location Components
(1) Valve control card.
25
Thermal protection circuit Accessory Circuits
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
26
Testing and Adjusting Cell Voltage Test
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.
28
Resistance to Chassis Checks
29
Programmable Parameters
Adjustable Parameters Description
30
Drive Motor
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
Pump Motor
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
Battery
Program Service
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:
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).
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.
38
Power module desaturation or Pump motor power module
overcurrent alarm overtemperature
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.
40
Pump motor overtemperature Main breaker fault
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.
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.
43
Wrong start Encoder alarm
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.
45
Capacitors pre-charge too slow
46
Troubleshooting Problem List
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
POSSIBLE CAUSE
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
Continuity No continuity
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.
49
PROBLEM 2
POSSIBLE CAUSE
CHECKS
12 volts 0 volts
Replace the CVMS module. Repair or replace open circuit between 5 wires
from controller to CVMS.
50
PROBLEM 3
POSSIBLE CAUSE
CHECKS
Continuity No continuity
Check for shorts to battery negative from Repair or replace open wire.
PIN 1 to PIN 8 on CVMS connector.
51
PROBLEM 4
POSSIBLE CAUSE
CHECKS
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.
52
PROBLEM 5
POSSIBLE CAUSE
CHECKS
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
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
POSSIBLE CAUSE
CHECKS
Continuity No continuity
Continuity No continuity
Continuity No continuity
54
PROBLEM 7
POSSIBLE CAUSE
CHECKS
Continuity No continuity
Continuity No continuity
Continuity No continuity
55
PROBLEM 8
POSSIBLE CAUSE
CHECKS
Continuity No continuity
Continuity No continuity
Continuity No continuity
56
PROBLEM 9
POSSIBLE CAUSE
CHECKS
Continuity No continuity
Continuity No continuity
Continuity No continuity
57
PROBLEM 10
Display=E1
The max speed of drive motor is reduced.
POSSIBLE CAUSE
CHECKS
Continuity Normal
Yes No
58
PROBLEM 11
Display=E2
The max speed of drive motor is reduced.
POSSIBLE CAUSE
CHECKS
Continuity Normal
Yes No
59
PROBLEM 12
Display=E3
The max speed of pump motor is reduced.
POSSIBLE CAUSE
CHECKS
Continuity Normal
Yes No
60
PROBLEM 13
Display=E4
The max speed of drive motor is reduced.
POSSIBLE CAUSE
CHECKS
Continuity Normal
Yes No
61
PROBLEM 14
Display=E5
The max speed of drive motor is reduced.
POSSIBLE CAUSE
CHECKS
Continuity Normal
Yes No
62
PROBLEM 15
Display=E6
The max speed of pump motor is reduced.
POSSIBLE CAUSE
CHECKS
Continuity Normal
63
PROBLEM 16
Display=EE,
No left truck operation.
POSSIBLE CAUSE
CHECKS
If no faulty component is
found, replace logics.
64
PROBLEM 17
Display=EE (Flashing)
No left truck operation
POSSIBLE CAUSE
CHECKS
No continuity Check OK
Continuity No continuity
65
PROBLEM 18
Display=EL
The max speed and max torque of drive & pump motor is
reduced to minimum value.
POSSIBLE CAUSE
CHECKS
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
CHECKS
OK If not ok
67
PROBLEM 20
Display=F0,
Lift truck operation.
POSSIBLE CAUSE
CHECKS
68
PROBLEM 21
Display=F1
Lift truck operation.
POSSIBLE CAUSE
CHECKS
69
PROBLEM 22
Display=F2
No lift truck operation.
POSSIBLE CAUSE
CHECKS
Connector Disconnector
Continuity No continuity
70
PROBLEM 23
Display=F3
No lift truck operation.
POSSIBLE CAUSE
CHECKS
Open 0 ohm
71
PROBLEM 24
Display=F4
No lift truck operation.
POSSIBLE CAUSE
CHECKS
Open 0 ohm
72
PROBLEM 25
Display=F5
No lift truck operation.
POSSIBLE CAUSE
CHECKS
Open 0 ohm
73
PROBLEM 26
Display=F6
No lift truck operation.
POSSIBLE CAUSE
CHECKS
Connection Disconnection
Check current of right power module when you turn on the lift
truck. (You can read temperature measures
usingCOMPACT display or EYE software.)
74
PROBLEM 27
Display=F7
No lift truck operation.
POSSIBLE CAUSE
CHECKS
Check the cable connecting from left power module to left drive
motor.
Connection Disconnection
75
PROBLEM 28
Display=F8
No lift truck operation.
POSSIBLE CAUSE
CHECKS
76
PROBLEM 29
Display=F9
The max speed of pump motor is reduced.
POSSIBLE CAUSE
CHECKS
No continuity Continuity
77
PROBLEM 30
Display=FH
No lift truck operation.
POSSIBLE CAUSE
CHECKS
78
PROBLEM 31
Display=Fc
No lift truck operation.
POSSIBLE CAUSE
CHECKS
If correct If no correct
79
PROBLEM 32
Display=Fd
No lift truck operation.
POSSIBLE CAUSE
CHECKS
If correct If no correct
80
PROBLEM 33
Display=FA
Lift truck operation.
POSSIBLE CAUSE
CHECKS
81
PROBLEM 34
Display=FL
No lift truck operation.
POSSIBLE CAUSE
CHECKS
Ok If not ok
Ok If not ok
82
PROBLEM 35
Display=A
No lift truck operation
POSSIBLE CAUSE
CHECKS
Continuity No continuity
Normal Open
83
PROBLEM 36
Display=60
Lift truck operation
POSSIBLE CAUSE
CHECKS
OK If not ok
84
PROBLEM 37
Display=61
No Lift truck operation.
POSSIBLE CAUSE
CHECKS
Continuity Normal
YES NO
85
PROBLEM 38
Display=62
No Lift truck operation
POSSIBLE CAUSE
CHECKS
Continuity Normal
YES NO
86
PROBLEM 39
Display=65
No lift truck operation
POSSIBLE CAUSE
CHECKS
Continuity Normal
YES NO
87
PROBLEM 40
Display=76
No lift truck operation
POSSIBLE CAUSE
CHECKS
If correct If no correct
88
PROBLEM 41
Display=77
Lift truck operation
POSSIBLE CAUSE
CHECKS
Continuity No continuity
89
PROBLEM 42
Display=78
Lift truck operation
POSSIBLE CAUSE
CHECKS
Continuity No continuity
90
PROBLEM 43
Display=79
Lift truck operation
POSSIBLE CAUSE
CHECKS
Continuity No continuity
91
PROBLEM 44
Display=80
Lift truck operation
POSSIBLE CAUSE
CHECKS
Normal Abnormal
92
PROBLEM 45
Display=81
Lift truck operation
POSSIBLE CAUSE
CHECKS
Normal Abnormal
93
PROBLEM 46
Display=82
Lift truck operation
POSSIBLE CAUSE
CHECKS
Normal Abnormal
94
PROBLEM 47
Display=83
No lift truck operation
POSSIBLE CAUSE
CHECKS
95
PROBLEM 48
Display=84
No lift truck operation
POSSIBLE CAUSE
CRC alarm
CHECKS
96
PROBLEM 49
POSSIBLE CAUSE
Encoder defect;
Logic board defect
CHECKS
OK If not ok
OK If not ok
Replace encoder
97
System Tests and Adjustments Hydrometer
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.
98
Electrical System Adjustment Lift Sensor
Parking Brake Switch 1. Disconnect the battery and discharge the head
capacitor.
4
2
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
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
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
102
Relation between battery charge level and Table 3: Contraction for dot matrix display.
number of visualized bars Alarm Code
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
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:
Table 5
SYSTEM IN USE CODE
BX (4WHEEL) C0
LED Indicators
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.
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.
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
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.
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.
114
Eye Software Interface
EYE is a diagnostic software environment designed
to communicate with the forklift truck.
115
To find further technical data and useful information about EYE software, refer its own user manual.
116
General Information PC-Controller Communication
Serial port
USB port
Recommended Requirements
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
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
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.
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.
120
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.
121
In Supervisor mode, you can access these further menus:
1. Calibration
2. Flash
WARNING
PANEL BLANK message is used to distinguish case of not programmed flash memory, so Flash menu
is obviously active.
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)
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)
From setup menu (Fig.10) you can select communication serial port and image file format used by Print function.
124
Test
Drive (Traction)
125
Pump
126
Battery
127
Timers
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.
129
Battery reset voltage calibration
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:
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
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:
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
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:
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
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:
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
133
Lift calibration
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:
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
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:
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.
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:
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
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:
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
138
Drive motor parameters 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:
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
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:
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)
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:
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)
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:
Discard changes:
1. Press CANCEL button; VALUE data fields will be restored with initial values
142
Lift truck setup (Optional 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:
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
Pay attention that using complete reset procedure you loose already calibrated values.
Both procedures, in any case, dont modify timers value and alarm history.
144
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
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.
To stop saving procedure you can press START button, or simply exiting the menu.
146
Fig. 37: Data logging menu saving mode
147
Flash
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.
NOTE: If programming phase fails after synchronization, panel has to be programmed with correct software
before being used.
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
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.
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.
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
160
C.2. Calibration Code
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
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
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 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
Systems Operation
Troubleshooting ...............................................15
Visual Checks ..............................................15
Warning temperature ........... 155 4C (311 10F) Drive axle is designed to be used mainly on 2.5 ~
3.5 ton-capacity lift trucks.
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
**Recommended oil
Parking brake
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.
Fig 6
Fig 7
Fig 9b
Oil filling
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.
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.
Probable Cause :
Probable cause :
Probable cause :
Probable cause :
Tools Needed
Digital Multimeter Or Equivalent 1
(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).
Fig 11
Fig 12c
Fig 13
Fig 14
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
Fig 17a
Fig 17b
Fig 19c
(1) Wheel hub, (3) Needle cage, (4) Seal ring, (5) Conical bearing
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).
Fig 20a
Vehicle System
Specification
Systems Operation
Testing & Adjusting
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
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
10 4
7
6
15
11
17
19
Steering system
12
Motor
18
20
13 14
16
External Configuration
Gage port
LIFT
TILT
AUX 1
T port
P port
To tank
Needle Valve
From priority valve
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.
Lift cylinder
The above figure shows the neutral position of lift spool when the start key is on. Solenoid valve is engaged.
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.
Lift cylinder
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.
Tilt cylinder
Tank 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.
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.
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. Plug
Released 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
(A)
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.
3
4
3
5
6
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.
Hydraulic Schematic
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.
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
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.
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
Thermal switch
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
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.
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.
Probable Cause:
1. The springs are broken. 1. The cylinders are not in correct alignment.
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.
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.
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.
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.
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.
Probable Cause:
Problem: Brakes will not make application after
1. Leakage or low brake fluid or oil level. being bled.
Probable Cause:
Problem: Brake oil low in master cylinder
1. Pedal adjustment is not correct. reservoir, fluid must be added frequently.
Probable cause :
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)
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.
Chain Adjustments
Chain Adjustment Check
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.
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.
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.
Bearing Adjustment
(1) Nut. (2) Lock
4. Adjust stop bolt (1) on one side and stop bolt (3)
on the other.
1
2
NOTICE
Reservoir Location
(1) Reservoir.
2
1
Pedal Adjustment
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
(1) Control brake lever. (2) Brake piston.
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
Hydraulic Control Valve (2) Adjust main system relief valve pressure for lift
as shown above. See Relief Valve Pressure
Check in Testing And Adjusting
(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.
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
Hydraulic Pumps
Displacement : 33 cc/rev
IDCS189S
(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)
Vehicle System
Disassembly & Assembly
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
(3)
(1) (2)
Start By:
a. Remove forks.
1
2
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.
5. Repeat steps 1 through 4 for the remaining fork. Retaining Ring Pliers 1
b. Remove backrest.
10
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
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.
End By:
Start By: 5
a. remove forks 6
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).
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.
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.
End By:
a. Install forks.
(Typical example)
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).
(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.
1. Make sure all parts are clean and free of dirt and
foreign material.
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.
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)
19
Start By:
2. Install wiper seal (2). Install the seal with the lip
toward the outside.
Tools Needed A B
Hydraulic Cylinder Repair Stand 1
Wrench Assembly 1
Start By:
End By:
3. Install O-ring (4), wear ring (5) and slyd ring (6) in
the bearing.
End By :
4. Install check valve (7), retaining ring (8) and
spacer (9).
a. Install secondary lift cylinders *
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.
End By:
a. Install carriage.
Tools Needed A B
Hydraulic Cylinder Repair Stand 1
Wrench Assembly 1
Start By:
3. Remove rod (3) from the cylinder body. 6. Remove O-ring (7).
Tools Needed A B
Hydraulic Cylinder Repair Stand 1
Wrench Assembly 1
End By:
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).
Start By:
NOTICE
2. Remove rod assembly (2) from the cylinder body. 8. Remove seal assembly (10) and O-ring seal (9)
from the piston.
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.
Start By :
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.
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
2
3
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]
Start By:
IOCD020P
2
1. Remove 10 screws (1), washer, covers (2) and
key switch (3).
5
4
EHCD127C
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.
12
11
10 13
EHCD129C
NOTICE
WARNING
Be sure the pressure in the hydraulic system is
released before any lines or hoses are
disconnected.
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).
5. Lower the steer axle onto the bolt heads with the
floor jack. disconnect the hydraulic lines from the
steering cylinder.
4
1
5
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.
Start By;
a. Remove mast.
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).
End By;
a. Install mast.
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.
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)
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
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.
2
Information Section
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.
3
Safety Section
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 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
5
Safety Section
6
Safety Section
WARNING 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
7
Safety Section
WARNING
WARNING
WARNING
8
Safety Section
WARNING
WARNING
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.
10
Safety Section
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.
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.
12
Safety Section
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.
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.
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 Extinguisher
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.
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
16
Safety Section
WARNING
Do NOT place your hand or fingers under the
seat. Injury may occur as the seat moves up and
down.
Seat Adjustment
17
Safety Section
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
Backrest Inclination
18
Safety Section
Seat Belt
Inspection
WARNING
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.
19
Safety Section
Hold the plate of the belt and allow the belt to slowly
WARNING retract.
20
Safety Section
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.
22
Safety Section
Safety Rules
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.
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.
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.
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.
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.
28
Safety Section
WARNING
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
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.
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
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
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
32
General Section
33
General Section
Capacity Chart
MODEL STD, FFL FFT
A A
B C B
B22X-5
A A
B
C B
C
D
B25X-5
A A
B B
C
B30X-5
A
A
B
B
C
C
D
B35X-5
E
F
34
General Section
A A
B
C B D C
B22X-5
A
A
B B
C C
D
B25X-5
A A B
C
C B D
E
B30X-5
A A
B B
C
C E D
F
B35X-5
35
General Section
A A
B
C B D C
B22X-5
A
A
B B
C C
D
B25X-5
A A B
C
C B D
E
B30X-5
A A
B B
C
C E D
F
B35X-5
36
General Section
Serial Number
Serial Numbers Locations
For quick reference, record the serial numbers in
the space provide below the illustration
photographs.
37
General Section
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.
38
General Section
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.
CW - Special Counterweight.
SF - Special Forks.
SS - SWS-Sideshift-Swing Shift.
39
Operation Section
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.
40
Operation Section
41
Operation Section
Relation between battery charge level and Table 3 : Contraction for dot matrix display.
number of visualized bars Alarm Code
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:
Table 5
SYSTEM IN USE CODE
BX (4WHEEL) C0
LED Indicators
44
Operation Section
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
46
Operation Section
NOTICE
47
Operation Section
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.
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.
49
Operation Section
50
Operation Section
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.
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.
4 5
10
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.
52
Operation Section
NOTICE
53
Operation Section
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.
54
Operation Section
55
Operation Section
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).
56
Operation Section
57
Operation Section
58
Operation Section
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 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"
.
Emergency Switch
59
Operation Section
2
2
1
To move the armrest up, turn the knob(2) clockwise.
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.
61
Operation Section
62
Operation Section
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.
63
Operation Section
NOTICE
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.
64
Operation Section
65
Operation Section
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.
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.
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
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.
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.
69
Maintenance Section
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.
70
Maintenance Section
71
Maintenance Section
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
z Bending or resetting.
73
Maintenance Section
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
NOTICE
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.
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
75
Maintenance Section
76
Maintenance Section
Lubricant Specifications
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
NOTICE
77
Maintenance Section
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
78
Maintenance Section
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.
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.
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.
80
Maintenance Section
81
Maintenance Section
82
Maintenance Section
83
Maintenance Section
*Brake
ISO VG 10 -30 +50 -22 +122
Reservoir
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
85
Maintenance Section
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.
ENTER key
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.
87
Maintenance Section
Moreover, ENTER key is used to confirm the new Run Time Diagnostic
value of the parameter in calibration procedure
UP key
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)
88
Maintenance Section
30 Seat switch[digit]
89
Maintenance Section
44 5V out [digit]
90
Maintenance Section
91
Maintenance Section
92
Maintenance Section
NOTICE
Horn - 10 amps
DC/DC converter- 10 amps
Lights(1) - 10 amps
Lights(2) - 10 amps
FAN - 10amps
Key Switch - 10amps
93
Maintenance Section
Typical example
Typical example
94
Maintenance Section
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.
96
Maintenance Section
Park the lift truck level, with the forks lowered and
the mast tilted forward until the fork tips touch the
floor.
97
Maintenance Section
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.
98
Maintenance Section
Battery Charging
Indicator - Check
99
Maintenance Section
100
Maintenance Section
101
Maintenance Section
102
Maintenance Section
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.
103
Maintenance Section
104
Maintenance Section
NOTICE
105
Maintenance Section
Tilt Cylinders
Lubricate-Pivot Eyebolts
106
Maintenance Section
Typical example
107
Maintenance Section
1. Lower the forks and tilt the mast forward. Lubricate fitting on steer axle.
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).
108
Maintenance Section
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.
109
Maintenance Section
110
Maintenance Section
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
111
Maintenance Section
11. Slowly lift the front of the lift truck and remove
the stands. Lower the lift truck to the floor.
Remove the chains.
112
Maintenance Section
113
Maintenance Section
Typical example
114
Maintenance Section
115
Maintenance Section
116
Maintenance Section
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.
118
Maintenance Section
Fork - Inspect
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.
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.
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.
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
123
Index Section
124
Index Section
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