Daewoo Doosan Forklift BC15S to BC20SC Service Manuals SB4163E00 (1) by www.heydownloads.com

For use in service manual form SB4162E SB4163E00 Apr. 2004

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

TITLE Service Manual Contents Safety Torque Specifications

FORM NUMBER SB4163E00 SB2003E00 SB2004E00

DRIVE & CONTROL SYSTEM MicroController Control Systems

SB4164E00

POWER TRAIN Power Train

SB4165E00

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

SB4166E00 SB4167E00 SB2143E03 SB4168E00 SB4169E00

OPERATION & MAINTENANCE Operation & Maintenance Manual

Models ; BC15S, BC18S, BC20SC

SB2338E00

SB2003E00 O c t. 1 9 9 6

WARNING

SAFETY WARNING

WARNING

Do not operate this machine unless you have read and understand the instructions in the OPERATOR'S GUIDE. Improper machine operation is dangerous and could result in injury or death.

The proper and safe lubrication and maintenance for this machine, recommended by DAEWOO, are outlined in the OPERATION & MAINTENANCE GUIDE for this machine. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE GUIDE before performing any lubrication or maintenance.

5. Use steps and grab handles (if applicable) when 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 and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component.

6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this Manual, Use proper lifting procedures when removing any components.

7. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

Following is a list of basic precautions that should always be observed.

8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.

1. Read and understand all Warning plates and decals on the machine before operating, lubricating or repairing the product. 2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when pounding on any part of the machine or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery.

9. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot. 10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work.

3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any disassembly.

11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts.

4. Lower the forks or other implements to the ground before performing any work on the machine. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.

12. If possible, make all repairs with the machine parked on a level, hard surface. Block machine so it does not roll while working on or under machine.

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WARNING 21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on machine. Hang "Do Not Operate" tag in the Operator's Compartment. 14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal.

22. On LP equipped lift trucks, be sure to close the valve on the LP tank before service work is performed. Always close the valve on the LP tank when the lift truck is being stored. Do not check for LP leaks with an open flame. 23. Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health. Components in DAEWOO products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates and some gaskets. The asbestos used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust which contains asbestos is not generated.

15. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.

If dust which may contain asbestos is present, there are several common sense guidelines that should be followed.

17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position.

a. Never use compressed air for cleaning. b. Avoid brushing or grinding of asbestos containing materials.

18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

c. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. d. Use exhaust ventilation on permanent machining jobs. e. Wear an approved respirator if there is no other way to control the dust. f. Comply with applicable rules and regulations for the work place (for example in the U.S.A., OSHA requirements as set forth in 29 CFR 1910. 1001).

19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

g. Follow environmental rules and regulations for disposal of asbestos. h. Avoid areas where asbestos particles may be in the air.

20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

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SB2004E00 Dec. 1998

Specifications TORQUE SPECIFICATIONS

STANDARD TORQUE FOR METRIC FASTENERS

NOTE : Take care to avoid mixing metric and inch dimensioned fasteners. Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possible injury. Exceptions to these torques are given in the Service Manual where needed. NOTE : Prior to installation of any hardware, be sure components are in near new condition. Bolt and nut threads must not be worn or damaged. Hardware must be free of rust and corrosion. Clean hardware with a non-corrosive cleaner and apply engine oil to threads and bearing face. If thread lock or other compounds are to be applied, do not apply engine oil.

METRIC NUTS AND BOLTS THREAD SIZE (mm)

STANDARD TORQUE (N i m)

12 ± 3

(lb i ft)

28 ± 7

20 ± 5

M10

55 ± 10

40 ± 7

M12

100 ± 20

75 ± 15

M14

160 ± 30

120 ± 22

M16

240 ± 40

175 ± 30

M20

460 ± 60

340 ± 44

M24

800 ± 100

600 ± 75

M30

1600 ± 200

1200 ± 150

M36

2700 ± 300

2000 ± 225

9 ± 2

METRIC TAPERLOCK STUDS THREAD SIZE (mm)

STANDARD TORQUE (N i m)

8± 3

(lb i ft)

17 ± 5

13 ± 4

M10

35 ± 5

26 ± 4

M12

65 ± 10

48 ± 7

M16

110 ± 20

80 ± 15

M20

170 ± 30

125 ± 22

M24

400 ± 60

300 ± 45

M30

650 ± 80

480 ± 60

M36

870 ± 100

640 ± 75

1 of 7

6 ± 2

STANDARD TORQUE FOR INCH FASTENERS Exceptions to these torques are given in the Service Manual where needed.

INCH NUTS AND BOLTS THREAD SIZE inch

STANDARD TORQUE (N i m)

(lb i ft)

1/4

12 ± 3

5/16

25 ± 6

18.0 ± 4.5

3/8

47 ± 9

35 ± 7

7/16

70 ± 15

50 ± 11

1/2

105 ± 20

75 ± 15

9/16

160 ± 30

120 ± 20

5/8

215 ± 40

160 ± 30

3/4

370 ± 50

275 ± 35

7/8

620 ± 80

460 ± 60

900 ± 100

660 ± 75

1-1/8

1300 ± 150

950 ± 100

1-1/4

1800 ± 200

1325 ± 150

1-3/8

2400 ± 300

1800 ± 225

1-1/2

3100 ± 350

2300 ± 250

9 ± 2

INCH TAPERLOCK STUDS THREAD SIZE inch

STANDARD TORQUE (N i m)

1/4

8 ± 3

(lb i ft)

5/16

17 ± 5

13 ± 4

3/8

35 ± 5

26 ± 4

7/16

45 ± 10

33 ± 7

1/2

65 ± 10

48 ± 7

5/8

110 ± 20

80 ± 15

3/4

170 ± 30

125 ± 22

7/8

260 ± 40

190 ± 30

400 ± 60

300 ± 45

1-1/8

500 ± 70

370 ± 50

1-1/4

650 ± 80

480 ± 60

1-3/8

750 ± 90

550 ± 65

1-1/2

870 ± 100

640 ± 75

2 of 7

6± 2

O-RING FACE SEAL FITTINGS O-RING FACE SEAL FITTING

O-RING GROOVE

O-RING FACE SEAL NUT

O-RING

IDAS001B

STRAIGHT THREAD O-RING FITTING (FOR O-RING FACE SEAL FITTING ONLY) THREAD SIZE inch

STANDARD TORQUE (lb i ft) (N i m)

45±15 lb i in

5/16-24

5.0 ± 1.5

3/8-24

12 ± 2

7/16-20

20 ± 4

1/2-20

30 ± 5

22 ± 4

9/16-18

40 ± 5

30 ± 4

3/4-16

100 ± 15

75 ± 10

7/8-14

135 ± 15

100 ± 10

1 1/16-12

200 ± 25

150 ± 20

1 3/16-12

250 ± 25

185 ± 20

1 5/16-12

300 ± 40

225 ± 30

1 5/8-12

300 ± 40

225 ± 30

1 7/8-12

300 ± 40

225 ± 30

2 1/2-12

300 ± 40

225 ± 30

110±20 lb i in 15 ± 3

O-RING FACE SEAL FITTING NUT THREAD SIZE inch

STANDARD TORQUE (N i m)

(lb i ft)

9/16-18

16 ± 3

12 ± 2

11/16-16

30 ± 4

22 ± 3

13/16-16

50 ± 7

37 ± 5

1-14

90 ± 10

65 ± 7

1 3/16-12

120 ± 15

90 ± 10

1 7/16-12

160 ± 20

120 ± 15

1 11/16-12

190 ± 20

140 ± 15

2-12

215 ± 25

160 ± 20

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STRAIGHT THREAD O-RING PORT FITTING END

FITTING 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 into the part it is used on until backup washer (4) just makes contact with the face of the part it is used on.

HYDRAULIC LINE INSTALLATION 1. For a metal tube to hose installation, install the tube and tighten all bolts finger tight. 2. Tighten the bolts at the rigid end.

2.To put the fitting assembly in its correct position, turn the fitting body (2) out (counterclockwise) a maximum of 359û. Tighten locknut (3) to the torque shown in the correct chart for the fitting used.

3. Install the hose and tighten all bolts finger tight. 4. Put the hose in a position so that it does not make contact with the machine or another hose.

NOTE: If the fitting is a connector (straight fitting), the hex on the body takes the place of the locknut. To install this type fitting, tighten the hex against the face of the part it goes into.

5. Tighten the bolts on both connections. 6. Start the engine. 7. Move the implement control levers to all positions. 8. Look at the hose during movement of the implement. Make sure hose is not in contact with the machine or other hoses.

TORQUES FOR FLARED AND O-RING FITTINGS The torques shown in the charts that follow are to be used on the nut part of 37û Flared, 45û Flared and Inverted Flared fittings (when used with steel tubing), O-ring plugs, O-ring fittings and swivel nuts when used in applications to 3000 psi (20 700 kPa).

9. Shut off the engine. 10. If necessary, put the hose in a new position where it will not make contact when the implement is moved.

ASSEMBLY OF FITTINGS WITH STRAIGHT THREADS AND O-RING SEALS

HOSE CLAMP-BAND TYPE

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

2 1

IDAS003B

CLAMP WIDTH 7.9 mm (.312 in) 13.5 mm (.531 in) 15.9 mm (.625 in)

3 5 6

IDAS002B

ELBOW BODY ASSEMBLY (1) End of fitting body (connects to tube). (2) Fitting body. (3) Lock-nut. (4) Backup washer. (5) O-ring seal. (6) End of fitting that goes into other part.

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TORQUE ON NEW HOSE 0.9 ± 0.2 N i m 8 ± 2 lb i in

RETIGHTENING TORQUE 0.7 ± 0.2 N i m 6 ± 2 lb i in

7.5 ± 0.5 N i m 65 ± 5 lb i in

4.5 ± 0.5 N i m 40 ± 5 lb i in

3.0 ± 0.5 N i m 25 ± 5 lb i in

37û FLARED AND STRAIGHT THREAD O-RING FITTINGS

37û FLARED

O-RING FITTING-PLUG

SWIVEL NUTS

IDAS004B

37û FLARED AND STRAIGHT THREAD O-RING FITTINGS (EXCEPT O-RING FACE SEAL FITTINGS)

METRIC

INCH

THREAD SIZE inch

3.18

.125

4.76

NOMINAL TUBE O.D.

STANDARD TORQUE (N i m)

5/16

5.0 ± 1.5

(lb i ft)

.188

3/8

11.0 ± 1.5

8 ± 1

6.35

.250

7/16

16 ± 2

12 ± 1

7.94

.312

1/2

20 ± 5

15 ± 4

9.52

.375

9/16

25 ± 5

18 ± 4

9.52

.375

5/8

35 ± 5

26 ± 4

12.70

.500

3/4

50 ± 7

37 ± 5

15.88

.625

7/8

65 ± 7

48 ± 5

19.05

.750

1-1/16

100 ± 10

75 ± 7

22.22

.875

1-3/16

120 ± 10

90 ± 7

25.40

1.000

1-5/16

135 ± 15

100 ± 11

31.75

1.250

1-5/8

180 ± 15

135 ± 11

38.10

1.500

1-7/8

225 ± 15

165 ± 11

50.80

2.000

2-1/2

320 ± 30

240 ± 22

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

IDAS005B

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 on the body. The remainder of space is used whenever the fitting is removed and installed again.

IDAS006B

5 of 7

4 ± 1

45û FLARED AND 45û INVERTED FLARE FITTINGS

INVERTED 45û FLARED

45û FLARED

IDAS007B

45û FLARED AND 45û INVERTED FLARE FITTINGS

METRIC

INCH

THREAD SIZE inch

3.18

.125

4.76

NOMINAL TUBE O.D.

STANDARD TORQUE (N i m)

5/16

5.0 ± 1.5

(lb i ft)

.188

3/8

8.0 ± 1.5

6 ± 1

6.35

.250

7/16

11 ± 2

8 ± 1

7.94

.312

1/2

17 ± 3

13 ± 2

9.52

.375

5/8

30 ± 3

22 ± 2

11.11

.438

11/16

30 ± 3

22 ± 2

12.70

.500

3/4

38 ± 4

28 ± 3

15.88

.625

7/8

50 ± 5

37 ± 4

19.05

.750

1-1/16

90 ± 8

65 ± 6

22.22

.875

1-1/4

100 ± 10

75 ± 7

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

IDAS008B

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

4 ± 1

AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS

O-RING

45û FLARE

IDAS010B

AIR CONDITIONING FITTINGS 45û FLARE FITTING END

O-RING FITTING END

STEEL TUBES

ALUMINUM TUBES

STANDARD TORQUE

THREAD SIZE inch

STANDARD TORQUE

5/8-18

18 ± 4

13 ± 3

30 ± 3

22 ± 2

23 ± 3

17 ± 2

3/4-16

37 ± 4

27 ± 3

52 ± 5

38 ± 4

33 ± 4

24 ± 3

7/8-14

40 ± 4

30 ± 3

60 ± 7

44 ± 5

38 ± 4

28 ± 3

1 1/16-14

45 ± 5

33 ± 4

75 ± 8

55 ± 6

50 ± 5

37 ± 4

N im

(lb i ft)

N im

(lb i ft)

N im

TAPERED PIPE THREAD FITTINGS STANDARD TORQUE

PIPE THREAD SIZE inch

THREADS WITH 1E2200E SEALANT

THREADS WITHOUT SEALANT

Nim

(lb i ft)

Nim

(lb i ft)

1/16-27

1/8-27

1/4-18

3/8-18

1/2-14

3/4-14

1-11 1/2

1 1/4-11 1/2

110

1 1/2-11 1/2

110

130

2-11 1/2

130

160

120

7 of 7

(lb i ft)

SB4164E00 A p r. 2 0 0 4

Specifications Systems Operation Testing & Adjusting MicroController Control System Models : BC15S, BC18S, BC20SC (36V P/N A304000) for Electric Lift Trucks

Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. 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. DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustration in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current information available.

Index Specifications Component measurements......................................... 5 Control Panel (Layout) ................................................ 9 Current Measurements ............................................... 5 Transistor Measurements ........................................... 6 Console ................................................................... 7 Contactors............................................................... 8 Direction Switch ...................................................... 7 Display Layout......................................................... 7 Fuses ...................................................................... 8 Head Capacitor ....................................................... 8 Instrument Panel ..................................................... 7 Thermal Switch - Control Panel .............................. 8 Tip Clearance (Gap)................................................ 8 Transistor Connections ........................................... 6

Systems Operation Accessory Circuits..................................................... 25 Actuation Circuit .................................................... 26 Control Circuit ....................................................... 28 DC-DC Converter .................................................. 25 Flyback Circuit....................................................... 32 Horn Circuit ........................................................... 25 Hour Meter Circuit ................................................. 25 Hydraulic Pump Motor Circuit ............................... 27 Power Circuit ......................................................... 29 Behind Logic Unit ...................................................... 17 General Information .............................................. 18 Logic Unit .............................................................. 18 Drive Circuit............................................................... 33 Bypass Circuit ....................................................... 38 Control Circuit ....................................................... 33 Current Limit.......................................................... 37 Failure Protection Circuit ....................................... 39 Flyback Circuit....................................................... 36 Power Circuit ......................................................... 34 Thermal Protection Circuits................................... 39 Location of Control Panel Components .................... 16 Operational Circuit Elements .................................... 19 Accelerator Control ............................................... 24 Battery Discharge Indicator (BDI) ......................... 23 Central Vehicle Monitoring System (CVMS) International Pictorial Symbols ................................. 21 Central Vehicle Monitoring System ....................... 19 Contactors............................................................. 22 Current Sensor ...................................................... 22 On Board “Run Time” Diagnostics (Fault Detection) .............................................................................. 19 MicroController Control System

Wait Mode............................................................. 22 Symbol Library.......................................................... 15 Systems Operation Glossary.................................................................11

Testing And Adjusting Electrical System Adjustments..................................116 Accelerator Control Linkage.................................116 Activating Default Settings .................................. 124 Battery Discharge Indicator (BDI) Adjustment.. 120 Current Limit Test and Adjustment ...................... 122 Electrical Braking (Plugging) Current Test and Adjustment .......................................................... 123 Lift Sensor............................................................117 Parking Brake Switch ...........................................116 Programmable Features ..................................... 123 Programmable or Settable Option Features ....... 125 Quick Procedure for Programmable Features .... 124 Rapid Tune-Up Procedure ...................................119 Setting Procedure Option Features .................... 123 Tilt and Auxiliary Switches....................................118 Valve Control Card Adjustment ............................117 Preparation Tests and Checks .................................. 40 Accessing Stored Error Codes.............................. 48 Battery Load Test .................................................. 41 Battery Maintenance ............................................. 41 Battery Tests ......................................................... 40 Built-In Diagnostic Operation ................................ 44 Cell Voltage Test ................................................... 41 Control and Power System Operational Checks... 43 Erased Stored Error Codes................................... 49 Hydrometer Test.................................................... 41 Quick Diagnostic Procedure ................................. 49 Removal of Shorts to Chassis............................... 42 Resistance to Chassis Checks ............................. 42 “Run Time” Diagnostics (Lift Truck in Operation) .. 44 Saving Service Records........................................ 48 “Self” Diagnostics (Lift Truck not in Operation) ..... 45 Stored Error Codes ............................................... 49 Visual Checks ....................................................... 42 System Tests and Adjustments ................................... 98 Capacitor (Head)................................................. 104 Component Tests ................................................ 101 Conductor and Switch Continuity........................ 104 Contactor Components ....................................... 105 Contactors........................................................... 105 Current Sensor.................................................... 107 Diode Replacement ............................................ 108 Diodes................................................................. 108 3 Index

Discharging Head Capacitor (HEAD CAP) ........... 98 Driver Board (Off Vehicle) ....................................111 Driver Board (On Vehicle) ................................... 109 Logic Unit Quick Reference Voltage Check ........ 101 Logics Removal..................................................... 99 Resistors (PR1 and PR2) .................................... 114 "Run Time” Tests ................................................... 99 Test Equipment ..................................................... 98 Thermal Switch ................................................... 115 Transistor Replacement DTR1 and HTR1 .......... 113 Transistors DTR1 and HTR1............................... 113 Troubleshooting ........................................................ 40 Troubleshooting Check List................................... 40 Troubleshooting Problem List ................................... 50

MicroController Control System

Index

Specifications Component measurements Component

Meter

Meter Positive

Meter Negative

Scale

(+) Test Lead

(-) Test Lead

Desired Indication

Diodes (voltage indication) All

Diode

Anode

Cathode

0.3 to 0.9 volts

All

Diode

Cathode

Anode

RESISTORS (resistance indication ) Panels With D557065 Transistor PR1, PR2

200Ω

90 ohms L 5%

R2, R5

200Ω

7.5 ohms L 5%

HEAD CAPACITORS (resistance indication) Head Capacitor

200KΩ

Positive side of

Negative side of

0 then change to

capacitor (+)

capacitor (-)

above 10K ohms

CONTACTOR COILS (resistance indication) Directional

200Ω

40.0 to 50.0 ohms

Line

200Ω

60.8 to 91.2 ohms

Bypass

200Ω

60.8 to 91.2 ohms

Current Measurements CURRENT VALUES (AMPS) Transistor

Current Limit

Plugging Limit

A154973

500 ±10A

500 ± 10A

MicroController Control System

Specifications

Transistor Measurements SPECIFICATIONS Multimeter Setting

(+) Test Lead

(-) Test Lead

A154973 Results

Resistance Diode

Emitter

Base

45 to 135 ohms

Base

Collector

.3 to .9V

Diode

Collector

Base

Diode

Emitter

Collector

.3 to .9V

Diode

Collector

Emitter

Transistor Connections 1 E

(1) Emitter Connection (2) Base Connection (3) Collector Connection

MicroController Control System

Specifications

Display Layout

Console

(1) Tighten bolts that fasten the cover to a torque of................................1.5 to 2.5 N· (13 to 22 lb·in)

Instrument Panel

Direction Switch

1 2

(1) Tighten screws that fasten the instrument panel to a torquel.......................0.5 to 0.7 N·m (4 to 6 lb·in)

(1) Tighten bolts that hold bracket to steering colum to……………………...2.8 to 3.4 N·m (25 to 31 lb·in) (2) Tighten bolts that hold clamp to switch to…………………...3.4 to 3.9 N·m (31 to 35 lb·in)

MicroController Control System

Specifications

Head Capacitor

Thermal Switch - Control Panel Contacts open at.................81 to 89℃ (178 to 192℉) Contacts close at……………69 to 77℃ (156 to 171℉)

Contactors

Torque for nuts that hold contactor bridge Assembly.........................................2.2 N·m (20 lb·in)

Tip Clearance (Gap) Line……………………...3.15 ± .10 mm (.124 L .004 in) Direction (forward and reverse)………. 2.62 ± .08 mm (.103 ± .003 in) Bypass…………………..3.15 ± .10 mm (.124 ± .004 in) Pump…………………….3.15 ± .10 mm (.124 ±.004 in)

NOTE:

Proper torque and assembly of capacitor hardware is critical. Avoid disassembly unless capacitor has to be replaced.

Fuses Key……………………………………………………..10A Line……………………………………………………675A Horn…………………………………………………….10A Shunt field……………………………...……………...10A Valtage Converter…………………………………….10A Light…………………………………………………….10A

(1) Tighten capacitor terminal bolt to a torque of.............................4.5 to 5.5 N·m (40 to 50 lb·in) (2) Spring washer D917069. (3) Ring terminal of wire assembly. (4) Lockwasher D917071. (5) Head capacitor terminal.

MicroController Control System

Specifications

Control Panel (Layout) 5

1 8 10

6 4 2 9

11 11 10 NEG/P2

BYPASS

DAEWOO

PART NO

POS

(4) Use a backup wrench to hold nuts and tighten bolts the fasten bus bars to the power transistors to a torque of……………..…..4 to 6 N·m (35 to 55 lb·in)

Apply a small amount of D557047 Themal Joint Compound on the surface of the transistor, diode or thermal switch that contacts the heatsink.

(5) Tighten screws that fasten power transistors to positive heatsink to a torque of………….4 to 6 N·m (35 to 55 lb·in)

(1) Control panel plate. Apply a small amount of D557047 Thermal Joint Compound on control panel plate and mating surface prior to assembly.

(6) Tighten screws that fasten wires to the base of the power transistors to a torque of…………….……..1.3 to 1.7 N·m (11.5 to 15 lb·in)

(2) Apply sealant (Loctite catalogue No. and name No.242, Adhesive/Sealant) on the threads of all screws that are used to fasten components on the control panel.

(7) Tighten diodes DD1, DD2 and HD1 to a torque of …………………………..9 to 11 N·m (81 to 99 lb·in)

(3) Apply Sealant (Loctite catalogue No. and nameNo.242, Adhesive/Sealant) to the bolts used to fasten the driver board to the positive heatsink and tighten to a torque of……………………..10 to 14 N·m (90 to 125 lb·in) MicroController Control System

SERIAL NO

NOTE:

(8) Tighten Head Capacitor terminal bolts to a torque of…………………………………….…4.5 to 5.5 N·m (40 to 50 lb·in)

Specifications

(9) Tighten all bolts that fasten bus bars of cables to either heatsink to a torque of……….5.5 to 9.5 N·m (50 to 85 lb·in) (10) Tighten bolts that hold the negative heatsink to the control panel to a torque of………10 to 14 N·m (90 to 125 lb·in) (11) Apply Sealant (Loctite catalogue No. and nameNo.242, Adhesive/Sealant) on portion of setscrew threads that are in the insulator and control panel plate. Tighten bolts to a torque of……………………..5.5 to 9.5 N·m (50 to 85 lb·in) (12) Use a backup wrench to hold bolts and tighten the nuts that fasten the cables or bus bars to the contactors to a torque of…………………4 to 6 N·m (35 to 55 lb·in) (13) Contactor bridge nuts

MicroController Control System

Specifications

Systems Operation Glossary NAME

DESCRIPTION

Accelerator

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

Activate

Word used with a component or circuit. To change from the normal condition to the “activated” condition because of an application of force or electricity.

Ammeter

An electric meter used to measure current flow in amperes.

Ampere (or Amp)

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

Analog to Digital Converter

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

Anode

The positive (+) side of a diode.

Armature

The rotating portion of an electric motor or generator.

Base

The terminal of a transistor through which control current flows (see Transistor).

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 battery charge.

Brush

A conductor, normally a block of carbon, that makes sliding contact between the stationary and moving part of the motor or generator.

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.

Cathode

The negative (-) side of a diode.

CVMS

Central Vehicle Monitoring System.

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.

Collector

A terminal of a transistor through which main current flows (see Transistor).

Commutator

An armature component used to transfer current from the brushes to the armature windings.

Conduct

To allow the flow of current.

Conductor

A material that provides a path for current flow.

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

MicroController Control System

Systems Operation

NAME

DESCRIPTION

Contactor Coil

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

Contactor Tips or Contacts

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

Continuity

Having the ability to allow current flow.

Control Circuits

The wires and components carrying low current used to signal the logic unit, turn on main components, or support auxiliary circuits (indicated by narrow lines on a schmatic).

Counter Electromotive Force (CEMF)

An opposing voltage set up by a collapsing or increasing magnetic field within a coil.

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.

Current Sensor

A hall-effect sensor in the drive motor circuit that produces an increasing voltage output as the drive motor current increases.

Deactivate

To change from the activated condition back to the normal (deactivated) condition. It can be caused by the application of force, the removal of force, or the removal of electricity.

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 Braking

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

Electromagnet

A coil of wire, most often wound on an iron core, which produces a strong magnetic field when current is sent through the coil.

Electromotive Force (EMF)

The force that causes an electric current to flow in a circuit. This force is measured in volts.

Emitter

A terminal of a transistor through which low control current and main current flow (see Transistor).

Field Windings

The stationary coils that produce a magnetic field in motors and generators

Filter

An electrical device or component for restriction or suppression of undesired voltage spikes.

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.

Hour Meter

An electrically activated device used to record the amount of usage a truck receives.

Indicator

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

Input

A voltage change at the incoming connection of a component.

MicroController Control System

Systems Operation

NAME

DESCRIPTION

Insulator

A material that has a very large resistance so that it will not let current flow through it.

LCD

Liquid Crystal Display.

Logics or Logic 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.

Magnetic Field

The area around a magnet where magnetic forces can be detected.

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.

Normally Close (N.C.)

A switch or relay whose contacts are closed in the normal condition.

Normally Open (N.O.)

A switch or relay whose contacts are opened in the normal condition.

OFF-Time

The amount of time current does not flow through a transistor. 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.

Output

The current flow from a component which initiated from a voltage change at the component's input.

Overload

The presence of voltage or current which is greater than an electrical circuit or component is designed to handle.

The male contact of a connector that fits into a female contact (socket) of another connector.

Plugging

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

Plugging Current Limit

The maximum allowable current at the drive motor armature during the plugging portion of electrical braking.

Potentiometer

An adjustable resistor to preset electronic controls for proper specifications.

Power Circuits

The main current carrying components and conductors (indicated by the heavy lines on a schematic).

Power Transistor

A component in the power circuit which allows main motor current to pass through when turned on.

Pulsing

Current flow in a circuit being turned on and off.

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.

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.

MicroController Control System

Systems Operation

NAME

DESCRIPTION

Semiconductor

Components such as, transistors, diodes, thyristors, etc. Having electrical characteristics between a conductor and an insulator.

Series Wound Motor

A motor in which the armature is connected in series with the field windings.

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.

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 Switch

A switch that activates at a set temperature.

Transistor

A semiconductor component used in electric lift trucks as an electronic switch. A transistor most often has three terminals, a base (B), a collector (C) and an emitter (E). The main current flow is between the collector and emitter. This main current flow is controlled by a much smaller current flow between the base and emitter.

Turn ON

When an electrical component conducts current.

Varistor

A component terminated across the horn connections to eliminate voltage spikes when the horn is activated.

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 overvoltage (too high a voltage) protector.

MicroController Control System

Systems Operation

Symbol Library

9 16

17 21

ARM. 11

18 14

P10-10

15 20 19

Schematic Symbols (1) Power Transistor. (2) Zener Diode. (3) NPN Transistor. (4) PNP Transistor. (5) Thermal Switch. (6) Battery. (7) Resistor. (8) Diode. (9) Normally Close Contacts. (10) Normally Open Contacts. (11) Male Terminal of Connector (pin). (12) Female Terminal of Connector (socket). (13) Wire Connection. (14) No Wire Connection. (15) Contactor Coil. (16) Current Sensor. (17) Armature. (18) Field Windings. (19) Capacitor. (20) Fuse. (21) Switch.

MicroController Control System

Systems Operation

Location of Control Panel Components

2,3

6 4 NEG/P2

DAEWOO

PART NO

SERIAL NO

POS

MicroController Control Panel (1) Logic unit(logics). (2) PR1. (3) PR2. (4) Shunt Field Fuse. Contactor. (9) Bypass Contactor. (10) Direction Contactor.

(5) Key Fuse.

MicroController Control System

(6) Line Fuse.

(7) Current Sensor.

(8) Line

Systems Operation

Behind Logic Unit

11 13

NEG/P2

BYPASS

DAEWOO

PART NO

SERIAL NO

POS

Components Behind Logic Unit (1). (11) Head Capacitor. (12) Shunt Resistor.(13) HTR1(Pump Transistor One). (14) Drive Board. (15) Control Thermostat. (16) DTR1(Drive Transistor One). (17) HD1 (Diode for Pump) Flyback Diode. (18) DD1 (Diode for Drive) Flyback Diode. (19) DD2(Diode for Drive) Plugging Diode. (20) Main Connector (MC)

MicroController Control System

Systems Operation

General Information

The speed of the hydraulic pump motor is controlled by switch inputs to and outputs from the logics. Outputs pulses the hydraulic pump power transistor. The power transistor pulse to control the speed of the hydraulic pump motor. To provide full speed the logics turns the power transistor ON 100%. The hydraulic pump system includes a failure protection circuit to protect against malfunctions of the power circuit.

The MicroControl Panel is the control center and the Logic Unit (logics) is the decision making part of the MicroController System. The logics provide a self contained Battery Discharge Indicator (BDI) with lift interrupt and built-in diagnostic capabilities. The battery charge state and built-in diagnostic are monitored by the logics and displayed by the Central Vehicle Monitoring System (CVMS) located on the steer console.

Thermal protection circuits are used on the hydraulic pump motor, the drive motor and the control panel to prevent permanent damage caused by over heating.

NOTICE Damage to all motors and control panels will result. The motors and control panels are 48 volt unit and must be operated at their designed voltage. The voltage can not be changed without changing motors and control panel.

Logic Unit

3 15 14 13 12 11 10 9 8

The drive motor and the hydraulic pump motor are controlled by pulsing transistors ON and OFF and controlling contactor operation. The speed and direction of the drive motor are controlled by voltage inputs to and outputs from the logics. Inputs to the logics are generated by the accelerator control and direction switch. Outputs from the logics control contactor coils and drive transistor pulsing. The drive circuit pulses transistors to provide travel speed control up to 90% of full speed, after which the bypass contactor closes to provide full speed. The drive circuit includes a failure protection circuit which detects malfunctions of the drive power circuit, a plugging circuit to provide electrical braking and a current limit circuit to prevent excessively high currents during transistor pulsing.

5 7 6

Components on Logic Unit (1) Connector P1. (2) Connector P2. (3) Connector P8 (4) Connector P6. (5) DIAG/RUN/SETUP (6) Jumper JP1 - 36V (7) Jumper JP2 - 48V (8) VR1 potentiometer - Drive current limit adjustment (9) VR2 potentiometer - Plugging current limit adjustment (10) VR3 potentiometer - Not used (11) VR4 potentiometer - Not used (12) VR5 potentiometer - BDI adjustment (13) VR6 potentiometer - Bypass drop out adjustment(Option) (14) VR7 potentiometer - Not used (15) VR8 potentiometer - Electrical Assisted Braking

MicroController Control System

Systems Operation

Operational Circuit Elements

On Board “Run Time” Diagnostics (Fault Detection)

Central Vehicle Monitoring System

“Run Time” diagnostics use letters and numbers on the seven segment LCD portion of the CVMS, International Pictorial Symbols and LCD to signal both improper operating sequences and truck circuit defects.

The Central Vehicle Monitoring System (CVMS) is located on top panel. It is a self contained, solidstate instrument panel with two seven segment liquid crystal displays, warning and system condition segments. The LCD consists of seven segments which are turned on or off to form numbers and letters.

Display = “EE” Static Return to Off (SRO) The logics has a Static Return to Off (SRO) circuit which assures that the direction switch has been returned to neutral and the accelerator returned to the neutral position after the key and seat switch are closed. This safeguards against an accidental actuation of direction and speed when an operator resumes operation of an idle truck. If SRO occurs, the direction lever can be moved to neutral and the accelerator pedal released. The direction can now be reselected and the accelerator pedal depressed to start normal lift truck drive operation. Display = “EE”(Flashing) Seat Circuit Problem Anytime the battery is connected, the key is turned to ON and no one is in the seat longer than 3 seconds the letter “EE” will flash on and off. The truck will not operate until the seat switch is closed.

Seven Segment Display Layout

The Central Vehicle Monitoring System interacts with the logics and failure detection circuits. It functions as a battery discharge indicator (BDI) and provides on-board diagnostic data on the operational condition of the truck. During normal operation it provides “Run Time” diagnostics, and during troubleshooting it provides “Self” diagnostics.

Display = “E1” Drive Motor Brush Problem The logics monitor the length of the brushes in the drive motor. As the brushes wear, a wire built into the brushes moves down and makes contact with the commutator. A wire from each motor brush set is connected to the logics. If any brushes wear down to a preset limit, an “E1” will display on the LCD. Display = “E2” Pump Motor Brush Problem The logics monitor the length of the brushes in the pump motor. As the brushes wear, a wire built into the brushes moves down and makes contact with the commutator. A wire from each motor brush set is connected to the logics. If any brushes wear down to a preset limit, an “E2” will display on the LCD. Display = “EL” Battery Lock-out When the battery is discharged, the CVMS displays “EL” and pump motor will not operate after 30 seconds. If key switch turn off and then on, pump will operate for only 10 seconds. Drive motor speed will not exceed 60% of the max. Regardless of an accelerator’s output voltage.

MicroController Control System

Systems Operation

Display = “F2” Drive System Problem

Display = “F7” Drive and Pump System Problem

The logics at P6-4 uses wire #64 from the emitter of the drive transistor to detect if the drive transistor, bypass contactor tips or the driver board are shorted. In normal operation P6-4 has battery voltage only when the logics is pulsing the drive transistor or the bypass contactor is activated. When a failure occurs the line contactor will be deactivated and an “F2” will display on the LCD.

The logics will deactivate the line contactor and display “F7” on the LCD when BOTH wires #64 and #74 detect battery negative or do not detect the proper pulsing. See “F5” and “F6” Display = “F8” Shunt Field System Failure The logics at P6-6 uses wire #60 from the collector of transistor TR5 to detect an open in the shunt field or a shorted TR5. If the field shunt is open the logics cannot detect battery positive voltage and a failure occurs. The line contactor will be deactivated and an “F8” will display on the LCD.

Display = “F3” Pump System Problem The logics at P6-5 uses wire #74 from the emitter of the pump transistor to detect if the pump transistor or the driver board are shorted. In normal operation P6-5 has battery voltage only when the logics is pulsing the pump transistor is activated. When a failure occurs the line contactor will be deactivated and an “F3” will display on the LCD.

Display = “F9” Shunt Field System Failure The logics at P6-6 uses wire #60 from the collector of transistor TR5 to detect when TR5 is full ON or pulsing. A failure occurs when the logics no longer detects TR5 full ON or pulsing. The line contactor will be deactivated and an “F9” will display on the LCD.

Display = “F4” Drive and Pump System Problem The logics will deactivate the line contactor and display “F4”on the LCD when BOTH wires #64 and #74 detect battery voltage when it should not be present. See “F2” and “F3”.

Display = “Fb” Battery Mis - Match The motors and control panels are 48 volt units and must be operated at 48 volt. If battery is mismatched, an “Fb” will display on the LCD.

Display = “F5” Drive System Problem

Display = “Fd” Pressure Switch Problem

The logics at P6-4 uses wire #64 from the emitter of the drive transistor to detect battery negative. The logics sends a test pulse out to the drive transistor when power up. This test pulse is detected at P6-4 also. If battery negative is present or the test pulse is not detected, the line contactor will be deactivated and an “R5” will display on the LCD. If current transducer (CT) is faulty or connections are shorted/opened, the line contactor will be deactivated and an “F5” will display on the LCD.

The logics at P2-1 uses wire #41 from the pressure switch to detect if the pressure switch is opened for more than 10 seconds after the key switch ON. The “Fd” will be displayed and the truck will be operated normally.

Display = “F6” Pump System Problem The logics at P6-5 uses wire #74 from the emitter of the pump transistor to detect battery negative. The logics sends a test pulse out to the pump transistor when power up. This test pulse is detected at P6-5 also. If battery negative is present or the test pulse is not detected the line contactor will be deactivated and an “F6” will display on the LCD.

MicroController Control System

Systems Operation

Central Vehicle Monitoring System (CVMS) International Pictorial Symbols Park Brake Symbol

Drive Motor Overtemperature Symbol

Park Brake Symbol

Drive Motor Overtemperature Symbol

If the park brake is applied, the park brake symbol will turn on to warn the operator that the brake is applied, and drive operation will be prevented.

The drive motor thermal switch, held against the drive motor field, will open if the motor gets too hot. The logics will reduce drive pulsing and prevent the bypass contactor from pulling in. The truck speed and acceleration will be reduced. The overtemperature symbol will display on until the motor cools. “Ed” will be saved as stored error code.

Overtemperature Symbol Normally closed thermal switches are constantly monitored by the logics and the CVMS. All these thermal switches are normally closed, so must open for the LCD to turn on. Truck performance will automatically be cut back by the logics, and the CVMS will light the LCD until the component cools.

Pump Motor Overtemperature Symbol

Control Panel Overtemperature Symbol

Pump Motor Overtemperature Symbol

The pump motor thermal switch, similar to the drive motor thermal switch, will open if the motor gets too hot. The logics will reduce pump motor speeds. The overtemperature symbol will display on until the pump motor cools. “EP” will be saved as stored error code.

Control Panel Overtemperature Symbol

If any of the control panel overheats, the thermal switch in the center of the positive heatsink will open. The logics will slow lifting speeds and reduce drive speed. Truck acceleration will decrease. The overtemperture symbol will display on until the controller cools. “Ec” will be saved as stored error code.

MicroController Control System

Systems Operation

Wait Mode If the seat switch is closed, key turned to ON and the direction lever is left in neutral with no other operator requests, the line contactor will deactivate after approximately six seconds. The LCD will display “PP” The lift truck will remain in this condition until the operator activates the direction switch, accelerator pedal or control valve levers. The line contactor then reactivates and the truck is ready for normal operatation.

Current Sensor The current sensor mounts around the bus bar that carries drive motor current. The logics supplies a constant voltage to one lead of the current sensor at P1-16 wire #25 (12V). A second lead of the current sensor is connected to battery negative at the negative heatsink. When current passes through the bus bar, the third current sensor lead wire #22 causes the voltage to change at logic P1-12. As the current passing through the bus bar increases, the voltage at logic P1-12 increases. The logics uses the voltage at P1-12 to determine the amount of current flowing through the drive motor.

Contactors The control panel is equipped with intermittent duty contactors. The logics controls the voltage supplied to the coils. When a contactor is first activated, full battery voltage is supplied to the coil. After the contactor tips have closed, the logics will pulse the coil to reduce the voltage across the coil to between 18 and 36 volts.

MicroController Control System

Systems Operation

Battery Discharge Indicator (BDI)

Battery Table of the Closed Circuits

The logics monitors the battery voltage during truck operation and shows the level of battery charge on the LCD. If the battery voltage is below 30.0V, this is a battery mismatch or misconnection. If these voltages are monitored, the display will show “Fb” on the LCD and no lift truck operate.

BAR SYM30LS DISPLAY

6 5 4 3 2 1 1* O/EL 1* = Display is flashing

Full 6 bars on the LCD indicates a fully charged battery. As the battery discharges, the bars decreases to 5, 4 etc, down to 1st bottom bar. When the battery nears the 80% discharge level, the 1st bar continuously flashes. This is a warning that lift interrupt is near. The operator should complete the current lift operation and travel to the battery replacement or charge area. If the truck is kept in operation, the display go to a “EL” The lift, tilt and auxiliary functions will be vastly reduced in speed, operating only with EPS and the vehicle travel speed will be cut in harf. At this point the battery is greater than 80% discharged. The logics will now remember that the battery has been discharged to lift interrupt and require a fully charged battery to reset the remembered interrupt. See Programmable Option Features “3”.

BAR SYM30LS DISPLAY

Descriptions of BDI symbol on the LCD

: Max. charged status

5: 4: 3:

36V above 37.2 36.8 to 37.2 36.3 to 36.7 35.9 to 36.2 35.4 to 35.8 35.0 to 35.3 34.5 to 34.9 below 34.5

BATTERY TERMINAL VOLTAGE TYPE 1 (OPT) : Closed Voltage

6 5 4 3 2 1 1* O/EL 1* = Display is flashing

Bar Symbols

36V above 37.2 36.8 to 37.2 36.4 to 36.7 36.0 to 36.3 35.6 to 35.9 35.2 to 35.5 25.8 to 35.1 below 25.8

BATTERY TERMINAL VOLTAGE TYPE 2 (STD) : Closed Voltage

6 5 4 3 2 1 1* O/EL 1* = Display is flashing

Due to different voltage characteristic of battery technologies, it may be necessary to use the battery voltage chart as shown below. You can choose a type in Programmable Option Features “10”.

6 : The highest position

BATTERY TERMINAL VOLTAGE TYPE 1 (OPT) : Closed Voltage

36V above 37.2 36.9 to 37.2 36.6 to 36.8 36.3 to 36.5 35.9 to 36.2 35.6 to 35.8 35.3 to 35.5 below 35.3

2: 1:

: A) Not flashing B) Flashing - 80% discharge warning

MicroController Control System

Systems Operation

Accelerator Control

ii) DEAD ZONEⅡ In order to eliminate the direction contactors chattering, the direction contactors will be engaged if the accelerator output voltage is over than 1.48V. But the direction contactors should be disengaged if the accelerator output voltage is less than 0.9V.

Accelerator Table

OUTPUT VOLTAGE

REMARKS

OVER 11.00

ACCELERATOR CIRCUIT DEFECT

9.60

BYPASS OPERATION DRIVE SPEED (100%) DRICE SPEED STEP 14

9.02 8.44

DRICE SPEED STEP 13 **DEAD ZONE I ** DRICE SPEED STEP 12

7.86 DRICE SPEED STEP 11 7.28 DRICE SPEED STEP 10 6.70 DRICE SPEED STEP 9 6.12 DRICE SPEED STEP 8 5.54 DRICE SPEED STEP 7 4.96 DRICE SPEED STEP 6 4.38 DRICE SPEED STEP 5 3.80 DRICE SPEED STEP 4 3.22 DRICE SPEED STEP 3 2.64 DRICE SPEED STEP 2 2.06 DRICE SPEED STEP 1 1.48 DRICE SPEED STEP 0 0.90 0.00

**DEAD ZONE II**

i) DEAD ZONEⅠ In order to eliminate the bypass contactor chattering, the bypass contactor will be engaged if the accelerator output voltage is over than 9.6V. But the bypass contactor should be disengaged if the accelerator output voltage is less than 9.02V.

MicroController Control System

Systems Operation

Accessory Circuits Horn Circuit

The DC-DC converter changes the lift truck battery voltage to 12 volts. This 12 volts is used to power accessories such as floodlights, brakes/side lights and backup alarms.

The horn will operate when the battery is connected and the horn button is pushed. Current flows from battery positive through horn fuse, horn switch and horn, back to battery negative.

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

Hour Meter Circuit The hour meter, dependent on marketplace, can be wired a number of different ways. Battery voltage is always supplied from the key switch to the positive terminal of the hourmeter. The negative terminal of the hourmeter go to seat switch to record seat switch hours, or can be wired into the drive motor armature through a diode assembly to record drive motor hours.

The 12 volt output of the converter is protected against short circuits and overloading by an internal 15 amp current limit circuit. A fuse on the converter protects it from reverse connection of the battery voltage. Refer to Prolem 32 in Troubleshooting section.

DC-DC Converter

NOTICE Do not connect the 12 volt negative output of the DCDC converter to battery negative. Damage to system components could occur.

D/D CONVERTER POS INPUT NEG INPUT 12V POS 12V NEG ENABLE

KEY SWITCH

10A

BATT. BATT. (-) (+)

DC-DC Converter Circuit System

MicroController Control System

Systems Operation

Actuation Circuit

This circuit supplies power to the MicroController Control System and the Central Vehicle Monitoring System (CVMS). It must be activated before hydraulics or drive will be operated.

NOTE : The circuit diagrams have shaded lines for illustration of current flow in each circuit. Other circuits can be activated at the same time, but each one is shown separately to illustrate current flow in each individual circuit.

MicroController Control System

Systems Operation

Hydraulic Pump Motor Circuit

When the battery is connected and the key switch is closed, current flows from battery positive through the key fuse, key switch, wire #3 to the logic connector P1-1 and P1-2, P1-10. The logic connection to battery negative is at P1-20, and P2-20. The logic circuits are powered up to accept voltage inputs and create voltage outputs whenever the battery is connected and the key is turned to ON.

Only one hydraulic pump motor (compound) is used for, lift, tilt and reach hydraulic functions. To activate the pump circuit, the seat switch, key switch and line contactor must be closed first as explained in the topic, Actuation Circuit. Followings are standard HTR1 pulsing rates of the signal at the logics.

The Central Vehicle Monitoring System (CVMS) is also powered at this time. The CVMS first does a “LCD test” which will light all the warning lights through 6 shield wires, wire #101(5V) and wire #108 (B-) for approximately five seconds.

Motor HTR1 Pulsing Rate Logic Pin# Speed IDLE 11% POWER 26% P2-1 STEERING TILT 50% P2-2 LIFT 1 35% P2-3 & P2-4 LIFT 2 50% LIFT 3 95% AUX. (1&2) 55% P2-16 The above pulsing rate can be adjustable in “Programmable Option Features”.

The logics will start to perform a set of “Run Time” diagnostic checks. The letter “EE” will flash on the CVMS display indicating the key is ON with no operator in the seat. When the seat switch is closed, current will flow from the logic P2-7 through the seat switch to battery negative. The logics then activates the line contactor by allowing current to flow from P1-3 through the line contactor coil and P1-4 back to battery negative. With the line contactor tips closed the logics continues its checks for any “Run Time” faults. If no faults are detected the display will indicate the battery charge level the power steering (IDLE) system operates, the pump and drive power circuits receive battery voltage and the logics receives battery voltage on wire #4 at P1-17.

MicroController Control System

Systems Operation

Control Circuit

Lift Circuit

NOTE:

The circuit diagrams have shaded lines for illustration of current flow in each circuit. Other circuits can be activated at the same time, but each one is shown separately to illustrate current flow in each individual circuit.

HIGH (12 volts). When a HIGH is present the logics knows that more hydraulic flow is required and will supply a pulse from P6-2 to HTR1 at rate 26% “ontime” for 36 volt trucks. The pump motor speed will increase. When the lift lever is pulled to lift 1, the logics will pulse the pump transistor HTR1. As shown in the chart under Lift Control circuit, If the lift lever is pulled to lift speeds 2 through 3 the pump transtors are pulsed with a higher percent “ on-time”. The pump motor armature will turn foster.

If the streeing wheel is turned, hydraulic pressure increases and a pressure switch (PRESSURE SW) located in the steering gear load sensing hose, will open. This causes the voltage at logic connector P2-1 to change from a LOW(less than one volt) to a

MicroController Control System

Systems Operation

Power Circuit

TR4 Base Input Signal

After the line contactor is closed and any hydraulic switches is activated, the logics generates a positive pulsing signal (approximately 0.7 volts) on P6-2 to the base of transistor TR4. This is a rapidly changing signal that can only be viewed on an oscilloscope. Because TR4 is a NPN type transistor, the positive signal into the base causes current flow through the

MicroController Control System

base/emitter junction. When current flows through the base/emitter junction the transistor turns ON and main current will flow through the collector/emitter junction. If the base signal from the logics is ON at TR4, TR4 will be ON. When the base signal is OFF, TR4 will be OFF.

Systems Operation

TR3 Base Input Signal, TR4 ON

When TR4 is ON, current flows through the emitter/base junction of transistor TR3, through PR2 and TR4 to battery negative. Because TR3 is a PNP type transistor, the current flow to battery negative through the emitter/base junction causes TR3 to turn ON. When TR4 is OFF, TR3 is OFF.

MicroController Control System

Systems Operation

HTRI Base Input Signal, TR3 and TR5 ON

When TR3 is ON current flows through TR3 into the base of transistor HTR1. This puts a voltage signal at the base of HTR1 causing them to turn ON. With HTR1 ON, high amperage motor current can flow through HTR1, motor field and motor armature to battery negative.

At the same time the logics is pulsing the pump motor circuit, a constant voltage (about 0.7 volts) is being supplied on P6-3 to the base of TR5 turning it 100% ON. With TR5 ON, current can flow through the shunt field, shunt fuse and TR5 back to battery negative.

When TR3 and TR4 are OFF, HTR1 is OFF. The percent “on time” of the signal at the logics is also the percent “on-time” of HTR1. HTR1 is pulsed at 11% “on-time” supplying 11% of battery voltage to the pump motor (IDLE). MicroController Control System

Systems Operation

Flyback Circuit

HD1 is a flyback diode for the power steering and hydraulic motor circuit. This circuit uses the current created by the collapsing magnetic field of the field windings in the pump motor to keep current flowing when transistor HTR1 is OFF. When HTR1 is OFF all current from the field the field goes through P2, HD1, P1 and pump motor armature (ARM) back to the field.

MicroController Control System

When HTR1 is pulsing the flyback circuit causes the average pump motor current to be greater than the average battery current through HTR1.

Systems Operation

Drive Circuit Control Circuit

Drive Control Circuit

NOTE:

The circuit diagrams have shaded lines for illustration of current flow in each circuit. With the actuation circuit complete the logics supplies a HIGH voltage (12volts) to the direction (F/R) switch at P2-5 and P2-6. A HIGH voltage is also supplied to the power of accelerator at P1-16. Releasing the park brake closes the park brake switch and provides a path to battery negative.

MicroController Control System

Selecting a direction will change the voltage from HIGH to LOW on P2-5 for forward or P2-6 for reverse. Depressing the accelerator pedal will cause the accelerator analog voltage on P1-15. With the forward direction selected current flows from the logic P1-3 through forward direction contactor coil to logic P1-5 back to battery negative. The forward contactor tips close.

Systems Operation

Power Circuit

TR2 Base Input Signal

NOTE:

The logics generates a positive pulsing voltage (approximately 0.7 volts) on P6-1, to the base of transistor TR2. This pulse turns ON TR2 which turns ON TR1. A more complete description of this transistor turn on circuit can be found in : Hydraulic Pump Motor Circuit under Power Transistor Pulsing.

The high amperage current, which provides the power and torque necessary to drive the lift truck, flows in this circuit. The speed of the drive motor is controlled separately from the pump motor circuit by the MicroController Control System.

MicroController Control System

Systems Operation

Power Transistor, TR1 and TR2 ON

When TR1 is ON, current flows through TR1 emitter/collector into the base of drive power transistor (DTR1). This puts a HIGH voltage at the base of the power transistor causing that to turn ON. With the power transistor ON, high amperage motor current can flow through that, the field, forward contactor tips, armature, forward contactor tips and current sensor back to battery negative. When TR1 is OFF, the power transistor is OFF.

MicroController Control System

The percent “on-time” of the voltage at logic P6-1 is also the percent “on-time” of the power transistor. As the “on-time” increases, the average voltage applied to the drive motor increases which increases the speed of the lift truck. The percent “on-time” out of the logics is determined by how far the accelerator is depressed.

Systems Operation

Flyback Circuit

Flyback Circuit.

When the drive power transistor (DTR1) is ON, battery current flows through the field windings of the drive motor and a magnetic field is created around the windings. When the power transistor is turned OFF battery current through the windings stops and the magnetic field collapses. This collapsing magnetic field induces current which is used to power the drive motor while the power transistor is OFF (during pulsing).

MicroController Control System

Induced current flows from the field windings through the forward contactor tips, armature, forward contactor tips, current sensor and diode DD1 back to the field windings. Because of this, the average drive motor armature current will be greater than the average battery current. Refer to following Average Current Flow chart.

Systems Operation

"ON" TRANSISTOR (SWITCH)

"OFF"

BATTERY CURRENT

AVERAGE

AVERAGE FLYBACK CURRENT

AVERAGE MOTOR CURRENT

D BATTERY CURRENT

FLYBACK CURRENT

Average Current Flow

Current Limit The logics monitors the current that flows through DTR1 and limit this current flow to a preset value. As this current flows through DTR1 the drive motor and the current sensor, a voltage is created by the sensor. This voltage is proportional to the current flowing through the sensor and will increase or decrease as current changes. The logics uses this voltage to monitor the current in the circult. When the current has increased too high, the logics decreases the pulse rate to the transistors to prevent current higher than the preset value.

MicroController Control System

Systems Operation

Bypass Circuit

Bypass Circuit Activated

The bypass circuit bypasses DTR1 and connects the drive motor in series with the battery, applying full battery voltage to the drive motor. If the accelerator pedal is fully depressed, and the logics has pulsed DTR1 through 92% “on-time” the logics will activate the BYPASS CTR after 1.5 seconds.

MicroController Control System

Systems Operation

Thermal Protection Circuits

Hydraulic Pump Motor

Control Panel

If the hydraulic pump motor overheats a thermal switch mounted in the pump motor housing will open at a predetermined temperature. When it opens, voltage at logic connection P2-13 will go HIGH. The Central Vehicle Monitoring System will display a “Run Time” diagnostic symbol. To decrease the amount of current allowed to flow through the pump motor, the logics will reduce the hydraulic pump motor to 50% pulsing. When the hydraulic pump motor cools off and the thermal switch closes, the truck will return to normal operation. An “EP” is stored in memory.

If the power transistors overheat, a thermal switch mounted in the transistor heatsink will open at a predetermined temperature. When it opens, voltage at logic connection P2-11 will go HIGH (12 volts). The Central Vehicle Monitoring System will display a “Run Time” diagnostic symbol. The logics will decrease the pulsing of the drive system and restrict the hydraulic circuit pulsing to 50%. The amount of current allowed to flow through the power transistors is decreased to permit them to cool. When the heatsink cools off and the thermal switch closes, the truck will return to normal operation. Drive system bypass is not affected by an overheated control panel, but due to the reduced pulsing acceleration performance will be decreased. An “Ec” is stored in memory.

Failure Protection Circuit If the logics detects an improper voltage at P6-4 wire #64 (drive circuit) or P6-5 wire #74 (pump circuit), the line contactor will be deactivated and a “Run Time” diagnostic code (display = “F2” through “Fd” will display.

Drive Motor

Current is also monitored in the drive motor, and should it exceed preset limits in either pulsing or bypass the truck will shut down and display an “F0” If the battery voltage is mismatched, the “Fb” will display. The logics will monitor the current sensor signal, wire #22 to determine if there is an wrong voltage pattern. An “F5” will be displayed. Once a failure has been detected the truck must be repaired before normal operation can resume.

If the drive motor overheats a thermal switch mounted in the drive motor housing will open at a predetermined temperature. When it opens, voltage at logic connection P2-12 will go HIGH. The Central Vehicle Monitoring System will display a “Run Time” diagnostic symbol. To decrease the amount of current allowed to flow through the drive motor, the logics will reduce the pulsing and disable the bypass contactor. When the drive motor cools off and the thermal switch closes, the truck will return to normal operation. Drive system acceleration performance and top travel speed is affected by an overheated drive motor. An “Ed” is stored in memory.

MicroController Control System

Systems Operation

Testing And Adjusting Troubleshooting

NOTICE Damage can be caused to the control panel. Do not switch the direction lever from one direction to the other (plug the lift truck) when the drive wheels are off the ground and in rotation at full speed.

The following Troubleshooting Check List is an aid in troubleshooting MicroController lift trucks. The troubleshooting check list, “Run Time” diagnostic indications, “Self” diagnostic tests, problem list and problem flow charts will assist in: 1. Defining the problem and verifying a problem exists.

Troubleshooting Check List

2. Performing the checks in a logical order.

1. Perform Preparation Tests and Checks.

3. Making the necessary repairs. 4. Verifying the problem has been resolved.

2. Correct any display problems and “Run Time” diagnostic faults. 3. Correct the “Self” diagnostic faults.

WARNING 4. Perform Operational Checks.

The lift truck can move suddenly. Battery voltage and high amperage are present. Injury to personnel or damage to the lift truck is possible. During any test or operation check, keep away from drive wheels. Before any contact with the control panel is made, disconnect the battery and discharge HEAD CAP. Ring's, watches and other metallic objects should be removed from hands and arms when troubleshooting, the MicroController Control System.

5. Correct “Failure Code Problems” in the Troubleshooting Problem List. 6. Perform Operational Checks to verify repairs.

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

NOTICE Damage can be caused to test equipment. Make resistance and continuity checks only after the battery is disconnected.

1. Verify proper polarity at the battery connector and the MicroController panel. Positive cable should be at the line contactor and negative at the negative heatsink. 2. If the lift truck is operational, perform a battery load test.

NOTICE Damage can be caused to the control panel. Do not use steam or solvent to clean the controls. Use pressure from an air hose with a maximum pressure of 205 kPa (30 psi) to clean the control panel when necessary. Make sure the air pressure supply is equipped with a water filter.

MicroController Control System

3. If the truck is not operational and the battery is suspected, perform a cell voltage or specific gravity test.

Testing And Adjusting

Battery Load Test

Hydrometer Test

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

Test each cell of the battery with a hydrometer. If the specific gravity indication is below 1.140, the battery must be charged. The battery is fully charged if the indication is 1.265 to 1.285.

2. Connect the battery.

NOTE:

The indication between cells should not differ more than .020. If it does, the battery needs an equalizing charge or needs to be repaired.

Battery Maintenance NOTE:

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It is important that all batteries be charged and maintained according to the battery manufacturers instructions.

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The care and maintenance of batteries is most important to maximize battery life and efficient truck operation. Periodic inspection and service will increase the life of batteries. Special attention should be given to the rules that follow:

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1 1. Keep batteries clean at all times. Cleaning will prevent corrosion, current leakage and shorts to chassis. Tighten all vent plugs, wash the battery with water and a brush, then dry with an air hose. It may be necessary to use a baking soda solution if water alone will not clean the top of the battery.

Battery Voltage Test. (1) Positive Cable Connection. (2) Negative Cable Connection.

3. Connect the multimeter leads between positive (+) cable connection (1), and negative (-) cable connection (2).

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

4. In a safe area, operate the hydraulic system, (hold tilt lever to maximum position momentarily) while reading the voltage indicated on the multimeter. 5. If the indication is less than 33.1 volts, the battery needs to be charged or repaired before continuing to troubleshoot.

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

Cell Voltage Test With the truck powered up, measure the voltage at each cell. Normal voltage should be between 1.95V and 2.12V per cell. If the voltage on each cell is below 1.95V the battery must be charged or repaired before continuing to troubleshoot. NOTE:

4. Operation with a low battery must be prevented. Low battery operation may damage the battery and will cause higher than normal current in the electrical system. High current draw due to a low battery will damage contactor tips and shorten motor brush life.

The indication between cells should not differ more than 0.05 volts. If it does, the battery must have an equalizing charge or be repaired.

MicroController Control System

Testing And Adjusting

Resistance to Chassis Checks

5. The battery’s maximum temperature is critical. The electrolyte temperature should never exceed 43℃ (110℉) either while operating or charging. Overcharging a battery will cause over heating and warp the battery plates. Maximum battery life will result from maintaining 25℃(77℉) electrolyte temperature. Most of the charging equipment is fully automatic but should be checked periodically to assure proper working order.

Resistance between any point in the truck wiring and the chassis should be a minimum of 10,000 ohms or more. Many malfunctions are caused by shorts to chassis. Usually, two shorts must exist before a malfunction will occur. But, since batteries can have chassis leakage, only one short to chassis in the truck wiring can cause problems. To prevent problems because of shorts, do the following:

6. Keep accurate battery records. Regular battery readings should be taken with a battery tester or voltmeter and a written record kept. Specific gravity and voltage of each cell should be checked and recorded at least once each month. This inspection should be made after an equalizing charge. Readings should never be taken directly after water has been added. Records of all battery maintenance should be made and filed so it will be known which batteries are being abused or wearing out. Repairs should be made immediately otherwise the battery may become damaged. Batteries stored in a discharged condition may be difficult to recharge due to sulfate formation.

1. Disconnect the battery and discharge the HEAD CAP. 2. Randomly measure any component connection or wiring connection in respect to the lift truck chassis for a minimum resistance of 10,000 ohms. Any test point with low resistance must have the short to chassis removed. 3. Always keep batteries clean to minimize current leakage to the chassis. 4. Routinely clean the brush dust from the motors. 5. Be sure that all attachments, such as horns and lights are designed for no chassis connection (a two wire system).

Visual Checks 1. Verify all components and wires are in their proper place. Check fuses, components, contactor tips, wires and connections. Verify that they are not burned, broken or loose.

Removal of Shorts to Chassis

2. Verify there is no mechanical binding or interference in the contactors.

When a short is found, it must be cleared even if the machine has normal operation. It is necessary to narrow the field of possible problem areas before inspection of individual wires and components.

3. Visually check the parking brake switch, the lift switch and accelerator linkage for adjustment or interference problems.

MicroController Control System

When a low resistance circuit is located, it should be opened at various points. This will permit the shorted wire or component to be pin-pointed for repair or replacement.

Testing And Adjusting

Control and Power System Operational Checks Check 5: Reverse Drive Performance All operational checks are to begin with the battery connected, directional switch in neutral and theaccelerator and park brake released. NOTE:

1. Select reverse direction and depress the accelerator slightly. The reverse contactor should activate and the drive wheel should turn in reverse slowly.

Perform all operational checks before returning to the Troubleshooting Check List.

2. Slowly increase the amount of accelerator depression. The reverse contactor should remain activated. The drive wheel should turn in reverse and slowly increase in speed.

Check 1: Key Switch, Seat Switch and Power Steering

3. Depress the accelerator fully. The reverse contactor should activated. The bypass contactor should activate. The drive wheel will turn in reverse at full speed.

1. Activate the key and seat switch. The line contactor activate. 2. Turning the steering wheel will activated the power steering system.

Check 6: Electrical Braking (Plugging) Performance

3. After five to ten seconds the line contactor deactivates. Check 2: Lift Performance

NOTICE Do not perform this check with the lift truck in bypass mode. Damage to the Drive Train can result.

1. Pull the lift lever half way. The hydraulic pump motor activates slowly to a preset speed. 2. Pull the lift lever to maximum. The hydraulic pump motor activates full speed.

1. Select forward direction and depress the accelerator to the point before bypass occurs. While continuing to depress the accelerator, change the direction switch to reverse. The forward contactor should deactivate and the reverse contactor should activate. There should be a smooth deceleration of forward tire rotation. After the forward tire rotation stops, there is a smooth acceleration of reverse tire rotation.

Check 3: Tilt and Auxiliary Performance. 1. Slowly pull and push the tilt and reach levers. The hydraulic pump motor activates to one of the preset speeds with each lever movement. Check 4: Forward Drive Performance.

2. Continue to depress the accelerator while in reverse direction. Change the direction switch to forward. The reverse contactor should deactivate and the forward contactor should activate. There should be a smooth deceleration of reverse tire rotation. After the reverse tire rotation stops, there is a smooth acceleration forward tire rotation.

1. Engage the parking brake. Select forward direction and depress the accelerator slightly. The forward contactor should NOT activate and the drive wheel should NOT turn. 2. Release the parking brake, select forward direction and depress the accelerator slightly. The forward contactor should activate and the drive wheel should turn forward slowly. 3. Slowly increase the amount of accelerator depression. The forward contactor should remain activated. The drive wheel should turn forward and slowly increase in speed. 4. Depress the accelerator fully. The forward contactor should remain activated. The bypass contactor should activate. The drive wheel will turn forward at full speed.

MicroController Control System

Testing And Adjusting

Built-In Diagnostic Operation

Display = “E1” Lift truck will not operate, see Troubleshooting Problem 19. Possible cause, drive motor brush problem.

The logics and the display provide built-in diagnostic analyzer functions. Several diagnostic functions occur while the lift truck is in operation. These are called “Run Time” diagnostics. The other diagnostics are called “Self” diagnostics. They are performed when the lift truck is not in operation by using a switch located in the logics.

Display = “E2” Lift truck will not operate, see Troubleshooting Problem 20. Possible cause, pump motor brush problem. Display = “EL” Lift truck will not operate, see Troubleshooting Problem 24. Possible cause, low battery voltage.

Central Vehicle Monitoring System (CVMS) If the display does not work, or it’s operation seems incorrect see Troubleshooting Problems 1, 2, 3 and 4.

Display = “Ec” Lift truck will not operate, see Troubleshooting Problem 21. Possible cause, control panel thermal problem. The overtemperature indication will display on LCD.

“Run Time” Diagnostics (Lift Truck in Operation)

Display = “Ed” Lift truck will not operate, see Troubleshooting Problem 22. Possible cause, drive motor thermal problem. The overtemperature indication will display on LCD.

The diagnostic functions that follow would occur during normal lift truck operation and are shown on the seven segment display. NOTE:

Display = “EP” Lift truck will not operate, see Troubleshooting Problem 23. Possible cause, pump motor thermal problem. The overtemperature indication will display on LCD.

Improper lift truck operation with normal battery indication, should be checked with “Self” diagnostics.

Display = “F0” Lift truck operates, then shuts down during travel. See Troubleshooting Problem 33. Possible cause, excessive currents in drive motor. Display = “F2” Lift truck will not operate, see Troubleshooting Problem 34. Possible cause, a failed drive power transistor (DTR1). Display = “F3” Lift truck will not operate, see Troubleshooting Problem 35. Possible cause, a failed pump power transistor (HTR1). Display = “F4” Lift truck will not operate, see Troubleshooting Problem 36. Possible cause, failed pump and drive power transistors. Display Layout

Display = “F5” Lift truck will not operate, see Troubleshooting Problem 37. Possible cause, drive flyback diode DD1 failed and current transducer (CT) failure or harness problem.

Display = “EE” No Lift truck operation, see Troubleshooting Problem 17. Possible cause, static return to off.

Display = “F6” Lift truck will not operate, see Troubleshooting Problem 38. Possible cause, pump flyback diode HD1 failed.

Display = “EE” (Flashing) Lift truck will not operate, see Troubleshooting Problem 18. Possible cause, seat switch open.

Display = “F7” Lift truck will not operate, see Troubleshooting Problem 39. Possible cause, pump and drive flyback diodes (HD1 and DD1) failed.

MicroController Control System

Testing And Adjusting

“Self” Diagnostics (Lift Truck not in Operation)

Display = “F8”Lift truck will not operate, see Troubleshooting Problem 40. Possible cause, a failed transistor (TR5) in drive board.

The diagnostic procedure should be used to aid in troubleshooting after a problem occurs. It will help to find the faulty circuit or component. Complete all the tests before returning to the MicroController Troubleshooting Check List. Before testing, do the steps that follow :

Display = “F9” Lift truck will not operate, see Troubleshooting Problem 41. Possible cause, a failed trausistor (TR5) in drive board. Display = “Fb” Lift truck will not operate, see Troubleshooting Problem 42. Possible cause, abnormal battery condition.

1. Turn the key to off.

Display = “Fd” Lift truck will operate, see Troubleshooting Problem 43. Possible cause, pressure switch failure or harness problem.

2. Disconnect the battery and discharge the head capacitor below 5 volts by holding the discharge resistor in place for 10 seconds.

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PART NO

SERIAL NO

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Location of Fuse (1) Line Fuse.

3. Disconnect line fuse (1) to prevent lift truck movement.

MicroController Control System

Testing And Adjusting

6. Move switch (4) to “Diagnostic” position. This places the controller in diagnostics when the battery is connected, open seat switch and key is turned to ON. If any of the tests that follow fail (except the line fuse test where the Display = “d” continue through the test that remain. The failed test should be solved and this will allow the next test to be performed.

WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Disconnect the battery and disconnect the line fuse to prevent lift truck movement.

7. Connect the battery and turn key to ON.

4. Release the parking brake to close the park brake switch.

Display = “blank” See Troubleshooting Problems 1 or 2. Display = “F” Logics has a failure. Replace logics.

Display = “d” Line fuse not disconnected or discharge the head capacitor. Return to step 2.

Display = “8b” Direction lever is in the reverse position. Move direction lever to neutral. NOTE:

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The LCD will display all symbols about 2 seconds. Display = “A0” Ready for test.

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This test does not check all the logics circuit, so the logics may pass this test and still have a failure.

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Test 1 : Seat Switch

Removing Cover From Logic Unit (Logics) (2) Screws. (3) Cover.

Press seat to close seat switch. Display = “A1” Seat switch circuit OK.

5. Loosen four screws (2) to remove logic cover (3).

Release seat to open seat switch. Display = “A0” Seat switch circuit OK. If still “A0” or “A1” see Troubleshooting Problem 8. Test 2 : Reverse Direction Switch

Move direction switch from neutral to reverse. Display = “A2” Direction switch circuit OK. Move direction switch from reverse to neutral. Display = “A0” Direction switch circuit OK. If still “A0” or “A2” see Troubleshooting Problem 9.

DIAG/RUN/SETUP Switch Location (4) Switch.

Test 3 : Forward Direction Switch Move direction switch from neutral to forward. Display = “A3” Direction switch circuit OK. Move direction switch from forward to neutral. Display = “A0” Direction switch circuit OK.

MicroController Control System

If still “A0” or “A3” see Troubleshooting Problem 9. Testing And Adjusting

Test 4 : Lift 1 Switch Circuit

Test 9 : Accelerator Control

Pull lift lever to minimum. Display = “A4” Lift 1 switch circuit OK.

Press accelerator pedal to maximum. Display = The speed symbols will increase from 0 to 10 on the LCD, Accelector circuit OK.

If still “A0” lift 1 switch circuit defect, see Troubleshooting Problem 10. Test 5 : Lift 2 Switch Circuit

Release accelerator pedal. Display = The speed symbols will decrease from 10 to 0 on the LCD, Accelector circuit OK.

Pull lift lever to maximum. Display = “A5” Lift 2 switches circuit OK.

If the speed symbols is not full on the LCD, see Troubleshooting Problem 14.

Release lift lever. Display = “A0” lift circuit OK.

Test 1 through 9 may be checked without sequence and there are repeatable checkings to adjust switches and levers.

If still “A0” or “A4” lift 2 switches circuit defect, see Troubleshooting Problem 10. Test 6 : Tilt Switch Circuit Pull lift lever to maximum. Display = “A6” Tilt switch circuit OK. Release tilt lever. Display = “A0” Tilt switch circuit OK. If still “A0” or “A6” tilt switch circuit defect, see Troubleshooting Problem 11. Test 7 : Aux Switch Circuit Pull Aux lever to maximum. Display = “A7” Aux switch circuit OK.

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PART NO

Release reach lever. Display = “A0” Aux switch circuit OK.

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If still “A0” or “A7” Aux switch circuit defect, see Troubleshooting Problem 12.

SERIAL NO

Test 8 : Parking Brake Switch Contactor Location (5) Line Contactor. (6) Bypass Contactor. (7) Direction Contactor.

Pull park brake lever to maximum. Display = “A9” Park brake circuit OK. Release park brake lever. Display = “A0” Park brake circuit OK. If still “A0” or “A9” Park brake circuit defect, see Troubleshooting Problem 13.

MicroController Control System

Testing And Adjusting

The error codes can now be accessed one at a time by pulling tilt lever and then release. This will display the most recent error code. By cycling the tilt lever more times, more error codes will appear on the display, up to a total of 24. When the display shows a solid “E” it will indicate that all of the stored error codes have been displayed. It is possible that the “E” will appear immediately, indicating no error codes have been encountered.

Contactor Test Test 10 through 13 may be activated in regular sequence by movement of the DIAG/RUN/SETUP (4) to “Run” then back to “Diagnostic” position only once, and “AC” will display on the LCD. Test 10 : Line Contactor (5) Test 11 : Bypass contactor (6) Test 12 : Forward Direction Contactor (7) Test 13 : Reverse Direction Contactor (7)

Saving Service Records

If the above any actions do not occur, see Troubleshooting Problem 15.

To save service records, the following procedures are used at the end of self diagnostics and service records are numbered from 1 to 9.

This completes the built-in diagnostic test. Contactor test may be repeated contiune by movement of the DIAG/RUN/SETUP to “Run” then back to “Diagnostic” position.

1. Access all of the error codes until display shows static “E” on the LCD.

After running through the contactor testing , pull tilt lever and then release to netural position will access the stored error codes. See Accessing Stored Error Codes.

2. Move the direction lever to the forward then display will show static “8d”. 3. Move the DIAG/RUN/SETUP switch to “Setup” and back to “Diagnostic” position two times.

Accessing Stored Error Codes

4. Pull the tilt lever to maximum position and then release.

The BC15/18S, BC20SC series of trucks remembers the last 24 error codes. This is useful in case the truck has had an intermittent problem, but the operator cannot remember which code appeared on the display. Also by analyzing the contents of the last 24 error codes, it may be possible to determine what sort of application the truck has been working in.

5. A saved service records will show for a few second. 6. Wait until the display will show a flashing “8d” the display indicates that a service record have been saved. 7. Turn OFF the key switch.

The stored error codes are accessed at the end of diagnostics by using the following procedure. 1. Access the self diagnostics procedure as usual. 2. Either step through the self diagnostics procedure, or override test by moving the DIAG/RUN/SETUP switch from “Diagnostic” to “Run” and back to “Diagnostic” position for the contactor testing is completed. 3. After running through the contactor testing , pull tilt lever and then release to netural position, now the display will indicate the stored error codes or a solid “E”.

MicroController Control System

Testing And Adjusting

Erased Stored Error Codes

Stored Error Codes

To erase all of the error codes, the following procedures are used at the start of self diagnostics.

The following are possible error codes stored in memory. Most error codes are identical to the ones displayed during RUN.

1. Move the direction lever to the reverse and the DIAG/RUN/SETUP switch to the “Diagnostic” position and close the seat switch.

E1 : Drive motor brush problem. E2 : Pump motor brush problem. Ec : Control panel thermal problem. Ed : Drive motor thermal problem. EL : Battery lock out. EP : Pump motor thermal problem. F0 : Excessive drive motor current in pulsing or bypass operation. F2 : Drive problem, voltage on drive transistor emitter (wire #64). F3 : Pump problem, voltage on pump transistor emitter (wire #74). F4 : Both F2 and F3 problems together. F5 : Drive problem, no voltage on drive transistor emitter (wire #64) and Current transducer (CT) problem. F6 : Pump problem, no voltage on pump transistor emitter (wire #74). F7 : Both F5 and F6 problems together. F8 : Shunt field problem, no voltage on shunt field transistor (TR5) collector (wire #60). F9 : Shunt field problem, voltage on shunt field transistor (TR5) collector (wire #60). Fb : Battery mis-match. Fd : Pressure switch problem.

2. Turn on the key switch and wait until display shows a solid “8b” then move the DIAG/RUN/SETUP switch to the “Setup” position and back to “Diagnostic” position two times. 3. Move the direction lever to neutral. 4. Wait until the display will show a “A1” the display indicates that all error codes have been erased. 5. Turn off the key switch.

Quick Diagnostic Procedure An alternative method of entering diagnostics has been programmed into the logics. This will enable quick diagnostics of some of the components without removing the controller room, line fuse, or placing the DIAG/RUN/SET switch to the “Diagnostic” position. Contactors and seat circuit will NOT be energized. To enter quick diagnostics, open the seat switch and place the direction lever to forward and ensure that the park brake is released. While depressing the accelerator to maximum position other than OFF, and key switch to ON. Display will go to a solid “A3” and the speed symbols will increase from 0 to 10 on the LCD, indicating that you have entered diagnostics and you are ready for Test: Place the direction lever to neutral and release accelerator pedal.You can test the direction control lever, all hydraulic levers, the park brake switch and the accelerator. See Built-In Diagnostic Operation on page 45-47. NOTE:

This test enables a salesman to demonstrate some of the diagnostic procedure without ever having to open up the controller room.

MicroController Control System

Testing And Adjusting

Troubleshooting Problem List TROUBLESHOOTING PROBLEM LIST Problem #

CENTRAL VEHICLE MONITORING SYSTEM (CVMS) PROBLEMS

CVMS does not work, with no lift truck operation.

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

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

Display portion of CVMS works until seat switch is closed then blank, no lift truck drive or pump motor operation. “SELF” DIAGNOSTIC PROBLEMS

Display = “d”, no lift truck operation or “Self-Diagnostics” operation.

Display = “F”, no lift truck operation.

Display = “8b” no lift truck operation.

Seat switch circuit defect.

Direction switch circuit defect.

Lift switches circuit defect.

Tilt switch circuit defect.

Aux (1& 2) switch circuit defect.

Park brake switch circuit defect.

Accelerator circuit defect.

Incorrect contactor operation.

Any contactor closes when key switch is activated. “RUN TIME” DIAGNOSTIC PROBLEMS

Display = “EE” no lift truck drive operation.

Display = “EE” (Flashing), no lift truck drive operation.

Display = “E1” lift truck operation normal.

Display = “E2” lift truck operation normal.

Overtemperature is ON and display = speed is slower than normal.

Lift truck accelerates slower than normal. Lifting

Overtemperature is ON and display = normal. Acceleration slow.

Bypass contactor will not close. Pump operation

Overtemperature is ON and display =

Lifting performance slow. Drive operation normal.

Display = “EL” No hydraulic (lift and tilt). BDI circuit defect.

Hourmeter does not work

Normal hydraulic operations, display is normal and no drive operations.

Current limit adjustment cannot be made.

Slow steering, but pump motor does turn. Drive system operation normal.

Pump motor runs continously when neutral is selected.

Drive motor does not operate or operates with low power or is erratic.

Horn does not function correctly. Lift and drive operation normal.

Auxiliary lighting and/or alarm does not function correctly. Lift and drive operation normal.

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Testing And Adjusting

TROUBLESHOOTING PROBLEM LIST Problem #

FAILURE CODE PROBLEMS.

Display = “F0” no lift truck operation.

Display = “F2” no lift truck operation.

Display = “F3” no lift truck operation.

Display = “F4” no lift truck operation.

Display = “F5” no lift truck operation.

Display = “F6” no lift truck operation.

Display = “F7” no lift truck operation.

Display = “F8” no lift truck operation.

Display = “F9” no lift truck operation.

Display = “Fb” no lift truck operation.

Display = “Fd” lift truck operation norma

MicroController Control System

Testing And Adjusting

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

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

CHECKS With battery connected, check control panel battery connections for correct polarity. Positive battery connected to line fuse and negative battery connected to negative heatsink. If correct

If not correct

Make correction to cables.

Push horn buttton to close horn switch. Horn works

Horn does not work

Does CVMS pass self test at actuation of key and seat switches. Yes

Disconnnect battery and check the horn fuse for continuity.

Continuity

See Problem 2, CVMS does not work, lift truck operation normal.

Check for shorts and replace fuse

Close key switch. Measure voltage on P1-1, P12 and P1-10. Battery voltage

No continuity

Check continuity from horn fuse to control panel battery positive connection at the line contactor. Also check continuity from key fuse to wire #3 on key switch

Less than Battery voltage

Continuity Replace key switch or repair broken wire #5 between key switch and P1-1 and P1-2.

Repair horn circuit.

No continuity

Repair or replace open wire.

Check continuity from negative heatsink to logic P1-20 and P2-20. Continuity

Replace logics.

No continuity

Repair or replace open wire.

MicroController Control System

Testing And Adjusting

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

POSSIBLE CAUSE Disconnected logic connector P8; Open circuit from P8-1 to CVMS connector PIN 1; Open circuit from P8-8 to CVMS connector PIN 8; CVMS defect.

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

If not connected

Connect CVMS connector.

Connect multimeter positive lead to P8-1 wire #101 and negative lead to P8-8 wire #108. Measure the voltage. 5 volts

Replace the CVMS module.

0 volt

Repair or replace open circuit between 8 wires from logics to CVMS

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Testing And Adjusting

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

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

CHECKS Check continuity from logics to CVMS connector (wire #101/WH/YL/GN/BU/BK/RD/108). Continuity

No continuity

Check for shorts to battery negative from PIN 2 to PIN 7 of CVMS connector. No shorts found

Replace logics.

Repair or replace open wire

Shorted

Repair or replace open wire.

MicroController Control System

Testing And Adjusting

PROBLEM 4 Display portion of CVMS works until seat switch is closed then blank, no lift truck drive or pump motor operation.

POSSIBLE CAUSE Line contactor defect; Line fuse open circuit; Wire #4 at P1-17 open circuit; Logics defect.

CHECKS Does the line contactor close and remain closed ? Yes

Check voltage at bottom of line fuse with line contactor activated. Battery voltage

See Problem 15, Incorrect contactor operation.

Less than Battery voltage

Repair or replace line contactor tips or power connections.

Check voltage at top of line fuse with line contactor activated. Battery voltage

Less than Battery voltage

Check voltage at logic connector P1-17, wire #4 with line contactor activated. Battery voltage

Replace logics.

Check for possible shorts in the power circuit (Head Capacitor, diode, shorted cables) and replace line fuse. If repeat failures occur, check drive motor current limit and/or lift truck application.

Less than Battery voltage

Repair open circuit between line fuse and P1-17, wire #4.

MicroController Control System

Testing And Adjusting

PROBLEM 5 Display = “d” no lift truck or “Self-Diagnostics” operation.

POSSIBLE CAUSE Logic DIAG/RUN/SETUP switch in “Diagnostic” position with line fuse installed; Head capacitor not discharged below 5 volts; L i d f t CHECKS Trying to run ”Self-Diagnostics”?

Trying to operate lift truck ?

Disconnect battery, discharge head capacitor below 5 volts, remove line fuse, set DIAG/RUN/SETUP switch to “Diagnostic” position, reconnect the battery and recycle key switch.

Disconnect battery, remove logic cover, set DIAG/RUN/SETUP switch to “Run” position, reconnect the battery and recycle key switch. Display remains at “d”

“Self-Diagnostic” Operation OK

Display remains at “d”

Replace logics. Measure voltage on P1-17. Below 5V

Lift Truck Operation OK

Continue with “SelfDiagnostics” operation.

Place lift truck into operation.

Replace logics.

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Testing And Adjusting

PROBLEM 6 Display = “F” no lift truck operation.

POSSIBLE CAUSE Wiring defect; Logics defect.

CHECKS With the key on, check the voltage at logic P1-1, P1-2 and P1-10, wire #5. Battery voltage

No voltage

Repair or replace open wire

Check continuity from control panel battery negative to logic P1-20 and P2-20. Continuity

Replace logics.

No continuity

Repair or replace open wire.

MicroController Control System

Testing And Adjusting

PROBLEM 7 Display = “8b” no lift truck operation.

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

CHECKS Does the DIAG/RUN/SETUP switch in “Diagnostic” position? No

Yes

Does the direction switch in neutral ? Yes

Check continuity from logic P2-6 to battery negative. No continuity

Replace logics.

Move switch to “Run” position.

Move switch to neutral.

Continuity

Repair or replace short wire or direction switch.

MicroController Control System

Testing And Adjusting

PROBLEM 8 Seat switch circuit defect.

POSSIBLE CAUSE Seat switch defect; Wiring to seat defect; Logics defect.

CHECKS Disconnect the battery and remove logic cover. Disconnect P2 connector. Check continuity from P2-7 harness connector to negative heatsink with multimeter. Should be closed circuit when seat is pressed on and open circuit when seat is released. No continuity

Constant continuity

Check OK

Replace logics.

Disconnect seat switch connector. Push on the seat and check the continuity across the seat switch. Continuity

No continuity Disconnect seat switch connector. Check continuity from logic harness connector P2-7 to control panel battery negative with multimeter. Replace seat switch.

Continuity

No continuity Replace seat switch.

Check continuity from terminal #1 of seat switch to control panel battery negative. Continuity

Check wiring for short circuits between harness connector P2-7 and control panel battery negative. Repair any short circuit found.

No continuity

Repair or replace open wire.

Check continuity from terminal #2 of seat switch to logic harness connector P2-7 with multimeter. Repair or replace open wire.

MicroController Control System

Testing And Adjusting

PROBLEM 9 Direction switch circuit defect.

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

CHECKS Disconnect the battery and remove logic cover. Disconnect P2 connector. Check continuity from control panel battery negative to logic connector P2-5; With direction lever in forward should have a closed circuit, in neutral should be open. Check OK

Check failed

Disconnect direction switch connector. Check continuity of wire #27.

Check continuity from control panel battery negative to logic connector P2-6. With direction lever in reverse should have a closed circuit, in neutral should be open. Check OK

Continuity

No continuity

Check failed Repair or replace wire.

Replace logics. Check continuity from terminal #3 of direction switch harness connector to control panel battery negative.

Disconnect direction switch connector. Check continuity of wire #28. Continuity

Continuity

No continuity

Replace direction switch.

Repair or replace wire.

Repair or replace open wire.

Check continuity from terminal #1 of direction switch harness connector to control panel battery negative. Continuity

Replace direction switch.

No continuity

Repair or replace open wire.

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Testing And Adjusting

PROBLEM 10 Lift sensor circuit defect.

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

CHECKS Disconnect the tilt and auxiliary switch connectors. Retest lift sensor circuit in self diagnostics. Circuit passes “Self-Diagnostics”

Circuit fails “Self-Diagnostics”

Perform Problem 11,12 Tilt or auxiliary circuit defect.

Disconnect PV connector at the valve control board. Connect multimeter negative lead to PV-5 and the positive lead to PV-2. Measure the voltage. Battery Voltage

Measure each voltage from : PV-1, PV-3 to battery negative PV-5. All = 11.5 to 12.5

Display does not change 0 to 3

Measure each voltage from P2-3, P2-4 to battery negaive.

Display changes 0 to 3

All = 11.5 to 12.5

Perform “Self-Diagnostics”. Lift circuit should work.

Replace logics.

NOTE :

Any one or all 0V

Repair or replace broken wire between P2 logic connector and PV connector.

Measure each voltage from P2-3, P2-4 to battery negative as the lever is pulled. 11.5 to 12.5 and .2 Measured on each

Repair or replace broken wire between key switch and PV-2 (wire #5) or between PV-5 and battery negative(-).

Any/All = 0V

Reconnect PV and adjust the lift sensor and valve control card to specifications.

0 Volt

Remove P2 logic connector. Check P2-3, P2-4 for shorts to negative.

11.5 to 12.5 and .2V NOT measured on each

If shorted

Replace valve Control Card.

Replace logics.

No shorts

Repair or replace wire.

Before lift truck is placed into service, connect tilt and auxliary switches and verify proper adjustment.

MicroController Control System

Testing And Adjusting

PROBLEM 11 Tilt switch circuit defect.

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

CHECKS Disconnect the battery and remove logic cover. Disconnect P2 connector. Pull tilt lever to maximum. Check continuity from logic connector P2-2 to control panel negative. Continuity

Replace logics.

No continuity

Check continuity of wire #49. Continuity

Check continuity from tilt switch terminal of wire #1 to control panel negative. Continuity

Replace tilt switch.

MicroController Control System

No continuity

Repair or replace wire.

No continuity

Repair or replace wire.

Testing And Adjusting

PROBLEM 12 Aux 1 & 2 switch circuit defect.

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

CHECKS Disconnect the battery and remove logic cover. Disconnect P2 connector. Pull reach lever to maximum. Check continuity from logic connector P2-16 to control panel negative. Continuity

No continuity

Replace logics.

Check continuity of wire #46. Continuity

Check continuity from Aux switch terminal of wire #1 to control panel negative. Continuity

Replace Aux switch.

MicroController Control System

No continuity

Repair or replace wire.

No continuity

Repair or replace wire.

Testing And Adjusting

PROBLEM 13 Park brake switch circuit defect.

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

CHECKS Disconnect the battery. Check continuity from wire #71 to #1 on the park brake switch; With park brake released should have a closed circuit; With park brake applied should have an open circuit. Check park brake switch to make sure it is activated by the park lever. Check OK

Check failed

Check continuity from wire #1 on the park brake to control panel battery negative. Continuity

No continuity

Check continuity from wire #71 on the park brake switch to logic P2-8. Continuity

Replace logics.

Replace park brake switch.

Repair or replace wire.

No continuity

Repair or replace wire.

MicroController Control System

Testing And Adjusting

PROBLEM 14 Accelerator circuit defect.

POSSIBLE CAUSE Wiring defect; Accelerator defect; Logics defect.

CHECKS With the key switch on, the seat switch closed, park brake released and connect multimeter positive lead to P1-16, negative lead to P1-20. Measure the voltage. 12 volts

Other voltage.

Connect multimeter positive lead to P1-15, negative lead to P1-20. Measure the voltage accelerator pedal released : 0 volt. Press accelerator pedal to max. : 9.6 to 11 volts.

Replace logics.

Check OK

Check failed

Disconnect P1 logic connector. Check continuity of wire #18. Continuit

Replace accelerator.

No continuity

Check continuity from terminal #1 of accelerator harness connector to logic harness connector P1-16. Continuity

Replace accelerator.

No continuity

Check continuity from terminal #3 of accelerator harness connector to logic harness connector P1-20. Continuity

Replace logics.

Repair or replace wire.

No continuity

Repair or replace wire.

MicroController Control System

Testing And Adjusting

PROBLEM 15 Incorrect contactor operation.

POSSIBLE CAUSE Wiring defect; Contactor defect; Logics defect.

CHECKS During the Self-Diagnostic test, which of the following occurs? Contactor does not activate or does not remain activated.

A contactor activates whenever the key switch is closed through all tests.

Disconnect the battery. Check for free mechanical movement of contactor tips. Movement OK

See Problem 16, Any contactor closes when key switch is activated.

Movement not free

Replace contactor.

Remove logic cover. Disconnect P1. Check continuity from P1-3 (wire #15) to terminal of the contactor with incorrect operation. Continuit

No continuity

Measure continuity from the appropriate P1 socket to the coil terminal of the contactor that has incorrect operation. Determine the P1 socket with respect to the contactor that has incorrect operation as follows: Line …………….. P1-4, wire #33 Forward direction …. P1-5, wire #34 Reverse direction …. P1-6, wire #35 Bypass ……… P1-7, wire #36 Continuity

No continuity

Check the contactor coil resistance. See Component Measurements in Specifications section. Check OK

Repair or replace wire.

Check not OK

Connect P1 and run “Selfdiagnostics” again. If contactor does not close, replace logics.

MicroController Control System

Repair or replace wire.

Testing And Adjusting

PROBLEM 16 Any contactor closes when key switch is activated.

POSSIBLE CAUSE Wiring defect; Logics defect.; Contactor defect.

CHECKS Connect the battery. Does the line contactor close when the key switch is closed ? Yes

Did the seat switch pass ”Self-diagnostics”? No

See Problem 8, seat circuit defect.

Yes

With contactor closed ? Disconnect the battery. Remove logic cover and disconnect logic P1 connector. Check for a short circuit from control panel battery negative to P1 harness connector socket. Determine the P1 socket with respect to the contactor that closed as follows: Line ........................................... P1-4 Forward direction ...................... P1-5 Reverse direction ...................... P1-6 Bypass ...................................... P1-7 Short circuit

Repair or replace shorted wire.

MicroController Control System

Open circuit

Replace logics.

Testing And Adjusting

PROBLEM 17 Display = “EE” no lift truck drive operation.

POSSIBLE CAUSE Static Return to Off (SRO) circuit activated by improper operation sequence; Direction and Accelerator switch defect; Wiring defect; Logics defect.

CHECKS Check SRO Circuit.

Remove logic cover. Check continuity from P2-6, P2-5 to negative heatsink. (directional or accelerator lever in neutral, brake switch is closed) Continuity

No continuity

Disconnect direction switch. Check continuity from logic P2-5, P2-6 to negative heat sink. Continuity

No continuity

Check wire #27 and #28 for short.

Check and repair directional switch.

Bad

Repair wire.

Measure the voltage at logic P1-15. Above 1V

Repair or replace accelerator.

Replace logics.

Good

Replace logics.

MicroController Control System

Testing And Adjusting

PROBLEM 18 Display = “EE” (Flashing), no lift truck drive operation.

POSSIBLE CAUSE No opterator in seat; Seat switch defect; Open wiring; Logics defect.

CHECKS See Problem 8, seat circuit defect.

MicroController Control System

Testing And Adjusting

PROBLEM 19 Display = “E1” lift truck operation normal.

POSSIBLE CAUSE Worn brushes; Short wiring; Display defect.

CHECKS If “E1” displays as soon as the accelerator is depressed, and the direction contactor pull in, then drive motor brush wear. Disconnect the wire #31 from drive motor. Connect the battery and close the key switch and seat switch. Does the LCD go out ? No

Yes

Check the brushes and replace as necessary.

Disconnect the battery. Check continuity of the respective wires to the display. Continuity

No continuity

Replace or repair wires.

Disconnect logic P2 and check for shorts from logic P2-14 to battery negative. Shorted

Replace logics.

Opened

Replace display.

MicroController Control System

Testing And Adjusting

PROBLEM 20 Display = “E2” lift truck operation normal.

POSSIBLE CAUSE Worn brushes; Short wiring; Display defect.

CHECKS If “E2” displays as soon as the key switch is turned ON, then hydraulic brush wear. Disconnect the wire #72 from pump motor. Connect the battery and close the key switch and seat switch. Does the LCD go out ? No

Yes

Check the brushes and replace as necessary

Disconnect the battery. Check continuity of the respective wires to the display. Continuity

No continuity

Replace or repair wires.

Disconnect logic P2 and check for shorts from logic P2-15 to battery negative. Shorted

Replace logics.

MicroController Control System

Opened

Replace or repair wires.

Testing And Adjusting

PROBLEM 21 Overtemperature is ON and Display = Lift truck accelerates slower than normal. Lifting speed is slower than normal.

POSSIBLE CAUSE Control panel overheated; Control thermostat (thermal switch) defect; Open wiring; Display defect; Logics defect.

CHECKS Let the truck cool for 15 minutes. Overtemperature indicator ON

Normal display

Disconnect the battery. With the controller at close to room temperature, disconnect the control thermal switch connector. Check continuity of thermal switches. Should have continuity below 69 ℃ (156 ℉). Continuity

Control panel was overheated, resume normal operation. If repeats occur, check drive and pump motors current draw or operating cycle for excessive ramp climbing, towing or excessive lifting.

No continuity

Check continuity of wire #1 at thermostat to negative heatsink (control panel negative). Continuity

Replace thermal switch.

No continuity

Repair or replace wire.

Remove logic cover. Check continuity of wire #69 to logic P2-11. Continuity

Replace logics.

No continuity

Repair or replace wire.

MicroController Control System

Testing And Adjusting

PROBLEM 22 Overtemperature is ON and Display = Bypass contactor will not close. Pump operation normal. Acceleration slow.

POSSIBLE CAUSE Drive motor Control paneloverheated; overheated;Drive Control motor thermostat thermostat (thermal (thermal switch) switch) defect; Open wiring; defect; Open Display wiring; Display defect; Logics defect; defect. Logics defect.

CHECKS Let the truck cool for 15 minutes. Overtemperature indicator ON

Normal display

Disconnect the battery. With the drive motor at close to room temperature, disconnect the drive motor thermal switch connectors. Check continuity of thermal switches. Should have continuity below 123 ℃ (253 ℉). Continuity

Drive motor was overheated, resume normal operation. If repeats occur, check drive motor current draw or operating cycle for excessive ramp climbing or towing.

No continuity

Check continuity of wire #1 at drive motor thermal switch to negative heatsink. Continuity

Replace thermal switch.

No continuity

Repair or replace wire.

Replace thermal switch.Remove logic cover. Check continuity of wire #43 at right drive motor thermal switch to logic P2-12. Continuity

Replace logics.

No continuity

Repair or replace wire.

MicroController Control System

Testing And Adjusting

PROBLEM 23 Overtemperature is ON and Display = Drive operation normal.

Lifting performance slow.

POSSIBLE CAUSE Pump motor Control paneloverheated; overheated;Pump Control motor thermostat thermostat (thermal (thermal switch) switch) defect; Open wiring; defect; Open Display wiring; Display defect; Logics defect; defect. Logics defect.

CHECKS Let the truck cool for 15 minutes. Overtemperature indicator ON

Normal display

Disconnect the battery. With the pump motor at close to room temperature, disconnect the pump motor thermal switch connector. Check continuity of thermal switch. Should have continuity below 123 ℃ (253 ℉). Continuity

Pump motor was overheated, resume normal operation. If repeats occur, check pump motor current draw or operating cycle for excessive lifting and tilting..

No continuity

Check continuity of wire #1 at drive motor thermal switch to negative heatsink. Continuity

Replace thermal switch.

No continuity

Repair or replace wire.

Remove logic cover. Check continuity of wire #42 at pump motor thermal switch connector to logic P2-13. Continuity

Replace logics.

No continuity

Repair or replace wire.

MicroController Control System

Testing And Adjusting

PROBLEM 24 Display = “EL” No hydraulic (lift and tilt). Battery discharge indicator (BDI) circuit defect.

POSSIBLE CAUSE Battery discharged or has a defect; Logics defect.

CHECKS Connect battery, turn on key switch, close seat switch and measure voltage from line contactor to negative heatsink. Voltage must be greater than 34.5 volts. Voltage OK

Voltage low

With key ON, seat switch and line contactor closed, measure voltage at P1-17. Battery voltage

Replace logics.

Check battery connections; Charge or replace battery.

Less than battery

Repair shorted wire or high resistance connection causing the improper voltage.

MicroController Control System

Testing And Adjusting

PROBLEM 25 Hourmeter does not work.

POSSIBLE CAUSE The hourmeter requires battery voltage to run. Measure voltage at hourmeter to ensure that it is battery voltage. No voltage

Battery voltage

Replace hourmeter.

Check continuity from key switch to hourmeter positive (+) terminal. Continuity

No continuity

Repair or replace wire.

Check continuity from hourmeter negative (-) to battery negative wire #1. No continuity

Repair or replace wire.

MicroController Control System

Testing And Adjusting

PROBLEM 26 Normal hydraulic operations, display is normal and no drive operations

POSSIBLE CAUSE Service brake switch shorted. Short wires(#27, #28).

CHECKS Disconnect the battery connector and discharge the head capacitor fully.

Check continuity from wire #27(logic P2-5) to wire #28(logic P2-6). Continuity

No continuity

Check service brake switch and check wires #27, #28 from logics to service brake switch. Check directional switch. All checks OK

Replace logics.

Any checks fail

Repair or replace wire or switches.

MicroController Control System

Testing And Adjusting

PROBLEM 27 Current limit adjustment cannot be made.

POSSIBLE CAUSE Current sensor defect; Wiring defect; Logics defect.

CHECKS Perform current sensor component check. Check OK

Check failed

Replace logics.

Repair wiring or replace current sensor.

MicroController Control System

Testing And Adjusting

PROBLEM 28 Slow steerung. but pump motor does turn. Drive system operation normal.

POSSIBLE CAUSE Steering pressure switch defect; Wiring defect; Logics defect.

CHECKS Check the battery, close the seat and key switches. Put the direction lever in forward. disconnect pressure switch connector. Pump motor speed remains the same

Pump motor speed increases

Replace the pressure switch.

Disconnect pressure switch connector. Check for a short circuit between P2-1 and battery negative. Not short

Replace logics.

MicroController Control System

Short

Repair the wiring.

Testing And Adjusting

PROBLEM 29 Pump motor runs continuously when neutral is selected(no wait mode). Pump motor turns at high power steering speed continuously.

POSSIBLE CAUSE Steering pressure switch defect; Pressure switch connector disconnected; Wiring defect; Logics defect

CHECKS Check steering pressure switch connector for proper connection. Connected

Disconnected

Disconnect the pressure switch connector. Place jumper wire both pressure switch connector terminals. With the key ON, seat switch closed and a direction selected, the pump motor should run at slow speed. Remains at high speed

Connect connector

Runs at slow speed

Disconnect the battery and discharge the head capacitor. Check continuity from terminal #1 of pressure switch connector to the control panel negative. Also check continuity from terminal #2 of pressure switch connector to logic connector P2-1. Continuity

Replace logics.

Replace the pressure switch.

No continuity

Repair or replace open wire.

MicroController Control System

Testing And Adjusting

PROBLEM 30 Drive motor does not operate or operates with low power or is erratic. Pump systems operation normal.

POSSIBLE CAUSE Accelerator defect; Direction control circuit defect; Current limit set too low; Wiring defect; Logics defect.

CHECKS Perform self-diagnostics. Passed

Does not pass

Readjust current limit to specifications. Check PR1 for correct resistance. Resistance is 90Ω ± 5%. In specification

See respective problem for defective circuit.

Not in specification

Replace resistor.

Check wires #67 and #68 for a good connection on PR1. Check wire #63 to base of transistor DTR1. Check continuity of wire #64 from emitter of power transistor to logic P6-4. All OK

Defective wiring

Check diode DD1 and DD2 for shorts or open circuit. Diode OK

Defective diode

Check drive motor, cables and contactor for open circuits. Check OK

Replace logics.

Repair or replace defective wiring or connection.

Replace defective diode.

Open circuit

Repair open circuit or replace drive motor.

MicroController Control System

Testing And Adjusting

PROBLEM 31 Horn does not function correctly. Lift and drive operation normal.

POSSIBLE CAUSE Open fuse; Faulty wiring; Defective switch; Horn defect.

CHECKS With the faulty horn circuit activated, check for voltage on the load side of the horn fuse. Battery voltage

No voltage

Check for voltage on the load side of the horn switch. Battery voltage

Check for short circuits; Replace horn fuse.

0 volt

Check for voltage at the negative connection of the load. 0 volt

Repair or replace open wire from fuse or replace defective switch.

Battery voltage

Repair or replace open wire from the horn switch or replace horn.

Repair or replace open wire from fuse or replace defective switch.

MicroController Control System

Testing And Adjusting

PROBLEM 32 Auxiliary lighting and/or alarm does not function correctly. Lift and drive operation normal.

POSSIBLE CAUSE Open fuse; Faulty wiring; Defective switch; Shorted load; Open load; Loss of input voltage to DC-DC converter; Defective DC-DC converter.

CHECKS Connect the battery and close the key switch. Measure from the DC-DC converter 12V positive terminal to the 12V negative terminal. No voltage output

Voltage above 13V

Voltage below 11V

Con’d Next Page

Voltage 11 to 13V

With the faulty auxiliary circuit activated, check for voltage on load side of the auxiliary fuse. 11 to 13 volts

Check for voltage on the load side of the auxiliary switch. 11 to 13 volts

Check for short circuits; Replace auxiliary fuse.

0 voltage

Check for voltage at the negative connection of the load. 0 volts

No voltage

Repair or replace open wire from fuse or replace detective switch.

11 to 13 voltage

Repair or replace open wire from the auxiliary switch or replace the defective auxiliary component.

Repair or replace open wire going to battery negative.

MicroController Control System

Testing And Adjusting

No voltage ouyput.

Measure the voltage from(POS INPUT) to (NEG INPUT). Battery voltage

0 volts

Measure the voltage from (12V POS) terminal of the DC-DC converter to battery negative. Battery voltage

Measure the voltage from the battery positive cable at the line contactor to the (NEG INPUT) terminal of the DC-DC converter.

0 volts

Battery voltage Measure the voltage from (ENABLE) terminal of the DC-DC converter to battery negative. Battery voltage

Replace the DC-DC converter.

Check for open fuse or wiring between the line contactor and the(POS INPUT) terminal of the DC-DC converter.

0 volts

Open fuse Repair or replace open wiring from the key sw to the (ENABLE) terminal of the DC-DC converter.

Fuse good

Replace the DC-DC Converter.

Replace fuse. If fuse continues to fail, replace the DC-DC

<11 or >13 volts

Check for a short circuit in each auxiliary circuit. No shorts found

Repair or replace faulty wiring.

Fuse open

Remove the load connections at the (12V POS) and (12V NEG) terminals of the DC-DC converter. Measure the voltage from the (12V POS) to the (12V NEG) terminals of the DC-DC converter. 11 to 13 volts

Repair open negative connection from converter (NEG INPUT) to battery negative.

Open wiring

Replace fuse and check wiring for shorts. If no shorts are found and the fuse continues to fail, replace the DC-DC converter.

Test the fuse at the DC-DC converter for continuity.

0 volts

Replace the DC-DC Converter

Shorts found

Repair or replace faulty wiring or components

. MicroController Control System

Testing And Adjusting

Voltage bellow 11 volts

Measure the voltage from(POS INPUT) or (+IN) terminal to the (NEG INPUT) or (-IN) terminal ot the DC-DC converter. 36 volts or above

Below 35 volts

Remove all connection at the (12V POS) and (12V NEG) or the (+OUT) and (-OUT) terminals of the DC-DC converter. Measure the voltage from (12V POS) to (12V NEG) or (+OUT) to (-OUT).minal of the DC-DC converter to battery negative. 11 to 13 volts

Check the battery and DC-DC converter input connections from the battery.

below 11 volts

Check for a short or low resistance in the auxiliary circuits and loads. NOTE: Excessive loading places the converter into current limit (12A maximum).

Battery low

Poor connection

Charge or replace battery.

Repair or replace faulty wiring or connections.

DC-DC converter faulty. Replace t

Voltage above 13 volts

Remove all connections at the (12V POS) and (12V NEG) or the (+OUT) and (-OUT) Terminals of the DC-DC converter. Measure the voltage from (12V POS) to (12V NEG) or (+OUT) to (-OUT). 11 to 13 volts

Above 13 volts

Check the output load circuits for incorrect wiring or shorts to battery negative.

MicroController Control System

DC-DC converter faulty. Replace converter.

Testing And Adjusting

PROBLEM 33 Display = “F0” no lift truck operation.

POSSIBLE CAUSE Refer to Option Program Feature #9. Logic potentiometers VR1 and VR6 out of adjustment. Excessive drive motor currents due to pushing or ramp application. Failed drive motor. Failed logics. Weak or discharged battery.

CHECKS Adjust current limit to specification : 36 V - 500 amps. OK

Still “F0”

Determine when the “F0” occurs.

Place lift truck into operation.

Before bypass

During bypass

Is there a steep ramp that the truck must stop on ? If so the Excessive Drive Motor Current option may not be applicable in this application. Set option Programmable Feature 9 to Data Codes 3.

Determine if there is a steep ramp in the application. Adjust VR6 so that current is greater than maximum drive motor current going up the ramp.

No ramp, or continues “F0”

No ramp, or continues “F0”.

Does the “F0” occur due to excessive pushing or abuse. Ensure that the battery is not being deep discharged, causing high currents. Inspect the battery for poor maintenance or bad cells. Explain situation to the customer. If abuse continues, any drive failure will not be warranted.

Discussion : The logic card monitors the current in the drive motor, and prevents high currents that may damage the drive motor, or possibly blow the line fuse. It uses current limit setting for this purpose. Potentiomenter VR1 sets current limit for transistor pulsing, and if drive motor current exceeds the VR1 current setting for longer than 3 seconds, it will failsafe and display an “F0” Similary, if the bypass contactor is closed, and the current exceeds the potentiometer VR6 setting for longer than 3 seconds, the truck will failsafe in a similar . manner. In addition, the bypass operation will be prevented if the drive motor currents exceed the VR1 current limit

MicroController Control System

Testing And Adjusting

PROBLEM 34 Display = “F2” no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Shorted DTR1; Welded bypass contactor tips; Open wiring; Driver board defect; Logics defect; Frame voltage on S1 drive motor cable.

CHECKS Disconnect the battery, check bypass contactor for welded tips. Check contactor for free tip movement. Not welded

Welded

Disconnect battery, remove logic cover, check continuity and connections of wire #64 at DTR1 emitter to P6-4 on logics. Continuity

No continuity

Disconnect S1 cable at panel and retry Still “F2”

Repair or replace contactor tips. Check BDI adjustment and battery. Check current limit adjustment.

Repair or replace wiring or connection.

Investigate voltage present on S1 cable.

Check DTR1 for failure Test OK

Replace transistor.

Test driver board. Test OK

Replace logics.

MicroController Control System

failed

Replace driver board.

Testing And Adjusting

PROBLEM 35 Display = “F3” no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Shorted HTR1; Open wiring; Driver board defect; Open circuit pump motor or P1, P2 cables; Logics defect.

CHECKS Connect the battery, close the seat and key switches. Line contactor closes then opens. Check HTR1 for a short circuit. Not failed

Failed

Check driver board.

Replace transistor.

Not failed

Failed

Replace driver board.

Disconnect battery, remove logic cover, check continuity of wire #74 at emitter connector of HTR1 to P6-5 on logics. Not continuity

Continuity

Repair or replace wiring.

Check continuity from P1 to P2 at control panel. Continuity

Replace logics.

MicroController Control System

No continuity

Check motor and cables and repair.

Testing And Adjusting

PROBLEM 36 Display = “F4” no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Bypass contactor tips shorted; Shorted DTR1 and HTR1. Poor connection at logic P6 connector; Driver board defect.

CHECKS See Problems 34 and 35, Display = “F2” and “F3” Do both procedures.

MicroController Control System

Testing And Adjusting

PROBLEM 37 Display = “F5” no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Faulty wire connections; DTR1 failed; Current limit set to low; Failed DD1 or DD2; Failed driver board; Current sensor defect; Logics defect. CHECKS Disconnect the following wires, visually inspect them for burnt or discolored terminals; Loose connections; Smashed or compressed connectors; Corrosion or foreign material. Wire #65 at P6-1. Wire #64 at P6-4 and emitter bus bar of drive power transistor. Wires #67 and #68 at resistor PR1. Wires #63 at DTR1. Wire #4 from driver board to positive heatsink. Wire #1 from driver board to negative heatsink. Wire #22 from logic P1-12 to current sensor. Wire #25 from logic P1-16 to current sensor. Current sensor PIN3 to negative heatsink. Repair any defects then reconnect the wires. Display = “F5”

Display normal

Test DTR1 for a failure. Not failed

Return truck to operation.

Failed

Test diodes DD1 and DD2 for a failure. Not failed

Replace transistor. Failed

Measure voltage at P1-16 with the key switch closed. Voltage = 11 to 12V

Replace failed components. Recalibrate current limit to specifications.

Any other voltage

Replace logics.

Perform Rapid Tune-Up procedure for current limit (VR1). Display “F5”

Display normal

Test driver board for a failure. Not failed

Replace logics.

Recalibrate current limit adjustments to specifications.

Failed

Replace failed components. Recalibrate current limit to

* See Notice #1

MicroController Control System

Testing And Adjusting

Problem 37 (Continued)

CHECKS Disconnect current sensor connectors. Check continuity of wires #22 and #25. Continuity

No continuity

Measure voltage at P1-16 with key switch ON. Votage 11 to 12 volts

Other voltage

Measure voltage at P1-12 with key switch ON. Voltage 0 to 0.05 volts

Replace logics.

Voltage above 0.05 volts

Replace current sensor.

Disconnect terminals of P1-12 at harness. Move direction lever to forward or reverse. Depress the accelerator pedal to half. Measure voltage at P1-12. Voltage 0.05 to 12 volts

Replace logics.

Repair or replaced wire.

Voltage below 0.05 or above 12

Replace current sensor.

NOTICE #1 Damage to the control panel could result. To prevent further damage, before DTR1 or driver board are replaced, complete the following checks: 1. Check the Diode DD1 and DD2 for a failure. 2. Check DTR1 for a failure. 3. Check Driver board for a failure. 4. Check Head capacitor for a failure. 5. Check for continuity from DTR1 emitter (wire #64) to logic P6-4.

MicroController Control System

Testing And Adjusting

PROBLEM 38 Display = “F6” no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Faulty wire connections; HD1, HTR1 failed; Failed driver board; Failed logics.

CHECKS Disconnect the following wires, visually inspect them for burnt or discolored terminals, loose connections, smashed or compressed connectors, corrosion or foreign material. Wire #75 at P6-2. Wires #77 and #78 at resistor PR2. Wire from driver board to positive heatsink. Wire #1 from driver board to negative heatsink. Wire #73 at base of transistor HTR1. Repair any defects then reconnect the wires. Display = “F6”

Display normal

Return truck to operation.

Check diode HD1 for a failure. Not failed

Failed

Replace failed diode.

Check transistor HTR1 for a failure. OK

Failed

Replace transistor.

Check driver board. Not failed

Failed

Replace logics.

Replace driver board.

* See Notice NOTICE Damage to the control panel could result. To prevent further damage, before HTR1 or driver board are replaced, complete the following checks: 1. Check the Diode HD1 for a failure. 3. Check HTR1 for a failure. 2. Check Head capacitor for a failure. 4. Check Driver board for a failure. 5. Check for continuity from HTR1 emitter (wire #74) to logic P6-5.

MicroController Control System

Testing And Adjusting

PROBLEM 39 Display = “F7” no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Failure in both the drive and pump circuits. Incorrect wiring of wires #67, #68, #77 and #78.

CHECKS See Problem 37 and 38, Display = “F5” and “F6” Do both procedures.

MicroController Control System

Testing And Adjusting

PROBLEM 40 Display = “F8” no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Open shunt field ; Poor wire connections ; Shorted TR5 transistor ; Logic defect.

CHECKS Disconnect the following wires, visurally inspect them for burnt or discolored terminals ; Loose connections ; Smashed or compressed connectors ; Corrosion or foreign material. Wire #4 at positive heatsink Wire #4 at drive board P12-1, P6-1 Wire #4 at shunt resistor Wire #60 at shunt resistor Wire #60 at drive board P6-2, P6-3 Wire #60 at logic P6-6 Repair any defects then reconnect the wires. Display = “F8”

Display normal

Return truck to operation

Disconnect the main connector and check continuity from wire #4 at shunt resistor to wire #60 at shunt resistor. 380 to 400 ohms

No continuity

Repair open wire or replace shunt resistor.

Check drive board (shunt field component only). Not failed

Replace logics.

Failed

Replace drive board.

MicroController Control System

Testing And Adjusting

PROBLEM 41 Display = “F9” no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Open wire #54 ; Open shunt field fuse ; Shorted diode D3 ; Open TR5 transistor ; Shorted shunt field ; Logics defect.

CHECKS Disconnect the following wires, visurally inspect them for burnt or discolored terminals ; Loose connections ; Smashed or compressed connectors ; Corrosion or foreign material. Wire #58 & #60 at shunt field fuse holder Wire #58 at drive board P6-4 Wire #54 at drive board P6-6 Wire #54 at logic P6-3 Wire #4 at drive board P12-1 Wire #1 at negative heatsink Repair any defects then reconnect the wires. Display = “F9”

Display normal

Return truck to operation

Check shunt field fuse. Not failed

Failed

Replace shunt field fuse. Display= ”F&9”

Return truck to operation

Disconnect the main connector and check continuity from wire #4 at shunt resistor to wire #60 at shunt resistor. 380 to 400 ohms

Display normal

Low resistance

Replace shunt resistor Check drive board (shunt field component only). Not failed

Replace logics

MicroController Control System

Failed

Replace drive board

Testing And Adjusting

PROBLEM 42 Display = “Fb” no lift truck operation, line contactor closes and opens.

POSSIBLE CAUSE Battery defect; Logics defect; Jumpers miss.

CHECKS Jumper is connected correctly? Yes

Disconnect battery, measure voltage at battery connector terminal. Voltage must be higher than 30 volts. Voltage OK

Connect the JP1 for 36V or JP2 for 48V.

Wrong voltage

With key on, seat switch and line contactor closed, measure voltage at logic P1-17. Battery voltage

No battery voltage

Replace logics.

Repair or replace wire.

MicroController Control System

Check battery connections; Replace battery.

Testing And Adjusting

PROBLEM 43 Display = “Fd” lift truck operation normal.

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

CHECKS Disconnect the battery. Check continuity from wire #41 to#1 on the pressure switch. Continuity

No continuity

Replace pressure switch

Check continuity from wire #1 on the pressure switch to control panel battery negative. Continuity

No continuity

Repair or replace wire.

Check continuity from wire #41 on the pressure switch to logic P 2-1 Continuity

Replace logics.

No continuity

Repair or replace wire.

MicroController Control System

Testing And Adjusting

System Tests and Adjustments Test Equipment

Hydrometer Hydrometers are usually available from any battery supplier. Battery maintenance is a crucial part of maintaining the electric vehicle. The ability to measure specific gravity and adjust the battery discharge indicator to match battery manufacturers specifications is an important part in the total maintenance of the electric vehicle.

Discharging Head Capacitor (HEAD CAP) There are various pieces of electric truck test equipment that Daewoo recommends for all service personnel. This equipment is available from a number of world wide manufacturers and local electronic suppliers. Contact your Daewoo dealer or the factory for further recommendations.

WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor before any contact is made with the control panel.

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

1 2

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

Discharging Head capacitor (HEAD CAP) (1) Resistor (2) Positive Heat sink (3) Negative Heat sink

1. Disconnect the battery and discharge the head capacitor. 2. Put a 82 ohm, 80 watt resistor (1), in position between the positive (2) and negative (3) heatsinks. Hold the resistor in position for 10 seconds. This will discharge the capacitor below 5 volts. Can also use 39 ohms, 30 watts resistor.

Potentiometer Adjustment Tool -Trimmer Available from most electronic suppliers, this insulated tool allows for fast and easy adjustments of potentiometers.

MicroController Control System

Testing And Adjusting

Logics Removal

WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

1. Disconnect the battery and discharge the head capacitor.

NEG/P2

DAEWOO

PART NO

SERIAL NO

POS

Logics Removal (7) Nuts. (8) Logics.

5. Remove screws (7) which hold logics (8) to control panel.

6. Remove logics and replace logic cover to prevent damage.

“Run Time” Tests WARNING

NEG/P2

DAEWOO

PART NO

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

SERIAL NO

POS

Component Location (1) Screws. (2) Logic Cover.

2. Loosen screws (1) that hold logic cover (2).

WARNING

3. Remove the logic cover.

Key ON, No Operator Warning, Display = “EE” (Flashing) 1. Connect the battery. Connector Removal (3) Connector P1. (4) Connector P2. (6) Connector P6.

2. Turn key to ON with no one on the seat. (5) Connector P8.

3. The display should show the letter “EE” flashing on and off.

4. Disconnect connectors P1(3), P2 (4), P8 (5) and P6 (6). When disconnecting connectors pull on plastic connector housing, not on the wires.

MicroController Control System

4. With an operator on the seat or by pressing on the seat the letter “EE” should stop flashing.

Testing And Adjusting

Overtemperature Protection

Static Return to Off (SRO), Display = “EE” 1. Connect the battery and sit on the seat. 2. Select a direction before turning key to ON. 3. Turn key to ON. An “EE” should appear on the display and the drive system should not operate. 4. Return the direction lever to neutral, then back to forward or reverse. The “EE” should disappear from the display and the drive system should operate. 5. Turn key to OFF. Depress and hold the accelerator pedal.

Overtemperature lndicator

6. Park brake must be released.

To turn on overtemperature indicator.

7. Turn the key to ON. An “EE” should appear on the display and the drive system should not operate.

1. Disconnect the battery and discharge the head capacitor.

8. Release the accelerator padal. The “EE” should disappear from the display and the drive system should operate.

2. Disconnect the control panel thermal switch connector. 3. Connect the battery, close the seat switch and turn the key ON. The overtemperature indicator should be truned on. The drive and hydraulic speed will be reduced. “Ec” stored.

Steps 1 through 3 can be repeated for the drive and pump motor thermal switches, the results should be:

Drive - Drive pulse ratio reduced, bypass operation prevented, and “Ed” stored. Pump - Lifting performance reduced, and “EP” stored.

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100

Testing And Adjusting

Component Tests

Logic Unit Quick Reference Voltage Check The chart that follows is a quick reference of the expected voltages at the logic pin connectors. All voltage measurements are made with respect to battery negative.

WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Keep away from drive wheels.

NOTICE Do not use steam or solvent to clean the controls. Damage can be caused to the control panel. Use pressure from an air hose with a maximum pressure of 205 kPa (30 psi) to clean the control panel when necessary. The air supply must be equipped with a water filter.

1. Disconnect the battery and discharge the head capacitor. 2. Remove the logic cover. 3. Set the multimeter to the 200 volt DC range.

NOTE:

When control wires and power cables or bus bars are to be connected to the same bolt or stud, place all control wires together on the top of the bus bar or power cable.

4. Connect the multimeter negative lead to control panel battery negative. 5. Use the multimeter positive lead with an Needle Tip to measure the voltages under normal and activated conditions as shown in the Logic Voltage Reference chart. Make sure the chart matches the control system being tested.

Connector Layout (1) Connector P1. (4) Connector P6.

MicroController Control System

101

(2) Connector P2.

(3) Connector P8.

Testing And Adjusting

Logic Voltage Checks Logic Termin al P1-1 P1-2

Wire No. 5

Function Battery (+) from key switch Battery (+) to all CTR coils Line CTR coil FWD. CTR coil REV. CTR coil BYPASS CTR coil

Normal Voltage

Activated Voltage

B (+)

B (+) B (+) B (+)

Low Low Low

B (+) to all coils with key ON, 0V key OFF. B (+) = Line CTR open, 0V: closed. B (+) = FWD. CTR open, 0V: closed. B (+) = REV. CTR open, 0V: closed.

B (+)

Low

B (+) = Byp. CTR open, 0V: closed.

B (+)

B (+) -0.8 to 0.2 0.05 to 12

Test Procedure

P1-3

P1-4 P1-5 P1-6

33 34 35

P1-7

P1-8 P1-9 P1-10 P1-11

Not used Not used

Plug sensor

P1-12 P1-13 P1-14

22 -

Drive CT Not used Not used

0 to 0.05 -

P1-15

Accelerator

0 to 0.89

0.9 to 12

P1-16

12 Voltage (+)

11 to 13

P1-17

B(+)

B(+) with line CTR closed.

P1-18 P1-19 P1-20

B(+) from positive heatsink Not used

Battery negative

Logic board negative.

P2-1 P2-2 P2-3 P2-4 P2-5 P2-6 P2-7

41 49 48 47 27 28 45

Pressure switch Tilt switch Lift 1 switch Lift 2 switch FWD. switch REV. switch Seat switch

Low High High High High High High

High Low Low Low Low Low Low

P2-8

Park brake switch

Low

High

P2-9

High

Low

Activate lever from OFF to ON.

P2-10

High

Low

Activate lever from OFF to ON.

P2-11

Low

High

P2-12

Low

High

P2-13

Low

High

P2-14

High

Low

P2-15

High

Low

Option (Height 1 switch) Option (Height 2 switch) Control thermal switch Drive motor thermal switch Pump motor thermal switch Drive brush wear indicator sensor Pump brush wear indicator sensor

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102

0V: key switch OFF, B (+): key switch ON. Voltage exchanges 0 to negative. Voltage increases with current.

Change drive speed according to accelerator pedal position. 0V = key switch OFF, 12V = key switch ON.

Activate handle to any where Activate lever from OFF to ON. Activate lever from OFF to ON. Activate lever from OFF to ON. Activate lever from OFF to ON. Activate lever from OFF to ON. High = switch open, Low = closed. Low : Park brake activated. High : Park brake released.

Activated by overtemperature of control panel. Activated by overtemperature of drive motor. Activated by overtemperature of pump motor. Activated by brush wear of drive motor. Activated by brush wear of pump motor.

Testing And Adjusting

Logic Voltage Checks Logic Termin al P2-16 P2-17 P2-18 P2-19 P2-20

Wire No.

Function

46 1 1

P6-1 P6-2 P6-3

65 75 54

P6-4

P6-5

P6-6

P8-1 P8-2 P8-3 P8-4 P8-5 P8-6 P8-7 P8-8

101 WH YL GN BU BK RD 108

NOTE:

Normal Voltage

ActivatedVolt age

Aux switch Not used Model selection Not used Battery negative

High

Low

Activate lever from OFF to ON.

Low

B15/18S model.

Logic board negative.

Drive TR base Pump TR base Hyd. shunt field Drive TR emitter sensor Pump TR emitter sensor Hyd.shunt field fail senser

0 0 0

0.1 to 1.3 0.1 to 1.3 0.1 to 1.3

1.5 to B(+)

B (+)

Low

4.5 to 5.5 0 0 0 0 B (+) 0 0

4.5 to 5.5 High/Low High/Low High/Low High/Low High/Low High/Low 0

LCD : DC 5 Volt LCD : DATA LCD : DATA-bar LCD : CLOCK LCD : CLOCK-bar LCD : LOAD LCD : LOAD-bar Battery negative

Test Procedure

Activated as drive TR pulses. Activated as pump TR pulses. Activated as pump TR pulses. Voltage increases as drive TR pulses faster. Voltage increases as pump TR pulses faster. Voltage decrease during pump pulsing Key switch OFF = 0 V, ON = 5 V. 0V = segment OFF, High = ON. 0V = segment ON, High = OFF. 0V = segment OFF, High = ON. 0V = segment ON, High = OFF. 0V = segment OFF, High = ON. 0V = segment ON, High = OFF. Logic board negative.

“Normal”= battery connected, key switch and park brake switch closed. High voltage signal should be 9 to 12 volts. Low voltage signal should be 0 to 0.9 volt.

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Testing And Adjusting

Conductor and Switch Continuity 4

1. Set the multimeter to the 200Ω range. 2. Use the multimeter to perform the continuity test. lf continuity exists, the measurement will be less than 1 ohm. lf the measurement is more than this, continuity does not exist and the problem will have to be repaired.

5 E

B BX E

Capacitor (Head) WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

3 Location of Components (1) Positive Connection point. (2) Positive Cable. (3) Negative Connection point. (4) Negative Cable. (5) Capacitor.

NOTICE Damage can be caused to the head capacitor. Do not remove bolts from capacitor to perform tests. Remove capacitor connecting cables at heatsink connections.

4. Disconnect positive cable (2) from the positive connection point (1). 5. Disconnect negative cable (4) from the negative connection point (3).

lf the capacitor fails the Head Capacitor Test, then replace capacitor.

6. Set the multimeter to the 20 KΩ range. Connect the multimeter positive lead to positive cable (2) of head capacitor (5). Connect the multimeter negative lead to negative cable (4) of head capacitor (5).

1. Disconnect the battery and discharge the head capacitor. 2. Visually inspect the capacitor for bulges at the terminals.

7. The meter must increment to above 10 KΩ 3. Verify the plastic top is not melted around the terminals and that the blow plug is not leaking.

8. If the head capacitor fails this test, then capacitor should be replaced. See Head Capacitor in Specifications section for proper assembly order of the head capacitor connections and bolt torque specifications.

WARNING Head Capacitor “blow plug” will rupture with reverse polarity. Vapors and contents of Head Capacitors are toxic, flammable and corrosive. Personal injury can be caused from breathing the fumes or if its contents make contact with the skin. Be sure to always connect the positive wire, from the positive heatsink, to the positive terminal of the Head Capacitor.

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Testing And Adjusting

Contactors

Contactor Components WARNING

WARNING

The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Keep away from drive wheel that turn.

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

1. Connect the battery and close the seat switch. 2. Turn the key to ON and release the park brake. The line contactor will close.

1. Disconnect the battery and discharge the head capacitor.

3. Select a direction and rapidly depress the accelerator pedal all the way to the floor.

Coil Suppression Diodes

4. Measure and record the time it takes the bypass contactor to close. This should be 1.5 to 2.5 seconds after the accelerator is fully depressed.

1 3

5. If the recorded value from Step 5 is less than 1.0 seconds, the logics may need to be replaced. (During normal operation this time will vary with the load on the truck).

2 4

6. If the recorded value from Step 5 is more than 2.5 seconds, check the bypass contactor tips for free movement. Check wiring for bad connections, and check current limit. NOTE:

Suppression Diodes (1) D1-Line. (2) D2-Forward. (4) D4-Bypass.

The bypass contactor will not close if the accelerator linkage is not adjusted correctly.

(3) D3-Reverse.

2. Disconnect the logic connector P1. 3. Set the multimeter to the diode test position. 4. Connect positive multimeter lead to anode, and the negative multimeter lead to cathode of diode in the logics. 5. The multimeter must indicate .3 to .9 volts. 6. Reverse the leads (positive multimeter lead to cathode and negative multimeter lead to anode). The meter must indicate OL.

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Testing And Adjusting

Contactor Tips

Coil Resistance 2. Disconnect all leads to both terminals of the coil. 3. Set the multimeter to the 200Ω range. 4. Measure the resistance of the coil at both teminals. If must be within specifications. See Component Measurements in Specifications section. 5. If the coil is not within specifications, the contactor assembly will be replaced.

Coil Pulsing

Checking Contactor Tip Gap

2. With the contactor coil leads and suppression assembly leads connected, set the multimeter to the 200 volts DC range.

2. Visually inspect the tips to verify they are not welded, melted, burned, or pitted. 3. Pull and release the tips quickly to verify there is no binding.

3. Connect the multimeter negative lead to the negative coil terminal wire #15 and the meter positive lead to the coil positive terminal wire #33.

4. Visually inspect the contactor assembly. Verify foreign objects don’t interfere with normal contactor operation.

4. Connect the battery and activate the controls necessary for the contactor to be activated.

5. Check contactor tip gap with a feeler gauge as shown. Refer to Specifications section for correct settings.

5. After the contactor activates the multimeter must indicate 24 to 36 volts. If the voltage is not correct and the contactor passed the Coil Suppression Diodes test and the Coil Resistance test, the logics must be replaced.

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106

Testing And Adjusting

Current Sensor 4. Check continuity from harness connector PIN2 wire #22 to logic P1-12 (2). Repair or replace any defective wires.

WARNING Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery. The head capacitor (HEAD CAP) must be discharged before any contact with the control panel is made. Disconnect the battery and discharge HEAD CAP.

5. Set the multimeter to the 200V DC range. With connector P1 disconnected, connect the multimeter positive lead to logic P1-16 (3). Connect the multimeter negative lead to control panel battery negative.

1. Disconnect the battery, discharge the head capacitor, and remove the logic cover.

6. Connect the battery and turn the key to ON. The measurement must be 11 to 13 volts. If the measurement is not correct replace the logics. 7. Disconnect the battery and discharge the head capacitor. Connect P1.

WARNING The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Keep away from drive wheel that turn.

NEG/P2

DAEWOO

PART NO

SERIAL NO

8. Set the multimeter to the 200V DC range and connect the positive lead to logic P1-12 (2).

9. Connect the battery and turn the key to ON. The measurement must be 0 volts. Location Of Components (1) Current Sensor

10. Move the direction lever to forward and depress the accelerator. The voltage being measured should increase. If there is no voltage measured or the voltage being measured does not change, the current sensor must be replaced.

2. Disconnect current sensor connector. 3. Make sure wire #1 from current sensors is connected to the negative heatsink.

NOTE:

If the current sensor is replaced current limit must be adjusted.

2 3

P1 Connector Locations (2) P1-12. (3) P1-16

MicroController Control System

107

Testing And Adjusting

Diodes

Diode Replacement WARNING

WARNING

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

1. Disconnect the battery and discharge the head capacitor.

6 i

2. Remove the logics. l

3. Disconnect the lead wire and remove the diode.

4 1 BYPASS

A2 S2

POS

3 Diode Installation (1) Contact Surfaces.

Location of Comporrents (1) DD1. (2) DD1 cathode lead wire. (3) DD2. (4) DD2 cathode lead wire. (5) HD1. (6) HD1 cathode lead wire. (7) Battery negative heatsink.

4. Wipe clean contact surfaces (1). Put a small amount of D557047 Thermal Joint Compound on contact surfaces (1), but not on the threads.

DD1 (1) is shown in the procedure that follows. Use a similar procedure for the other diodes. DD1 (1), DD2 (3), HD1 (5) have a cathode lead wire.

5. lnstall the diode and tighten to the specification listed in the chart that follows.

1. Disconnect the battery and discharge the head capacitor.

Diode DD1, DD2, HD1

2. Disconnect DD1 cathode lead wire (2).

Torque 9 to 11 N·m (81 to 99 Ib·in)

6. Connect all wires that were removed.

3. Set the multimeter to the diode test position. 4. Connect the negative multimeter lead on DD1 cathode lead wire (2). Connect the positive multimeter lead to battery negative heatsink (7). The multimeter should indicate .3 to.9 volts. 5. Reverse the multimeter leads. The multimeter should indicate OL. If any of the measurements are not correct, replace the diode.

MicroController Control System

108

Testing And Adjusting

Driver Board (On Vehicle)

Drive Side Tests Refer to Driver Board Components and Connections. If any of the measurements that follow are incorrect the driver board must be replaced.

1. Disconnect the battery, discharge the head capacitor. 2. Disconnect CONN P12 from driver board. 3. Transistor TR1 (collector/emitter) and ZD1 test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-9. Connect the negative lead to CONN P12-1. The measurement must be .3 to .9 volts.

NOTICE Damage to the control panel could result. To prevent further damage before the Driver Board is replaced, complete the check list that follow;

Reverse the test leads. The measurement must be OL.

1. Check head capacitor for a failure.

4. Transistor TR1 (collector/base) test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-9. Connect the negative lead to CONN P12-10. The measurement must be .3 to .9 volts.

If the drive circuit failed: 2. Check diodes DD1, DD2. 3. Check transistor DTR1. 4. Check continuity of current sensor wires. 5. Check continuity from DTR1 emitter (wire #64) to logic connector P6-4.

Reverse the test leads. The measurement must be OL.

If the hydraulic pump circuit failed: 5. Transistor TR1 (base/emitter) and R1 test. Set the multimeter to the 200Ω range. Connect the positive lead to CONN P12-10. Connect the negative lead to CONN P12-1. The measurement must be 3.5 to 4.3 ohms.

2. Check diode HD1. 3. Check transistor HTR1. 4. Check continuity from HTR1 emitter (wire #74) to logic connector P6-5. NOTE:

6. Resistor R2 test. Set the multimeter to the 200Ω range. Connect the positive lead to CONN P12-8. Connect the negative lead to CONN P12-9. The measurement must be 7.1 to 7.9 ohms.

Visually inspect the following connections to ensure proper connection and lack of corrosion.

1. Wire #63 to the base of DTR1. 2. Wire #64 to the emitter of DTR1. 3. Wire #73 to the base of HTR1. 4. Wire #74 to the emitter of HTR1. 5. Wire #4 to the positive heatsink. 6. Wire #1 to the negative heatsink. 7. Wires #67 and #68 to PR1. 8. Wires #77 and #78 to PR2. 9. Wires #65 and #75 to connector P6-1 and P6-2. NOTE:

7. Transistor TR2 (emitter/collector) test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-7. Connect the negative lead to CONN P12-11. The measurement must be .3 to .9 volts. Reverse the test leads. The measurement must be OL.

Driver board components are soldered parallel to each other. The tests that follow may not be typical of individual components tests. The driver board must be replaced if any incorrect test results are obtained.

8. Transistor TR2 (base/collector) test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-12. Connect the negative lead to CONN P12-11. The measurement must be .3 to .9 volts. Reverse the test leads. The measurement must be OL.

MicroController Control System

109

Testing And Adjusting

6. Transistor TR4 (base/collector) test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-6. Connect the negative lead to CONN P12-5. The measurement must be .3 to .9 volts.

9. Transistor TR2 (emitter/base) and R3 test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-7. Connect the negative lead to CONN P12-12. The measurement must be .3 to .9 volts as above

Reverse the test leads. The measurement must be OL.

Reverse the test leads. The measurement must be almost same as above.

7. Transistor TR4 (emitter/base) and R6 test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-7. Connect the negative lead to CONN P12-6. The measurement must be .3 to .9 volts.

10. Resistor R3 test. Set the multimeter to the 2 KΩ range. Connect the positive lead to CONN P12-7. Connect the negative lead to CONN P12-12. The measurement must be 1000 to 1400 ohms.

Reverse the test leads. The measurement must be almost same as above.

11. Connect all disconnected connectors. Hydraulic Pump Side Tests

8. Resistor R6 test. Set the multimeter to the 2 KΩ range. Connect the positive lead to CONN P12-7. Connect the negative lead to CONN P12-6. The measurement must be 1000 to 1400 ohms.

1. Transistor TR3 (collector/emitter) and ZD2 test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-2. Connect the negative lead to CONN P12-1. The measurement must be .3 to .9 volts.

9. Connect all disconnected connectors. Reverse the test leads. The measurement must be OL. Shunt Field Side Tests 2. Transistor TR3 (collector/base) test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-2. Connect the negative lead to CONN P12-4. The measurement must be .3 to .9 volts.

1. Tranistor TR5 (emitter/collector) test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-7. Connect the negative lead to CONN P6-4. The measurement must be .3 to .9 volts.

Reverse the test leads. The measurement must be OL.

2. Transistor TR5 (base/collector) test. Set the multimeter to the diode test position. Connect the positive lead to CONN P6-6. Connect the negative lead to CONN P6-4 The measurement must be .3 to .9 volts.

3. Transistor TR3 (base/emitter) and R4 test. Set the multimeter to the 200Ω range. Connect the positive lead to CONN P12-4. Connect the negative lead to CONN P12-1. The measurement must be 3.5 to 4.3 ohms. 4. Resistor R5 test. Set the multimeter to the 200Ω range. Connect the positive lead to CONN P12-2. Connect the negative lead to CONN P12-3. The measurement must be 7.1 to 7.9 ohms.

3. Transistor TR5 (emitter/base) and R6 test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-7. Connect the negative lead to CONN P6-6. The measurement must be .3 to .9 volts. Reverse the test leads. The measurement must be almost same as above.

5. Transistor TR4 (emitter/collector) test. Set the multimeter to the diode test position. Connect the positive lead to CONN P12-7. Connect the negative lead to CONN P12-5. The measurement must be .3 to .9 volts.

4. Resistor R7 test. Set the multimeter to the 2 KΩ range. Connect the positive lead to CONN P12-7. Connect the negative lead to CONN P6-6. The measurement must be 1000 to 1400 ohms. 5. Connect all disconnected connectors.

Reverse the test leads. The measurement must be OL.

MicroController Control System

110

Testing And Adjusting

Driver Board (Off Vehicle)

2 1

Driver Board Components and Connections (1) CONN P12. (2) CONN P6. (3) TR1. (4) TR2.

MicroController Control System

(5) TR3.

(6) TR4.

111

(7) TR5.

(8) Positive Heatsink.

Testing And Adjusting

Component

DRIVER BOARD TEST (OFF VEHICLE) Multimeter Range + Lead - Lead

Result

Drive Side TR1 (C to E) TR1 (E to C) TR1 (C to B) TR1 (B to C) TR1 (B to E) and R1 R2 TR2 (E to C) TR2 (C to E) TR2 (B to C) TR2 (C to B) TR2 (E to B) and R3 R3

Diode Diode Diode Diode 200Ω 200Ω Diode Diode Diode Diode Diode 2kΩ

P12-9 (#63) P12-1 (#4) P12-9 (#63) P12-10 (#67) P12-10 (#67) P12-8 (#64) P12-7 (#1) P12-11 (#68) P12-12 (#65) P12-11 (#68) P12-7 (#1) P12-7 (#1)

P12-1 (#4) P12-9 (#63) P12-10 (#67) P12-9 (#63) P12-1 (#4) P12-9 (#63) P12-11 (#68) P12-7 (#1) P12-11 (#68) P12-12 (#65) P12-12 (#65) P12-12 (#65)

0.3 to 0.9 volts OL 0.3 to 0.9 volts OL 3.5 to 4.3 ohms 7.1 to 7.9 ohms 0.3 to 0.9 volts OL 0.3 to 0.9 volts OL 0.3 to 0.9 volts 1000 to 1400 ohms

P12-1 (#4) P12-2 (#73) P12-4 (#77) P12-2 (#73) P12-1 (#4) P12-3 (#74) P12-5 (#78) P12-7 (#1) P12-5 (#78) P12-6 (#75) P12-6 (#75) P12-6 (#75)

0.3 to 0.9 volts OL 0.3 to 0.9 volts OL 3.5 to 4.3 ohms 7.1 to 7.9 ohms 0.3 to 0.9 volts OL 0.3 to 0.9 volts OL 0.3 to 0.9 volts 1000 to 1400 ohms

P6-4 (#58) P12-7 (#1) P6-4 (#58) P6-6 (#54) P6-6 (#54) P6-6 (#54)

0.3 to 0.9 volts OL 0.3 to 0.9 volts OL 0.3 to 0.9 volts 1000 to 1400 ohms

Pump Side TR3 (C to E) TR3 (E to C) TR3 (C to B) TR3 (B to C) TR3 (B to E) and R4 R5 TR4 (E to C) TR4 (C to E) TR4 (B to C) TR4 (C to B) TR4 (E to B) and R6 R6

Diode Diode Diode Diode 200Ω 200Ω Diode Diode Diode Diode Diode 2kΩ

P12-2 (#73) P12-1 (#4) P12-2 (#73) P12-4 (#77) P12-4 (#77) P12-2 (#73) P12-7 (#1) P12-5 (#78) P12-6 (#75) P12-5 (#78) P12-7 (#1) P12-7 (#1)

Shunt Field Side TR5 (E to C) TR5 (C to E) TR5 (B to C) TR5 (C to B) TR5 (E to B) and R7 R7

MicroController Control System

Diode Diode Diode Diode Diode 2kΩ

P12-7 (#1) P6-4 (#58) P6-6 (#54) P6-4 (#58) P12-7 (#1) P12-7 (#1)

112

Testing And Adjusting

Transistors DTR1 and HTR1

1. Check head capacitor for a failure. If drive circuit failed:

WARNING 2. Check DD1, DD2 for a failure. 3. Check DTR1 for a failure. 4. Check driver board (drive side) for a failure. 5. Check continuity from DTR1 emitter bus bar (wire #64) to logic P6-4. 6. Perform Current Sensor test.

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

If the pump circuit failed: 1. Disconnect the battery, discharge the head capacitor and remove the logics.

2. Check HD1 for a failure. 3. Check HTR1 for a failure. 4. Check driver board (pump side) for a failure. 5. Check continuity from HTR1 emitter (wire #74) to logic P6-5.

2. Remove wires and bus bars from base and emitter terminals of the transistors to be tested.

1 E

Transistor Replacement DTR1 and HTR1

WARNING

D557065 Transistor (1) Emitter. (2) Base.

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

(3) Colectror.

TRANSISTOR SPECIFICATIONS Multimeter (+) (-) A154973 Setting Test Lead Test Lead Results Resistance Emitter Base 45 to 135Ω Diode Base Collector 3 to .9V Diode Collector Base OL Diode Emitter Collector .3 to .9V Diode Collector Emitter OL

6 4

5 3 2

NOTICE

Damage to the control panel could result. To prevent further damage before a power transistor is replaced, complete the check list that follows:

Location of Components (1) Bolt. (2) Bar. (3) Emitter wire #64. (4) Base wire #63. (5) Transistor DTR1. (7) Bolts.

(6) Screw.

DTR1 and HTR1 are all replaced in the same way. DTR1(5) is shown in the procedure that follows.

MicroController Control System

113

Testing And Adjusting

Resistors (PR1 and PR2)

1. Disconnect the battery, discharge the head capacitor, and remove the logics. 2. Remove bolt (1), bar (2) and emitter wire #64 (3).

WARNING

3. Remove screw (6) and base wire #63 (4).

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

4. Remove mounting bolts (7).

8 NOTE:

Look for visual breaks or cracks on resistors.

1. Disconnect the battery, discharge the head capacitor, and remove the logics.

Transistor Removal (8) Contact surface.

Location of Components (1) PR1. (2) Wire #67. (3) PR2. (4) Wire #77

2. Disconnect wire #67 (2) from resistor PR1 (1) and disconnect wire #77 (4) from resistor PR2 (3).

Transistor Removal (5) DTRI Transistor (8) Contact Surface

3. Set the multimeter to the 200Ω range. Connect the multimeter leads to terminals on resistor (1) to check the resistance of PR1. Connect the multimeter leads to terminals on resistor (3) to check the resistance of PR2.

5. The contact surface (8) of transistor (5) is coated with D557047 Thermal Joint Compound. Carefully remove the transistor.

4. The measurement for each resistor must be: 85 to 95 ohms.

6. To Replace the transistor, wipe clean contact surfaces. Put a small amount of D557047 Thermal Joint Compound on the contact surface (8). Coat transistor so that compound covers only the contact area.

5. If the measurement is not correct, the resistor must be replaced.

7. Install transistor (5) with mounting bolts (7). See Specifications section for proper torques. 8. Install base wire #63 (4) with screw (6). See Specifications section for proper torques. 9. Install bar (2) and emitter wire #64 (3) with bolt (1). See Specifications section for proper torques.

MicroController Control System

114

Testing And Adjusting

Thermal Switch

The Thermal Switch (1) will open circuit if the temperature is 81 to 89℃ (178 to 192℉) and close circuit at 69 to 77℃ (156 to 171℉).

WARNING If the thermal switch is removed from the heatsink, it can be tested in an oven.

Battery voltage and high amperage are present. Injury to personnel is possible. Disconnect the battery and discharge the head capacitor (HEAD CAP) before any contact is made with the control panel.

See Troubleshooting Problem 21. Possible cause, pump or drive transistors overtemperature. Pump Motor and Drive Motor The Thermal Switch(1) will open circuit if the temperature is 144 to 156℃ (291 to 313℉) and close circuit at 123 to 137℃ (253 to 279℉).

NOTICE Damage to the thermal switch will occur. Do not heat the thermal switch over an open flame.

If the thermal switch is removed from the motor, it can be tested in an oven. Control Panel See Troubleshooting Problems 22 and 23, Possible cause, drive or pump motors overtemperature.

Location of Components (1) Thermal Switch.

MicroController Control System

115

Testing And Adjusting

Electrical System Adjustments

Parking Brake Switch

Accelerator Control Linkage Method A (Mechanical) ENGA

GE ENGAGE POSITION

DESENGAGE POSITION

Parking Brake Switch Adjustmeant (1) Switch. (2) Bracket. (3) Hex Nuts.

(4) Pin.

1. Close the seat switch and turn the key to ON. 1. Disconnect the battery.

2. Release the parking brake and put the truck in neutral.

2. Assemble the lever (1) to accelerator as per above drawing. Adjust the dimension to 55L1mm and tighten the nut.

3. Reposition bracket (2) so the switch (1) actuator is against the pin (4). Tighten hex nuts (3). 4. Engage the parking brake and the park brake symbol will be displayed. Repeat the procedure until adjustment is correct.

Method B (Electrical) Place the truck in “Self Diagnostics”. 1. Proceed test to “Parking Brake Switch” and push down the accelerator pedal slowly, the speed symbols will increase from 0 to 10 on the LCD. 2. Release the accelerator, the speed symbols will decrease from 10 to 0 on the LCD.

MicroController Control System

116

Testing And Adjusting

Lift Sensor

Valve Control Card Adjustment

1. Disconnect the battery and discharge the head capacitor.

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

4 2

1. Verify the lift sensor clearance is adjusted correctly. 2. Disconnect all tilt and auxiliary switch connectors. 3. Place the lift truck in “Quick” or “Self” diagnostics so that the display is flashing the lift speed.

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

NOTICE Lift sensor may be damaged. Do not allow the magnet (2) to make contact with the plastic bracket when the lift lever is activated.

2. Loosen setscrew (4).

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

Valve Control Card Adjustment (1) P1 Potentiometer. (2) P2 Potentiometer.

4. Tighten setscrew (4). Check lift sensor circuit. The valve control card may need adjusting.

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

MicroController Control System

117

Testing And Adjusting

Tilt and Auxiliary Switches

8. Pull the lift lever all the way back. A flashing “3” must be displayed.

Because each tilt and auxiliary switch can turn on the pump motor, it is recommended that only one be connected to start with. After adjusting the first switch proceed with the next one.

9. If a flashing “3” is not displayed, adjust P2 (2) clockwise until it is. 10. Release the lift lever and adjust P1 counterclockwise until a “0” is displayed.

1. Disconnect the battery and discharge the head capacitor. Disconnect all but one switch connector.

11. Repeat steps 9 and 10 until “0” to “3”speeds correct.

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

COM

13. Connect the battery, close the seat switch and turn the key to ON.

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

If the motor turns on too far in advance of the valve opening, adjust P1 (1) counterclockwise.

Tilt and Auxiliary Switch Adjustment (1) Screw. (2) Screws.

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

MicroController Control System

118

Testing And Adjusting

Rapid Tune-Up Procedure

1. Turn off the key switch. 2. Place direction lever to reverse or forward or seat switch open. 3. Turn on the key switch and then wait until display “EE”(SRO) or “EE” flashing shows on the LCD and the line contactor will be opened.

8 7 6 5 4 3 2 1

1) VRI : Drive Motor Current Limit Potentiometer Fully counterclockwise (CCW) and then slowly turn VR1 (17 full turns) clockwise (500A).

Location of Potentiometers (1) Drive Current Limit Potentiometer VR1. (2) Plugging Current Limit Potentiometer VR2. (3) Not Used. (4) Not Used. (5) BDI Adjustment Potentiometer VR5. (6) Bypass Dropout Adjustment Potentiometer VR6 (Option) (7) Not Used. (8) Electrical Assisted Braking VR8

2) VR2 : Plugging Current Limit Potentiometer Fully counterclockwise (CCW) and then slowly trun VR2 (12.5 full turns) clockwise (500A). 3) VR6 : Bypass dropout current limit potentiometer. Turn VR6 clockwise fully (standard) If you need to use, set Option Program Feature #9 to 1 or 2 as an option. To decrease current, turn VR6 CCW.

The rapid tune-up procedure establishes a starting point for logic card adjustments. The following procedure allows the truck to run without damage to the truck or its components.

4) VR8 : Electrical Assisted Braking Potentiometer. Fully counterclockwise (CCW) and then slowly turn VR8(8.0 full turns) clockwise.

WARNING

4. Make the final adjustments as specified in each of the Testing And Adjusting procedures before putting the truck into service. Perform these procedures in the order listed below.

The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Keep away from drive wheels that turn.

1) Battery Discharge Indicator (BDI) 2) Current Limit 3) Plugging Current Limit 5. Turn off the key switch.

MicroController Control System

119

Testing And Adjusting

Battery Discharge Indicator (BDI) Adjustment

Bar Symbols

Accurate adjustment of the BDI is only possible with a battery of the same voltage that the truck is going to operate at, and at a voltage within the range of the display. If a lift interrupt has occurred, with a “EL” on the display, it may be necessary to reprogram Feature “10” to select TYPE1, and then make the necessary adjustments. If 36 volt European tubular batteries are used, it is recommended that logic board is programmed TYPE1 on Programmable Feature “10”

6: The highest position 5: 4: 3: 2:

: A) Not flashing B) Flashing - 80% discharge warning

BDI Adjustment 1. Disconnect the battery and discharge the head capacitor. Remove logic cover and verify the DIAG/RUN/SETUP switch is in the “Run” position.

BAR SYM30LS DISPLAY

2. Set the multimeter to measure battery voltage.Connect the multimeter positive lead to the battery positive cable at the line contactor. Connect the multimeter negative lead to the battery negative cable.

BATTERY TERMINAL VOLTAGE TYPE 1 (OPT) : Closed Voltage

6 5 4 3 2 1 1* O/EL 1* = Display is flashing

3. Put the direction lever in neutral and connect the battery. 4. Close the seat switch and turn the key to ON. The BDI display must show the correct bar for the voltage measured. To correct values are shown in the charts that follow.

BAR SYM30LS DISPLAY

EXAMPLE: If the measurement is 37.2 volts for a 36.8 volt battery, the bar display should be at “5”

6. If the voltage was 37.2V, VR5 should be turned to find the transition point between 6 and 5 on the bar display. This will assure that the BDI is calibrated at a high 5.

120

36V above 37.2 36.8 to 37.2 36.4 to 36.7 36.0 to 36.3 35.6 to 35.9 35.2 to 35.5 25.8 to 35.1 below 25.8

BATTERY TERMINAL VOLTAGE TYPE 2 (STD) : Closed Voltage

6 5 4 3 2 1 1* O/EL 1* = Display is flashing

5. If the display is not correct, turn the key to OFF and make an adjustment to potentiometer VR5. Turn VR5 clockwise to increase and counterclockwise to decrease the bar display. Approximately a 1/2 turn of VR5 will change the display one bar. Turn the key to OFF between adjustments otherwise the display WILL NOT CHANGE.

MicroController Control System

:: Max. charged status

36V above 37.2 36.8 to 37.2 36.3 to 36.7 35.9 to 36.2 35.4 to 35.8 35.0 to 35.3 34.5 to 34.9 below 34.5

Testing And Adjusting

BAR SYM30LS DISPLAY

BATTERY TERMINAL VOLTAGE TYPE 1 (OPT) : Closed Voltage

6 5 4 3 2 1 1* O/EL 1* = Display is flashing

NOTE:

36V above 37.2 36.9 to 37.2 36.6 to 36.8 36.3 to 36.5 35.9 to 36.2 35.6 to 35.8 35.3 to 35.5 below 35.3

Closed Voltage means that line contactor close.

BDI Adjustment with display at “EL” If the logics has already gone into lift interrupt (display = “EL” it is not possible to adjust the BDI until a battery above a certain programmed voltage is connected to the vehicle. The factory default setting to reset the lift interrupt is any voltage equivalent to a bar display of 3 or higher. This level can be adjusted. See Program Feature “3”. By reprogramming Feature “3”, from the factory default code of 3, to a temporary code of 0, it will become possible to adjust the BDI with a battery with a voltage less than a 3 on the bar display . After adjustment of the BDI, reprogram Feature “3” back to the default setting of 3.

MicroController Control System

121

Testing And Adjusting

Current Limit Test and Adjustment

5. Move the directional lever in forward, and operate the accelerator so that duty ratio of LCD can be 80%. To prevent bypass operation ensure that the accelerator is not depressed all the way down. To get an accurate current reading the wheels must not slip.

NOTICE Damage to the drive motor will result. Do not stall the drive motor for longer than absolutely necessary. To protect the drive motor from excessive currents, and “F0” can occur during current limit setting. Allow for the motors to cool between stalls, and let the motor run between stalls

WARNING 6. The current measurement must be within specification. Adjust logic potentiometer VR1 clockwise to increase the current and counterclockwise to decrease the current. 36V between 490 and 510 amps.

The lift truck can move suddenly. Injury to personnel or damage to the lift truck is possible. Keep away from drive wheel that turn.

NOTE:

Current limit is preset at the factory and should not be adjusted unless the truck malfunctions, or the logic board is replaced. Only qualified service personnel with the correct instrumentation should adjust current limits.

7. Repeat steps 5 and 6 until setting is correct. 8. Don’t forget to re-engage the brake switch and park brake switch prior to putting the vehicle back into operation.

1. Put the truck against the wall so drive wheel do not turn. 2. Connect clamp-on ammeter (1) around the A1 cable to measure drive motor current. Use multimeter to read current remotely from the operator’s seat. 3. Remove the floor plate and disconnect the service brake switch connector. 4. Connect the battery. Close the seat switch and turn the key to ON.

MicroController Control System

122

Testing And Adjusting

Electrical Braking (Plugging) Current Test and Adjustment

Programmable Features There are 20 programmable features that effect the operation of the lift truck. A table of these features, the default setting, the minimum setting and the maximum setting are shown below: Feature Minimum Maximum Default Number Setting Setting Setting

Ammeter Connection (1) Digital Ammeter.

1. Make sure current limit is adjusted to specification before adjusting Electrical Braking current. 2. Connect clamp-on current probe (1) around A1 cable to measure drive motor current. Use multimeter to read current remotely from the operator’s seat. 3. Move the lift truck FORWARD at full speed. Keep the accelerator pedal fully depressed and change the direction to REVERSE.

5 6 2 6 5 2 4 2 5 3 3 6 6 6 6 9 5 2

4 2 0 3 0 P 2 1 4 3 2 2 3 6 3 9 3 P

Description

Creep Speed Steering Duty Electrically Assisted Braking Discharged Battery Reset Value Top Travel Speed Auto plugging Wait Timer (seconds) Discharged Battery Drive Speed Acceleration Travel Speed Time Excessive Drive Motor Current Battery Type Selection Maximum Idle Speed Maximum Lift1 Speed Maximum Lift2 Speed Maximum Tilt Speed Maximum Aux Speed HYD. Ramp Timer Regeneration Operation Field Shunt/Pump Bypass Operation Pump Shunt Field Pulsing Control

The programming procedures are described on the following.

5. If the correct current is not measured, disconnect the battery and discharge the head capacitor. Remove the logic cover and adjust potentiometer VR2. Turn the potentiometer adjustment screw counterclockwise to decrease the plugging current.

1. Initial conditions Move the DIAG/RUN/SETUP switch to “SETUP” and then turn on the key switch.

Though the plugging distance (Recommended plugging distance is approximately 5 meters) is an application specific adjustment, plugging current should not exceed 280 amps. If the recommended current produces a short stopping distance, the distance may be lengthened by turning potentiometer VR2 counterclockwise to reduce plugging current.

MicroController Control System

1 1 0 0 0 1 0 1 1 1 1 1 1 1 1 1 1 1

Setting Procedure Option Features

4. The current measured during the electircal braking (plugging )must be 500 amps ±10A.

NOTE:

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Wait until display “0” shows on the LCD. This code indicates that truck is in the SETUP mode. 2. Programming methods To change the Programmable Feature Numbers, pull the tilt lever to maximum position and then release once. The display will show Feature Number 1.

123

Testing And Adjusting

Quick Procedure for Programmable Features

Cycling the tilt switch advances the display to the next Feature Number. Cycle the tilt switch until the Feature Number of the parameter to be programmed is shown on the display.

An alternative method of entering option programmable features has been programmed into the logics. This will enable quick option programmable features without removing the controller room, line fuse, or placing the DIAG/RUN/SET switch to the “Set Up” position.

With the desired Feature Number being shown, move the direction lever to forward or reverse and then neutral. The display will flash the preset data value. To increase the value, cycle the direction lever to forward and then back to neutral. The display will increment number. Repeat this cycle until the desired value for this feature is flashed.

To enter quick option programmable features, open the seat switch and place the direction lever to reverse and ensure that the park brake is released. While depressing the accelerator to maximum position other than OFF, and key switch to ON.

To save a new setting, pull the tilt lever to maximum position and then release slowly while holding a wanted setting. The display will show the next feature number.

Display will go to a solid “O” indicating that you have entered option programmable features and you are ready for setting: Place the direction lever to neutral and release accelerator pedal. You can set the option programmable features. See programmable or Settable Option Features on page 124-127.

3. Repeat again on the above NO.2 until static display, 19 will show. A “PE” indicates the end of the feature list and can be cycled to return to the beginning of the feature list.

NOTE:

This test enables a salesman to demonstrate some of the option programmable features without ever having to open up the controller room.

Activating Default Settings All of the programmable features can be set to the factory default settings by the following procedure.

1. Turn the key switch to OFF. 2. Seat switch must be open. 3. Move the direction lever to reverse. 4. Place the DIAG/RUN/SETUP switch to SETUP. 5. Park brake must be released. 6. Depress the accelerator pedal to maximum. 7. Turn the key switch to ON. 8. After the display performs the LCD test, a “d” (Flashing) will be displayed. This indicates that the default settings have been programmed.

MicroController Control System

124

Testing And Adjusting

Programmable or Settable Option Features The logics contains a number of features which are either settable or programmable. The following is a list of the features, however the “Service Manual” or your Daewoo Dealer should be consulted in determing which options may be beneficial to the application. NOTE : Marked

means default setting.

FEATIRE

DESCRIPTIONS ※ Creep Speed

Creep Speed Selection provides for slower creep speed control, especially at high mast application. Depending on truck chassis configuration and customer preference, the creep speed can be selected. The default setting of 2 gives improved creep speed control, especially at higher mast. The higher “Number” makes more faster creep speed. Data Codes Contents

2 Slowest

Slowest

3 Normal

4 Faster

5 Faster

※ Steering Duty 1

This can be used to limit the maximum steering speed of the truck. These values are on-duty ratio of the pump main transistor base. Data Codes On–Duty (%)

1 17

2 20

3 23

5 29

6 32

※ Electrically Assisted Braking 2

To automatically activate plugging braking when the service brake is depressed and accelerator pedal is released. Data Codes Contents

1 EAB by Accel & Service Brake

No. EAB

2 EAB by Service Brake

※ Discharged Battery Reset Value

This feature sets the level of battery charge required to enable the hydraulics after a lift interrupt (EL) occurs. The battery discharge indicator (BDI) must read a level greater than the value set in this feature to enable the hydraulics after a lift interrupt occurs. (1* = Display is flashing) Data Codes Symbol No.

0 1*

1 1

2 2

4 4

5 5

6 6

※ Top Travel Speed

The value of this feature is set to select the drive motor top travel speed. Values between 0 and 5 allow for varying speeds, 1 being the slowest and 5 being the fastest without using the bypass contactor. 0 being the normal travel and bypass operation. Data Codes Speed

Max.Speed : Bypass operation

MicroController Control System

125

1 Slow

5 Fast

Testing And Adjusting

※ Auto plugging 5

In case of this feature, data code shows only P flashing and can not be changed. Not used this models. Data Codes Contents

P Not used

※ Wait Timer 6

This feature varies the time before the line contactor drops out after the truck has been inactive (wait mode-no operator requests, and direction lever in neutral). The delay may be set in 6 second, increments between 0 and 12 seconds. Data Codes Time(Sec)

0 0

1 3

3 9

4 12

※ Discharged Battery Drive Speed 7

This feature sets the drive motor top speed during lift interrupt, battery lock-out. If the display shows “EL” the logics limits the drive motor top speed to the value set in this feature. Data Codes

Contents

1. Max. speed = 60 %. 2. No bypass operation.

2 1. Normal operation. 2. Bypass operation.

※ Acceleration Travel Speed Time 8

This feature allows for varying amounts of time until the bypass contactor close when accelerator pedal has been depressed from zero to max. position rapidly. Data Codes Time(Sec)

1 Slowest

2 Slower

3 Normal

5 Fastest

Faster

※ Excessive Drive Motor Current

This prevents the truck from entering bypass when the truck is in current limit, thus extending the life of the bypass contactor tips, reducing line fuse failures, and extending drive motor brush life. If the motor is stalled for longer than 3 seconds, the vehicle will failsafe to prevent motor damage and an “F0” will be displayed. Data Codes

Contents

This is to protect drive motor from excessive current in either pulsing or bypass modes.

2 This is to protect drive motor from excessive current in only bypass modes.

3 Not Used

※ Battery Type Selection 10

Due to different voltage characteristics of battery technologies, specifically european tubular designs, it may be necessary to use a battery voltage chart with a reduced voltage range. Data Codes Battery Voltage(Volt)

MicroController Control System

1 Max. 37.2/Min. 25.8

126

Max. 37.2/Min. 34.5

3 Max. 37.2/Min. 35.3

Testing And Adjusting

※ Maximum Idle Speed 11

This can be used to limit the maximum idle speed of the truck. These values are on-duty ratio of the pump main transistor base. Data Codes On–Duty (%)

1 7

2 9

4 13

5 15

6 17

※ Maximum Lift 1 Speed 12

This can be used to limit the maximum lift 1 speed of the truck. These values are on-duty ratio of the pump main transistor base. Data Codes On–Duty (%)

1 25

2 30

4 40

5 45

6 50

5 90

6 95

6 85

※ Maximum LIft 2 Speed 13

This can be used to limit the maximum lift 2 (and Aux 2) speed of the truck. These values are on-duty ratio of the pump main transistor base. Data Codes On–Duty (%)

2 60

3 70

4 80

※ Maximum Tilt Speed 14

This can be used to limit the maximum tilt speed of the truck. These values are on-duty ratio of the pump main transistor base. Data Codes On–Duty (%)

1 30

2 40

4 60

※ Maximum Aux(1 & 2) Speed 15

this can be used to limit the maximum Aux(1 & 2) speed of the truck. These values are on-duty ratio of the pump main transistor base. Data Codes Contents

1 30

2 35

3 40

4 45

6 65

7 75

8 95

9 95

※ HYD. Ramp Timer 16

When the hydraulic switches are activated, the time which is to take to maximum pulsing can be adjusted. Data Codes Contents

1 Slowest

2 Slowest

Normal

4 Faster

5 Faster

※ Regeneration Operation 17

In case of this feature, data code shows only P flashing and can not be changed. Not used this models. Data Codes Contents

MicroController Control System

1 Not Used

2 Used

127

Testing And Adjusting

※ Drive Field 18

Shunt/Pump Bypass Operation.

In case of this feature, data code shows only P flashing and can not be changed. Not used this models. Data Codes On–Duty (%)

1 Not Used

2 Field shunt

3 Pump bypass

※ Pump Shunt Field Pulsing Control. 19

In case of this feature, data code shows only P flashing and can not be changed. Not used this models. Data Codes On–Duty (%)

1 30

MicroController Control System

2 40

3 50

128

4 60

5 70

6 100

Testing And Adjusting

SB4165E00 A p r. 2 0 0 4

Specifications Systems Operation Testing & Adjusting Disassembly & Assembly Lift Trucks Power Train BC15S, BC18S, BC20SC

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

Index Specifications Drive Motor.................................................................7 Final Drives And Wheels ............................................8 General Tightening Torque .........................................5 Power Transfer Group ................................................8 Wheel Bearing Adjustment .........................................9

Systems Operation Differential And Drive Axles ......................................12 Drive Motor...............................................................10 Power Transfer Group ..............................................11

Testing And Adjusting Drive Motor...............................................................18 Armature Terminal Test .........................................23 Armature Tests ......................................................19 Brush Holder Test..................................................23 Brush Life Estimate ...............................................24 Commutator Inspection .........................................21 Field Coil and Terminal Tests ................................22 Motor Brushes.......................................................18 Thermal Switch Tests ............................................24 Power Transfer Group Adjustments..........................25 Pinion Depth Check ..............................................26 Pinion Installation ..................................................25 Power Transfer Group Bearing and Gear Clearance (Backlash) Adjustments.........................................27 Transaxle Adjustments ..........................................25 Troubleshooting........................................................13 Checks During Operation......................................13 Drive Motor .........................................................13 Power Transfer Group and Final Drive................17 Visual Checks........................................................13

Disassembly & Assembly Differential ................................................................33 Drive Axle .................................................................29 Power Transfer Group ..............................................37 Special Service Tools and Jigs .................................42

Power Train

Index

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

Thread size

Use these torques for bolts and nuts with standard threads (Conversions are approximate)

Standard thread

Use these torques for bolts and nuts on hydraulic valve bodies.

inches

lb•ft

N•m*

1/4

9±3

12 ± 4

5/16

18 ± 5

25 ± 7

3/8

32 ± 5

45 ± 7

7/16

50 ±10

70 ± 15

1/2

75 ± 10

100 ± 15

9/16

110 ± 15

150 ± 20

5/8

150 ± 20

200 ± 25

3/4

265 ± 35

360 ± 50

7/8

420 ± 60

570 ± 80

640 ± 80

875 ± 100

1-1/8

800 ± 100

1100 ± 150

1-1/4

1000 ± 120

1350 ± 175

1-3/8

1200 ± 150

1600 ± 200

1-1/2

1500 ± 200

2000 ± 275

5/16

13 ± 2

20 ± 3

3/8

24 ± 2

35 ± 3

7/16

39 ± 2

50 ± 3

1/2

60 ± 3

80 ± 4

5/8

118 ± 4

160 ± 6

1/4

5±2

7±3

5/16

10 ± 3

15 ±5

3/8

20 ± 3

30 ± 5

7/16

30 ± 5

40 ±10

Use these torques for

1/2

40 ± 5

55 ± 10

studs with taperlock threads.

9/16

60 ± 10

80 ± 15

5/8

75 ± 10

100 ± 15

3/4

110 ± 15

150 ± 20

7/8

170 ± 20

230 ± 30

260 ± 30

350 ± 40

1-1/8

320 ± 30

400 ± 40

1-1/4

400 ± 40

550 ± 50

1-3/8

480 ± 40

650 ± 50

1-1/2

550 ± 50

750 ± 70

Taperlock stud

*1 newton meter (N•m) is approximately the same as 0.1 kg•m. Power Train

Standard Troque

B80625P1 Specifications

Metric Fasteners

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

Metric ISO thread Thread Size Torque (mm) (N•m)* (lb•ft) M6 12 ± 4 9±3 M8 25 ± 7 18 ± 5 M10 55 ± 10 40 ± 7 M12 95 ± 15 70 ± 10 M14 150 ± 20 110 ± 15 M16 220 ± 30 160 ± 20 M18 325 ± 50 240 ± 35 M20 450 ± 70 330 ± 50 M22 600 ± 90 440 ± 65 M24 775 ± 100 570 ± 75 M27 1150 ± 150 840 ± 110 M30 1610 ± 200 1175 ± 150 M33 2000 ± 275 1450 ± 200 M36 2700 ± 400 2000 ± 300 ISO - International Standard Organization

Hose clamps-worm drive band type

Clamp Width 15.9mm (.625 inch) 13.5mm (.531inch) 7.9mm (.312 inch) *1 newton meter (N•m) is approximately the same as 0.1 kg•m.

Power Train

Initial Assembly Troque on New Hose N•m* lb•in 7.5 ± 0.5 65 ± 5 4.5 ± 0.5 40 ± 5 0.9 ± 0.2 8±2

Reassembly or Retightening Troque N•m* lb•in 4.5 ± 0.5 40 ± 5 3.0 ± 0.5 25 ± 5 0.7 ± 0.2 6±2 B80625P1

Specifications

Drive Motor

NAME PLATE S1

INBS005I

Drive Motor Model

Voltage

1 New Brush Thickness X Width X Length

Minimum Brush Length*

BC15S BC18S BC20SC

48V

12.5 mm X 25 mm X 45 mm (.49 in. X .98 in. X 1.77 in.)

19 mm (.75 in.)

New Commutator Diameter

Minimum Commutator Diameter**

98 mm (3.86 in.)

96 mm (3.78 in.)

*As measured on longest side. **All rough edges (burrs) must be removed after the commutator is machined.

Torque for the terminal bolts (not shown) that hold cable connections ..............................12 N•m (10 lb•ft) Maximum difference between commutator high and low point (out of round) .............0.03 mm (.001 in.)TIR Maximum difference between bar to bar .............................................0.005 mm (.0002 in.) TIR Thermal switch Opening temperature ...... 150°C ± 6°C (302°F ± 43°F) Closing temperature........ 130°C ± 7°C (266°F ± 45°F)

Power Train

Specifications

(5) Install shims as needed. See power transfer group adjustment in testing and adjusting.

Power Transfer Group 1 7

(6) Torque for bolts (6) that hold plate ................................... 8 to 12 N•m (5.7 to 8.6 lb•ft)

(7) Torque for bolts (7) that hold differential cases ................................... 50 to 75 N•m (36 to 54 lb•ft)

4 (8) Torque for bolts (8) that hold transfer case ................................... 50 to 75 N•m (37 to 55 lb•ft) (9) Torque for bolts (9) that hold cap .......................................................147 to 167 N•m (109 to 123 lb•ft)

Final Drives And Wheels

INPS050I

4 1

INPS052I INPS051I

Apply Loctite 271 to bolts (1), (2) and (4)

Apply Loctite 271 to bolts (1), (6), (7), (8) and (9)

(1) Tighten nut slowly until torque required to turn bearings is........ 2.45 ± 0.49 N•m (1.80 ± 0.35 lb•ft)

(1) Torque for bolts (1) that hold ring gear to differential case assembly ............... 88 to 156 N•m (65 to 115 lb•ft)

(2) Torque for bolts that hold drive shaft to hub ............................. 59 to 83 N•m (44 to 61 lb•ft)

(2) Adjust differential bearings with locknut (2) to a rolling torque of............................ 3.1 to 4.8 N N•m (27 to 42 lb•in)

(3) Torque for drive wheel mounting bolts .................................. 135 ± 15 N•m (100 ±10 lb•ft) (4) Troque for bolts that hold spindle to drive axle housing .................. 100.5 ± 12.3 N•m (74 ± 9 lb•ft)

(3) Amount of free play (backlash) between bevel gear and pinion (3)........................0.18 to 0.23 mm (0.007 to 0.009 in) (4) Tightening nut (4) to obtain a rolling torque of 2 to 3 N•m (17.6 to 26.5 lb•in) at the pinion without the differential case assembly. Power Train

Specifications

Wheel Bearing Adjustment

INPS053I (1) Hub.

(2) Bolt.

(3) Nut.

(1) Tighten nut (3) slowly until torque required to turn bearings is 2.5 N•m (1.8 lb•ft), while hub (1) is turned to put the bearings in position. (2) Tighten the bolts to hold the nut in position. (Apply Loctite No. 272) Tightening Torque .......................... 7.9 to 11.7 N•m (5.8 to 8.6 lb•ft)

Power Train

Specifications

Systems Operation Drive Motor

NAME PLATE S1

1 1

INPS005I Drive Motor (1) Input Gear. (2) Brush Cover. (3) Thermal Switch (thermostat). (7) Frame. (8) Brush Holder.

(4) Commutator. (5) Armature. (6) Field Coils.

The drive system is operated by a direct current (DC)motor. Electric storage batteries are the source of power for the DC motor.

The four motor brushes are held in four brush holders (8). A spring holds each of the brushes against commutator (4) as the brushes wear.

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

Drive motor is protected from overheating by a thermal switch (thermostat) (3). The thermal switch opens at 150 ± 6°C (302 ± 11°F). It closes at 130 ± 7°C (266 ± 13°F). When the normally closed thermal switch is open, the amount of current through the motor is limited to allow the motor to cool. The motor has a fan for cooling.

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

The drive motor is activated when the parking brake is released, the key and seat switch are closed, a direction is selected and the accelerator pedal is depressed.

Power Train

The drive motor powers the power transfer group through input gear (1). 10

Systems Operation

Power Transfer Group

5 2

6 7

INPS054I Power Transfer Group (1) Input Pinion. (2) Helical Gear. (3) Spiral pinion. (4) Bevel Gear. (5) Differential Case. (6) Differential Pinion Gears. (7) Side Gears

The power transfer group is mounted under the frame in the front of the lift truck. It’s a double reduction unit with the final reduction through spiral pinion (3) and bevel gear (4).

This holds(stops) differential pinion gears (6) which give the same effect as if both wheels were on the same axle. During a turn, the force(traction) that is on the drive wheels is different. These different forces are also felt on opposite sides of the power transfer group and cause differential pinion gears (6) to turn. The rotation of differential pinion gears (6) stops or slows the inside wheel and lets the outside wheel go faster. This moves the machine through a turn under full power.

Power for the power transfer group comes from the electric drive motor through the input pinion (1). The input pinion(1) turns helical gear(2) that is mounted on the shaft of the spiral pinion (3). The spiral pinion is engaged with bevel gear (4) which is mounted to differential case (5). Differential case (5) has four pinion gears (6) that are engaged with two side gears (7). The side gears turn the axle shafts.

The power transfer group gets lubrication from oil thrown about inside the housing, by rotating gears.

The power transfer group is used to send the power from the electric drive motor to the wheels. When one wheel turns slower than the other. The power transfer group lets the inside wheel stop or turn slower in relation to the outside wheel. When the truck is moving straight in a forward direction with the same traction under each wheel, there is equal torque on each axle. Power Train

Systems Operation

Differential And Drive Axles

INPS053I (1) Spider. (2) Pinion.

(3) Gear. (4) Differential case.

(5) Nut. (6) Tube.

The location of the differential is in the front of the lift truck. The differential is a part of the transaxle. It is a single reduction unit with a differential drive gear (3) fastened on the differential case (4).

During a turn, the force (traction) that is on the drive wheels is different. These different forces are also felt on opposite sides of the differential and cause pinions (2) to turn. The rotation of pinions (2) stops or slows the inside wheel and lets the outside wheel go faster. This moves the machine through a turn under full power.

The differential is used to send the power from the transaxle to the wheels. When one wheel turns slower than the other, the differential lets the inside wheel stop or turn slower in relation to the outside wheel.

The differential gets lubrication from oil thrown about inside the housing.

Case (4) has four differential pinion (2). The pinions are engaged with two side gears. The side gears are splined to the axle shafts (8). When the lift truck moves in a forward direction and there is same traction under each wheel, there is also the same torque on each axle and pinions (2) are stopped. This gives the same effect as if both wheels were on the same axle.

Power Train

(7) Hub. (8) Shaft.

The differential turns axle shaft (8). Tube (6) which is pressed into axle housing is used as a support for hub (7). The hub (7) and bearings are turned by axle shaft (8) through a direct connection between the hub and axle shaft. The drive wheel is fastened to hub (7) and turns with the hub.

Systems Operation

Testing And Adjusting

WARNING

Troubleshooting

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

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

Checks During Operation

Do not operate the drive motors without a load, as too much speed may cause damage to the motor and injury to personnel.

Drive Motor Before an analysis is made of any electric drive motor problem, always make reference to the Troubleshooting section of the MicroController System Operation module.

Problem 1 : Drive Motor Will Not Operate. Probable Cause : 1.

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

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

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

Control panel operation not correct : See the MicroController System Operation module.

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

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

Power Train

Testing and Adjusting

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

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

Check for a short circuit in the armature windings : Loose field winding pole ends, make the necessary repairs. Failed armature bar insulation. Repair or rebuild the insulation or make a replacement of the armature.

Problem 3 : Neither traction or hydraulic will last through a complete normal work period. Probable Cause :

Static return to off circuit (S.R.O.) actuated: If the static return to off is activated, the control will not start again until the accelerator is released and the directional control lever is returned to neutral.

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

Battery not being fully charged or equalized during the battery charging operation : Check the battery cells for an equalization charge(a charge to make the specific gravity the same in all cells). Check the battery charger for defects.

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

Battery has one or more defective cells which results in less than the rated capacity and ability of the battery : Replace the battery.

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

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

Lift truck working more than the capacity of its design with no available power after one work shift :

Problem 2 : Traction will not operate through a normal work period, but hydraulic operation is normal. Probable Cause : 1.

Brakes have a defect, cause a resistance(lack of free movement). Heat increases, which causes the motor to stall :

Too much heat in MicroController control panel because: a. Extra heavy traction loads. Decrease the duty cycle load. b. Faulty thermal switch. See the MicroController System Operation module. c. Too high current limit (C/L) setting. Lower the setting on the C/L adjustments.

These can cause transistors to become defective, control panel failure or drive fuse to go bad.

Have available an extra (exchange) battery. Decrease the speed and work load required to complete the work shift.

Power Train

Testing and Adjusting

Problem 4 : Sparks at the commutator and/or rapid brush wear.

Check the brush holder for oversize (larger size than for brush). Replace the brush spring if necessary.

Probable Cause : 1.

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

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

Defective drive motor : See Armature Commutator Inspection in Testing And Ajusting. a. Commutator bars burnt in two or more positions at 180° apart because: (1) Armature bars open. Replace the armature. (2) Motor was stalled against a heavy load while power discharged and caused the two bars, in contact with the brushes, to burn.

d. Loose brush leads or motor bus bar connections. Loose cable connections at motor terminals. Results are : (1) High resistance and heating. (2) Faster brush wear. Check brushes for tight connections. Replace the brushes if leads are loose in brush material. Check all cable and wire connections for tightness. e. Wrong grade of brushes installed that are not adaptable to the motor : Make sure all the brushes are of DAEWOO standards. Do not use other brands of brushes. f. Possibly heavy working condition that causes too much motor heat and rapid brush wear: Make a replacement of the brushes and make sure the brushes are seated. See New Brush Installation and Brush Inspection in Testing And Adjusting. Check the brush springs for the correct installation and for the correct spring usage. Too strong a spring rate will increase current draw and brush wear rate. Prevent operation in stall condition. Excessive (too much) duty cycle which increases motor temperatures and rapid brush wear. 4.

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

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

Drive motor, armature or field windings have a defect that results in high current draw at low torque output: See Armature Tests and Field Coil and Terminal Tests in Testing And Adjusting.

Restriction caused by components : Correct and make adjustments to wheel brakes and parking brakes that drag. Changes to tire with less friction. Check and correct wheel bearing torques.

NOTICE Too heavy a load can stall the motor, and result in a failure to the drive motor. (3) Short circuit in the armature. See Armature Tests in Testing And Adjusting. (4) Armature not in balance, out of round, off center or with high commutator bars. This causes the brushes to bounce (move up and down). Make sure the diameter is the same all the way around and is in center line with the shaft. See Specifications. b. Dirty motor that has a metallic or carbon dust. This dust is a conductor which causes electrical shorts, increase current draw and decrease drive motor output : Remove any dirt with air pressure. c. Brush movement causing arcing and brush wear: Check the brush springs for cracks, and overheat signs (blue). Compare spring force with a new brush spring. Power Train

Testing and Adjusting

Problem 5 : Low resistance to ground [battery polarity either positive (+) or negative (-) or a medium voltage is in direct contact with truck frame (body) or drive motor body.

Problem 7 : Lift truck moves faster in one direction than the other direction with the same amount of accelerator pedal movement in Bypass mode (speed).

Probable Cause :

Probable Cause:

Dirty battery, electrolyte on top of cells and is in contact with the frame. Current flows through battery box, which places a voltage on the truck frame : Clean the battery with baking soda and water solution.

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

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

One directional contactor worn more than the other or loose connection on one contactor : Check contactor for wear and tighten any loose connections.

Problem 8 : Lift truck will not get to top speed. 3.

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

Probable Cause : 1.

Battery not fully charged or battery has bad cells : Charge the battery. Check for bad cells. Replace battery if necessary.

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

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

Problem 6 : Commutator surface has grooves or abnormal wear. Probable Cause : 1.

Brushes are worn too low, brush wires caused arcing on the commutator : Replace the brushes. See Brush Inspection in Testing And Adjusting and the method to make the Brush Life Estimate in Testing And Adjusting.

Dirty motor ; and possibly salt water got inside : Disassemble motor, remove the debris with air pressure. If necessary, dry the motor with heat to 90°C (194°F).

Problem 9 : Lift truck does not have enough power to position itself under a load. Lift truck does not have enough power on ramps or towing trailers.

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

Probable Cause:

Power Train

Current limit (C/L) set too low : Set current limit (C/L) to specification in the MicroController System Operation module.

Current limit (C/L) circuit has a defect : Test the MicroController control panel as stated in the respective service module. Repair or replace components as necessary.

Testing and Adjusting

Unpolished or improperly positioned forks : Install tapered and polished forks. Position forks correctly for load being lifted.

Problem 2: Noise at different intervals.

Lift truck equipped with tires that have poor traction : Install tires that have good traction per recommendation from DAEWOO Inc.

Bevel gear does not run evenly a. Nut on gear not tightened correctly. b. Drive gears have a defect (warped).

Loose or broken bearings.

Lift truck work load is too heavy or the duty cycle too long : Decrease the work load and/or duty cycle.

Failure of or not enough lubricant.

Probable Cause:

Problem 10 : Lift truck has slow acceleration.

Problem 3: One drive wheel does not turn (motor operates).

Probable Cause:

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

Broken axle shaft. a. Loose wheel bearings. b. Loose flange studs or nuts. c. Bent housing.

Pinion gear teeth have damage.

Bevel gear, pinion or gears broken.

NOTE : The thermal switch will open if the temperature is 150 ± 6°C (302 ± 11°F) and close at 130 ± 7° C(266 ± 13°F).

Problem 4: Leakage of lubricant.

Drive control overheated and the thermal switch opens :

Probable Cause:

Power Transfer Group and Final Drive

Loss through axle shafts. a. Lubricant above specified level. b. Wrong kind of lubricant. c. Restriction of axle housing breather. d. Axle shaft oil seal installed wrong or has damage.

Loss at pinion. a. Lubricant above specified level. b. Wrong kind of lubricant. c. Restriction of axle housing breather. d. Drive motor seal worn or not installed correctly.

Problem 1 : Constant noise in drive axle housing. Probable Cause: 1.

Lubricant not to the specified level.

Wrong type of lubricant.

Wheel bearings out of adjustment or have a defect.

Bevel gear and pinion not in adjustment for correct tooth contact.

Teeth of bevel gear and pinion have damage or wear.

Too much or too little pinion to bevel gear clearance (backlash).

Loose or worn drive motor bearings.

Loose or worn side bearings.

Power Train

Testing and Adjusting

Drive Motor Motor Brushes Brush Inspection 1.

Measure the radial length of brush.

S0608003 Install Brushes (1) Brushes.

NOTICE Installation of the wrong brushes can cause early motor failure. Always make sure the correct DAEWOO brushes are installed. S0608002 Brush Measurement

5. 2.

If the brush length is less than 19 mm (.7 in) on the longest side, replace the brushes.

Install new brushes (1). Make sure the brushes move freely in the brush holders. Use a piece of plain bond paper to remove brush material if there is a restriction of brush movement.

New Brush Installation NOTE : Installation of new brushes is a two person operation. 1.

Disconnect the batteries.

Lift the truck and put blocks under the chassis it so that the drive wheels are off the ground.

Discharge the head capacitor.

2 S0608004

Remove the brush covers. Loosen two screws of the brush and BWI wires. Pull out the old brushes from the brush holder by lifting up the brush springs.

Power Train

Install Springs (2) Spring.

Place carefully the brush spring(2) on the top of brush and make sure they fasten into the brush holder box.

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

Connect the batteries to the battery connector. Testing and Adjusting

WARNING

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

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

12. After the brushes have the correct seat contact surface, operate the motor at slow speed. Use compressed (pressure) air to remove all dust and abrasive grit.

Armature Tests Tools Needed Digital Multimeter Or Equivalent Growler Tester

A 1 1

Test For Short Circuit

S0608005

Brush Seating (3) ZLX - 036 Brush seater stone.

Put ZLX - 036 Brush Seater Stone (3) on the commutator and operate the motor at a slow speed. 2

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

S0608017 Short Circuit Test (1) Growler. (2) Armature. (3) Hacksaw blade. (4) Green light. (5) Red light.

10. Move stone (3) across the commutator at the backe edge of the brushes for a short time. This will take the shiny finish off the commutator and seat the new brushes.

Turn the growler (1) on.

Slowly turn the growler on the armature (2) while a hacksaw blade (3) is held over the windings.

11. Turn the key switch to the OFF position and disconnect the batteries. Check the contact surface of each brush. At least 85% of the brush contact surface of each brush must show wear. If necessary, do Steps 8 through 11 again until the correct wear can be seen on the brush contact surface.

If the windings are shorted, the green light (4) will be on. The red light (5) will be on if the windings do not have a short.

Power Train

The odor of burned insulation from the drive motor while it is in operation is an indication of a short in the armature.

Testing and Adjusting

Ground Test

Open Circuit Test

S0608015

S0608016

Ground Test.

Open Circuit Test (1) Armature. (A) Multimeter.

A digital multimeter can also be used to test for grounds. Put the Function/Range Switch on the 2M resistance (Ω) scale. When the test probes are put on the commutator and the shaft, the meter must give an indication of over load (OL). This means that the resistance is more than 2 megohms.

Put the digital multimeter Function / Range Switch on the 200 ohm resistance (Ω) scale.

Put one test lead on one commutator bar. Put the other test lead on an adjacent (next to) bar and there must be less than one ohm resistance. This test can also be done with an instrument, such as a Kelvin Double Bridge, that can make a measurement of very low resistance. Do the test the same as above and make a comparison of the resistance measurements.

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

If there is an indication of a ground in the above test, remove any dirt or debris form the armature with compressed (pressure) air.

Two burned areas on opposite sides of the commutator are indications of an open armature winding. These burned areas can cause very rapid brush wear.

Do the test for grounds again. If there is still an indication of a ground, make a replacement of the armature.

Power Train

Testing and Adjusting

Commutator Inspection Surfaces of Commutators that need Replacement

EHPS011B

Grooves on the Commutator Surface

Grooves on the commutators surface are caused by a cutting material in the brush or atmosphere.

EHPS00a9 Marks on the Commutator Surface

Marks on the commutator surface are an indication that metal has moved from the commutator surface to the carbon brushes. Marks will cause fast brush wear.

EHPS012B Copper Drag on the Commutator Surface

Copper drag is an extra amount of commutator material at the back edge of the commutator bars.

EHPS010B Threads on the Commutator Surface

Threads (grooves that look like threads) on the commutator surface, will also cause fast brush wear.

Power Train

Testing and Adjusting

Ground Test

EHPS013B Pitch Bar - arks on the Commutator Surface S0608006 Ground Test (1) Field Terminal.

Pitch bar - arks cause low or burnt marks on the commutator surface.

Put the digital multimeter Function/Range Switch on the 20M resistance (Ω) scale.

Put one test lead to either outer field terminal (1) and the other test lead to the motor housing (2). There must be more than one megohm resistance.

If there is a measurement of less than one megohm, it can be caused by wet insulation on the field windings or excessive brush dust in housing. Heat the motor at 88°C (190°F) until the resistance goes above one megohm. If the resistance does not go above one megohm, the shell and field assembly must be replaced.

Field Coil and Terminal Tests Tools Needed Digital Multimeter

A 1

Open Circuit Test

(2) Motor housing.

S0608007 Open Circuit Test

Put the digital multimeter Function/Range Switch on the 200 ohm resistance (Ω) scale.

Put one test probe to each outer field terminal (S1,S2).

The resistance must be less than one ohm. If the resistance is too high, it is an indication of corrosion on the terminals or an open field coil.

Power Train

Testing and Adjusting

Armature Terminal Test Tools Needed Digital Multimeter Or Equivalent

A 1

Put the digital multimeter Function/Range Switch on the 20M resistance (Ω) scale.

Put one test lead to an outer Armature terminal (1) and the other test lead to the motor housing (2). There must be more than one megohm resistance.

Do the test again with one test lead on the other outer brush terminal.

Test for Continuity

Brush Holder Test Tools Needed Digital Multimeter Or Equivalent

S0608013

Brush Test (1) Test Lead.

Put the digital multimeter Function/Range Switch on the 200 ohm resistance (Ω) scale.

Put one test lead to an outer Armature terminal (1) and the other test lead to each brush lead that connects to that terminal. There must be less than one ohm resistance.

A 1

S0608012 Brush Holder Test (1) Brush Holder. (2) End Bell.

Do Step 2 again with the other outer Armature terminal (A1, A2) and brush leads.

The brush holders are mounted on the rocker at the commutator end of the motor. Make a visual inspection of the brush holders and the rocker.

Put digital multimeter Function/Range Switch (A) on the 200 ohm resistance (Ω) scale. Put one test lead to a brush holder (1) and the other test lead to the end bell (2). The meter must show overload (OL).

Check each brush holder. If meter reading is low, the brush holder is grounded. Replace the rocker.

Too much resistance is an indication of corrosion at the connection to the terminal.

Ground Test

2 S0608014

Ground Test (1) Armature Terminal. (2) Motor Housing.

Power Train

Testing and Adjusting

Thermal Switch Tests Tools Needed Digital Multimeter Or Equivalent

Brush Life Estimate A 1

Open Circuits Test

Open Circuit Test

Put the digital multimeter Function/Range Switch on the 200 ohm resistance (Ω) scale.

Put one test lead to each side of the thermal switch harness.

The resistance must be less than one ohm.

Before installation of new brushes, make an inspection of the armature commutator, see Armature Commutator Inspection in Testing and Adjusting.

Do the steps and procedures for New Brush Installation in Testing and Adjusting.

Make the initial (first) inspection of brush wear between 250 smh and 500 smh. The reason for this initial inspection is to see if the brush wear rate is normal and not too fast. The measurement will help make an estimate of the length of brush life to be expected.

NOTE : If there is an indication that brush wear is too fast, see Troubleshooting, Problem: Sparks at the commutator and/or rapid brush wear; for probable causes of this problem.

S0608008

Inspect all brushes in the motors. Measure and record each brush length (see Specification for each new brush length and minimum brush length).

Estimate expected brush life (hours). Use the shortest measurement from Step 4 and the following Sample Procedure: Length of new brush .............. 35 mm (1.387 in.) Minimum length of brush ......... 18 mm (.708 in.) New brush length [35 mm (1.387 in.)] Minimum brush length [18 mm (.708 in.)] = Total amount of usable brush wear [17 mm(.67 in.)].

Ground Test

Length of shortest brush at 500 smh is 32.5 mm (1.279 in.). New brush length [35 mm (1.378 in.)] - Length of shortest brush at 500 smh [32.5 mm (1.279 in.)] = Amount of brush wear at 500 smh [2.5 mm (.10 in.)]. Amount of brush wear at 500 smh [2.5 mm (.10 in.)] Total amount of usable brush wear [17 mm (.67 in.)] = Portion of brush used at 500 smh (.1).

S0608009 Ground Test

Put the digital multimeter Function/Range Switch on the 20M resistance (Ω) scale.

Service Meter Hours (smh) at brush wear measurement (500 smh) Portion of brush used (.1) = Approximate total brush life of a new brush (5000 smh).

Put one test lead to either of the plug prongs. The other test lead must be grounded to the motor housing. There must be more than one megohm resistance.

Approximate total brush life of a new brush (5000smh) - Amount of smh at brush life estimate (500 smh) = Remainder of usable brush life (4500 smh).

Power Train

Testing and Adjusting

The smh estimate of brush life can be used if the machine is to work at the same rate (duty cycle), the battery is not discharged too much or the battery cells have not become damaged. If the machine is made to work harder, the battery is discharged too much, or the battery cells become damaged, the motor temperature will get hot very fast. This will cause rapid wear of the brush.

It is important to check brush length and brush condition at a specific time, such as during the preventive maintenance check. If an inspection shows that brush life will not extend to the next preventive maintenance check, install new brushes.

Bevel gears and pinions are available in sets that are machined for each other and must never by installed separately. The same identification mark of letters and numbers is put on both the pinion and bevel gear. The bevel gear is marked on the flat face, the pinion is marked on the diameter behind the teeth. Make sure they have the same identification mark before going to the procedures that follow. The distance from the centerline of bevel gear (1) to the flat end of pinion (2) is 128.25 mm (5.049 in).The end of each pinion has a mark of measured monnting distance of each pinion. These numbers indicate the position where each gear set runs best. The dimension is controlled by shim pack (3) behind inner bearing cup (4). If a pinion has a mark of (128.35), it needs 0.10 mm (0.004 in) less shims than a pinion with a mark of (128.25). If the pinion has a mark of (128.15), it needs 0.10mm (0.004 in) more shims than a pinion with a (0) mark.

Power Transfer Group Adjustments Transaxle Adjustments

Pinion Installation 1

4 6

2 INPS056I INPS060I

Pinion Configuration (1) Gear. (2) Shim Pack. (3) Bearing Cup. (4) Bearing Cup. (5) Bearing Cone. (6) Pinion Gear. (7) Bearing Cone. (8) Locknut. (9) Lock Washer.

Power Transfer Group (1) Bevel Gear. (2) Pinion Gear. (3) Shim Pack. (4) Bearing Cup

If the original bevel gear and pinion set is to be used again, measure old shim pack (2) and make a new shim pack the same thickness. If a new bevel gear and pinion set is used, the original shim pack should be changed. If three or more shims are used, the smaller shims are to be put in the center of the shim pack.

EXAMPLE: If the old pinion has a mark of (128.15) and the new pinion has a mark of (128.00) add 0.15 mm (.006 in) shims to the original shim thickness.

Power Train

Testing and Adjusting

Put the pinion shaft assembly into the housing and install bearing cone (7), washer (9) and nut (8). Tighten nut (8) slowly while rotating the pinion until the pinion rolling torque is 2 ~ 3 N•m (1.5 ~ 2.2 lb•ft).

Pinion Depth Check

Install bearings cups (3) and (4) with new shim pack (2) behind bearing cup (3). Install bearing cone (5) on pinion shaft (6).

X Z

After pinion bearing preload and pinion depth are correct, bend a tab on the lockwasher (9) into a slot of nut (8) to lock it in position.

1 INPS057I Pinion Depth Check (1) Housing.

Power Train

Put the Jig A and Jig B on the housing as shown.

Measure the gap (X) between Jig A and B. If the height of (Y) is 107.0 mm, and distance of (Z) is 48.5 mm, the gap (X) is. gap (X) = 156.1 - (Z + Y) = 0.6 mm

Read the mark of the pinion shaft. If the mark is 128.00 mm, then the deviation of the mounting distance (M) is. deviation (M) = 128.25 - 128.00 = 0.25mm

Required shim of the pinion is as follows. Required shim (S) = gap (X) + deviation (M)

Testing and Adjusting

Power Transfer Group Bearing and Gear Clearance (Backlash) Adjustments

Tools Needed: Dial Indicator Group (A)

4 1 6 3 2

5 10

INPS059I

Install Carrier Assembly (5) Bearing Cap. (8) Bolts.

Put the carrier assembly in position in the housing assembly. Install bearing caps (5) and four bolts (8). Tighten bolts (8) to a torque of 150 ± 15 N•m (113 ± 12 lb•ft).

Install locknuts (6). Use tooling (A) to check gear clearance (backlash) between bevel gear (2) and pinion (7). Adjust locknuts (6) until the clearance is 0.18 to 0.23 mm (.007 to .009 in.). Adjust the clearance by turning one locknut (6) in and the other locknut out an equal amount.

Tighten locknuts (6) equally to preload the differential case bearings. Proper bearing preload of the gear is 3.1 to 4.8 N•m (27 to 42 lb•in).

Measure backlash again. After backlash and preload are correct, install the plate (9) into each locknut (6) to hold them in position and tighten the bolt (10) to a torque of 12 ± 4 N•m (9 ± 3 lb•ft).

INPS058I Backlash Adjustment (1) Bearing Cone. (2) Bevel Gear. (3) Bolt. (4) Bearing Cup. (5) Bearing Cap. (6) Locknut. (7) Pinion Gear. (9) Plate. (10) Bolt

Install bearing cones (1) on the differential case.

Put bevel gear (2) on the differential case and tighten bolts (3) to a torque of 110 ± 5 N•m (82 ± 5 lb•ft). Put bearing cups (4) on bearing cones (1).

Power Train

Testing and Adjusting

IBPS010B

IBPS012B

Correct Tooth Contact Setting.

Short Heel Contact Setting.

Check the tooth contact pattern as follows. Check the tooth contact setting between the bevel gear and pinion after the gear clearance (backlash) and bearing preload adjustments have been made as follows. a. Put a small amount of Prussian blue, red lead or paint on the bevel gear teeth. Turn the pinion in both directions and check the marks made on the bevel gear teeth.

c. If bevel pinion shaft is too far away from bevel gear, short toe contact will be the result as shown. The teeth of pinion will be in contact with toe ends of convex faces (part that makes a curve toward the outside), and top edge of heel end of concave faces (part that makes a curve toward the inside). To correct this, add shims under pinion bearing cup. After this is done, check gear clearance (backlash) and tooth contact again. d. If bevel pinion shaft is too near to center of bevel gear, short heel contact will be the result as shown. The teeth of pinion will be in contact with the toe ends of concave faces (part that makes a curve toward the inside) and the heel ends of convex faces (part that makes a curve toward the outside). To correct this, remove shims from under pinion bearing cup. After this is done, check gear clearance(backlash) and toothe contact again.

IBPS011B

NOTE : Several adjustments of both pinion and bevel gear can be needed before correct tooth contact and gear clearance (backlash) is made. Always remember that a change to gear clearance (backlash) will also change the tooth contact. Therefore, be sure gear clearance (backlash) is in correct adjustment before tooth contact is checked.

Short Toe Contact Setting. b. With no load, correct tooth contact setting will be as shown. The area of contact starts near the toe of the gear and goes 30 to 50% up the length of the tooth. With this setting, when a load is put on the gear, the load will be over the correct area of the teeth.

Power Train

e. After gear clearance (backlash) and tooth contact are correct, remove extra Prussian blue, red lead or paint from bevel gear and pinion.

Testing and Adjusting

Disassembly & Assembly Drive Axle Disassembly 1.

Drain the drive axle oil. 4

5. 1

Loosen lock nut and remove the plate (4). (Tool Ref. No. : 2)

Loosen the bolts (1). 5

Remove bearing cone (5) from the hub.

Remove the drive shaft (2).

Remove the hub and drum (6) from the drive axle.

Loosen the bolts from the lock nut (3).

Power Train

Disassembly & Assembly

14 7

Loosen the bolts (7) and remove the spindle (8).

11. Remove snag ring (11) from adapter (14). Remove four discs (12) and three plates (13) from adapter.

NOTE : Be careful not to drop the spindle sub assembly (8).

12. Remove plate (15) from spindle. 9.

Remove the plate (9) from spindle sub assembly.

10. Remove plate sub assembly (10) from spindle sub assembly.

Power Train

Disassembly & Assembly

Assembly The assembly procedure is the reverse order of removal, but requires additional care as noted below.

IBPD233P

13. Remove piston (16) with using special tool T185 (17).

Assemble two square seals (18) into axle housing. Apply drive oil or grease on the area of square seals and on the outer surface of piston.

14. Remove two square seals (18) from axle housing.

IBPD250P

Assemble piston (16) into axle housing by using special tool T186 (19).

Power Train

Assemble plate (15) into spindle.

Disassembly & Assembly

11 5

Assemble four discs (12) and three plates (13) alternately. Start and end with disc. Align the lubrication slots among discs. Install snap ring (11).

Install hub (6) and bearing cone (5) into spindle. Fill 50~60% of space between bearing with Lithium grease.

8. 5.

Install plate sub assembly (10) and plate (9) into spindle (8). Apply continuous bead of Three Bond Liquid Gasket TB#1215 on the spindle surface.

Apply Loctite No.271 Thread Lock to threads of spindle bolts (7). Assemble bolts (7) with tightening torque of 100.5 ± 12.3 N•m (74 ± 9 lb•ft). Fill 50~70% of space between bearing with Lithium grease. Coat rib of seal.

Power Train

Install plate (4) onto spindle.

Install nut (3) and tighten slowly until torque required to turn hub is 2.45 ± 0.49 N•m (1.80 ± 0.35 lb•ft). Apply Loctite No.272 on thread of bolt to hold nut in position and tighten bolt with tightening torque 7.9~11.7 N•m (5.8~8.6 lb•ft).

Disassembly & Assembly

Differential Disassembly

10. Coat mating surface of hub with Three Bond Liquid Gasket TB #1215. Install drive shaft (2).

IBPD167P

Remove the plate (1) from the differential cap (2).

1 4

IBPD168P

11. Apply Loctite No.271 on thread of bolt (1) to hold drive shaft to hub. Tighten bolts with torque of 59~83 N•m (44~61 lb•ft).

IBPD126P

Power Train

Loosen adjusting screw with special tool (Ref.No.1) on both side. Mark differential caps (2) and housing for the purpose of reassembly. Loosen the bolts (3) and remove the differential assembly (4).

Disassembly & Assembly

Assembly The assembly procedure is the reverse order of removal, but requires additional care as noted below.

INPS064P

Mark case-halves for the purpose of reassembly. INPS065P

1. 5

Heat bearings to a temperature of 100°C (212°F) and install them on each case half.

IBPD169P

INPS066P

Install ring gear and tighten bolts (1) to a torque of 88 to 156 N•m (65 to 115 lb•ft).

IBPD170P

Loosen the bolts (5) and disassemble differential assembly completely.

If needed, loosen the bolts (6) and disassemble ring gear (7). INPS067P

Power Train

Assemble differential inner parts.

Disassembly & Assembly

IBPD172P

INPS064P

6. 2

Tighten the bolts (3) to a torque of 147 to 167 N•m (108.8 to 123.6 lb•ft).

NOTE : Consider same marking on differential caps to the housing.

IBPD169P

Align case-halves and tighten bolts (2) to a torque of 49 to 73 N•m (37 to 53 lb•ft).

IBPD168P

IBPD127P

Install differential assembly into housing. IBPD173P

Power Train

Install adjusting screws (4) with special tool (Ref. No. 1) Adjust gear clearance (backlash) by turning one adjusting screw in and the other screw out an equal amount. Rotate the axle drive through 100° and check the tooth backlash at several points of the ring gear using a dial gauge. The tooth backlash should be 0.18 to 0.23mm (0.007 to 0.009 in). Disassembly & Assembly

Adjusting tooth contact

Correct tooth contact

a. Coat the tooth face of the bevel pinion lightly with red lead (minimum). b. Rotate the bevel gear forward and backward. c. Inspect the pattern left on the teeth. (Shown in diagram below.) Correct tooth contact (No load)

IBPS175P

a. Increase the shim thickness at the pinion shaft to move the pinion in direction A. The move the bevel gear away from the pinion gear in direction B. Adjust the backlash again.

REVERSE side

Heel

FORWARD side IBPS176P

Toe IBPD174P

b. Reduce the shim thickness at the pinion shaft to move the pinion in direction A. Then move the bevel gear closer to the pinion gear in direction B. Adjust the backlash again.

• Tooth contact should be checked with no load on the bevel pinion. The tooth contact pattern should cover about 40-75% of the lenght of the tooth, with weak contact at both ends. d. If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows. Adjust shims at pinion shaft Adjust backlash of bevel gear • The tooth contact should be correct on both the FORWARD and REVERSE side of the teeth. However, if it is impossible to adjust both sides correctly, the FORWARD side must be correct.

IBPS177P

c. Reduce the shim thickness at the pinion shaft to move the pinion in direction A. Then move the bevel gear closer to the pinion gear in direction B. Adjust the backlash again.

Power Train

Disassembly & Assembly

Power Transfer Group Disassembly Start By : a. Remove transaxle. b. Remove final drives, hubs and brakes. IBPS175P

d. Increase the shim thickness at the pinion shaft to move the pinion in direction A. Then move the bevel gear away from the pinion gear in direction B. Adjust the backlash again.

INPS029P

1. 5

Loosen the bolts and nuts and remove axle housing (1).

6 IBPD167P

10. Tighten the bolts (5) to a torque of 7.9 to 11.7 N•m (5.8 to 8.6 lb•ft). Secure adjusting screw with lock plate (6).

INPS030P

Power Train

Remove gasket (2).

Disassembly & Assembly

7 IBPD126P

INPS070P

Remove differential assembly from housing. Refer to Differential Section for further information.

Remove input gear (7).

4 3

9 INPS071P INPS068P

Straighten the lock tab with a punch. Remove nut (8), washer (9) and gear (10).

Remove bolts (3) and cover (4).

5 6

INPS072P INPS069P

8. 5.

Tap pinion shaft (11) and remove it.

Remove gasket (5) and bearing (6).

Power Train

Disassembly & Assembly

Assembly

INPS073P

INPS076P

Check gab between two jigs and determine the thickness of shim.

NOTE : Refer to Power Transfer Group Adjustments section for further information.

INPS077P

1 INPS077P

Install shim (1) below internal bearing cup.

INPS075P

Remove bearing cups and shim if needed.

Power Train

Disassembly & Assembly

2 INPS081P

INPS078P

Position pinion shaft assembly into the housing. Install bearing cone (5) on the pinion shaft.

3 INPS079P

Install bearing cups (2) and (3) with tool.

INPS082P

Install bearing (6) with tool and gear (7).

INPS080P

Heat bearing (4) to a temperature of 100°C (212°F) and install it on the pinion shaft.

INPS071P

Install lockwasher (8) and nut (9). Tighten nut (9) slowly while rotating the pinion until the pinion rolling torque is 2~3 N•m (1.5~2.2 lb•ft). Bend a tab on the lockwasher (8) into a slot of nut (9) to lock it in position.

NOTE : Refer to Power Transfer Group Adjustments for further information.

Power Train

Disassembly & Assembly

11 10

INPS083P

INPS084P

Install input gear (10) and bearing (11).

11. Install drain plug (15).

13 12

INPS069P

Install lock pin (12) and gasket (13).

INPS068P

10. Position the cover. Tap the cover into position over lock pin and tighten bolts (14) to a torque of 50 to 75 N•m (37 to 55 lb•ft).

Power Train

Disassembly & Assembly

Special Service Tools and Jigs Ref.No.

Tool/Jig Name

Jig A

Pinion Depth Check Jig

Illustration

Remark

* Locally Manufactured

Jig B

Pinion Depth Check Jig

* Locally Manufactured 45 40

Differential Screw Installer

5 15

-0.2

Drive Axle Hub Nut Installer

55 -0.4

0 109 -0.5

* Locally Manufactured

0 30 -0.8

90 +0.8 +0.4

* Locally Manufactured

Power Train

Disassembly & Assembly

Ref.No.

Tool/Jig Name

Illustration

Remark

13 100

M12 x 1.75 THD NUT

Pistion Remover

DAEWOO Tool No: T185

ITEM 2 M8 x 1.25 THD R2 60

M12 x 1.75 THD

M12 x 1.75 THD 30

183

TOOL NO. LOCATION

200

ITEM 1 ITEM 3

*Locally Monufactured M12 x 1.75 BOLT (L=130)

Pistion Installer

170

20 M16 x 2.0 BOLT (L=100)

ITEM 1 M16 x 2 THD

13 HOLE

DAEWOO Tool No: T186

TOOL NO. LOCATION

M12 x 1.75 BOLT (L=130)

110

260

ITEM 2

*Locally Monufactured

Power Train

Disassembly & Assembly

SB4166E00 A p r. 2 0 0 4

Specifications Systems Operation Testing & Adjusting Lift Trucks Vehicle Systems BC15S, BC18S, BC20SC

WARNING

Index Specifications Hydraulic Control Valve ..............................................5 Hydraulic Pump ..........................................................6 Hydraulic Pump Motor..............................................13 Lift Cylinders...............................................................7 Priority Valve ............................................................10 Sideshift Cylinder .......................................................6 Steer Axle And Wheel...............................................12 Steering Unit.............................................................11 Steering Wheel .........................................................10 Tilt Cylinders...............................................................9

Systems Operation Brake System ...........................................................29 Control Valve ............................................................18 Electric Motors..........................................................32 Hydraulic System .....................................................14 Steering System .......................................................25

Testing & Adjusting Brake System ...........................................................48 Hydraulic Pump Motor..............................................51 Hydraulic System .....................................................44 Steering System .......................................................46 Troubleshooting........................................................33

Vehicle Systems

Index

Specifications Hydraulic Control Valve 3

Model

BC15S-2 BC18-S-2 BC20SC-2

Control Valve Main Relief Valve Pressure Eu NON – EU

Mast

STD FFL FFT

± 250 kPa

± 35 psi

17600

2550

19860

2880

21550

3125

± 250 kPa

± 35 psi

19860

2880

Auxiliary Relief Valve Pressure

13960

2025

(1) Torque for nuts that hold control valve sections together ......45 ± 4.7 N•m (396 ± 42 lb•in) (2) Torque for nuts that hold control valve sections together .........19 ± 2 N•m (168 ± 18 lb•in) (3) Torque for main and auxiliary relief valve ..................................45 ± 4.7 N•m (396 ± 42 lb•in)

Vehicle Systems

Specifications

Hydraulic Pump

Sideshift Cylinder

2 1

EHCS003B

Rotation is counterclockwise when seen from drive end.

(1) Torque for head .................................270 ± 35 N•m (200 ± 25 lb•ft)

Type of pump : Gear Displacement : 16.0 cc/rev

(2) Torque for piston nut .........................260 ± 25 N•m (190 ± 20 lb•ft)

Vehicle Systems

Specifications

Full Free Triple Lift and Full Free Lift Primary

Lift Cylinders Standard

1 1

FFL

EHCS004B

FFT

EHCS005B

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

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

NOTE : All seals to be lubricated with hydraulic oil.

Put Pipe Sealant of the last three threads of bleed screw(not shown) and tighten to a torque of ............................................... 6 ± 1 N•m (53 ± 9 lb•in) NOTE : All seals to be lubricated with hydraulic oil.

Vehicle Systems

Specifications

Full Free Lift Secondary

Full Free Triple Lift Secondary

1 2

EHCS006B

EHCS007B

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

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

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

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

NOTE : All seals to be lubricated with hydraulic oil.

Vehicle Systems

Specifications

Tilt Cylinders

X Y

EHCS008B

Tilt Group

Forward Tilt Angle

A165168 A165177 A165180

6° 6° 6°

Backward Tilt Angle 10° 6° 3°

Stroke (X) mm 124 93 69

Closed Length (Y) mm 430 461 485

(1) Adjust pivot eye to dimension(Y) with cylinder open(extended). (2) Torque for bolt...............95 ± 15 N•m (70 ± 10 lb•ft) (3) With mast at tilt back position shim as required to permit no gap between eye (1) and spacer. Torque for head ........270 ± 35 N•m (200 ± 25 lb•ft) (4) Torque for jam nut ..................................260 ± 25 N•m (190 ± 20 lb•ft)

Vehicle Systems

Specifications

Steering Wheel

Priority Valve

EHCS017B

(1) Torque for steering wheel nut ..........................................80 ± 6 N•m (60 ± 4 lb•ft)

Type................................. Load sensing closed center.

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

Vehicle Systems

Specifications

Steering Unit

3 VIEW B-B

VIEW C-C TIGHTENING SEQUENCE FOR BOLTS

4 A

C 5 B

B SECTION A-A

EHCS019B

(1) Pin (1) in the body must be aligned with internal pump gear (gerotor) (2) and drive (3) as shown. (4) Tighten bolts in sequence shown. Tighten to a first torque of ...............................14.1 ± 2.8 N•m (125 ± 25 lb•in) Tighten to a final torque of ...............................28.2 ± 2.8 N•m (250 ± 25 lb•in) (5) Torque for plug........................ 11.3 N•m (100 lb•in) Plug to be flush (even) with or below mounting surface.

Vehicle Systems

Specifications

Steer Axle And Wheel

5 A

4 3

1 2 IBCS020B

NOTE : Steer axles with tapered roller bearings shown. (1) Do the steps that follow for steer wheel bearing adjustment. a. Tighten nut (1) slowly to 133 N•m (98 lb•ft) while turning the wheel. b. Loosen nut (1) completely. Tighten it again to .................................50 ± 5 N•m (37 ± 4 lb•ft) c. Bend lock (2) over nut (1). (2) Torque for bolt that holds pin ................ 11 ± 1 N•m (100 ± 9 lb•in) (3) Loosen nuts (5). Adjust bolts to get steering knuckle turning angle (A) of.................... 78 to 80° See Steering Axle Stop Adjustment in Testing And Adjusting section. Torque for nuts that hold steer wheel ................................... 113 ± 10 N•m (83 ± 71 lb•ft)

Vehicle Systems

Specifications

Hydraulic Pump Motor

2 1

Hydraulic Pump Motor New Brush Minimum Thickness B Width B Length Brush Length * 12.5 mm X 32 mm X 35 mm 18 mm (.49 in X 1.25 in X 1.37 in) (.70 in) 1

Model

Voltage

B15S-2 B18S-2

48V

Minimum Commutator Diameter** 78 mm (3.07 in)

Thermal switch

Machine chamfer on the commutator bars .........................................................0.40 mm (.016 in)

Opening temperature ..............150 ± 6°C (302 ± 11°F) Torque for the terminal bolts (not shown) the hold cable connections ..............................14 N•m (10 lb•ft)

Closing temperature ............... 130 ± 7°C (275 ± 13°F)

Depth of the insulation below commutator bars. .............................................................1.5 mm (.05 in) Width of the insulation below commutator bars ...........................................................0.8 mm (.031 in) Maximum difference between commutator high and low point(out of round) .............. 0.03 mm (.001 in) TIR Maximum difference between bar to bar .............................................. 0.005 mm (.0002 in) TIR

Vehicle Systems

Specifications

Systems Operation Hydraulic System Basic Schematic - Standard Lift

1 2 4 3 6

5 7

14 8 13 11

Basic Hydraulic Schematic With Standard Lift (1) Lift Cylinders. (2) Excess Flow Protector. (3) Sideshift Cylinder(if equipped). (4) Flow Regulator Valve. (5) Hydraulic Control Valve. (6) Tilt Cylinders. (7) Relief Valve (lift and tilt). (8) Relief Valve (Sideshift). (9) Hydraulic Oil Filter. (10) Hydraulic Oil Tank. (11) Priority Valve. (12) Oil line. (13) Oil Lline. (14) Hydraulic Strainer. (15) Hydraulic Pump. (16) Oil line to Steering Unit.

Vehicle Systems

Systems Operation

The hydraulic system has a hydraulic oil tank (10), which holds the oil for gear-type hydraulic pump (15). Hydraulic pump (15) sends pressure oil to the control valve and steering systems through priority valve (11). Pump oil flows from pump (15) to priority valve (11) where the oil flows to the control valve (5) through line (12). The control valve levers move the valve spools in control valve (5) to let the pump oil in the control valve go to lift cylinders (1), tilt cylinders (6), sideshift cylinder (3) or other attachment. The return hydraulic oil from the cylinders flows through hydraulic control valve (5), line (13), into filter (9) and hydraulic tank (10). Relief valve (7) in the control valve body will make the flow control valve release extra pressure to the hydraulic tank when the pressure in the lift and tilt goes higher than relief valve pressure shown in the Control Valve section of Specifications. Relief valve (8) does the same thing for sideshift circuit when it goes higher than the secondary relief valve pressure shown in the Control Valve section of Specifications. The maximum speed at which the lift cylinder(s) are lowered is controlled by flow regulator valve (4). Excess flow protector (2) will act as flow regulator valve if an oil line between it and flow regulator valve (4) is broken when the mast is raised or lowered. This prevents a sudden fall of the mast or carriage if an oil line is broken. REFERENCE : For the Hydraulic Systems Schematics.

Vehicle Systems

Systems Operation

Basic Schematic - Full Free Lift or Full Free Triple Lift

18 1

4 3 5 6

8 11

14 13

Basic Hydraulic Schematic Full Free Lift Or Full Free Triple Lift (1) Lift Cylinders. (2) Excess Flow Protectors. (3) Sideshift Cylinder(if equipped). (4) Flow Regulator Valve. (5) Hydraulic Control Valve. (6) Tilt Cylinders. (7) Relief Valve(lift and tilt). (8) Relief Valve(Sideshift). (9) Hydraulic Oil Filter. (10) Hydraulic Oil Tank. (11) Priority Valve. (12) Oil Line. (13) Oil Line. (14) Hydraulic Strainer. (15) Hydraulic Pump. (16) Oil Line to Steering Unit. (17) Lift Cylinder (Primary). (18) Excess Flow Protectors.

Vehicle Systems

Systems Operation

The hydraulic system has a hydraulic oil tank (10), which holds the oil for gear-type hydraulic pump (15). Hydraulic pump (15) sends pressure oil to the control valve and steering systems through priority valve (11). Pump oil flows from pump (15) to priority valve (11) where the oil flows to the control valve (5) through line (12). The control valve levers move the valve spools in control valve (5) to let the pump oil in the control valve go to lift cylinders (1) and/or (17), tilt cylinders (6) sideshift cylinder (3) or other attachment. The return hydraulic oil from the cylinders flows through hydraulic control valve (5), line (13), into filter (9) and hydraulic tank (10). Relief valve (7) in the control valve body will make the flow control valve release extra pressure to the hydraulic tank when the pressure in the lift and tilt goes higher than relief valve pressure shown in the Control Valve section of Specifications. Relief valve (8) does the same thing for sideshift circuit when it goes higher than the secondary relief valve pressure shown in the Control Valve section of Specifications. The maximum speed at which the lift cylinder(s) are lowered is controlled by flow regulator valve (4). Excess flow protectors (2) and (18) will act as flow regulator valve if an oil line between them and flow regulator valve (4) is broken when the mast is raised or lowered. This prevents a sudden fall of the mast or carriage if an oil line is broken. REFERENCE : For the Hydraulic Systems Schematics.

Vehicle Systems

Systems Operation

Control Valve Lift Valve Neutral Position

2 7 1

10 8

ICCS009S Control Valve for Lift (Shown In NEUTRAL Position) (1) Spool. (2) Outlet To Head End Of Lift Cylinders. (3) Load Check Valve. (4) Passage. (6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring.

(5) Inlet Passage For Pump Oil.

Oil from pump enters the valve through a passage in the inlet section. From there it goes to both chamber (6) and chamber (9). Since spool (1) is in the NEUTRAL position, the only path the oil can take is from chamber (9) into the tilt valve. It would go out through passage (8). The mast can be stopped and held in any position when the lift control valve is in neutral. This is because the flow to and from the cylinders is stopped by spool (1). In the NEUTRAL position, oil can not flow from passage (4) to outlet (2) or back.

Vehicle Systems

Systems Operation

Lift Position

2 7 1

10 8

ICCS010S Control Valve for Lift (Shown In LIFT Position) (1) Spool. (2) Outlet To Head End Of Lift Cylinders. (3) Load Check Valve. (4) Passage. (6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring.

(5) Inlet Passage For Pump Oil.

When the control lever is moved to the LIFT position, lift spool (1) is moved into the valve. Movement of spool (1) opens a path for oil to flow from chamber (6) through load check valve (3) into passage (4). From passage (4) the oil goes to outlet (2) and then to the lift cylinders. Pressure oil to the head end of the lift cylinders moves the rod up and the mast will raise.

Vehicle Systems

Systems Operation

Lower Position

2 7 1

10 8

ICCS011S Control Valve For Lift (Shown In LOWER Postion) (1) Spool. (2) Outlet To H ead End Of Lift Cylinders. (3) Load Check Valve. (4) Passage. (6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring.

(5) Inlet Passage For Pump Oil.

When the control lever for lift is moved to the LOWER position, lift spool (1) moves until a path is opened between outlet (2) and passage for return oil (7).

Vehicle Systems

Systems Operation

Tilt Neutral Position

6 7 8 1

13 9

11 14 16

ICCS012S Tilt Spool In Neutral Position (1) Spool. (2) Outlet To Rod End Of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil. (6) Chamber. (7) Outlet To Head End of Tilt Cylinders. (8) Passage For Return Oil. (9) Spring. (10) Spool. (11) Passage. (12) Chamber. (13) Spring. (14) Orifice. (15) Orifice. (16) Passage.

Oil from lift valve goes to both chamber (6) and (12). Since spool (1) is in the NEUTRAL position, the only path the oil can take is from chamber (12) to tank through passage (11). The mast can be stopped and held in any position when the tilt control valve is in neutral. This is because the flow to and from the tilt cylinders is stopped by spool (1). In the NEUTRAL position, oil can not flow from passage (4) to outlet (2) or (7).

Vehicle Systems

Systems Operation

Tilt Forward Position

7 8 1

13 9

11 14 16

ICCS013S Tilt Spool In Forward Position (1) Spool. (2) Outlet to Rod End Of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil. (6) Chamber. (7) Outlet To Head End Of Tilt Cylinders. (8) Passage For Return Oil. (12) Chamber. (13) Spring. (14) Orifice. (15) Orifice. (16) Passage.

(10) Spool.

(11) Passage.

As tilt spool (1) is moved to the TILT FORWARD position, two paths are opened for the flow of oil to the tilt cylinders. One is from passage (4) to outlet (7), which allows pressure oil to go to the head end of the tilt cylinders. The other path is for return oil from the rod end of the tilt cylinders. As spool (1) moves, orifice (15) moves into position to send pressure oil to the chamber behind spool (10). Spool (10) moves against the force of spring (9) and opens a path for return oil between passage (16) and orifice (14). This has the effect of slowing down the flow of oil from the rod end of the tilt cylinders and preventing cavitation in the head end. If pump flow (pressure) is lost, for any reason, spool (10) will return to the NEUTRAL position and the path for return oil is closed.

When the control lever for tilt is moved to TILT FORWARD position, spool (1) is moved until a path is opened between passage (4) and outlet (7) and oil flow from chamber (12) to passage (11) is stopped. This causes the oil pressure to increase and open load check valve (3). The pressure oil from the pump can now flow from passage (4) to outlet (7). It then flows to the head end of the tilt cylinders and the mast tilts forward. Return oil from the rod end of the tilt cylinders flows into the valve through outlet (2) in to passage (8) and then to tank.

Vehicle Systems

(9) Spring.

Systems Operation

Tilt Back Position

6 7 8 1

13 9

11 14 16

ICCS014S Tilt Spool In Tilt Back Position (1) Spool. (2) Outlet To Rod End Of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil. (6) Chamber. (7) Outlet To Head End Of Tilt Cylinders. (8) Passage For Return Oil. (9) Spring. (10) Spool. (11) Passage. (12) Chamber. (13) Spring. (14) Orifice. (15) Orifice. (16) Passage.

When the control lever for tilt is moved to TILT BACK position, tilt spool (1) is moved until a path is opened between passage (4) and outlet (2), and oil flow from chamber (12) to passage (11) is stopped. This causes the oil pressure to increase and open load check valve (3). The pressure oil from the pump can now flow from passage (4) to outlet (2). It then flows to the rod end of the tilt cylinders and the mast tilts back. Return oil from the head end of the tilt cylinders flows into the valve through outlet (7) into passage (8) and then to tank.

Vehicle Systems

Systems Operation

Relief Valve

If the control lever is held in LIFT or TILT position after the cylinder rod is fully extended or retracted, the flow of oil from outlet port to the cylinders is stopped. The oil under pressure must be released. The pressure oil flows through piston (11) of the main relief valve. The pressure oil opens pilot valve (14). This lets the oil flow go through spring chamber (13) to passage (7). The oil then returns to tank. When the pilot valve opened, it caused a decrease in the pressure in spring chamber (13) that let piston (11) move against the force of the spring in spring chamber (13). This stops the flow of oil around the pilot valve to passage (7) and moves piston (12) down until a path is open for pump flow to go to the tank through passage (7). This action will continue until the control lever is moved to NEUTRAL position.

14 7

IBCS032B Relief Valve (7) Passage for return oil. (11) Piston. (13) Spring chamber. (14) Pilot valve.

Vehicle Systems

(12) Dump valve.

Systems Operation

Steering System Hydraulic Operation (Load Sensing Closed Center Steering System)

10 12 11

IBCS036B Steering System Schematic (1) Steering Unit. (2) Hose (to hydraulic tank). (3) Priority Valve. (4) Hose (from hydraulic pump). (5) Hose (to control valve). (6) Hose. (7) Hose. (8) Steering Axle. (9) Check Valve (in steer gear). (10) Hose (from priority valve). (11) Hydraulic Pump. (12) Hydraulic Tank. (13) Hose (load sensing).

pressure drops in these lines, the priority valve metering spool will shift to meet the flow demand. As the metering spool shifts, more oil flow is diverted to hose (10) than to hose (5). The priority valve metering spool will shift back and forth to meet the steering flow demand while maintaining the Load Sensing Pressure between load sense hose (13) and the priority valve internal sensing line. At times flow to hose (5) will be closed completely. The combination of flow restrictors in the lines and spring tension on the priority valve metering spool work together to maintain this balance.

The steering system is a load sensing closed center type and uses hydraulic oil for its operation. Oil flow through the steering system is closed unless the steering wheel is turned. The flow through the steering gear is sensed by the priority valve, which then allows additional oil flow to the steering system. The priority valve also fills the requirements of the power brakes (if equipped) and then the mast. Hydraulic oil is pulled from hydraulic tank (12) through a strainer to hydraulic pump (11). The pump sends the oil through hose (4) to priority valve (3).

Check valve (9) is in the steering unit (pump) to prevent oil flow back to priority valve (3), which could cause a sudden jerk of the steering wheel.

When the steering gear is in NEUTRAL position, pressure in hose (10) and the priority valve internal sensing line rises. When this pressure rises more than load sensing signal hose (13) the priority valve metering spool shifts to stop oil flow to the steering unit. Oil flows hose (5) to the hydraulic control valve. When the unit (pump) is moved, oil starts to flow to steer axle (8). The pressure in line (10) and the priority valve internal sensing line will drop. As Vehicle Systems

Relief valve in steering unit valve body will open if the steering pressure goes above 8000 kPa (1143 psi).

Systems Operation

Steering Unit - Steering Gear

2 3

Oil Flow PUMP OIL METERED OIL RETURN OIL

B 4

6 7

3 10

11 5 14 15 16

13 9 10 11

IBCS037B

IBCS038B

Steering Unit A. Control valve section. B. Metering section. (1) Spool. (2) Sleeve. (3) Outlet to tank. (4) Check valve. (5) Inlet from pump. (6) Rotor. (7) Stator. (8) Centering springs. (9) Pin. (10) Left turn port. (11) Right turn port. (12) Body. (13) Drive.

Steering Unit (Shown in RIGHT TURN Position) (1) Spool. (2) Sleeve. (3) Outlet to tank. (5) Inlet from pump. (8) Centering springs. (9) Pin. (10) Left turn port. (11) Right turn port. (13) Drive. (14) Passage. (15) Passage. (16) Gerotor. (17) Passage.

When the steering wheel is turned for a right turn, pump oil flows into the STEERING UNIT through inlet (5) and passage (14). From passage (14) it goes into the gerotor through passage (17). With the steering wheel turning, gerotor (16) is turning and pumping oil. The Metered flow comes out through passage (15), where it is directed out to the steering cylinder through right turn port (11). When the steering wheel started to turn ; spool (1), pin (9) and drive (13) also started to turn. Sleeve (2) did not start to turn at the same time as the spool because the diameter of the holes in the sleeve are slightly larger than the diameter of pin (9). This allows spool (1) to turn inside of sleeve (2) enough to put the small holes in sleeve (2) in line with the grooves in spool (1). The alignment of the small holes in the sleeve with the grooves in the spool provides the path for oil flow to gerotor (16) and also to the steering cylinder. Centering springs (8) are compressed when the spool moves in relation to the sleeve. When the steering wheel is no longer turning, the springs will bring the spool and sleeve back to a NEUTRAL position. This means that the wheels will stay in the position they were in when the steering effort stopped. The steering wheel must be turned in the opposite direction to bring the wheels back to straight ahead, or to make a left turn. As the metered oil goes out to the cylinder through outlet (11) for a right turn, return oil from the cylinder is coming back into the STEERING UNIT through outlet (10). This oil is sent to the tank.

The steering unit has two main sections ; control section (A) and pump or metering section (B). These two sections work together to send oil to the steering cylinder. Oil from the priority valve enters the steering unit through inlet (5) into the control section. When the steering wheel is turned, the control section sends the oil to and from the metering section, and also to and from the steering cylinder. The metering section is a small hydraulic pump. It meters the oil that goes to the steering cylinder, As the steering wheel is turned faster, there is an increase in the flow of oil to the steering cylinder. This increased flow causes the steering cylinder to move farther and faster. As the steering cylinder moves farther, more oil can flow from the metering section to the steering cylinder and a faster turn is made.

Vehicle Systems

4 13

Systems Operation

PUMP OIL METERED OIL RETURN OIL

3 10 11

15 16

18 2 18

19 20 19 9

IBCS039B

17 LEFT TURN

IBCS040B

Steering Unit (Shown in a LEFT TURN Position) (1) Spool. (2) Sleeve. (3) Outlet to tank. (5) Inlet from pump. (9) Pin. (10) Left turn port. (11) Right turn port. (13) Drive. (14) Passage. (15) Passage. (16) Gerotor. (17) Passage.

Spool And Sleeve (1) Spool.

(2) Sleeve.

(19) Holes for pin.

(18) Slots for spring.

(20) Small holes for oil flow.

(21) Grooves for oil flow.

When the steering wheel is turned to the left, spool (1), pin (9) and drive (13) turn with it. After spool (1) has turned a small amount pin (9) will cause sleeve (2) to move with the spool. They will rotate together but will be a few degrees apart. The flow of oil through the STEERING UNIT is in the opposite direction to that of a right turn. It comes in through inlet (5) and passage (14) and then goses into gerotor (16) through passage (15). From the gerotor, the oil leaves through passage (17), goes through the sleeve spool combination and then to left turn port (10). From the left turn port it goes to the steering cylinder.

Vehicle Systems

The rate of flow the gerotor sections is determined by how fast the steering wheel is turned. The faster the steering wheel turns, the greater the flow and the faster the vehicle will turn.

Systems Operation

TANK OIL (SUPPLY) METERED OIL RETURN OIL

3 10 11

4 EHCS035B

15 16

17 EMERGENCY

EHCS036B

Steering Unit (Shown in Manually Operated Right Turn Position) (3) Outlet to tank. (4) Ball check. (10) Left turn port. (11) Right turn port. (15) Passage. (16) Gerotor. (17) Passage.

Pump Gears In The Metering Section (6) Rotor. (7) Stator. (9) Pin. (13) Drive.

When the steering wheel is turned, in either direction, pin (9) turns with the sleeve and spool and causes drive (13) to turn also. The drive cause rotation of rotor (6) inside of stator (7). This rotation of the rotor sends a controlled (metered) flow of oil back to the spool sleeve combination where it is then directed to either port (10) or (11) and then to the steering cylinder.

If there is a pump failure or the engine stops and can not be started again, the STEERING UNIT can be manually operated. Turning the steering wheel will take oil from the tank and bring it in through outlet (3). It will then open check valve (4) and go to the gerotor (16) through passage (17). It will come out of (16) through passage (15) and go to the right turn port (11). This is the flow for a right turn. It would be reversed for a left turn.

If the unit is taken apart for any reason, it must be put back together with the relationship between pin (9) and rotor (6) as shown.

During normal operation, check valve (4) will be held closed by pressure oil from the pump.

Vehicle Systems

Systems Operation

Brake fluid from remote reservoir (1) to replenish master cylinder (2). The master cylinder has a piston which pushes brake liquid into the brake lines. The reservoir, located on the cowl, is connected to inlet of master cylinder. The supply lines keep master cylinder (2) filled so no air enters the system. Reservoir (1) supplies brake liquid to the system. When the brake pedal is first pushed, the piston moves into the master cylinder and push brake liquid through outlet into the brake lines. When floating piston seats on seal, the liquid that is pushed by piston goes around cup seal, out through loading piston and outlet. This action continues until the liquid pressure in piston bore reaches the pressure that opens relief valve. The liquid, being pushed by piston, now returns to reservoir (1). Cup seal, seals and the liquid inside piston is pushed through piston and outlet. The liquid pushed through outlet goes through the brake lines to wheel cylinders (3). Check valve in the master cylinder keeps a small amount of pressure in the brake lines and wheel cylinders (3) when the pedal is released. This small amount of pressure helps the wheel cylinder piston cup seal seat, which keeps air out of the brake system.

Brake System Master Cylinder

Master Cylinder And Wheel Cylinder (1) Master cylinder reservoir. (2) Master cylinder. (3) Wheel cylinder.

(1) Master cylinder reservoir.

Vehicle Systems

Systems Operation

Shoe Type Brakes

Automatic Adjustment

Brakes with automatic adjustment are adjusted on the reverse braking action. In this example the drum rotation is counterclockwise (in reverse) which causes a counterclockwise rotation of the brake shoes. Secondary shoe (4) moves away from cylinder (2) that causes link (1) to move toggle lever (6) in a clockwise rotation. Link (8) is connected to the lower part of toggle lever (6) and to adjustment lever (9). By this connection, adjustment lever (9) is moved in a counterclockwise rotation.

1 6

When the brakes are released at the end of a reverse brake application, adjustment spring (11) puts adjustment lever (9) into its original position. If the brake shoe lining has worn enough to let lever (9) engage, a tooth on adjustment screw (10), lever (9) will rotate screw (10) to put the brakes into the correct adjustment.

7 8 11

IBCS044B Brakes With Automatic Adjustment (Right Side Shown) (1) Upper adjustment link. (2) Cylinder assembly. (3) Piston. (4) Secondary shoe. (5) Primary shoe. (6) Toggle lever. (7) Support plate. (8) Lower adjustment link. (9) Adjustment lever. (10) Adjustment screw. (11) Adjustment spring.

When the brake pedal is pushed down, the master cylinder sends brake fluid to wheel cylinder (2). Wheel cylinder pistons (3) are pushed out and move primary shoe (5) and secondary shoe (4). The brake shoes move until they make contact with the brake drum. When the brake action first starts, primary shoe (5) comes in contact with the brake drum as it is in rotation. This contact of the primary shoe puts some force on secondary shoe (4) to help put it in position against the drum.

Vehicle Systems

Systems Operation

Parking Brake

Parking brakes use the shoe brake system described above. The brakes are activated mechanically instead of hydraulically. The brakes are designed to hold the truck positively for sure parking. Using parking lever (1) and cables (2).

Vehicle Systems

Systems Operation

Electric Motors Hydraulic Pump Motor

Electric Motor (1) Brush cover. (2) Thermal switch.

(3) Motor frame.

(4) Brush.

(5) Commutator. (6) Armature. (7) Fleld coil. (8) Fan.

The parts of armature (6) include the shaft, core, windings and commutator.

The hydraulic system is operated by a direct current (DC) motor. Electric storage batteries are the source of power for the DC motor

The motor is protected from over temperature by a thermostat switch (2). When the normally closed thermostat switch is open, the amount of current through the motor is limited to allow, the motor to cool. All motors are fan (8) cooled.

The hydraulic pump motor is a series wound motor and uses high temperature insulation. Armature (6) is mounted with single row ball bearings at each end. The ball bearings are permanently lubricated with high temperature lubricant.

The hydraulic pump motor is activated when the key and seat switches are closed and lift, tilt or auxiliary lever is moved. In lift operation, the speed of the motor is variable. The larger the distance the lever is moved, the faster the motor will rotate. The speed of the motor is fixed in tilt or auxiliary operation.

The electrical connections to the motor are made of corrosion resistant terminals on motor frame (3). On the outside of the motor frame is cover (1) that can be removed for easy access to brushes (4) and commutator (5). Field coils (7) are fastened to the inside of the motor frame.

On the Option MicroController Control, the speed of lift or tilt or auxiliary operation could be pre-settable.

The motor brushes are held in the four brush holders by springs. The springs hold the brushes against commutator (5) and compensate for brush wear.

Vehicle Systems

Systems Operation

Visual Checks

Testing & Adjusting

A visual inspection of the hydraulic system and its components is the first step when a diagnosis of a problem is made. Lower the carriage to the floor and follow these inspections:

Troubleshooting Troubleshooting can be difficult. A list of possible problems and corrections is on the pages that follow. This list of problems and corrections will only give an indication of where a problem can be and what repairs are needed. Normally, more or other repair work is needed beyond the recommendations on the list. Remember that a problem is not necessarily caused only by one part, but by the relation of one part with other parts. This list can not give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs. Before any test is made, visually inspect the complete hydraulic system for leakage of oil and for parts that have damage.

Measure the oil level. Look for air bubbles in the oil tank.

Remove the filter element and look for particles removed from the oil by the filter element. A magnet will separate ferrous particles from nonferrous particles (piston rings, O-ring seals, etc.).

Check all oil lines and connections for damage or leaks.

Check all the lift chains and mast and carriage welds for wear or damage.

Performance Tests The performance tests can be used to find leakage in the system. They can also be used to find a bad valve or pump. The speed of rod movement when the cylinders move can be used to check the condition of the cylinders and the pump.

Troubleshooting can be difficult. A list of possible problems and corrections is on the pages that follow. This list of problems and corrections will only give an indication of where a problem can be and what repairs are needed. Normally, more or other repair work is needed beyond the recommendations on the list. Remember that a problem is not necessarily caused only by one part, but by the relation of one part with other parts. This list can not give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs. Before any test is made, visually inspect the complete hydraulic system for leakage of oil and for parts that have damage.

Lift, lower, tilt forward and tilt back the forks several times. 1.

Watch the cylinders as they are extended and retracted. Movement must be smooth and regular.

Listen for noise from the pump.

Listen for the sound of the relief valve. It must not open except when the cylinders are fully extended or retracted, when the forks are empty.

Hydraulic Oil Temperature (Too Hot) When The temperature of the hydraulic oil gets over 98.8°C (210°F), polyurethane seals in the system start to fail. High oil temperature causes seal failure to become more rapid. There are many reasons why the temperature of the oil will get this hot.

Vehicle Systems

Hydraulic pump is badly worn.

Heavy hydraulic loads that cause the relief valve to open.

Testing & Adjusting

Hydraulic System And Mast

The setting of the relief valve is too low.

Too many restrictions in the system.

Hydraulic oil level in the tank is too low.

Problem: The hydraulic system will not lift the load.

High pressure oil leak in one or more circuits.

Probable Hydraulic Cause:

Very dirty oil.

Air in the hydraulic oil.

There is an air leak, which lets air into the hydraulic system on the inlet side of the hydraulic pump.

The relief valve opens at low oil pressure.

The hydraulic pump has too much wear.

The priority valve does not work correctly.

The load is not correct.

NOTE : If the problem is because of air in the oil, it must be corrected before the system will operate at normal temperatures. There are two things that cause air in the oil (aeration). a. Return oil to the tank goes in above the level of the oil in the tank. b. Air leaks in the oil suction line between the pump and the tank.

Probable Mechanical Cause:

Hydraulic System and Mast During a diagnosis of the hydraulic system, remember that correct oil flow and pressure are necessary for correct operation. The output of the pump (oil flow) increases with an increase in engine speed (rpm) and decreases when engine speed (rpm) is decreased. Oil pressure is caused by resistance to the flow of oil.

The mast is not in alignment with the other lifting components and does not move freely.

Not enough lubricant on the parts of the mast that move.

The carriage or mast rollers and bearings are worn and do not move (seized).

Problem: Lift cylinder extends too slowly.

Visual checks and measurements are the first step when troubleshooting a possible problem. Then do the operation checks and finally, do instrument tests with pressure gauges.

Probable Hydraulic Cause: 1.

Not enough oil supply to lift cylinder.

Use the Fittings Group, a stop watch, a magnet, a thermometer, and an inch (mm) ruler for basic tests to measure:

Defective lift cylinder seals.

Probable Mechanical Cause:

The pressure of the oil to open the relief valve. Relief valve pressures that are too low will cause a decrease in the lift and tilt characteristics of the lift truck. Pressures that are too high will cause a decrease in the life of hoses and components. Drift rates in the cylinders. Cylinder drift is caused by a leakage past cylinder pistons, Oring seals in the control valve, check valves that do not seat correctly or poor adjustment or fit in the control valve spools.

The mast is not in alignment with the other lifting components and does not slide freely.

Not enough lubricant on the parts of the mast that move.

The carriage or mast rollers and bearings are worn and do move (seized).

Cycle times in the lift and tilt circuits: Cycle times that are too long are the result of leakage, pump wear and/or pump speed (rpm).

Vehicle Systems

Testing & Adjusting

Problem: Mast does not move smoothly.

Probable Mechanical Cause:

Probable Hydraulic Cause:

Air in the hydraulic system.

Relief valve sticks of defective.

Damaged cylinders.

Damage or failure of the tilt cylinders.

Problem: The carriage will not lower correctly. Probable Hydraulic Cause:

Probable Mechanical Cause: 1.

Not enough lubricant on the parts of the mast that move.

Load rollers defective or not adjusted correctly.

There are restrictions in the lift line.

The lift spool in the control valve has a restriction caused by foreign material and does not operate freely.

The lift cylinder flow control valve has a restriction.

Air in the hydraulic system.

Problem: Mast will not lower completely or will not lower at all. Probable Mechanical Cause: Probable Hydraulic Cause: 1.

The mast is not in alignment with the other lifting components and does not move freely.

Carriage chains need an adjustment.

Not enough lubricant on the part of the mast that moves.

The carriage or mast rollers and bearings are worn and do not move (seized).

Lift cylinder damaged or bent.

Probable Mechanical Cause: 1.

Load rollers defective or not adjusted correctly.

Not enough lubricant on the parts of the mast that move.

Problem: The lift or tilt cylinders do not hold their position with the valve control levers in neutral position.

Problem: The mast does not tilt correctly or moves too slowly. Probable Hydraulic Cause:

Probable Cause: 1.

There is a restriction in the hydraulic tilt lines.

There is an air leak, which lets air into the hydraulic system on the inlet side of the hydraulic pump.

The relief valve opens at low oil pressure.

The hydraulic pump has too much wear.

The internal valve of the tilt spool is stuck.

Control valve tilt spool has a restriction.

The priority valve does not work correctly.

Vehicle Systems

The valve spools do not hold their positions because the springs for the valve spools are weak or broken.

Control valve leakage caused by worn valve spools.

The load check valves in the control valve are defective.

Leakage of the cylinder lines or piston seals.

There is foreign material in the control valve.

Testing & Adjusting

Hydraulic Pump

Seal cut on shoulder of pump or keyway during installation.

Seal lips are dry and hardened fromheat.

Problem: Noise in the pump Probable Cause: Problem: There is failure of the pump to deliver fluid

The oil level is low.

The oil is thick (viscosity too high).

The pump inlet line has a restriction in it (strainer plugged).

Low level of the oil in the tank.

Worn parts in the pump.

There is a restriction in the pump inlet line.

Oil is dirty.

There is air leakage in the pump inlet line.

Air leaks into the inlet line.

The viscosity of the oil is wrong.

The pump has too much wear.

Failure of the pumps shaft or coupling.

The bolts of the pump do not have the correct torque.

Probable Cause:

Problem: The oil temperature is too high. Probable Cause: 1.

The oil level is low.

There is a restriction in an oil passage.

The relief valve setting is too low.

The oil is too thin.

There is air leakage in the system.

The pump has too much wear.

The system operates at too high a pressure. a. Relief valve setting too high. b. Attachment components cause a restriction during movement. c. Restrictions in flow control valve, load check valve and in oil lines.

Hydraulic Control Valve Problem: The control spools do not move freely. Probable Cause:

Problem: Leakage on the shaft seal.

The temperature of the oil is too high.

There is foreign material in the fluid.

The fitting connections in the valve body are too tight.

The mounting bolts of the valve assembly do not have the correct torque and have twisted the body.

Linkage of the lift and tilt levers does not operate smoothly.

Bent lift or tilt spools.

Damage to the return springs of the spools.

The valve is not at normal temperature for operation.

Probable Cause: 1.

The shaft seal is worn.

There is a broken gasket behind the seal.

The inner parts of the pump body are worn.

Operation with too low oil level in tank causes suction on the seal.

Vehicle Systems

Testing & Adjusting

Lift and Tilt Cylinders

Problem: Control valve spools have leakage around the seals.

Problem: Leakage around the piston rod. Probable Cause: Probable Cause: 1.

There is foreign material under the seal.

The valve spools are worn.

The seal plates are loose.

The seals have damage or arebadlyworn.

Cylinder head (bearing) seals are worn.

Piston rod is worn, scratched or bent.

Problem: There is leakage of oil inside the cylinder or loss of lift or tilt power.

Problem: The load lowers when the lift spool is moved from the neutral position to the raise position.

Probable Cause: 1.

The piston seals are worn and let oil go through.

Probable Cause:

Cylinder has damage.

There is foreign material in the load check valve area.

Problem: The piston rods show wear.

The load check valve and seat show wear.

Probable Cause:

Sudden loss of pump oil pressure.

The cylinders are not in correct alignment.

Damage to the relief valve which causes low oil pressure.

Oil is dirty.

Problem: Spools do not return to neutral.

Problem: Foreign material behind the wiper rings causing scratches on the cylinder rod.

Probable Cause:

The springs are broken.

The spool is bent.

The system or valve has foreign particles in it.

Steering System

The control linkage is not in alignment.

Problem: Too much force needed to turn steering wheel.

The fastening bolts of the valve have too much torque.

The wiper rings show wear and do not remove dirt and foreign material.

Probable Cause: 1.

Priority valve releases pressure oil at a low setting.

Pump oil pressure is low, worn pump.

Problem: No motion or slow, then a too sudden action of the hydraulic system. Probable Cause: 3.

Steering gear covers are too tight.

The relief valve is not correctly set, or will not move in base and/or is worn.

Steering column not aligned with steering gear.

There is air in the system.

Priority valve spool is held in one position.

Dirt or foreign particles between relief valve control poppet and its seat.

Steering gear without lubrication.

7. 4.

Valve body has a crack inside.

Low fluid level in the hydraulic supply tank. Problem: Steering wheel does not return to center position correctly.

Spool not moved to a full stroke.

Vehicle Systems

Testing & Adjusting

Problem: Steering wheel does not return to certer position correctly.

Problem: Lift truck does not turn when steering wheel is slowly turned.

Probable Cause:

Steering gear covers are too tight.

The oil level of the tank is low.

Steering column is not in correct alignment.

There is air in the steering system.

Valve spool in the steering gear has a restriction.

The pump operation is not correct.

Priority valve check valve permits lift and tilt hydraulic oil to affect steering hydraulic circuit.

Dirt in the steering system.

Steering gear operation is not correct.

Problem: Oil leakage at the pump.

Steering cylinder has worn parts.

Probable Cause:

Restriction in the steer axle linkage.

Loose hose connections.

Defective shaft seal.

Problem: The temperature of the oil is too hot. Probable Cause: Problem: Low oil pressure.

The viscosity of the oil is wrong.

Probable Cause:

Air mixed with the oil.

Low oil level.

The relief valve is set too high (priority valve).

Priority valve relief valve spring weak.

There is a restriction in the line circuit.

Relief valve (priority valve) will not move from the open position.

Brake System

Oil leakage inside or outiside of the system.

Problem: Brakes make noise or pull (grab).

Defective pump.

Probable Cause: 1.

Brake shoe adjustment not correct.

Problem: Pump makes noise and the steering cylinder rod does not move smoothly.

Lining surface looks like glass (glazed) or is worn.

Probable Cause:

Oil or brake fluid is on the lining.

Air in the steering hydraulic circuit.

Dirt on the brake drum lining surface.

The pump has too much wear.

Brake drum is badly worn or has grooves (scored).

Loose connection of the oil line on the inlet side of the pump.

Restriction in the brake line.

The viscosity of the oil is wrong.

Brake drum is out of round.

The oil level in the hydraulic tank is low.

Vehicle Systems

Testing & Adjusting

Problem: Both brake shoes will not release all the way (drag).

Defective master cylinder.

Lining surface looks like glass (glazed), or worn.

Operation of brake adjuster is not correct.

Pedal adjustment is not correct.

Probable Cause: 1.

Brake shoe adjustment not correct.

Brake pedal adjustment not correct.

Mechanical resistance at the pedal or shoe.

Problem: Brake will not make application.

Restriction in the brake line.

Probable Cause:

Defective wheel cylinder.

Leakage or low fluid level.

Lining surface looks like glass (glazed), or worn.

Oil or brake fluid is on the lining.

Air in the brake hydraulic system.

Defective master cylinder.

Linkage is not in correct adjustment, or is bent.

Problem: Pedal resistance is not solid (spongy). Probable Cause: 1.

Leakage or low fluid level.

Air in the brake hydraulic system.

Loose master cylinder mounting.

Problem: Hard pedal.

Problem: Not braking evenly, or rough feeling of braking (chatter).

Probable Cause:

Mechanical resistance on the pedal or shoe.

Lining surface looks like glass (glazed), or worn.

Brake shoe adjustment not correct.

Oil or brake fluid is on the lining.

Restriction in the brake line.

Defective contact between the lining and drum.

Defective master cylinder.

Loose lining.

Lining surface looks like glass (glazed), or is worn.

Brake drum out of round.

Loose wheel bearing.

Defective wheel cylinder.

Problem: Pedal gradually goes to the floor, Probable Cause:

Parking Brakes 1.

Leakage or low fluid level.

Defective master cylinder.

Problem: Brakes will not hold. Probable Cause: Problem: Extra (excessive) pedal travel.

Parking brake assembly out of adjustment.

Probable Cause:

Parking brake control cable out of adjustment.

Leakage or low fluid level.

Worn brake shoes.

Air in the brake hydraulic system.

Vehicle Systems

Testing & Adjusting

Electric Motors

Key switch, seat switch or line contactor not closed. Close the seat and key switch. Use a multimeter(VOM) to check power flow thru the seat switch, key switch, line contactor coil and line contactor. The key switch, seat switch and line contacor must be closed for the power steering function to operate. The key switch, seat switch, control valve switch and the line contactor must be closed for the hydraulic pump motor to operate.

Not enough voltage. High resistance in battery cells or cables. Charge the battery or replace the battery. Check all the cells for one or more that has defects. Check the specific gravity of each cell. The maximum density difference from the highest to lowest cell must not be more than .020 SG (specific gravity). Check cable terminals for tight fit at battery terminal and control panel connectors. Check for broken inner wires in cables.

Brushes are worn. Disconnect the battery and discharge the commutating capacitor(HEAD CAP). Inspect the pump motor commutator for burnt marks or scoring (scratches). Make corrections or repair the armature commutator, replace the brushes as necessary. See Armature Commutator Inspection and Brush Inspection in Testing And Adjusting. Make reference to Problem : Pump Motor Overheat (Too Much Heat). Check for open circuits in the field coil. Test coils according to procedures in Testing And Adjusting. If there are open circuits, replace the coils.

Check for short or open circuit in the armature or between armature and field. Loose field winding pole pieces. Check poles for damaged insulation, repair or replace damaged insulators. Failed armature bar insulation or armature bar connector open. Repair or rebuild the insulation, replace the armature.

Before an analysis is made of any electric motor problem, always make reference to the troubleshooting section of MicroController Control System module.

If an electrical failure or an overload of the motor is present, personnel must not breathe the toxic fumes which are a product of the burnt insulation. All power must be disconnected from the motor before any inspection is made to find the failure. The area around the motor must be well ventilated(air flow) and the motor is to be cooled before any repair work is done. Water must not be used on any electrical equipment because of the danger of electrical shock. If a fire is present, disconnect the electrical power and use a carbon dioxide extinguisher to put the flame out. Do not operate the drive motor without a load as too much speed may cause damage to the motor and injury to personnel.

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

Problem 1 : Hydraulic pump motor will not operate. Probable Cause : 1.

Bad connections or fuses. Check battery connections. Check the key fuse and power steering fuse. Check the hydraulic pump motor for possible reasons for a bad fuse. Some causes are: a) Operation with too high hydraulic pressures. b) Operation with too much current draw. c) Possible short circuit in motor.

NOTE : If armature open circuits cause commutator bar pitting or burnt areas, armature will need replacement. Heat from the arcing causes the hardened copper commutator bars to be annealed (soft). Just machining (turned to a lesser diameter) of the commutator will not correct the problem from occurring again. The armature must be replaced.

Vehicle Systems

Testing & Adjusting

Opens in the armature bar connections must be found and soldered(repaired). 6.

Lift and drive system operation not correct. See troubleshooting section of the Micro Controller Control System module.

Problem 2 : Battery will not last a complete normal work period. Probable cause : 1.

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

Hydraulic system draws too much battery power because of lifting and tilting arrangements or hydraulic controls are not correct for the duty cycle. Decrease hydraulic relief valve setting to the capacity needed for the application. Change to a smaller hydraulic pump (if available). Check the mast for restriction during operation. Remove quick disconnects and install fittings with lesser resistance to oil flow. Check for defective hydraulic control valve, the pilot operated relief valve. Remove any restrictions in the hydraulic circuit. Make an inspection of the movable hydraulic attachments for restrictions. Check for components that slide, bearing wear, hinges binding and the correct amount of lubrication on necessary components.

Battery not being fully charged or equalized during the battery charging operation. Check the battery cells for an equalization charge (a charge to make the specific gravity the same in all cells). Check the battery charger for defects.

Problem 3 : Sparks at the commutator and/or rapid brush wear. Probable Cause :

Battery Discharge Indicator (BDI) lift interrupter circuit which protects the battery, shuts off the hydraulic motor circuit too soon. See Battery Discharge Indicator Operation Adjustment and Troubleshooting in the MicroController Control System module.

Battery charge interval is too long or charged battery cooling time is too short. This causes excessive (too much) cell temperatures which decreases the capacity of the battery to supply the rated amp hours. Decrease the battery work duration before a change. Increase the battery cooling time after a charge before it is put to use.

Battery has one or more defective cells which can result in less than the rated capacity and ability of the battery. Test and locate the defective cells. Replace the defective cell (s). Battery cells are connected in series, one bad cell causes a high resistance in series with the other cells. This slows down the speed of the motor as the cell resistance increases. This can occur with the other cell almost fully charged.

Vehicle Systems

Worn brushes. Replace the brushes and make sure the brushes are seated. See New Brush installation and Brush Inspection in Testing And Adjusting.

Loose cable connections at the motors terminals cause a high resistance in the circuit. The resistance increases amperage draw(consumption), as a result brushes deteriorate(destroy), there is arcing on the commutator, insulation on wires burns and causes a short circuit to lift truck frame. Tighten the nuts or bolts that hold the cable connections on the motor terminals.

Overheating(too much heat) of the pump motor. Check for an overload or a motor with defects. See Armature Commutator Inspection in Testing And Adjusting. The duty cycle is too heavy, use the hydraulics only to the limited capacity of the lift truck. If the motor has EE covers and the duty cycle is heavy and within the lift truck capacity, remove the covers if permitted.

Testing & Adjusting

11. Pump motor armature or field windings have a defect that results in high current draw at low torque output. See Armature Tests and Field Coil and Terminal Tests in Testing And Adjusting.

Commutator bars burnt in two or more positions at 180° apart because : Armature bars open, replace armature, Short circuit in the armature, see Armature Tests. Armature not in balance which causes brush bounce, see Specifications. Motor was stalled against a heavy load and caused the two bars in contact with the brushes to burn, see Armature Commutator Inspection.

Dirty motor that has metallic or carbon dust. This dust is a conductor which causes electrical shorts, increase current draw and decrease pump motor output. Remove any dirt with air pressure.

Brushes too tight in brush holder. Brush springs not strong enough to force one or more brushes in contact with commutator.

12. Possible heavy working conditions that cause too much motor heat and rapid brush wear. Commutator skin is very black which gives an indication of high temperatures. Make a replacement of the brushes and make sure the brushes are seated. See New Brush Installation and Brush Inspection in Testing And Adjusting. Install extra heavy duty brushes when available. Check the brush springs for the correct installation and for the correct spring usage. Too strong a spring force will increase amperage draw and brush wear rate. Prevent operation in an overload condition caused by excessive duty cycle which increases motor temperature and gives rapid brush wear.

a. At installation, pull upon brush leads to make sure they return to contact with commutator correctly. See Brush Installation in Testing And Adjusting. b. If brushes are too tight remove the brush material with sandpaper until brush movement in brush box is free. 7.

13. Restriction caused by system components. Operate the hydraulic and steering system with an ammeter and a pressure gauge installed. If amperage draw and oil pressure are too high, see Testing And Adjusting and Specifications for the acceptable amperage draws and oil pressure, the system must be inspected for both mechanical and hydraulic restrictions.

Loose movement of the brushes. Check the brush springs for cracks and overheating signs (bluing). Compare spring force with a new brush spring. Check the brush holder for oversize (too large for brush size). Replace the brush spring if necessary.

Problem 4 : Low resistance to ground [ battery potential either positive (+) or negative (-) or a medium voltage is in direct contact with truck frame (body) or drive motor body].

Loose brush leads or motor bus bar connections. Check the brushes for tight connections. Replace if leads are loose in brush material. Check all cables and wire connections for tightness.

Probable Cause : 1.

Dirty battery, electrolyte on top of cells and is in contact with the frame. Current flows through battery box which places a voltage on the truck frame. Clean off the battery with baking soda and water solution.

Battery or control panel wire connections in contact to truck frame. Make a continuity test to move the wire from contact. Remove wires in sequence until the fault is cleared. The fault will be in the wire last disconnected.

Dirty motor. Remove the metallic or carbon dust with air pressure.

Wrong grade of brushes installed that are not adaptable to the motor. Make sure all the brushes are of DAEWOO standards. Do not use other brand brushes.

10. Replacement brushes are not seated, the current goes through a small contact area with the commutator. As a result the brush temperature increases. Possibly if the contact area is poor the brushes will be destroyed in a few service meter hours. Always seat new brushes when installed, see New Brush Installation, in Testing And Adjusting.

Vehicle Systems

Testing & Adjusting

Wet pump motor. Dry the motor with heat to 190 °F (90 °C).

Problem 5 : Commutator surface is grooved or extra wear. Probable Cause : 1.

Brushes are worn too low, brush wires caused arcing on commutator. Inspect the commutator for damage. If the arcing caused light pitting on commutator, install new brushes and seat the brushes with the Brush Seater Stone which will also clean the commutator surface. Make another inspection, if there is still pitting, commutator surface must be machined only to the minimum diameter as shown is in Specifications.

Dirty motor, and possibly salt water got inside. Disassemble motor, remove the debris with air pressure. If necessary, dry the motor with heat to 190 °F (90 °C).

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

Overload on brushes. Check the brush springs for the correct installation and make sure the lift truck is operating at a rated capacity.

Problem 6 : Lift truck has slow hydraulic speeds. Probable Cause : 1.

Hydraulic pump motor overheated and pump motor thermal switch opens. Allow the motor to cool so the thermal swithch will close. See Specifications for thermal switch opening and closing temperatures.

Pump motor control circuit overheated and thermal switch opens. Allow the control panel to cool so the Controller thermal switch will close. The thermal switch Opens at 85 ± 4°C (185 ± 7°F) and close at 73 ± 4°C (163 ± 7°F) for this model.

Vehicle Systems

Testing & Adjusting

Hydraulic System 2

Relief Valve Pressure Check Relief Valve Pressure Check Use the Pressure Gauge Group to check the relief valve pressure.

IBCS047B

Hydraulic oil, under pressure can remain in the hydraulic system after the engine and pump have been stopped. Personal injury can be caused if this pressure is not released before any work is done on the hydraulic system. To prevent possible injury, lower the carriage to the ground, engine off and move control levers to make sure all hydraulic pressure is released before any fitting, plug, hose or component is loosened, tightened, removed or adjusted. Always move the lift truck to a clean and level location away from the travel of other machines. Be sure that other personnel are not near the machine when engine is running and tests or adjustments are made.

Relief Valve Adjustment (2) Control valve. (3) Screw. (4) Jam nut. (5) Acorn nut.

(6) Relief Valve

With the key switch off, remove plug (1) from control valve and install a pressure gauge.

Turn the key switch ON and tilt the mast back to the end of its travel.

With the motor at fast rpm, hold the tilt control lever in the TILT BACK position and watch the gauge. This indication of the gauge is the pressure of the oil that opens the relief valve. For the correct pressure setting, see the topic Control Valve in SPECIFICATIONS.

If an adjustment to the relief valve setting is necessary, do the steps that follow : a. Turn the key switch OFF. b. Remove acorn nut (5) and loosen jam nut (4). c. Turn Screw (3) either clockwise for an increae or counterclockwise for a decrease. d. Hold screw (3) and tighten jam nut (4). Install acorn nut (5).

Check the relief valve pressure setting again.

Control Valve Pressure Check. (1) Plug

Vehicle Systems

Testing & Adjusting

Lift Cylinders Air Removal After the lift cylinder has been disassembled and then assembled again, it may be necessary to remove the air (bleed) from the cylinder. 1.

With no load, lift and lower the mast and carriage through one complete cycle.

With the forks on the floor, check the oil level in the hydraulic tank. Add oil (if necessary)to bring the oil level to the full mark.

EHCS009C Lift Cylinder Air Removal (FFTL - Secondary Cylinders) (24) Bleed Screw.

With no load, left and lower the mast and carriage again through four complete cycles.

The oil will have high pressure present. To prevent personal injury, do not remove the bleed screws completely . Keep hands and feet away from any parts of the truck that move, because the forks will lower when the bleed screw is loose.

Open bleed screws (23 and 24) no more than one turn. The weight of the carriage will force air and hydraulic oil out of the cylinders through the bleed screws. Close the bleed screws before all the pressure is out of the cylinders. This will prevent air from entering back through the bleed screws.

Repeat Steps 4 and 5 until there is no air bubbles at the bleed screws.

After all the air is removed, tighten the bleed screws.

Fill the hydraulic tank to the full mark.

Lift and lower the mast and carriage again through one complete cycle. If the mast does not operate smoothly, repeat Step 3 through 9.

Lift the forks high enough to put a load on all stages of the lift cylinders. (The illustrations shown are of a full free triple lift mast.).

EHCS008C Lift Cylinder Air Removal (FFTL - Primary Cylinder) (23) Bleed Screw.

Vehicle Systems

Testing & Adjusting

Tilt Cylinders

Steering System

Loosen bolt (1).

Steer Wheel Bearing Adjustment

Slide spacer (2) down so rod (3) can be turned into or out of pivot eye (4) to obtain the correct length.

2 1 1 2

Tilt Cylinder Adjustment (1) Bolt. (2) Spacer. (3) Rod.

(4) Pivot Eye.

Tighten bolt (1) and the nut to a torque of 95 ± 15 N•m (70 ± 10 lb•ft).

With mast at tilt back position, install shims (5) as required to permit no gap between pivot eye (4) and spacer (2). Shim so mast does not twist at full tilt back.

Vehicle Systems

IBCS054B

(5) Shims.

Bearing Adjustment (1) Nut (2) Lock.

Tighten nut (1) slowly to 133 N•m (98 lb•ft) while the wheel is rotated to put the bearings into position.

Loosen nut (1) completely. Tighten nut (1) again to 50 ± 5 N•m (37 ± 4 lb•ft).

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

Testing & Adjusting

Steer Axle Stop Adjustment

Steering System Air Removal

2 1

1 IBCS055B

IBCS056C

Steer Angle (1) Bolt. (2) Nut.

Line Fittings Location (1) Alternate location.

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

Fill the hydraulic tank nearly full. Be ready to add oil when the purnp motor is started. Do not let oil level go below the outlet to the pump.

Close the seat switch and turn the key switch on. Add oil immediately to the tank as needed.

Adjust the cylinder rod extension so it is equal on both sides of the axle.

Loosen nut (2).

Turn the steer wheel one direction until the steer cylinder rod extension measures 87 mm (3.4 in).

Adjust stop bolt (1).

Tighten nut (2). Turn the steer wheel the opposite direction and do the same procedure for the opposite stop bolts. This will give a maximum cramp angle of 80°

NOTE : This oil will now flow from the pump, through the priority valve and the steering gear, then back to the priority valve, hydraulic control valve, hydraulic tank and finally to the pump again. When no more oil can be added and oil is clear, do the procedure that follows : 3.

Lift a capacity load to take the weight off of the steer axle. Turn the steering wheel fully clockwise. This will move the cylinder piston to the left end of the cylinder.

Loosen the left side hose fitting at the steer cylinder or alternate location (1). Slowly turn the steering wheel counterclockwise until fluid free of bubbles flows from the fitting. Tighten the fitting.

NOTICE Be sure to keep the oil level in the hydraulic tank above the outlet to the pump. Do not hold steer wheels against stops for an extended period of time. This will cause the oil to get hot and damage the components.

Vehicle Systems

Testing & Adjusting

Loosen the right side hose fitting at the steer cylinder or alternate location (1). Slowly turn the steering wheel clockwise until fluid free of bubbles flows from the fitting. Tighten the fitting.

Brake System Brake System Air Removal When the brake pedal resistance is spongy(not solid)it is usually an indication that there is air in the brake hydraulic system. The cause may be low fluid or oil level, leakage in the system, a broken brake line or a brake line that is not connected.

Turn the steering wheel left and right several times to remove any remaining air.

To remove air from the brake system. Do the procedure that follows :

Hydraulic pressure can cause personal injury. Before any steering system hydraulic lines or components are disconnected, make sure all hydraulic pressure is released in the steering system. Move the steer wheels to the left and right and then to the straight forward direction.

When the oil in the tank is clear (not cloudy), the system is free of air.

Fill the tank to the recommended level.

Reservoir Loaction (1) Reservoir.

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

Bleed Screw Location (2) Bleed Screw.

Vehicle Systems

Put pressure on the brake pedal and open bleed screw (2) to let air out of the system. Close bleed screw (2) while pressure is still on the brake pedal, then let the pedal return to the original position.

Testing & Adjusting

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

(If equipped) : Use the procedure in Steps 2 and 3 again, except this time use the other bleed screw (not shown).

Fill the reservoir again, with the correct fluid, to the level explained in Step 1.

Wood blocks or jack stands of the correct capacity must be used under the machine to prevent the machine from a fall that is not expected. Failure to do so can result in injury or death.

Put wood blocks or jack stands of the correct capacity under the machine.

Remove the plugs from wheel brake plate.

Put a brake adjustment tool through hole and into a tooth on the adjustment screw (1).

Brake Adjustment The brakes make an adjustment automatically when an application is made in reverse, but only after an application has been made in the forward direction. With each reverse brake application there will be an adjustment made, until the lining-to-drum clearance is made small enough to stop the movement of the automatic adjustment linkage. Manual brake adjustment is necessary only when new brake shoes are installed and the automatic adjustment has been moved.

To make a manual adjustment to the brakes:

1 IBCS056B Brake Assembly (1) Adjustment screw.

(2) Adjustment lever.

Turn adjustment screw (1) up until a heavy resistance (drag) is felt on the brake shoes as the drum is turned.

Put a thin blade screwdriver into hole and hold adjustment lever (2) away from the adjustment screw.

IBCD067C Brake Adjustment (1) Adjustment screw.

NOTE : The adjustment lever must be held away from the adjustment screw when the adjustment screw is turned backwards.

Vehicle Systems

Put the brake tool through hole into a tooth on the adjustment screw and turn screw (1) backward until the brake shoes are free of resistance (drag).

Do steps 3 through 6 to adjust the other brake lining to drum clearance.

Install the plugs. Test the brakes to be sure both wheels stop evenly when a brake application is made. Testing & Adjusting

Pedal Adjustment The brake pedal must have enough free play to let the master cylinder piston return to the release position and open the relief outlet. Hydraulic pressure in the brake lines goes back through the relief opening and releases the brakes. If there is no pedal free play, the pressure can not go back through the relief opening, and the brakes will tighten and not release.

If there is too much free play, the brake pedal will be low even with the correct brake adjustment.

Brake Pedal Adjustment (2) Jamnut. (3) Yoke. (4) Nut.

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

Loosen jamnuts (2) of rod (4).

Adjust yoke (3) until there is the correct amount of free play.

If the pedal free play adjustment is not correct, do the procedure that follows:

Hold rod (4) and tighten jamnuts (2).

Parking Brake Test

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.

Location Of Master Cylinder (1) Master Cylinder

Vehicle Systems

Drive the fully loaded lift truck up a 15% incline.

Half way up the incline, stop the lift truck with the service brakes. Apply the parking brake.

If the parking brake has the correct adjustment, the lift truck will be held in this position.

If the parking brake does not hold, do the steps in parking Brake Adjustment.

Testing & Adjusting

Parking Brake Control Group Adjustment

Hydraulic Pump Motor Motor Brushes Brush Inspection 1.

Measure the radial length of the brush.

2 EHCS039C

Brush Measurement

Brush measurement : a. If the brush length is less than 18 mm (.7 in) on the radial side, replace the brushes.

Parking Brake Control Group (1) Switch Assembly. (2) Pin.

New Brush Installation

Put the parking brake in the OFF position.

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

Adjust the switch assembly (1) which is depressed by pin (2) when parking brake put in the ON position.

Disconnect the batteries and remove them from the lift truck. Put the batteries close enough to the truck that the battery connector can be plugged in.

Discharge the head capacitor.

Remove the brush covers. Loosen the two screws of the brush and BWI Wires. Pull out the old brushes from the brush holder while lifting up the brush spring.

Vehicle Systems

Testing & Adjusting

Connect the batteries to the battery connector.

EHCS040C Install Brushes (1) Brushes.

NOTICE Installation of the wrong brushes can cause early motor failure. Always make sure the correct DAEWOO brushes are installed. 3

Install new brushes(1). Make sure the brushes move freely in the brush holders. Use a piece of plain bond paper to remove brush material if there is a restriction of brush movement.

EHCS042C Brush Seating (3) Brush seater stone.

8. 2

Put ZLX-0036 Brush Seater Stone (3) on the commutator and operate the motor at a slow speed.

NOTICE Do not let stone (3) stay in contact with the commutator bar too long time. This causes more wear than is necessary to the brushes and the commutator. EHCS041C Install Springs (2) Spring.

Place carefully the brush spring (2) on the top of brush and make sure they fasten into the brush holder box.

Vehicle Systems

Move stone (3) across the commutator at the back edge of the brushes for a short time. This will take the shiny finish off the commutator and seat the new brushes.

10. Turn the key switch to the OFF position and disconnect the batteries. Check the contact surface of each brush. At least 85% of the brush contact surface of each brush must show wear. If necessary, do Steps 8 through 11 again until the correct wear can be seen on the brush contact surface.

Testing & Adjusting

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

11. After the brushes have the correct seat contact surface, operate the motor at slow speed. Use compressed (pressure) air to remove all dust and abrasive grit.

Armature Tests Tools Needed Digital Multimeter Or Equivalent Growler Tester

EHCS044C Ground Test (A) Multimeter.

1 1

Digital multimeter (A) can be used to test for grounds. Put the Function / Range Switch on the 2M resistance (Ω) scale. When the test leads are put on the commutator and the shaft, the meter must give an resistance is more than 2 megohms.

Short Circuit Test

NOTICE Never use air pressure that is more than 205 kPa (30psi). Make sure the air line has a water filter. 3

EHCS043C

If there is an indication of a ground in the above test, remove any dirt or debris from the armature with compressed (pressure) air.

Short Circuit Test (1) Glowler. (2) Armature. (3) Hacksaw blade. (4) Green light. (5) Red light.

Do the ground test again, If there is still an indication of a ground, replace the armature.

The odor of burned insulation from the pump motor while it is in operation is an indication of a short in the armature.

Open Circuit test

Turn the growler (1) on.

Slowly turn the growler on the armature (2) while a hacksaw blade (3) is held over the windings.

If the windings are shorted, the green light (4) will be on. The red light (5) will be on if the windings do not have a short.

EHCS045C Open Circuit Test (1) Armature.

Vehicle Systems

Testing & Adjusting

Put the digital multimeter Function/Range Switch on the 200 ohm resistance (Ω) scale.

Put one test lead on one commutator bar, Put the other test lead on an adjacent (next to) bar and there must be less than one ohm resistance.

This test can also be done with an instrument, such as a Kelvin Double Bridge, that can make a measurement of very low resistance. Do the test the same as above and make a comparison of the resistance measurements. Two burned areas on opposite sides of the commutator are indications of an open armature winding. These burned areas can cause very rapid brush wear.

EHCS050B Threads on the Commutator Surface

Commutator Inspection

Threads (grooves that look like threads) on the commutator surface, will also cause fast brush wear.

Surfaces of Commutators that need Replacement

EHCS051B EHCS049B

Grooves on the Commutator Surface

Marks on the Commutator Surface

Grooves on the commutators surface are caused by a cutting material in the brush or atmosphere.

Marks on the commutator surface are an indication that metal has moved from the commutator surface to the carbon brushes. Marks will cause fast brush wear.

Vehicle Systems

Testing & Adjusting

Field Coil And Terminal Tests Tools Needed Digital Multimeter Or Equivalent

Open Circuit Test

EHCS052B Copper Drag on the Commutator Surface

Copper drag is an extra amount of commutator material at the back edge of the commutator bars.

EHCS046C Open Circuit Test

Put the digital multimeter Function / Range Switch on the 200 ohm resistance (Ω) scale.

Put one test lead to each outer field terminal (P1, P2).

The resistance must be less than one ohm. If the resistance is too high, it is an indication of corrosion on the terminals or an open field coil.

1 2

EHCS053B

Pitch Bar-Marks on the Commutator Surface.

Pitch bar-marks cause low or burnt marks on the commutator surface. EHCS047C Brush Test (1) Field terminal.

Vehicle Systems

(2) Brush leads.

(A) Multimeter.

Put one test lead to one of outer field terminals (1). Put the other test lead to each of brush leads (2) that connect to the brush holders. There must be continuity to two of the leads with a resistance of less than 1 ohm.

Put one test lead to the other outer field terminal. There must be continuity from this field terminal to the other two brush holder leads. Testing & Adjusting

Ground Test

EHCS048C Ground Test (1) Field terminal.

The brush holders are mounted in the cover at the commutator end of the motor. Make a visual inspection of the brush holders and the cover.

Put digital multimeter (A) Function / Range Swich on the 200 ohm resistance (Ω) scale. Put one test lead to brush holder (1) and the other test lead to the end bell (2). The meter must show overload (OL).

Check each brush holder. If meter reading is low, the brush holder is grounded. Replace the cover.

Thermal Switch(Thermostat) Tests (2) Motor housing.

Tools Needed Digital Multimeter Or Equivalent

Put the digital multimeter Function / Range Switch on the 20M resistance (Ω) scale.

Open Circuit Test

Put one test lead to either outer field terminal (1) and the other test lead to motor housing (2). There must be more than one megohm resistance.

If there is measurement of less than one megohm, it can be caused by wet insulation on the field windings or excessive brush dust in housing. Heat the motor at 88°C (190°F)until the resistance goes above one megohm. If the resistance does not go above one megohm, the shell and field assembly must be replaced. EHCS050C Open Circuit Test

Brush Holder Test Tools Needed Digital Multimeter Or Equivalent

Put the digital multimeter Function / Range Switch on the 200 ohm resistance (Ω) scale.

Put one test lead to each side of the thermal switch harness.

The resistance must be less than one ohm.

2 EHCS049C Brush Holder Test (1) Brush holder. (2) End bell.

Vehicle Systems

(A) Multimeter.

Testing & Adjusting

Ground Test

Length of shortest brush at 500 smh is 32.5 mm(1.279 in) New brush length [35mm (1.378 in)] - Length of shortest brush at 500 smh [32.5mm (1.279) in)]=Amount of brush wear at 500 smh [2.5 mm(.10in)]. Amount of brush wear at 500 smh [2.5mm(.10 in)] Total amount of usable brush wear [17mm (.67 in)]=Portion of brush used at 500 smh (.1). Service Meter Hours (smh) at brush wear measurement (500 smh) - Portion of brush used (.1)=Approximate total brush life of a new brush (5000 smh). Approximate total brush life of a new brush (5000smh) - Amount of smh at brush life estimate (500smh)=Remainder of usable brush life(4500 smh).

EHCS051C Ground Test

Put the digital multimeter Function / Range Switch on the 20M resistance (Ω) scale.

Put one test lead to either of the plug prongs. The other test lead must be grounded to the motor housing. There must be more than one megohm resistance.

Brush Life Estimate 1.

Before installation of new brushes, inspect the armature commutator. See Armature commutator Inspection in Testing and Adjusting.

Do the steps and procedures for New Brush Installation in Testing and Adjusting.

NOTE : If there is an indication that brush wear is too fast, see Troubleshooting, Problem: Sparks at the commutator and/or rapid brush wear. 4.

Estimate expected brush life (hours). Use the shortest measurement from Step 4 and the following Sample Procedure : Length of new brush ................ 35mm (1.387 in) Minimum length of brush ........... 18mm (.708 in) New brush length [35mm (1.387 in)] – Minimum Brush length [18mm (.708 in)] = Total amount of Usable brush wear [17mm (.67in)]

The smh estimate of brush life can be used if the machine is to work at the same rate(duty cycle), the battery is not discharged too much or the battery cells have not become damaged. If the machine is made to work harder, the battery is discharged too much, or the battery cells become damaged, the motor temperature will get hot very fast. This will cause rapid wear of the brushes.

Inspect all brushes in the motors. Measure and record each brush length. See Hydraulic Pump or Steering Pump Motor in Specifications for new and minimum brush length.

Vehicle Systems

Testing & Adjusting

SB4167E00 A p r. 2 0 0 4

Disassembly & Assembly Lift Trucks Vehicle Systems BC15S, BC18S, BC20SC

WARNING

Index Brake Master Cylinder..............................................33 Control Panel............................................................34 Counterweight ..........................................................44 Drive Motor...............................................................42 Drive Wheel..............................................................42 Hood(with seat) Assembly..........................................5 Hydraulic Control Valve ..............................................7 Hydraulic Pump Motor..............................................13 Overhead Guard.........................................................6 Primary Lift Cylinder .................................................21 Priority Valve.............................................................32 Standard Lift Cylinder ...............................................17 Steer Wheels Bearings.............................................35 Steering Axle ............................................................38 Steering Cylinder ......................................................38 Steering Knuckles, Kingpins & Bearings ..................40 Steering Wheel .........................................................27 Tie Rods ...................................................................37 Tilt Cylinders.............................................................23 Trans-Axle ................................................................43

WARNING Disconnect batteries before performance of any service work.

Vehicle Systems

Index

Hood(with seat) Assembly Remove & Install Hood(with seat) Assembly 3

INCD003P

Remove nuts (3), bolts and washers.

INCD001P

Raise the hood. Support the hood with a hoist.

4 INCD004P

2 5.

Use the hoist to remove hood and seat assembly (4).

Install the hood and seat assembly in the reverse order of removal.

INCD002P

Disconnect harness connector (1) for seat brake.

WARNING The hood and seat assembly can fall when nut (2) is removed from the support cylinder rod. To avoid personal injury, support the seat and hood assembly before removing nut (2).

Remove nut (2) from the support cylinder. Remove the cylinder rod from the bracket.

Vehicle Systems

Disassembly and Assembly

Overhead Guard

Remove & Install Overhead Guard

INCD007P

Remove bolts and washers (3) from the front leg.

1 INCD005P

Disconnect harness connector (1) from inside of the cowl.

Support overhead guard (2) with lifting straps and a hoist as shown. INCD008P

INCD006P

Vehicle Systems

Remove bolts and washers (4) from the rear leg.

Remove overhead guard (2).

Install overhead guard (2) in the reverse order of removal.

Disassembly and Assembly

For purposes of reassembly, put identification marks on all lines, tubes and hoses before any disconnections are made.

Hydraulic Control Valve Remove & Install Hydraulic Control Valves

Disconnect all lines (2) from control valve (3).

NOTE : Plug and cap all openings to avoid contamination and debris from entering the system after removing any tubes or lines.

WARNING Hydraulic oil under pressure can remain in the hydraulic system after the pump motor have been stopped. Personal injury can result if the pressure is not released before any work is done to the hydraulic system. To prevent possible personal injury, turn the key switch off and move the control levers to make sure the hydraulic pressure is released before any fitting, plug, hose or component is loosened, tightened, removed or adjusted. Always move the lift truck to a clean and level location away from the travel of other machines.

4 3

S0525207

Support control valve (3). Remove three bolts (4), washers and control valve (3).

Install the control valve (3) in the reverse order of removal.

Fill the hydraulic tank to the correct level with fluid. Refer to the Operation And Maintenance Manual for further information.

Start By : a. Remove hydraulic control valve switch group (1). 1.

Drain the hydraulic tank.

1 End By : a. Install the hydraulic control valve switch group.

A2010001

Vehicle Systems

Disassembly and Assembly

Disassemble Hydraulic Control Valve Start By : a. Remove hydraulic control valve.

6 INCD043P

Remove lift section assembly (6) from the valve body.

INCD041P

8 6

NOTE : For purpose of assembly, put identification marks on all valve sections. 1.

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

11 INCD044P

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

Remove plug (7) and O-ring (8) from the lift section assembly (6).

Remove O-ring (9), poppet (10) and spring (11) from lift section assembly (6).

INCD042P

Remove O-ring (3) from inlet section assembly (2).

Remove relief valve (4) and O-ring (5).

INCD045P

Vehicle Systems

Remove two screws (12) and cap (13) from lift section assembly.

Disassembly and Assembly

INCD046P

INCD048P

13. Remove tilt section assembly (26) from the valve body.

Remove two screws (16) and seal plate (17).

10. Remove lift spool (18).

24 23

20 25

INCD049P

INCD047P

14. Remove O-ring (27), poppet (28) and spring (29) from tilt section assembly (26).

11. Remove the wiper seals (19) and O-rings (20) from the spool. Check the condition of O-rings and wiper seals and replace with new ones if needed. NOTE : Remove the spool end (21) from the spool. The centering spring (22) has a slight preload and will extend to its free length when the spool end is removed.

12. Remove the spring seats (23 and 24), centering spring (22) and seal plate (25).

INCD050P

15. Remove two screws (30) and cap (31) from tilt section assembly.

Vehicle Systems

Disassembly and Assembly

45 33

43 INCD051P

INCD054P

16. Remove two screws (32) and seal plate (33).

20. Remove side shift section assembly (43) and fourth section (44) from the valve body.

17. Remove tilt spool (34). NOTE : Do step 7 through 12 to disassemble valve spools of side shift and fourth section assembly. 21. Remove section assembly (45).

38 INCD052P

18. Remove the wiper seals (35) and O-rings (36). Check the condition of wiper seals and O-rings and replace with new ones if needed.

INCD055P

NOTE : Remove the spool end (37) from the spool. The centering spring (38) has a slight preload and will extend to its free length when the spool end is removed.

22. Remove relief valve (46) and O-ring (47) from the section assembly (45).

42 INCD053P

19. Remove spring seats (39 and 40), spring (38 and 42) and piston (41).

Vehicle Systems

Disassembly and Assembly

Assemble Hydraulic Control Valve

24 23

NOTICE Do not use caustic (corrosive) materials to clean any parts in this valve group. Caustic materials will cause corrosion and damage to parts.

20 25

21 22

INCD047P

Make sure all valve parts are clean and free of dirt.

5 4

Install the spring seats (23 and 24), centering spring (22) and seal plate (25) on the lift spool.

Compress the spring with spool end (21) and tighten spool end. Torque the spool end to 8 ~ 11 N•m (70 ~ 97 lb•in).

Install the wiper seals (19) and O-ring (20) to the spool (18).

INCD042P

Install O-ring (3) to inlet section assembly (2).

Install relief valve (4) with O-ring (5) to inlet section assembly (2). The torque for the relief valve is 44 ~ 49 N•m(32 ~ 36 lb•ft).

INCD046P

Vehicle Systems

Install the spool (18), seal plate (17) and the screws (16).

Disassembly and Assembly

47 46

INCD045P

INCD055P

13. Install O-ring (47) and relief valve (46) to the section assembly (45).

Install cap (13) and two screws (12).

7 12

8 6

11 INCD044P

Install O-ring (9), poppet (10) and spring (11) to lift section assembly (6).

INCD041P

14. Assemble all the sections on the studs.

10. Install O-ring (8) and plug (7) to the lift section assembly.

15. Install the nuts (1) that hold the valve sections together. Tighten the single top nut to torque of 26 N•m (19 lb•ft) and two bottom nuts to torque of 26 N•m (19 lb•ft).

End By : a. Install hydraulic control valve.

42 INCD053P

11. Install piston (41), spring (42), spring seats (39 and 40) and spring (38) on the tilt spool assembly. 12. Compress the spring with spool end (37). Torque the spool end to 8 ~ 11 N•m (70 ~ 97 lb•in). NOTE : Do step 6, 7, 8 and 9 to assemble the tilt spool to the tilt section assembly. NOTE : Do same steps to assemble the side shift section and fourth section assembly. Vehicle Systems

Disassembly and Assembly

Hydraulic Pump Motor Remove And Install Hydraulic Pump Motor NOTE : For purpose of reassembly, put identification marks on the wires and cables for proper installation.

S0525007

Remove two cables (8) from hydraulic pump motor.

9 2

P0004849

Remove side bolts (1) and panel (2) from lift truck. S0525005

4 5

Disconnect hose as (9) from hydraulic pump.

NOTE : Plug and cap all openings to avoid contamination and debris from entering the system after removing any tubes or lines.

S0525003

Disconnect harness connector (3). Remove bolt (4) and disconnect wire (5).

11 S05250101

Vehicle Systems

Loosen bolts (10) and remove tube (11).

Disassembly and Assembly

Hydraulic Pump Disassemble Hydraulic Pump Start By : a. Remove hydraulic pump.

S0525009

Remove nuts and washers (12)and hydraulis motor and pump assembly. For the reassembly purpose, the torque is 25 ~ 30 N•m (19 ~ 22 lb•ft).

1 3 EHCD050C

NOTE : Identify and mark all sections of the hydraulic pump for purposes of reassembly.

Remove four bolts (1) and washers (2) to remove pump cover (3).

S0525010

To remove hydraulic pump from hydraulic pump motor, remove two bolts (13) and washers, gasket. For the assembly purpose, the torque of bolts (13) is 50 N•m (37 lb•ft). Replace with a new gasket if needed.

Install hydraulic pump motor and hydraulic pump in the reverse order of removal.

EHCD051C

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

7 6

EHCD052C

Vehicle Systems

Remove seal (5), back up-ring (6) and bushes (7) from the pump gears. Disassembly and Assembly

Assemble Hydraulic Pump

8 13

EHCD053C

Remove two gears (8) from the pump body. Separate the pump sections.

EHCD055C

NOTE : When installing seal (13), make sure the lip of the seal is positioned toward the inside of the pump housing.

Install seal (13) in the pump body.

EHCD054C

Remove O-ring (9), seal (10), back up-ring (11) and bush (12) from the pump body. Replace seals, back up-ring, O-ring with new ones if needed.

10 EHCD054C

Install bush (12), back-up ring (11), seal (10) and O-ring (9) in the pump body.

EHCD055C

Remove seal (13) from the flange (14).

Vehicle Systems

Disassembly and Assembly

2 8

1 3 EHCD053C

EHCD050C

Install two gears (8) in the pump body.

Install the bolts (1), washers (2) and pump cover (3) onto the pump body. Tighten the bolts for cover (3) to a torque of 39 to 40 N•m (28 to 30 lb•ft).

End By :

a. Install the hydraulic pump.

7 6

EHCD052C

Install back-up ring (6) and seal (5) in the bushes (7).

Install bushes (7) in the pump body.

EHCD051C

Install seal (4) on the pump body.

Vehicle Systems

Disassembly and Assembly

Standard Lift Cylinder 3

Disassemble Standard Lift Cylinder Start By : a. Remove standard lift cylinders. EHCD101P

Remove rod (3) from the cylinder body.

EHCD099P

Put standard lift cylinder (1) in position as shown. EHCD102P

Remove ring (4) from the cylinder rod.

EHCD100P

Remove rod-cover assembly (2) with wrench.

6 EHCD103P

Vehicle Systems

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

Disassembly and Assembly

Assemble Standard Lift Cylinder

7 8

12 9 10 EHCD104P

Remove O-ring seal (7) and backup ring (8) from the rod cover.

11 EHCD105P

Install two slyd rings (12), backup ring (11) Upacking (10) and wiper seal (9) on the inside of the rod cover.

8 EHCD105P

Remove wiper seal (9), U-packing (10), backup ring (11) and two slyd rings (12) from the rod cover. EHCD104P

Install backup ring (8) and O-ring seal (7) onto the rod cover.

6 EHCD103P

Vehicle Systems

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

Disassembly and Assembly

3 2

EHCD101P

EHCD100P

Install rod (3) with a ring into the cylinder body.

Remove rod-cover assembly (2) with wrench.

3 2

EHCD100P EHCD101P

Install rod cover assembly (2) on the cylinder and tighten using wrench.

Remove rod (3) from the cylinder body.

End By : a. Install standard lift cylinder.

Secondary Lift Cylinder Disassemble Secondary Lift Cylinder Start By : a. Remove secondary lift cylinders.

EHCD102P

Remove ring (4) from the cylinder rod.

EHCD099P

Put secondary lift cylinder (1) in position as shown.

Vehicle Systems

Disassembly and Assembly

Assemble Secondary Lift Cylinder 12 9

5 10

6 EHCD103P

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

EHCD105P

Install two slyd rings (12), backup ring (11) Upacking (10) and wiper seal (9) on the inside of the rod cover.

7 8 7 8

EHCD104P

Remove O-ring seal (7) and backup ring (8) from the rod cover.

EHCD104P

Install backup ring (8) and O-ring seal (7) onto the rod cover.

9 10

EHCD105P

Remove wiper seal (9), U-packing (10), backup ring (11) and two slyd rings (12) from the rod cover.

6 EHCD103P

Vehicle Systems

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

Disassembly and Assembly

Primary Lift Cylinder 3

Disassemble Primary Lift Cylinder Start By : a. Remove primary lift cylinder.

EHCD101P

Install rod (3) with a ring into the cylinder body.

2 EHCD108P

Remove head assembly (1).

Remove rod (2) from the cylinder body.

EHCD100P

Install rod cover assembly (2) on the cylinder and tighten using wrench.

End By : a. Install secondary lift cylinder.

EHCD109P

Remove ring (3) from the cylinder rod.

EHCD110P

Vehicle Systems

Remove O-ring seal (4) and backup ring (5) from the head assembly. Disassembly and Assembly

Assemble Primary Lift Cylinder

6 7

EHCD111P

Remove wiper seal (6), backup ring (7), Upacking (8) and two slyd rings (9) from the head assembly.

9 EHCD111P

Install backup ring (7) and U-packing (8) in the head assembly.

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

Install two slyd rings (9) in the head assembly.

EHCD110P

NOTE : Install the back-up ring with the curved side contacting the O-ring seal. 4.

Install the backup ring (5) and O-ring seal (4) on the head assembly.

EHCD109P

5. Vehicle Systems

Install ring (3) on the cylinder rod. Disassembly and Assembly

Tilt Cylinders

Remove & Install Tilt Cylinder NOTE : The procedure for removing and installing the tilt cylinders is the same for both cylinders.

WARNING EHCD108P

Install cylinder rod (2) in the cylinder body.

Install head assembly (1) on the cylinder body. Tighten the head assembly.

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

End By : a. Install primary lift cylinder.

1 P0004850

Remove the floormat (1).

Remove floor plate.

P0004851

Vehicle Systems

Disconnect harness connector (2) from accelerator and remove the bolt (3) and accel mtg plate (4) with accelerator.

Disassembly and Assembly

Disassemble & Assemble Tilt Cylinder Start By :

6 7

a. Remove tilt cylinder.

5 INCD020P

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

2 EHCD113P

Use wrench to remove rod cover (1) from the cylinder body.

Disconnect hoses (5) and (6). Remove bolt (7) and pin assembly (8). NOTICE Use extra care not to damage the highly finished surface of the cylinder rod and the bore of the cylinder body during disassembly and assembly of the tilt cylinder.

NOTE : Plug and cap all openings to avoid contamination and debris from entering the system after removing any hoses or lines.

12 2.

Remove rod assembly (2) from the cylinder body.

9 INCD021P

Remove bolt (9) and pin assembly (10).

Remove tilt cylinder (11).

Install the tilt cylinder in the reverse order of removal.

Adjust tilt cylinders as follows: a. Loosen bolt (12). b. Slide spacer down so rod can be turned into or out of pivot eye to obtain the correct length. c. Tighten bolt (12) and nut to a torque of 95 ± 15 N•m (70 ± 10 lb•ft). d. With mast at tilt back position, install shims (13) as required to permit no gap between pivot eye and spacer. Shim so mast does not twist at full tilt back.

Vehicle Systems

EHCD114P

Remove nut (3) from the cylinder rod.

Remove piston and seal assembly (4) from the cylinder rod.

Remove rod cover assembly (5).

Disassembly and Assembly

14 12

EHCD115P

EHCD118P

Remove spacer with a O-ring seal and shims from the cylinder rod (2) if they are installed.

10. Remove wiper seal (12) and U-packing (14) from the rod cover.

Loosen the nut and bolt (6) on the rod eye. Remove cylinder rod.

15 8

EHCD119P

11. Remove the DU-bush (15) from the rod cover. If the DU-bush has a large amount of wear, Replace the DU-bush.

EHCD116P

Remove slipper seal (7) and O-ring seal (8) from the piston (9).

NOTE : Use the following steps to assemble the tilt cylinder.

NOTICE Check the condition of all seals. If any parts are worn or damaged use new parts for replacement.

14 12

11 EHCD118P

12. Install wiper seal (12) in the rod cover. Position the lip of the seal toward the outside of the rod cover as shown.

EHCD117P

13. Install U-packing (14) in the rod cover. 9.

Remove O-ring seal (10) and backup ring (11) from the rod cover.

Vehicle Systems

Disassembly and Assembly

EHCD117P

EHCD115P

14. Install O-ring seal (10) and backup ring (11) on the rod cover.

16. Position the cylinder rod eye in a vise as shown. 17. Install cylinder rod (2) and shims. Tighten the nut and bolt (6) on the rod eye to a torque of 95 ± 15 N•m (70 ± 10 lb•ft). 18. Install the spacer with O-ring seal onto the cylinder rod if needed.

7 8

1 5

EHCD116P

15. Install slipper seal (7) and O-ring seal (8) on the piston (9). EHCD114P

19. Install rod cover assembly (5) on the cylinder rod. 20. Install piston assembly (4) onto the cylinder rod. The torque for the nut (3) is 260 ± 25 N•m (190 ± 20 lb•ft).

Vehicle Systems

Disassembly and Assembly

Steering Wheel Remove And Install Steering Wheel

2 EHCD113P

21. Install the rod assembly (2) in the cylinder body. 22. Use wrench to tighten rod cover (1). The torque for rod cover (1) is 270 ± 35 N•m (200 ± 25 lb•ft). End By : a. Install tilt cylinder.

Remove cap (1) from the steering wheel.

Remove nut (3) and cup (2) from the steering wheel.

Use a suitable puller to remove the steering wheel.

NOTE : The following steps are for installation of the steering wheel. 4.

Put the steering wheel in position on the shaft. Install cup (2) and nut (3). Tighten the nut to a torque 81 ± 6 N•m (60 ± 41 lb•ft).

Install cap (1) on the steering wheel.

NOTE : When assembling steering gear (pump), tighten steering gear (pump) mounting four bolt to a torque of 15 N•m (11 lb•ft).

Vehicle Systems

Disassembly and Assembly

Disassemble & Assemble Steering Unit (Pump)

8 7

Start By:

6 4

a. Remove steering unit (pump).

IACD048C

IACD046C

Remove the components from housing (3) as follows: a. Remove plate (6) from housing (3) and cap (4). b. Remove shaft (7) from gerotor (9). c. Remove gerotor (9) from housing (3). d. Separate cap (4) from housing (3). e. Remove O-rings seal (8) from housing (3). f. Remove O-ring seal (10) from housing (3).

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

3 2 14 13

IBCD168C

IBCD046C

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

Remove seven bolts (5) from gerotor housing (3) and cap (4).

2 3.

Separate housing (3) and cap (4) from pump body (2).

16 IBCD169C

Vehicle Systems

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

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

Disassembly and Assembly

18 33 32 31

IBCD170C

28 IBCD171C

11. Remove plug (27) and ring (28).

17 21

16 12. Remove plug (31), spring (32) and spool (33) from pump body.

23 IACD052C

22 35

Remove the components from sleeve (16) as follows: a. Remove pin (18) from spool (17) and sleeve (16). b. Remove spool (17) from sleeve (16). c. Remove two bearing races (19), (20) and bearing (21) from spool (17). d. Remove six springs (23) and ring (22) from spool (17).

IBCD172C

13. Remove check valve (35) from pump body. NOTE : The following steps are for assembling the steering unit (pump).

26 25 24 35

IACD053C

IBCD172C

14. Install check valve (35) into body.

Remove O-ring seal (24) and king-ring (25) from body.

10. Check the condition of lip seal (26) and dust seal ring. Replace seals with new if worn or damaged.

Vehicle Systems

Disassembly and Assembly

NOTICE For purposes of installation, note that springs (23) are installed in two stacks of three. Make sure the curves of the two stacks are in contact and positioned in the center of spool (17). The notched side of springs (23) must be positioned toward sleeve (16).

33 32 31

18. Install springs (23) into spool (17).

28 IBCD171C

19. Install spool (17) into sleeve (16).

15. Install sleeve (34), spool (33), spring (32) and plug (31) into pump body.

16. Install plug (27) with ring (28) into pump body.

25 24

IBCD170C

20. Install pin (18), ring (22), two bearing races (19), (20) and bearing (21) in their original positions on spool (17).

IACD053C

17. Install lip seal (26) and dust seal ring. Install O-ring seal (24) with king-ring (25) into pump body.

2 15

17 21

16 IBCD169C

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

23 IACD052C

Vehicle Systems

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

Disassembly and Assembly

NOTICE Gerotor (9) must be aligned with shaft (7) and pin (18) as shown in the illustration.

14 13

26. Install gerotor (9). Make sure gerotor (9) is properly aligned with pin (18) and shaft (7) as shown in the illustration. 27. Install O-ring seal (8) and housing (3).

IBCD168C

28. Install O-ring seal (10) and cap (4). 23. Install check valve ball (14) and screw (13). Tighten the screw (13).

EHCD005B EHCD004B

NOTICE To assure proper operation of the pump, make sure bolts (5) are clean and dry before installing. Tighten bolts (5) in the sequence shown in the illustration.

8 7 6 4 3

IACD048C

24. Install plate (6) onto pump body (2).

NOTICE Make sure the notch of shaft (7) properly seats on pin (18) when installed into body (2) and spool (14).

25. Install shaft (7) into body (2) and spool (17).

Vehicle Systems

Disassembly and Assembly

Priority Valve

3 2

Remove & Install Priority Valve

Start By :

a. Remove floorplate.

IBCD046C

WARNING 29. Install bolts (5) into cap (4). Tighten bolts (5) as follows: a. Tighten bolts (5) in correct sequence to a first torque of 15.0 ± 0.6 N•m (132 ± 5 lb•in). b. Tighten bolts (5) in correct sequence to a second torque of 30.0 ± 0.6 N•m (264 ± 5 lb•in).

Hydraulic oil under pressure can remain in the hydraulic system after the pump motor have been stopped. Personal injury can result if the pressure is not released before any work is done to the hydraulic system. To prevent possible personal injury, turn the key switch off and move the control levers to make sure the hydraulic pressure is released before any fitting, plug, hose or component is loosened, tightened, removed or adjusted. Always move the lift truck to a clean and level location away from the travel of other machines.

End By: a. Install steering unit (pump).

Drain the hydraulic tank.

2 1

S0525203

S0525204

Vehicle Systems

Disassembly and Assembly

NOTE : For purposes of reassembly, put identification marks on all lines, tubes and hoses before any disconnections are made. 2.

Disconnect four hydraulic lines (1) from priority valve (2). Plug and cap all openings to prevent contamination and debris from entering the system.

Support valve (2). Remove the two bolts (3) and priority valve and mount rubbers, washers.

Install priority valve (2) in the reverse order of removal.

Fill the hydraulic tank with fluid to the correct level. Refer to the Operation and Maintenance Manual for further information.

Brake Master Cylinder Remove And Install Brake Master Cylinder

P0004850

End By : a. Install the floorplate.

Remove floormat and rear floor plate from the lift truck.

Drain the brake fluid from the brake reservoir.

2 1

P0004853

Vehicle Systems

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

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

Disassembly and Assembly

Control Panel Remove And Install Control Panel WARNING

5 P0004854

Battery voltage and high amperage are present. Injury to personnel is possible. The head capacitor (HEAD CAP) must be discharged before any contact with the control panel is made. Disconnect the battery and discharge HEAD CAP.

Remove two bolts (4) and master cylinder (5) from the lift truck.

Install the brake master cylinder in the reverse order of removal.

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

Bleed the brake system, and if necessary, adjust the pedal free level. See Brake System Air Removal And Pedal Adjustment in Testing And Adjusting.

1 2

EX000001

Remove bolt (1), washers and rear panel (2) from the counter weight.

3 4

EX000004

Vehicle Systems

Remove four screw (3) and cover (4).

Disassembly and Assembly

Steer Wheels Bearings Remove Steer Wheels & Bearings

NOTE : The procedure to remove the steer wheels is the same for the right and left steer wheel.

7 P0004855

Disconnect connectors (6) and remove bolts (5), logic box (7).

P0003019

Support the steer axle with a floor jack.

Remove wheel cap (1).

P0004856

Disconnect connectors and remove bolts (9), control panel (10).

Install the control panel in the reverse order of removal.

P0003020

Vehicle Systems

Bend the tab in locking washer (2) clear of the slot in nut (3).

Remove nut (3). Remove locking washer (2).

Disassembly and Assembly

P0003022

IDCD074P

Remove bearing cone (4) from steer wheel (5).

Remove steer wheel (5). Steer wheel (5) weighs 34 kg (75 lb).

Remove bearing cup (8) from the front of steer wheel (5).

NOTE : Check the condition of all seals, bearings and components. If any parts are worn or damaged use new parts for replacement. For purposes of assembly, lower the temperature of the bearing cups and before installing into steer wheel (5). Use tooling (B) to install bearing cups and seals.

5 6

10. Pack bearing cones (4) and (7) and lubricate the contact surfaces of the bearing cups with Multipurpose Grease.

7 11. Reverse the procedures and steps 4 through 9 to install the steer wheels and bearings. IDCD073P

Remove seal (6) from the back of steer wheel (5).

Remove bearing cone (7) and the bearing cup from the back of steer wheel (5).

12. Adjust the steer wheel bearings as follows : a. Tighten nut (3) to a torque of 70 N•m (52 lb•ft) while slowly rotating steer wheels (5). b. Loosen nut (3) completely. c. Tighten nut (3) again to a torque of 50 ± 5 N•m (37 ± 4 lb•ft). d. Bend a tab of locking washer (2) into a slot of nut (3). 13. Install wheel cap (1). 14. Remove floor jack and lower the lift truck.

Vehicle Systems

Disassembly and Assembly

Install Tie Rods

Tie Rods Remove Tie Rods

3 2

1 IMCD041P

P0003033

Remove the cotter pin (1), pins (2) and seals from the tie rod.

Remove tie rod (3).

Install the bearing in the tie rod.

P0003037

IMCD040P

Put seals (1) in position as shown. Install tie rod (2) with the others seals.

Install the pins and retaining rings that hold the tie rod in position.

Remove bearing (4) from the tie rod.

Vehicle Systems

Disassembly and Assembly

Steering Axle

Steering Cylinder

Remove & Install Steering Axle

Remove & Install Steering Cylinder Start By :

WARNING

a. Remove steer axle.

Be sure the pressure in the hydraulic system is released before any lines or hoses have been disconnected

b. Remove tie rods.

2 1

P0003042 P0003044

Put identification marks on steering lines (1). Disconnect steering lines (1) from the steering cylinder.

Put a floor jack in position under the steer axle. Remove bolts (2).

Remove four bolts (1). For installation purposes, the torque for bolts (1) is 100 ± 20 N•m (74 ± 14 lb•ft).

Remove steering cylinder (2).

NOTE : There are dowels in the cylinder mounting holes.

Lower steer axle with the floor jack to remove it from under the machine. The weight of the steer axle is about 150 kg (330 lb).

Install steering cylinder (2) in the reverse order of removal.

End By :

Install the steer axle in the reverse order of removal.

a. Install tie rods. NOTE : When installing bolts (2), torque to the bolts (2) to 270 ± 40 N•m(199 ± 29 lb•ft)

Vehicle Systems

b. Install steer axle.

Disassembly and Assembly

Disassemble & Assemble Steering Cylinder

8 7 IMCD048P

IMCD045P

Put location marks on end caps (1) as to their position on the steering cylinder tube (2).

Remove end caps (1) from the steering cylinder.

Remove rod assembly (3) from the tube.

Remove wiper seal (6), U-cup seal (7) and wear ring (8) from each end cap assembly.

Assemble the steering cylinder in the reverse order of disassembly.

IMCD046P

Remove seal (4) from the rod assembly (3).

IMCD047P

Remove O-ring (5) from each end cap assembly (1).

Vehicle Systems

Disassembly and Assembly

Steering Knuckles, Kingpins And Bearings Remove Steering Knuckles, Kingpins And Bearings

Start By : IMCD051P

a. Remove steer wheels and bearings.

b. Remove tie rods.

Push kingpin (4) and the bearing out of the steering axle with a brass drift and hammer.

1 P0003038 IMCD052P

Remove bolt and nut (1) that hold the kingpin in position.

Remove steering knuckle (5) from the steering axle. Remove the bearings (6) and seals (7).

2 3

P0003039

Remove cotter pin (2), nut (3) and washer.

Vehicle Systems

Disassembly and Assembly

Install Steering Knuckle, Kingpins And Bearings

IMCD050P

Tighten kingpin nut (1) to a torque of 21 N•m (15.5 lb•ft). While rotating knuckle in both directions to seat bearings. Then loosen kingpin nut completely. Retorque nut to 6 to 7 N•m (4.5 to 5.1 lb•ft).

Install cotter pin to lock nut at this torque.

IMCD053P

Install the seal and bearing in the steering knuckle. Install the seal with the sealing lip away from the bearing.

End By : NOTE : Prepack bearings with multipurpose EP NLGI NO.2 LITHIUM GREASE prior to assembly.

a. Install tie rods.

Put steering knuckle in position on the steering axle.

b. Install steer wheels and bearings.

Lubricate pins with EP NLGI NO.2 LITHIUM GREASE.

Vehicle Systems

Disassembly and Assembly

Drive Wheel

Drive Motor

Remove and Install Drive Wheel

Remove and Install Drive Motor a. Remove floor mat b. Remove floor plate. c. Remove master cylinder bracket assemblies.

1 3

2 2 INCD029P

Put a hydraulic jack in position under the frame.

Loosen nuts (1) that hold the drive wheel (2) in place.

S0525011

NOTE : Tighten the nuts (1) to a torque of 176 ± 19 N•m (130 ± 14 lb•ft) when installing. 3.

Lift the frame until the tire is clear of the ground. Remove nuts (1) and drive wheel (2).

Install is the reverse order of removal.

Disconnect connector (1) and wire (2) by removing bolt (3).

4 5

S0525018

Disconnect cables (4) and remove bolts (5).

NOTE : When Assembling, tighten the bolts (5) to a forque of 50 ~ 61 N•m (37 ± 45 lb•ft) with LOCTITE NO.242.

Vehicle Systems

Remove drive motor (6) with a hoist.

Install the drive motor in the reverse order of removal. a. Install master cylinder bracket. b. Install floor plate c. Install floor mat

Disassembly and Assembly

Trans-Axle Remove and Install TransAxle

Remove trans-axle (1).

Install is the reverse order of removal. a. Install all lines. b. Install drive wheel.

a. Remove mast

c. Install drive motor.

b. Remove drive motor

d. Install mast.

c. Remove drive wheel d. Remove all lines connected to trans-axle.

2 A303000

Hoist frame with a hoist.

Put a hydraulic jack under trans-axle (1).

Remove bolts (2) from the cap in both sides. When installing tighten the bolts to a torque of 150 ± 20 N•m (110 ± 15 lb•ft).

P0004877

Remove bolts(3) from the frame in both sides. When installing, tighten the bolts to a torque of 220 ± 20 N•m (160 ± 15 lb•ft) with applying LOCTITE NO. 262

Vehicle Systems

Disassembly and Assembly

Counterweight Remove and Install Counterweight

1 3

EX000003

WARNING Battery voltage and high amperage are present. Injury to personnel is possible. The head capacitor (HEAD CAP) must be discharged before any contact with the control panel is made. Disconnect the battery and discharge HEAD CAP.

Remove the protector cover from the counterweight. Disconnect the battery and discharge the the MicroCommand Control System module.

Disconnect all cable (1) from the control panel.

Hoist the counte weight (2) with a hoist. The approximate weight of the counterweight is as follows :

B15S-2 .............................................................. 475 kg B18S-2 .............................................................. 650 kg

Vehicle Systems

Disassembly and Assembly

SB2143E03 A p r. 2 0 0 4

Disassembly & Assembly Testing & Adjusting Lift Trucks Mast Systems G15S-2, G18S-2, G20SC-2 GC15S-2, GC18S-2, GC20SC-2 D15S-2, D18S-2, D20SC-2 B16X, B18X, B20X B13T-2, B15T-2, B18T-2 BC15T, BC18T, BC20T B15S, B18S BC15S, BC18S, BC20SC

WARNING

Index Disassembly & Assembly Forks ..........................................................................5 Backrest .....................................................................5 Carriage......................................................................6 Mast............................................................................9

Testing & Adjusting Carriage Adjustment.................................................22 Chain Adjustments ...................................................23 Chain Wear Test .......................................................23 Carriage and Mast Height Adjustment......................24 Forks Parallel Check ................................................24 Tilt Cylinder Alignment..............................................25 Drift Test ...................................................................25 Tilt Cylinder Adjustment............................................26 Lift & Tilt Mounting Group Adjustment ......................27 Mast mounting Group Adjustment ............................28

Lift Trucks Mast System

Index

Disassembly & Assembly

Backrest

Forks

Remove & Install Backrest

Remove & Install Forks 1

3 IBCD501P

IDCD001P

Fasten a hoist to the backrest. Remove bolts (2) that fasten the backrest to the carriage.

Remove backrest (1). Backrest weighs 32 kg (71 lb).

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

IDCD002P

Remove stopper bolt and washer (3).

Lift fork pin (1).

Use a suitable C-clamp, strap and hoist to support the fork as shown.

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

Remove the fork. The weight of the fork is 35 kg (77 lb).

Repeat steps 1 through 4 for the remaining fork.

Install the forks in the reverse order of removal.

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

Install stopper bolt and washer (3).

Lift Trucks Mast System

Disassembly & Assembly

Carriage Remove & Install Carriage Start By: a. Remove forks. b. Remove backrest. 6 IBCD504P

Remove two nuts (6). Remove carriage stop bolt (7).

1 3

IBCD502P

Remove two bolts (1) and hose guard (2) from the cross head (3).

Remove cross head (3) from the cylinder rod (4).

IBCD510P

5 IBCD503P

Remove hoses (5).

Raise the inner mast to pull out carriage as shown.

Remove carriage from bottom of inner mast (9). Carriage weighs 64kg (141 lb).

NOTE : Use the following steps to install the carriage. 7.

Lift Trucks Mast System

Raise the inner mast (9) to put in the carriage (8) onto the mast, and lower the inner mast to cover carriage bearing fully.

Disassembly & Assembly

End By: a. Install backrest. b. Install forks.

Disassemble Carriage Start By:

6 IBCD504P

a. Remove carriage.

Install stop bolt (7). Shim stop bolt as required to obtain a 4 to 6 mm (.157 to .242 in) lap with top carriage stop on the inner upright.

Put the chains in position over cross head. Install nuts(6) onto the chain anchors to a torque of 300 ± 30 N•m (220 ± 22 lb•ft).

2 IBCD571P

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

5 IBCD503P

10. Install hoses (5).

2 IBCD572P

Remove lower roller bearings (3) and the shims from the carriage.

1 3

IBCD502P

11. Install cross head (3) to cylinder rod (4). 12. Install hose guard (2) and bolts (1) to a torque of 8 ± 2 N•m (6 ± 1.5 lb•ft). Lift Trucks Mast System

Disassembly & Assembly

1. 7 8

Select bearings from the chart to obtain minimum clearance (C) between bearings and channel leg for full channel length. Use same bearing at all four locations.

CARRIAGE BEARING CHART

Part No.

Bearing Size

Bearing O.D.*

D580006

Undersize

98.5 mm (3.878 in)

D580007

Standard

99.0 mm (3.898 in)

D580008

Oversize

99.5 mm (3.917 in)

IBCD573P

* Permissible tolerance of ± 0.08 mm (.003in) 3.

Remove screw 5) and washer (4). Remove two top roller bearings (6) and the shims.

Remove bolt (7), washer, pin-adjust (8) and sideroller bearing (9) from the carriage.

Refer to carriage Adjustment in Testing & Adjusting.

Assemble Carriage NOTE : The standard, Full Free Lift and Full Free Triple Lift carriage load bearings are all adjusted the same way. The Full Free Triple Lift carriage is shown in the following illustrations. IBCD543P

To make the carriage clearance adjustments, carriage must be removed from the mast.

Use the procedure that follows to adjust carriage load bearings.

5 (STD) 3 A

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

1 C

C C B

5 (FF, FFT)

VIEW A - A

C C

8 IBCD574P

Install enough shims (1) that have been divided into two equal groups behind bearings (2). At installation, there is to be contact [zero clearance (A)] between the bearings and the narrowest point of inner mast.

Do step 2 through 3 for other sets of bearings.

VIEW C - C VIEW B - B IBCD581I

Carriage Adjustment (3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw. (7) Side-roller bearings. (8) Lower bearings. (9) Pin-adjust. (10) Bolt. (A) Zero clearance. (B) 4.0 to 6.0 mm. (.157 to .242 in) clearance. (C) Minimum clearance. (D) 4.5 ± 0.5 mm

Lift Trucks Mast System

Disassembly & Assembly

Mast Remove & Install Mast

Start By: a. Remove forks. Move the truck to the place where pit is set up. 3 IDCD016P

Tighten screw (3) that holds the top and middle bearings (4) to the carriage to a torque of 34 ± 7 N•m (25 ± 5 lb•ft).

IBCD511P

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

5 IBCD571P

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

End By: a. Install carriage, raise the inner mast and insert the carriage from the bottom of inner mast IBCD512P

NOTICE Place identification marks on all hydraulic connectors and hoses to assure proper installation. Plug and cap all hydraulic connectors and hoses to avoid debris and contamination from entering the system.

Disconnect hose(3).

NOTE : For BC15/18/20T and B13/15/18T-2, see article 6 prior to disconnecting hose (3).

Lift Trucks Mast System

Disassembly & Assembly

4 IBCD513P

6. Tilt cylinders (4) can drop when pin(6) is removed. To avoid component damage or personal injury, support tilt cylinder (4) while removing pin(6).

Remove bolt (5) from each side of mast assembly (2).

Remove pin (6) from the tilt cylinders on each side of the mast assembly.

IBCD502S

WARNING

BC15/18/20T, B13/15/18T-2 Raise the carriage and mast to open outer lower part. Remove bolt (9) from the front of mast each side. Remove bolt (8) from the pit each side. Disconnect hose (3) of article 2.

3 IBCD582I

B16/18/20X Tilt forward mast assembly with the hoist. Remove bolts (8) from each side.

IBCD514P

WARNING

D,G15/18/20S(C)-2, GC15/18/20S(C)-2, B15/18S Tilt forward mast assembly about 8° with the hoist. Remove four bolts (7) from pit each side of the base of mast assembly.

Loosen the tension of straps to be connected with hoist when mast assembly is tilted forward. If straps are too tight, mast assembly could slide off when bolts (7), (8), (10) are removed.

Use the hoist to remove mast assembly from the truck.

Install the mast in the reverse order of removal.

End By: a. Install forks. Lift Trucks Mast System

Disassembly & Assembly

Disassemble Mast Start By: a. Remove lift chain to be connected primary lift cylinder. b. Remove primary lift cylinder. 5

NOTE : The following disassembly and assembly procedure is for a full free triple lift mast. IBCD520P

Disconnect and remove chains (5) from the bottom of the mast.

6 IBCD518P

Remove hoses (1) along with the hose support clamps (2).

8 IBCD521P

Remove clamp (6) and bolt (7) from stationary mast and disconnect regulator (8) from secondary cylinder (For D,G15/18/20S(C)-2, GC15/18/20S(C)-2, B15/18S).

IBCD519P

Remove hose sheave (3).

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

9 10

IBCD504S

Lift Trucks Mast System

Remove tube ass’y (9) and bolt (10) from stationary mast and disconnect regulator (8) from secondary cylinder (For BC15/18/20T, B13/15/18T-2, B16/18/20X). Disassembly & Assembly

15 11

16 17

IBCD523P

D,G15/18/20S(C)-2, GC15/18/20S(C)-2, B15/18S 7.

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

IBCD524P

BC15/18/20T, B13/15/18T-2

Remove cylinder retainer brackets(12) from each cylinder.

13 IBCD527P

B16/18/20X

Remove secondary cylinders(13). Each cylinder weighs 38 kg (84 lb).

IBCD584I

11. Remove bearing mounting pins(15) and screw (16) from the mast lower hinge mounting part. 12. Check the condition of the bearings(17) located in each of the mast mounting bracket. Replace the bearings (17) with new if worn or damaged.

IBCD526P

10. Check the condition of bearings(14) located in each of the tilt cylinder pin bores. Replace bearings(14) with new if worn or damaged. Lift Trucks Mast System

Disassembly & Assembly

24 24

23 19

IBCD528P

IBCD534P

13. Move inner mast channel (21) downward.

18. Move intermediate mast channel (24) downward.

14. Remove bearings (18) and shims from the intermediate mast channel (24).

19. Remove bearings (22) and the shims from the stationary mast channel.

15. Remove nylon pads (19) and shims.

20. Remove nylon pads (23) and the shims.

24 25

IBCD529P

IBCD533P

16. Remove bearings (20) and shims from the inner mast channel (21).

21. Remove bearings (25) and the shims from the intermediate mast channel (24).

IBCD530P

IBCD535P

17. Fasten nylon straps and hoist to inner channel (21). Remove inner channel. The weight of the inner channel is 110 kg (243 lb).

22. Fasten nylon straps and a hoist to the intermediate mast channel (24). Remove intermediate mast channel. The intermediate mast channel weighs 112kg (247 lb).

Lift Trucks Mast System

Disassembly & Assembly

Assemble Mast NOTE : The standard, Full Free Lift and Full Free Triple Lift mast load bearings are all adjusted the same way. The mast shown in the following illustrations is the Full Free Triple Lift mast. 1.

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

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

IBCD541P

A. Lower Bearing Adjustment of Intermediate Mast

Find narrowest point by ruler on the stationary mast in the area where the bearings make contact at 420 mm (16.5 in) channel lap.

NOTICE When the correct amount of shim has been installed behind bearings (1) there will be contact (zero clearance) between the bearings and the inner mast at most narrow point of mast.

IBCD505S Mast Adjustment Lower Bearings (A) Zero clearance. (B) Minimum clearance. (C) Zero clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims.

Select lower bearings (3) and (4) from the chart to obtain minimum clearance (B) between bearing and channel leg for full channel length. Use same bearing on left and right side.

IBCD535P

Lifting by crane, insert intermediate mast into stationary mast from the upper side.

Mast And Carriage Bearings Part No.

Bearing Size

Bearing O.D.*

D580006

Undersize

98.5 mm (3.878 in)

D580007

Standard

99.0 mm (3.898 in)

D580008

Oversize

99.5 mm (3.917 in)

*Permissible tolerance ±0.08 mm (.003 in)

Lift Trucks Mast System

Disassembly & Assembly

3 4

IBCD534P

IBCD533P

Install 1mm shim and bearing (1) of stationary upper basically.

Install 1mm shim and bearing (4) of intermediate lower basically.

IBCD538P

NOTE : When installing shims (2) behind bearings (1), make sure the amount of shim is divided equally when positioned behind each bearing.

IBCD505S

Install the correct amount of shim (2) behind rollers until contact (zero clearance) is made between the bearings.

Mast Adjustment Lower Bearings (A) Zero clearance. (B) Minimum clearance. (C) Zero clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims.

Install pads (3) to each side. Refer to “Upper Pad Adjustment” of Disassebly & Assembly.

Lift Trucks Mast System

NOTE : When installing shims (5) behind bearings (4), make sure the amount of shim is divided equally when positioned behind each bearing (4).

Disassembly & Assembly

IBCD531P

IBCD534P

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

13. Install 1 mm shim to each bearing of stationary mast upper basically. Bearing should be selected D580006 undersize bearing.

11. In case of standard and full free mast, inner lower bearings can be easily extruded by pulling down the inner mast from the bottom of stationary mast. If intermediate mast is stuck and cannot move by rolling up and down, there might be excessive shim. Pull out the intermediate mast from the stationary mast and remove shim 0.5 mm to both intermediate lower bearings. Repeat same procedure of above until properly shimmed. There is to be contact zero clearance (C) between intermediate lower bearings and stationary channel at approximately 420 mm (16.5 in) channel lap.

IBCD533P

14. Install 1mm shim and bearing (4) of intermediate lower basically.

B. Upper Bearing Adjustment of Stationary Mast

IBCD535P

12. Lift by crane, insert intermediate mast into stationary mast from the upper side.

Lift Trucks Mast System

Disassembly & Assembly

C. Upper Pad Adjustment

7 8

7 F

9 E

10 IBCD506S

Mast Adjustment Upper Bearings

(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.

IBCD506S

(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims. Mast Adjustment Upper Bearings (D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum. (F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.

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

IBCD532P

15. Make sure stationary mast upper bearings are properly shimmed by rolling up and down and moving intermediate mast to right and left. If clearance between both masts can be detected, pull out the intermediate mast from the stationary mast with crane and add shim 0.5 mm or 1 mm to both stationary upper bearings. 16. In case of standard and full free mast, stationary upper bearings can be easily extruded by pulling down the inner mast from the bottom of stationary mast. If intermediate mast is stuck and cannot move by rolling up and down, there might be excessive shim. Pull out the intermediate mast from the stationary mast and remove shim 0.5 mm to both stationary upper bearings. Repeat same procedure of above until properly shimmed. There is to be contact zero clearance (F) between stationary upper bearings and the widest point of intermediate mast to be checked before.

Lift Trucks Mast System

Disassembly & Assembly

D. Lower Bearing Adjustment of Inner Mast

A IBCD542P

19. Find narrowest point by ruler on the intermediate mast in the area where the inner lower bearings make contact full length of intermediate mast excluding minimum channel lap 420 mm (16.5 in).

IBCD505S Mast Adjustment Lower Bearings (A) Zero clearance. (B)Minimum clearance. (C)Zero clearance. (3)Bearing. (4)Bearing. (5)Shims. (6)Shims.

18. Select lower bearings (3) and (4) from the chart to obtain minimum clearance (B) between bearing and channel leg for full channel length. Use same bearing on left and right side.

Mast And Carriage Bearings Part No.

Bearing Size

Bearing O.D.*

D580006

Undersize

98.5 mm (3.878 in)

D580007

Standard

99.0 mm (3.898 in)

D580008

Oversize

99.5 mm (3.917 in)

IBCD530P

20. Lifting by crane, insert inner mast (11) into intermediate mast (12) from the upper side.

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

IBCD528P

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

Lift Trucks Mast System

Disassembly & Assembly

E. Upper Bearing Adjustment of intermediate Mast Follow same procedure with above B.

F. Upper Pad Adjustment of Intermediate Mast Follow same procedure with above C. 24. If the bearings were removed from the mast mounting brackets, install new ones. IBCD529P

25. Put a small amount of clean grease on mounting bearing. Install mounting pins and screw into mast mounting brackets. Refer to Mast Mounting Group Adjustment of Testing & Adjusting.

22. Install 1mm shim and bearing (14) of inner lower basically.

A 15

IBCD526P

26. If the bearings were removed from the tilt cylinder pin bores (15), install new ones.

IBCD505S Mast Adjustment Lower Bearings (A) Zero clearance. (B) Minimum clearance. (C) Zero clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims.

23. Make sure inner mast lower bearings are properly shimmed in the intermediate mast by rolling up and down and moving inner mast to right and left. If clearance between both masts can be detected, pull down the inner mast from the bottom of intermediate mast. Inner lower bearings can be easily extruded. Add shim 0.5 mm or 1 mm to both inner lower bearings. If inner mast is stuck and cannot move by rolling up and down, there might be excessive shim. Pull out the inner mast from the intermediate mast and remove shim 0.5 mm to both inner lower bearings. Repeat same procedure of above until properly shimmed. There is to be contact zero clearance (C) between inner lower bearings and intermediate channel at narrowest point.

Lift Trucks Mast System

16 IBCD527P

27. Install secondary cylinders (16) into the stationary mast.

Disassembly & Assembly

9 23

IBCD524P

28. Install secondary cylinder mounting brackets (17) over the secondary cylinders.

22 10

IBCD504S

31. Install regulator (22) to secondary cylinder and tube ass’y (23) and bolts (24) to stationary mast. (For BC15/18/20T, B13/15/18T-2, B16/18/20X)

18 IBCD523P

29. Install top cylinder retainer bolts (18) for the secondary cylinders.

25 IBCD520P

32. Connect chains (25) at the bottom of the mast. 20

IBCD521P

30. Install regulator (21) to secondary cylinder and clamp (19) and bolt (20) to stationary mast. (For D,G15/18/20S(C)-2, GC15/18/20S(C)-2, B15/18S)

IBCD519P

33. Connect chains (26) at the chain bracket of stationary mast upper. 34. Install sheave (27) of lift hose. Lift Trucks Mast System

Disassembly & Assembly

28 IBCD518P

35. Install hoses (28) along with the hose support clamps. End by : a. Install primary lift cylinder. b. Install lift chain to be connected primary lift cylinder.

Lift Trucks Mast System

Disassembly & Assembly

Testing & Adjusting

Mast And Carriage Bearings

Carriage Adjustment

Part No.

Bearing Size

Bearing O.D.*

D580006

Undersize

98.5 mm (3.878 in)

D580007

Standard

99.0 mm (3.898 in)

D580008

Oversize

99.5 mm (3.917 in)

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

* Permissible tolerance of ±0.08mm (.003in)

To make the carriage clearance adjustments, carriage must be removed from the mast.

Equally shim both sides until contact (A) is made (zero clearance) between bearings and inner mast at narrowest point.

Shim bolt as needed to obtain a 4.0 to 6.0 mm (.157 to .242 in) overlap (B) between bolt (3) and the carriage stop on the inner upright. (See Carriage Adjustment in Testing & Adjusting).

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

Refer to “Carriage Assembly” of Disassembly & Assembly.

Use the procedure that follows to adjust carriage load bearings.

5 (STD) 3 A

C C B

5 (FF, FFT)

VIEW A - A C

A VIEW C - C VIEW B - B IBCD581I Carriage Adjustment (3) Upper Bearings. (4) Shims. (5) Bolt. (6) Screw. (7) Side-roller Bearings. (8) Lower Bearings. (9) Pin-adjust. (10) Bolt. (A) Zero Clearance. (B) 4.0 to 6.0 mm. (.157 to .242 in) Clearance. (C) Minimum Clearance. (D) 4.5 ± 0.5 mm

Select lower bearings from the chart to obtain minimum clearance (C) between bearings and channel leg for full channel length. Use same bearing in all two locations.

Select upper bearing from the chart to obtain minimum clearance (C) between bearings and channel leg for full channel length. Use same bearing at all two locations. (For G20SC-2, GC20SC-2, BC20T, D20SC-2, and B20X, bearings are same with upper, middle 4 locations.)

Lift Trucks Mast System

Testing & Adjusting

Chain Adjustments

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

Put LOCTITE NO.242 Thread Lock on the threads of the locknuts after the adjustment is completed.

Chain Adjustment Check

IBCD505P

Lift the carriage and mast high enough to put their full weight on the carriage and mast chains. Check the chains, and make sure the tension is the same.

IBCD508P Outer Lift Chains (2) Chain Anchor Bolts.

Chain Adjustment

Chain Wear Test

If the tension is not the same on both chains, do the procedure that follows:

Chain wear test is a measurement of wear of the chain links and pins. Do the steps that follow to check chain wear.

WARNING Personal injury can be caused by sudden movement of the mast and carriage. Blocks must be used to prevent the mast and carriage from any movement while the adjustments are made. Keep hands and feet clear of any parts that can move.

Lift the mast and carriage enough to put tension on the lift chains.

Measure precisely ten links of chain distance at the center of pins in millimeter. A chain wear gauge can also be used.

Calculate chain wear rate. New one pitch = 15.88 mm Chain wear rate (%) =

Actual measurement - 158.8

x 100

158.8

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

1 IBCD506P Inner Lift Chains (1) Chain Anchor Nuts.

Lift the mast and carriage and put blocks under the mast and carriage to release the tension from the lift chains.

Lift Trucks Mast System

If the chain wear indication is 2% or more, replace the lift chain.

Testing & Adjusting

Carriage and Mast Height Adjustment

Forks Parallel Check

Move the mast either forward or backward so it is in the vertical position

Lower the carriage completely.

Lift the mast and operate the tilt control lever, until the top surface of the forks is parallel with the floor. Place two straight bars, that are the same width as the carriage, across the forks as shown. Measure the distance from the bottom of each end of the two bars to the floor. The forks must be parallel within 3 mm (.12 in) for Full Tapered and Polished (FTP) forks, all other forks 6.4 mm (.25 in), for their complete length.

If not parallel, determine which one is defective and replace it.

IBCD585I

IDCS130S

On Full Free Lift and Full Free Triple Lift models, the bottom of the inner mast must be even with the bottom of the stationary mast.

Measure the distance from the bottom of the inner upright to the bottom of carriage bearing end.

The measurement (A) must be as follows:

Forks Parallel Check (Typical Example)

<STD> D,G15/18/20S(C)-2.....................22 mm(0.866 in) B15/18S.......................................7 mm (0.276 in) B16/18/20X, GC15/18/20S(C)-2, B13/15/18T-2, BC15/18/20T..... -6 mm (-0.236 in) <FFL & FFTL> D, G15/18/20S(C)-2....................36 mm (1.417in) B15/18S.....................................21 mm (0.827 in) GC15/18/20S(C)-2..................... 11 mm (0.433 in) B16/18/20X, B13/15/18T-2, BC15/18/20T ...............................8 mm (0.315 in) NOTE : If the above measurements are not correct, make adjustments to the chains to get the correct measurement. See Chain Adjustments in TESTING AND ADJUSTING.

Lift Trucks Mast System

Testing & Adjusting

Tilt Cylinder Alignment

Tilt Cylinder Length Check

If the tilt cylinders are out of alignment, extra stresses in the mast assembly and the mast hinge area will result. To prevent damage, the tilt cylinders must stop evenly at the end of the tilt back and tilt forward strokes.

Tilt Angle Check

IDCD009P

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

IDCD008P

Drift Test

Tilt Angle Check (Typical Example)

Drift is movement of the mast or carriage that is the result of hydraulic leakage in the cylinders or control valve. Before testing the drift:

The tilt angle of the mast must be checked in the full tilt back and full tilt forward positions. A tilt indicator or a protractor can be used to measure the angle. Both sides of the mast must be checked to make sure that the mast is not twisted.

WARNING

The tilt angle is determined by the tilt cylinders used. See tilt cylinders in specifications to determine the tilt angle from the cylinder being used.

Lift Trucks Mast System

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.

Check the chain adjustment and tilt cylinder alignment and make necessary adjustments.

Lift the mast approximately 762 mm (30 in). Use wood blocks and clamps to hold the mast in this position.

Check the mast hinge bolts to make sure they are tight.

Remove the blocks and clamps and lower the mast.

Testing & Adjusting

Drift Test For Lift System 1.

Secure a rated capacity load on the forks of the lift truck. Operate the lift truck through a complete lift and tilt cycle until the oil is at normal temperature of operation, 45 to 55 °C (113 to 131 °F).

Put the mast in a vertical position. Raise a rated capacity load to a sufficient height to test the lift cylinders. IDCD008P

Measure any drift of the carriage for a ten minute period. Drift for all models shall not exceed 100.0 mm (4.00 in).

Tilt Cylinder Adjustment (1) Pivot eye. (2) Bolt. (3) Rod.

Tilt Cylinder Adjustment

Loosen bolt (2) at pivot eye (1).

Turn rod (3) into or out of pivot eye (1) to obtain the correct length. The minimum length from the end of rod to the rear face of eye is 16 mm.

WARNING Tilt cylinder pivot eyes can loosen if the torque on the pivot eye clamping bolt is not tight enough. This will let the tilt cylinder rod turn in the tilt cylinder eye. The cylinder rod may twist out of the pivot eye and the tilt cylinder will be out of alignment or may let the mast fall and cause personal injury or damage. When the rod lengths are made even, the tilt angle differences or the mast alignment will no longer be a problem.

16mm

To correct the tilt angle or tilt cylinder length, an adjustment must be made to the tilt cylinder as follows :

EHCS046S

Lift Trucks Mast System

Tighten bolt (2) and the nut to a torque of 95 ± 15 N•m (70 ± 10 lb•ft).

Testing & Adjusting

Lift & Tilt Mounting Group Adjustment

(1) With chains adjusted for equal tension, run mast to full lift. If mast does not kick (move) to one side, no shims are needed. If mast does kick (move) to one side, disconnect cylinder from the bar on that side. Add shim, connect cylinder, adjust chains and run mast to full lift to check for kick. Repeat process if necessary. The total shim pack must not be more than three shims maximum. (2) Install bearing outer race to a depth of (F) ....................... 4.5 ± 0.8 mm (.177 ± .031 in).

(3) Tilt cylinder installation shown.

(4) (Full Free Lift Mast Only): Tighten nuts until U-bolt is firm against cylinder, do not apply standard torque.

VIEW A-A

B 2

VIEW B-B

IBCD508S

Lift Trucks Mast System

Testing & Adjusting

Mast mounting Group Adjustment

3 1

IBCD502S

For B13/15/18T-2, BC15/18/20T

3 1 IBCD509S

For D,G15/18/20S(C)-2, GC15/18/20S(C)-2

2 IBCD582I

For B16/18/20X

1 3

Tighten screw (1) that holds bearing (3) to hinge bracket of stationary mast to a torque of 34 ± 7 N•m (25 ± 5 lb•ft).

Install roll pin (2) to a depth 2 ~ 3 mm (0.079 ~ 0.118 in) from surface of bearing.

Apply the crean grease to a surface of bearing.

Apply Loctite No242 to bolts and tighten with a torque 180 ± 20 N•m (130 ± 15 lb•ft).

IBCD510S

For B15/18S

Lift Trucks Mast System

Testing & Adjusting

SB4168E00 A p r. 2 0 0 4

Schematic Lift Trucks Hydraulic System BC15S, BC18S, BC20SC

MODEL : B15S-2, B18S-2 15

16 5

9 8 10

7 em 1 2 3 4 5 6 7

9 10 11 12 13 14 15 16

Components Hydraulic Tank Suction Strainer Hydraulic Pump Priority Valve Hydraulic Control Valve Flow Regulator Flow Protector-Secondary Lift Cylinder-STD (Secondary-FFL and FFTL) Lift Cylinder-Primary(FFL and FFTL) Flow Protector-Primary Steering Unit Steering Cylinder Pressure Switch Hydraulic Oil Filter Tilt Cylinder-LH Tilt Cylinder-RH

SB4169E00 A p r. 2 0 0 4

Schematic Lift Trucks Electric System BC15S, BC18S, BC20SC

WIRING SCHEMATIC - ELECTRIC MODEL : BC15S, BC18S, BC20SC HEAD LAMP-R

LIGHT SW 3

MC-1 TAIL

GND

T/S

86 81

KEY S/W

5 81

6 REAR LAMP

FRONT COMB LAMP-R (OPTION)

P1-3

BOARD AS-DRIVE

P1-1

P1-2

P1-10

P1-4

P1-5 P8-1

101

+5V

P1-6

P8-2

DATA

P8-3

DATA

36 BYPASS

P1-7

P8-4

CLK

85 86 87 30

MC-2

LINE R4

R1 D1

ZD2 D2 77

FLASHER UNIT (OPTION)

10A

E L

67 15 TR1

R5 78 4 10A

10A

REV. PR1

FWD.

P12-10

D4 R8

PR2

4 2

ZD1

P12-4

TR3

P12-1

TR5

P6-6

CLK

P8-6

LOAD

P8-7

P6-3

P6-2

P6-1

P8-8

P12-6

10A SHUNT FUSE

P12-2

P12-3

P12-9

P2-18

P2-5

MC-10 MC-11

1 2

60 HORN SW

TURN SIGNAL SW

BYPASS CTR.

1 1

P2-11

BACK UP

R F R

F/R S/W

8 18

MC-8

OUT

+12V

GND

ACCELERATOR

99 84

MC-9

P2-3

MC-13

P2-4

MC-14

P2-2

MC-12

P2-16

MC-15

P2-8

PARKING S/W

P6-4 P6-5

90 HORN SHUNT RESISTOR

STROBE

STOP

(OPTION)

7 3

P1-17

LOGIC

DTR1

LINE CTR

TAIL

THERMAL S/W

63 HTR1

P6-6

P1-15

LINE FUSE

TURN SIGNAL

4 88

GND

MC-3

94 82

REAR COMB LAMP-R

P12-8

P2-6

MONOPED(OPTION)

INSTRUMENT

84 1

1 P6-1

F R

GND

SERVICE BRAKE SW

P12-7

60 P6-3

TR2 R3

P6-2

P12-12

TR4

FUSE BOX AS CONTROL 10A FUSE

MONOPED

LOAD

108

27 HOUR METER

P8-5

P12-11

P12-5

P6-4

RELAY-BACK UP ALARM

MC-24

2 1

P2-15

BWI

LIFT SENSOR

3 4 5

1 2

TILT

VALVE B/D

FAN-D/MOTOR

6 8

AUX1

AUX2

BACK UP

STOP

TAIL

GND

TURN SIGNAL

+ 12V

- 12V

ENABLE

BATT -

FAN

FILED DRIVE MOTOR

BATT +

REAR COMB LAMP-L

P2-7

S2 ARM.

P1-11

P2-14

MC-16

BWI MC-25

SEAT S/W 2

BATTERY

HEAD CAPACITOR

FWD

REV P2-12

MC-20

P2-13

MC-21

FIELD

1 ARM. A1

DC DC CONVERTER

FWD

HD1 88 100 91

DD1

85 86 87 30

POS OUT

P1-19

P1-16

P1-12

DD2

PRESSURE S/W

CURRENT SENSOR P1-20

P2-20

71 100

RELAY-ALARM AS T/S

GND

TAIL

45 91 1

6 2 5 3 1 4

GN WH YL RD BK

PARKING BR SW BACK-UP SW SEAT SW BAT + BAT -

6 2 5 3 1 4

PARKING BR SW BACK-UP SW SEAT SW BAT + BAT -

81 99 94 82 93 88 84 92

TO ALARM AS

ALARM AS-PARKING/BACKUP-STATIC

ALARM AS-PARKING 6

(OPTION)

BACK-UP SMART ALARM(OPTION)

1 FRONT COMB LAMP-L

BACK-UP SMART ALARM

2 1

MC-5

MC-22

MC-35

MC-36

GRD

MC-37

P/MTR THERMAL S/W P2-1

STOP LAMP SW (OPTION)

99 88

P2 2

SEAT BELT WARNING(OPTION)

D/MTR THERMAL S/W A2

REV

PUMP MOTOR

(DAEWON)

SEAT BELT SW

TO OPTION LIGHT

TO ALARM AS OPTION LIGHT & ALARM

93 92 94 99 82 81 84 88

RUN TIME DIAGNOSTICS

SYSTEM CHECK WITH STATIC DIAGNOSTICS

HEAD LAMP-L TO OPTION LIGHT

WHILE OPERATING THE TRUCK. THE FOLLOWING INDICATES.

DISCONNECT BATTERY PRIOR TO DISCONNECTING DRIVE FUSE. SWITCH IN BOX TO DIAGNOSTIC POSITION CIRCUIT A

B C

INTERNAL CIRCUITRY FUSE REMOVAL DIRECTION SWITCH SEAT SWITCH DIRECTION SWITCH

D E F G

LIFT 1,2 SWITCH TILT SWITCH AUX. SWITCH PARK BRAKE SWITCH

ACCELERATOR CONTROL

CONTACTORS

PROCEDURE CONNECT BATTERY. KEY SWITCH "ON" CONNECT BATTERY. KEY SWITCH "ON" MOVE DIRECTION LEVER TO NEUTRAL PRESS SEAT CUSHION AND RELEASE RELEASE PARK BRAKE. AND MOVE TO REVERSE THEN TO NEUTRAL MOVE TO FORWARD THEN TO NEUTRAL PULL LIFT LEVER TO MAX. AND RELEASE PULL TILT LEVER TO MAX. AND RELEASE PULL AUX. LEVER TO MAX. AND RELEASE RELEASE PARK BRAKE LEVER AND PULL ENOUGH RELEASE PARK BRAKE. AND THEN PRESS ACCELERATOR PEDAL TO MAX. AND RELEASE

DISPLAY ACTIVE A0 A0 A0 A1 A2 A3 A4 & A5 A6 A7 A9

DISPLAY NORMAL

A0 A0 A0 A0 A0 A0 A0

ACCELERATOR GRAPH

TOGGLE SWITCH TO "RUN" THEN "DIAG" DISPLAY = "AC", CONTACTORS ARE CLOSED THEN OPEND IN TURN AS FOLLOWS. LINE CONTACTOR -> BYPASS CONTACTOR -> FWD CONTACTOR -> REV CONTACTOR

NO DISPLAY OK PP E1 E2 EL EE EE(FLASHING) F0 F2 F3 F4 F5 F6 F7 F8 F9 Fb Fd

STATUS CHECK LINE AND KEY FUSE SYSTEM NORMAL OPERATION WAIT OPERATION DRIVE MOTOR BRUSH PROBLEM PUMP MOTOR BRUSH PROBLEM BATTERY LOCK-OUT STACTIC RETURN TO OFF ERROR (SRO ERROR) SEAT CIRCUIT PROBLEM DRIVE CURRENT LIMIT WARNING DRIVE CIRCUIT PROBLEM PUMP CIRCUIT PROBLEM DRIVE AND PUMP CIRCUIT PROBLEMS DRIVE CIRCUIT PROBLEM PUMP CIRCUIT PROBLEM DRIVE AND PUMP CIRCUIT PROBLEMS PUMP MOTOR SHUNT FIELD CIRCUIT PROBLEM PUMP MOTOR SHUNT FIELD CIRCUIT PROBLEM BATTERY MIS-MATCH STEERING PRESSURE SWITCH CIRCUIT PROBLEM

A304110

SB2338E00

Operation & Maintenance Manual LIFT TRUCKS BC15S, BC18S, BC20SC

WARNING Do not start, operate or service this machine unless you have read and understood these instructions and received proper training. Unsafe or improper use of the machine may cause serious injury or death. Operators and maintenance personnel must read this manual and receive training before operating or maintaining the machine. This manual should be kept with the machine for reference and periodically reviewed by the machine operator and by all personnel who will come into contact with it.

The following warning is provided pursuant to California Health & Safety Code Sections 25247.5 et, seq,

WARNING California Proposition 65 Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

Table of Contents

Maintenance Section

Table of Contents

Inspection, Maintenance and Repair of Lift Truck Forks..................................................................64 Torque Specifications.........................................68 Battery Discharge Indicator ................................70 Battery ...............................................................71 Lubricant Specifications......................................73 Cold Storage Applications ..................................75 Lubricant Viscosities and Refill Capacities ..........77 Maintenance Intervals ........................................78 Quick Reference to Maintenance Schedule ........79 When Required ..................................................80 Every 10 Service Hours or Daily .........................95 First 50 - 100 Service Hours or a Week ............100 First 250 Service Hours or a Month ..................101 Every 250 Service Hours or Monthly.................102 Every 500 Service Hours or 3 Months...............107 Every 1000 Service Hours or 6 Months.............111 Every 2000 Service Hours or Yearly .................117 Every 2500 Service Hours or 15 Months...........123

Information Section Foreword ............................................................. 2

Safety Section Important Safety Information ................................ 4 Safety .................................................................. 5 Warning Signs and Labels ................................ 5 General Hazard Information .............................. 9 Operation Information ..................................... 11 Maintenance Information................................. 13 Operator Restraint System(If Equipped) .......... 16 Avoiding Lift Truck Tipover.............................. 20 Safety Rules ................................................... 22 How to Survive in a Tipover............................. 27

General Section Environment Section

Specifications .................................................... 28 Capacity Chart – without Sideshifter................... 30 Capacity Chart – with Hook-On type Sideshifter . 32 Capacity Chart – with Integral type Sideshifter ... 34 Noise and Vibration............................................ 36 Serial Number.................................................... 37 Operator’s Warning and Identification Plate........ 38

Environment Protection ....................................124

Index Section Index................................................................125

Operation Section

• WORLDWIDE NETWORK

Operator’s Station and Monitoring Systems........ 40 Lift Truck Control ............................................... 45 Before Operating the Lift Truck .......................... 49 Operating Techniques........................................ 55 Parking the Lift Truck ......................................... 58 Lift Fork Adjustment ........................................... 60 Storage Information ........................................... 61 Transportation Hints........................................... 62 Towing Information ............................................ 63

-1-

Information Section

Foreword Photographs or illustrations guide the operator through correct procedures of checking, operation and maintenance of the DAEWOO operator restraint system.

Literature Information This manual should be stored in the operator’s compartment in the literature holder or seat back literature storage area. This manual transportation, information.

contains lubrication

SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on the skill and alertness on the part of the operator. To develop this skill the operator should read and understand the Safe Driving Practices contained in this manual.

safety, operation, and maintenance

Some photographs or illustrations in this publication show details or attachments that can be different from your lift truck. Guards and covers might have been removed for illustrative purposes.

Forklift trucks seldom tipover, but in the rare event they do, the operator may be pinned to the ground by the lift truck or the overhead guard. This could result in serious injury or death.

Continuing improvement and advancement of product design might have caused changes to your lift truck which are not included in this publication. Read, study and keep this manual with the lift truck.

Operator training and safety awareness is an effective way to prevent accidents, but accidents can still happen. The DAEWOO operator restraint system can minimize injuries. The DAEWOO operator restraint system keeps the operator substantially within the confines of the operator’s compartment and the overhead guard.

Whenever a question arises regarding your lift truck, or this publication, please consult your DAEWOO dealer for the latest available information.

This manual contains information necessary for Safe Operation. Before operating a lift truck, make sure that the necessary instructions are available and understood.

Safety The Safety Section lists basic safety precautions. In addition, this section identifies the text and locations of warning signs and labels used on the lift truck. Read and understand the basic precautions listed in the Safety Section before operating or performing lubrication, maintenance and repair on this lift truck.

Operation The Operation Section is a reference for the new operator and a refresher for the experienced one. This section includes a discussion of gauges, switches, lift truck controls, attachment controls, transportation and towing information. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the lift truck.

Operator Restraint System(If Equipped) This manual contains safety, operation and maintenance information for the DAEWOO operator restraint system. Read, study and keep it handy.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the lift truck and its capabilities.

WARNING Your DAEWOO truck comes equipped with an operator restraint system. Should it become necessary to replace the seat for any reason, it should only be replaced with another DAEWOO operator restraint system.

-2-

Information Section

Maintenance

Environment Management

The Maintenance Section is a guide to equipment care. The illustrated, step-by-step instructions are grouped by servicing intervals. Items without specific intervals are listed under “When Required” topics. Items in the “Maintenance Intervals” chart are referenced to detailed instructions that follow.

Note that DAEWOO INDUSTRIAL VEHICLE DIVISION is ISO 14001 certified which is harmonized with ISO 9001. Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by internal and external inspection entities. LIFECYCLE ANALYSIS has also been made through out the total product life. ENVIRONMENT MANAGEMENT SYSTEM includes DESIGN FOR ENVIRONMENT from the initial stage of the design. ENVIRONMENT MANAGEMENT SYSTEM considers environmental laws & regulations, reduction or elimination of resource consumption as well as environmental emission or pollution from industrial activities, energy saving, environment-friendly product design (lower noise, vibration, emission, smoke, heavy metal free, ozone depleting substance free, etc.), recycling, material cost reduction, and even environmentally oriented education for the employee.

Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the “Maintenance Intervals” chart might be necessary. Perform service on items at multiples of the original requirement. For example, at “Every 500 Service Hours or 3 Months”, also service those items listed under “Every 250 Service Hours or Monthly” and “Every 10 Service Hours or Daily”.

-3-

Safety Section

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

WARNING

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

-4-

Safety Section

Safety Warning Signs and Labels

The safety rules and regulations in this section are representative of some, but not all rules and regulations noted under the Occupational Safety and Health Act(OSHA) and are paraphrased without representation that the OSHA rules and regulations have been reproduced verbatim.

There are several specific safety signs on your lift truck. Their exact location and description of the hazard are reviewed in this section. Please take the time to familiarize yourself with these safety signs. Make sure that you can read all safety signs. Clean or replace these if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use solvent, gasoline, etc.

Please refer to 1910. 178 in Federal Register Vol.37, No.202, the National Fire Protection Association No.505(NFPA), American National Standard, ANSI B56. 1 Safety Standard for Low Lift and High Lift Trucks and subsequent revisions for a complete list of OSHA rules and regulations as to the safe operation of powered industrial lift trucks. Since regulations vary from country to country outside the U.S.A., operate this lift truck in accordance with local regulations.

You must replace a label if it is damaged, missing or cannot be read. If a label is on a part that is replaced, make sure a new label is installed on the replaced part. See your dealer for new labels.

DAEWOO lift trucks are manufactured according to the regulations and standards laid down in EU Machinery Directive 98/37/EC and EMC directive 89/336/EC. Please refer to the Directives 89/655/ EC and 89/391/EC and its amendments for the safe use of DAEWOO lift trucks.

Training Required Service Warning

Operate

The most effective method of preventing serious injury or death to the lift truck operator or others is for the lift truck operator to be familiar with the proper operation of the lift truck, to be alert and to avoid actions or conditions which can result in an accident. Do not operate a lift truck if in need of repair, defective or in any way unsafe. Report all defects and unsafe conditions immediately. Do not attempt any adjustments or repairs unless trained and authorized to do so.

Located on the right side of the lift truck.

WARNING Improper operation or maintenance could result in injury or death. Do not operate or work on this truck unless you are properly trained. Read and understand the Operation and Maintenance Manual. Additional manuals are available from DAEWOO Lift Truck dealers. This also provides allowable lift truck capacity information.

-5-

Safety Section

a load. 14. Use extreme care when handling long, high, or wide loads. 15. Forks should be completely under load and spread apart as far as load permits. 16. Machine should be equipped with overhead guard or equivalent protection. Where load requires it, use a load backrest extension. Use extreme caution if operating without these devices. 17. Parking-Lower lifting mechanism to floor. Put directional control or shift lever in neutral. Set parking/secondary brake. Turn “ON-OFF” switch off. Chock wheels if machine is on incline. Disconnect battery when storing electric machines. 18. Observe safety rules when handling fuel for engine powered machine and when changing batteries for electric machines.

General Warnings to Operator

Located on the right side of the operator’s seat, on the battery cover.

WARNING

Battery Restraint Warning

Only trained and authorized personnel may operate this machine. For safe operation, read and follow the Operation and Maintenance Manual furnished with this lift truck and observe the following warnings: 1. Before starting machine. Check all controls and warning devices for proper operation. 2. Refer to machine identification plate for allowable machine capacity. Do not overload. Operate machines equipped with attachments as partially loaded machines when not handling a load. 3. Put directional control or shift lever in neutral before “ON-OFF” switch is turned on. 4. Start, turn and brake smoothly. Slow down for turns, slippery or uneven surfaces. Avoid running over loose objects or holes in the roadway surfaces. Use extreme caution when turning on inclines. 5. Travel with load as low as possible and tilted back. If load interferes with visibility, travel with load trailing. 6. On grade operations travel with load up grade. 7. Watch out for pedestrians and obstructions. Check overhead clearances. 8. Do not permit riders on forks or machine at any time. 9. Do not allow anyone to stand or pass under the elevated portion of any machine. 10. Be sure operating surface can safely support machine. 11. Operate machine and attachments only from operator’s position. 12. Do not handle unstable or loosely stacked loads. 13. Use minimum tilt when picking up or depositing

Located on front of battery cover.

WARNING Before operating truck, ensure that hood is securely locked by hood latch, and turn stopper to locking position. Otherwise, a battery may come out of a truck in case of tipover. It could cause the risk of serious injury or death.

-6-

Safety Section

No Riders Warning

No Standing on Forks Warning, No Standing under Forks Warning

WARNING

To avoid personal injury, allow no riders. A lift truck is designed for only one operator and no riders.

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.

Located on the right side of the operator station.

Hard Placement Warning Located on the mast.

WARNING

Load Backrest Warning

Must

Place

WARNING No hands. Do not place hands in this area. Do not touch, lean on, or reach through the mast or permit others to do so.

Operation without this device in place may be hazardous.

Located on the load backrest.

Located on the mast

-7-

Safety Section

Apply Parking Brake Warning

Battery Disconnect Before Servicing Warning

WARNING

When leaving machine apply parking brake! Parking brake is not automatically applied.

Disconnect battery from truck and also discharge high voltages between B+ and B with a 150 ohm, 24 watt Resistor before attempting to service this truck.

Overhead Guard Must Be In Place Warning WARNING

WARNING

Operation without this device in place may be hazardous. This guard conforms to ANSI B56.1 and F.E.M. Section IV. This design has been tested with an impact of 10,800 N•m (8,000 lb•ft).

Do not steam to clean the controls. Use a low pressure air hose to blow off controls when required.

Located outside top frame member of overhead guard.

Located on the logic unit cover behind the control panel cover for electrical controls.

-8-

Safety Section

General Hazard Information

WARNING

In many countries, recognized standards and/or regulations apply to the use, operation and maintenance of lift trucks.

Install any seat to this seat frame. Switch must shut off all power when operator is not seated.

In the USA, please refer to current revisions of: • 29 Code Federal Register, 1910.178 Powered Industrial Trucks. • American National Standard, ANSI B56.1 Safety Standard for Low Lift and High Lift Trucks. • National Fire Protection (NFPA) 505, Powered Industrial Trucks, Type designation, Areas of Use, Maintenance, and Operation. • Tagged to steering wheel, when not equipped with seat cushions.

Other OSHA Regulations applicable to the place of use.

which

may

Do not start or service the lift truck when a “DO NOT OPERATE” or similar warning tag is attached to the start switch or controls. Wear a hard hat, protective glasses and other protective equipment as required by job conditions. Do not wear loose clothing or jewelry that can catch on controls or other parts of the lift truck. -9-

Safety Section

Keep the lift truck, especially the deck and steps, free of foreign material, such as debris, oil, tools and other items which are not part of the lift truck.

Keep hands, feet and head inside the operator station. Do not hold onto the overhead guard while operating the lift truck. Do not climb on any part of the mast or overhead guard or permit others to do so.

Secure all loose items such as lunch boxes, tools and other items which are not part of the lift truck.

Do not allow unauthorized personnel to ride on the forks or any other part of the lift truck, at any time.

Make sure all protective guards, shields and covers are properly installed and secured in place on the lift truck.

Observe floor load limits and overhead clearances.

Always use the overhead guard. The overhead guard is intended to protect the lift truck operator from overhead obstructions and from falling objects.

Never put maintenance fluids into glass containers. Use all cleaning solutions with care. Do not use steam, solvent or high air pressure to clean electrical components.

The overhead guard is not intended to protect against every possible impact. The overhead guard may not protect against some objects penetrating into the operator’s station from the sides or ends of the lift truck.

Report all needed repairs.

If the lift truck must be operated without the overhead guard in place due to low overhead clearance, use extreme care. Make sure there is no possibility of falling objects from any adjacent storage or work area. Make sure the load is stable and fully supported by the carriage and the load backrest extension (if equipped). Do not raise loads any higher than necessary and never raise a load higher than 1830 mm (72 in) with the overhead guard removed. Always use load backrest extension when the carriage or attachment does not full support the load. The load backrest extension is intended to prevent the load or any part of the load from falling backwards into the operator’s station.

Inspect the part of the chain that is normally operated over the crosshead roller. When the chain bends over the roller, the movement of the parts against each other causes wears. Inspect to be sure that chain link pins do not extend outside of the bore hole.

When operating the lift truck, do not depend on flashing lights or back-up alarm (if equipped) to warn pedestrians.

If any single link pin is extended beyond its connecting corresponding link, it should be suspected of being broken inside of its bore hole. Inspect the chain anchor and the anchor links for wear.

Always be aware of pedestrians and do not proceed until the pedestrians are aware of your presence and intended actions and have moved clear of the lift truck and/or load. Do not drive lift truck up to anyone standing in front of an object. Obey all traffic rules and warning signs. Know the appropriate work-site hand signals and who gives them. Accept signals from one person only.

- 10 -

Safety Section

Operation Information

Starting the Lift Truck

Mounting and Dismounting

Start the lift truck only from the operator’s station. Make sure no one is standing and/or working on, underneath or close to the lift truck before starting or beginning to move the lift truck. Refer to the topic “Start the Lift Truck” in the “Operation Section" of this manual for specific starting instructions.

Before Operating the Lift Truck Operate the lift truck and controls only from the operator’s station. • Mount and dismount the lift truck carefully.

Make sure the lift truck horn, lights, backup alarm (if equipped) and all other devices are working properly.

• Clean your shoes and keep your hands and steering wheel free of slippery material.

Check for proper operation of mast and attachments. Pay particular attention to unusual noises or erratic movement which might indicate a problem.

• Use both hands and face the lift truck when mounting and dismounting. • Maintain a three point contact (two feet and one hand or one foot and two hands contact) with the steps and handholds.

Make sure service and parking brakes, steering, and directional controls are operational.

• Never get on or off a moving lift truck.

Make sure all personnel are clear of lift truck and travel path.

• Never jump off the lift truck.

Operating the Lift Truck

• Do not try to climb on or off the lift truck when carrying tools or supplies.

Always keep the lift truck under control.

• Do not use any controls as handholds when entering or leaving the operator’s station.

• Lower mast, with or without load, before turning or traveling. Watch out for overhead obstructions.

Before Starting the Lift Truck

• Start, turn, and brake smoothly, slow down for turns, grades, slippery or uneven surfaces.

Perform a walk-around inspection daily and at the start of each shift. Refer to the topic “Walk-around Inspection” in “Every 10 Service Hours or Daily” section of this manual.

• Use special care when operating on grades. Do not angle across or turn on grades. Do not use lift truck on slippery grades. Travel with forks downgrade when unloaded. Travel with load upgrade.

Adjust the seat so that full pedal travel can be obtained with the operator’s back against the seat back. Make sure all hydraulic controls are in the HOLD position. Make sure the direction control lever is in the NEUTRAL position. Make sure the parking brake is engaged.

• When turning the lift truck, slow down to a safe speed. Use extra caution when turning with the load not fully lowered. • When turning on inclines, be extremely careful. • Do not overload, or handle offset, unstable, or

- 11 -

Safety Section

Lift Truck Parking

loosely stacked loads. Refer to load capacity plate on the lift truck. Use extreme caution when handling suspended, long, high or wide load.

When leaving the operator station, park the lift truck in authorized areas only. Do not block traffic.

• Do not stunt ride or indulge in horseplay.

Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor.

Always look and keep a clear view of the path of travel. • Travel in reverse if load or attachment obstructs visibility. Use extreme caution if visibility is obstructed.

Move the direction control lever to NEUTRAL.

• Stay in designated travel path, clear of dock edges, ditches, other dropoffs and surfaces which cannot safely support the lift truck.

Turn the key switch off and remove the key.

• Slow down and use extra care through doorways, intersections and other location where visibility is reduced.

Block the drive wheels when parking on an incline.

Engage the parking brake.

Disconnect the battery.

• Slow down and avoid pedestrians, other vehicles, obstructions, pot holes and other hazards or objects in the path of travel. Refer to the topic “Operating Techniques” in the “Operation Section” of this manual. Loading or Unloading Trucks/Trailers • Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. • Be certain truck or trailer brakes are applied and wheel chocks in place (or be certain unit is locked to the loading dock) before entering onto trucks or trailers. • If trailer is not coupled to a tractor, make sure the trailer landing gear is properly secured in place. On some trailers, extra supports may be needed to prevent upending or corner dipping. • Be certain dock plates are in good condition and properly placed and secured. Do not exceed the rated capacity of dock boards or bridge places.

- 12 -

Safety Section

Maintenance Information

Crushing or Cutting Prevention

Perform all maintenance unless otherwise specified as follows:

Support equipment and attachments properly when working on or beneath them. Do not depend on hydraulic cylinders to hold it up. Any attachment or mast can fall if a control is moved, or if a hydraulic line breaks.

• Lift truck on level ground. • The mast fully lowered and the forks tilted forward until the fork tips are touching the ground/floor.

Never attempt adjustments while the lift truck is moving or the motor is running unless otherwise specified.

• All attachment controls are in HOLD position.

• Parking brake engaged.

Where there are implement linkages, the clearance in the linkage area will increase or decrease with movement of the implement.

• The key start switch off and the key removed.

Stay clear of all rotating and moving parts.

• Disconnect the battery.

Keep objects away from moving fan blades. They will throw or cut any object or tool that falls or is pushed into them.

• Direction control lever in the NEUTRAL position.

Pressure Air

Do not use a kinked or frayed wire rope cable. Wear gloves when handling the wire rope cable.

Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

Retainer pins, when struck with force, can fly out and injure nearby persons. Make sure the area is clear of people when driving retainer pins.

Fluid Penetration

Wear protective glasses when striking a retainer pin to avoid injury to your eyes.

Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possibly death. If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury immediately.

Chips or other debris can fly off objects when struck. Make sure no one can be injured by flying debris before striking any object.

- 13 -

Safety Section

Service, exchange and handle batteries only in authorized areas when proper safety and ventilation facilities are provided.

Burn Prevention Oils

Do not smoke, or expose battery to sparks or flame when checking, charging or servicing battery. Keep chains and metallic tools away from top of battery. Batteries give off flammable fumes which can explode. Highly explosive gases are especially hazardous toward the end of the charging period as the battery approaches a full charge condition. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Hot oil and components can cause personal injury.

Service batteries in accordance with battery manufacture instructions.

Do not allow hot oil or components to contact the skin.

Refer to the topic “Batteries” in the “Maintenance Section” of this manual.

At operating temperature, the hydraulic tank is hot and can be under pressure. Remove the hydraulic tank filler cap only after the motor has been stopped and the filler cap is cool enough to remove with your bare hand. Remove the hydraulic tank filler cap slowly to relieve pressure. Relieve all pressure in air, oil or cooling systems before any lines, fittings or related items are disconnected or removed.

Batteries

Only trained and designated personnel should inspect, recharge or exchange batteries. Always wear protective glasses when working with batteries. - 14 -

Safety Section

the improper servicing and changing of tires and rims. This work should be done only by trained personnel using the proper tools and procedures.

Fire or Explosion Prevention General Have a fire extinguisher-type BC and 1.5 kg minimum capacity-on rear overhead guard leg with latch and know how to use it. Inspect and have it serviced as recommended on its instruction plate. Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons. All fuels, most lubricants and some coolant mixtures are flammable. Clean and tighten all electrical connections. Check daily for loose or frayed electrical wires. Have all loose or frayed electrical wires tightened, repaired or replaced before operating the lift truck.

Do not approach a tire closer than the outside of the area represented by the shaded area in the above drawing.

Store all oil rags or other flammable material in a protective container, in a safe place.

To inflate a tire, stand behind the tread and use a self-attaching chuck. Make sure all personnel are away from the danger area where they will not be struck by flying debris, should an explosion occur.

Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.

Never inflate tires that have been run flat or are at less than 80% of the recommended inflation pressure, or where damage to the tire or rim components is present or suspected.

Remove all flammable materials such as oil and other debris before they accumulate on the lift truck.

Whenever possible remove the wheel from the truck and inflate the tire in a tire restraining cage or rack.

Do not expose the lift truck to flames, extreme heat, etc.

Deflate the tire completely by removing the valve core before starting to remove or to work on the wheel.

Do not operate in areas where explosive gases exist or are suspected.

Inspect the rim parts and tire for defects, damage and foreign particles. Replace the rim, any side or lock rings which are bent out of shape, heavily rusted or broken. Clean the wheel parts and tire as necessary.

Tire Information A tire explosion is much more violent than a blowout. The explosion can propel the tire, rim and final drive components as far as 500 m (1500ft) or more from the lift truck. Both the force of the explosion and the flying debris can cause personal injury or death, and property damage.

Never intermix rim parts made by different manufacturers or of different brands, or rim parts designed to fit a different size or type of rim. Make sure the lock ring is correctly seated and locked before inflating the tire. Do not attempt to seat partially seated side and/or lock rings while or after inflating tire.

Explosions of air inflated tires have resulted from heat induced gas combustion inside the tires. The heat, generated by welding or heating rim components, external fire, or excessive use of brakes can cause gaseous combustion.

Refer to the “Tire Inflation Information” section for the proper tire inflation pressures.

Explosions of air inflated tires have resulted from - 15 -

Safety Section

Lines, Tubes and Hoses

Operator Restraint Equipped)

Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses.

System(If

Warning Signs and Labels

Repair loose or damaged oil lines, tubes and hoses. Leaks can cause fires. Contact your DAEWOO Lift Truck dealer for repair or replacement.

Your DAEWOO lift truck has the following tipover warning decals. Make sure that you can read all safety signs. Clean or replace these if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use solvent, gasoline, etc. You must replace a label if it is damaged, missing or cannot be read. If a label is on a part that is replaced, make sure a new label is installed on the replaced part. See you DAEWOO Lift Truck dealer for new labels. The most effective method of preventing serious injury or death to yourself or others is to familiarize yourself with the proper operation of the lift truck, to be alert, and to avoid actions or conditions which can result in an accident.

Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. See “Fluid Penetration” in the safty section for more details. Tighten all connections to the recommended torque. Replace if any of the following conditions are found. • End fittings damaged or leaking. • Outer covering chafed or cut and wire reinforcing exposed. • Outer covering ballooning locally.

WARNING • Evidence of kinking or crushing of the flexible part of hose.

Tipover can occur if the truck is improperly operated. In the event of tipover, injury or death could result.

• Armoring embedded in the outer cover. • End fittings displaced. Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration, rubbing against other parts, and excessive heat during operation.

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Safety Section

WARNING Do NOT place your hand or fingers under the seat. Injury may occur as the seat suspension mechanism moves up and down. NOTICE Before getting on the truck, adjust the level of the suspension using the grip in the rear of the seat.

The “Survive in tipover” warning is located on the overhead guard. It shows the proper use of the operator restraint system.

Seat Adjustment

WARNING When raising and lowering the seat backrest, avoid placing hand or fingers in the hinge area indicated by the circle. Injury may occur.

Move the lever, slide the seat to the desired position, and release the lever. Adjust the seat before operating the lift truck. After adjusting, set the seat to make sure it is properly locked. DO NOT adjust the seat while the truck is in motion.

- 17 -

Safety Section

Seat Belt

If Optional Suspension Seat (weight adjusting type) Equipped

The Operator Restraint System, Prevents the operator from jumping from the operator’s compartment in the event of a forward or side tipover. The system is designed to keep the operator on the seat and in the operator’s compartment in the event of a tipover. Inspection

1. If the seat belt is torn, if pulling motion is interrupted during extension of the belt, or if the belt cannot be inserted into the buckle properly, replace the seat belt assembly.

2. Belt Maintenance – Every 500 service hours. Check that the belt fastening works properly and that winding device is free from run lock when jerked. Check that the belt is suitably fastened to the seat. Check that the seat is correctly secured to the hood and the chassis. On visual inspection, fastenings must be intact, otherwise, contact the safety manager.

WARNING Your DAEWOO truck comes equipped with a DAEWOO operator restraint system. Should it become necessary to replace the seat for any reason, it should only be replaced with another DAEWOO operator restraint system.

- 18 -

Safety Section

2. Make sure the belt is not twisted.

WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident.

3. In the event of a tipover, the seat and restraint system should be inspected for damage and replaced, if necessary. NOTE: Operator restraints shall be examined at the regular truck service intervals. It is recommended that they be replaced if any of the following conditions are found: 3. Be sure to fasten the belt across your hips, not across your abdomen.

z Cut or frayed strap z Worn

or damaged hardware including anchor points z Buckle or retractor malfunction z Loosen stitching

NOTE: The belt is designed to automatically adjust to your size and movement. A quick pull on the belt will confirm that the automatic adjuster will hold the belt position in the event of an accident.

WARNING

Release the Seat Belt

The seat belt may cause the operator to bend at the waist. If you are pregnant or have suffered from some abdominal disease, consult a doctor before you use the seat belt.

Fasten the Seat Belt

Push the button of the buckle to release the belt. The belt will automatically retract when released. Hold the plate of the belt and allow the belt to slowly retract. 1. Grip the plate (connector) of the belt and pull the belt from the retractor. Then insert the plate into the slot of the buckle until a snap is heard. Pull on the belt to confirm it is latched.

- 19 -

Safety Section

Stability and Center of Gravity

Avoiding Lift Truck Tipover Lift Truck Stability

The stability of the lift truck is determined by the location of its CG; or, if the truck is loaded, the combined CG of the truck and load. The lift truck has moving parts and, therefore, has a CG that moves. The CG moves forward or backward as the mast is tilted forward or backward. The CG moves up or down as the mast moves up or down. The CG and, therefore, the stability of the loaded lift truck, are affected by a number of factors such as: z the size, weight, shape and position of the load

Counterbalanced lift truck design is based on the balance of two weights on opposite sides of a fulcrum (the front axle). The load on the forks must be balanced by the weight of the lift truck. The location of the center of gravity of both the truck and the load is also a factor. This basic principle is used for picking up a load. The ability of the lift truck to handle a load is discussed in terms of center of gravity and both forward and sideways stability.

Center of Gravity (CG)

the height to which the load is lifted

the amount of forward or backward tilt

tire pressure

dynamic forces created when the lift truck is accelerated, braked or turned

condition and grade of surfaces on which the lift truck is operated

The point within an object, at which the whole weight of the object may be regarded as being concentrated, is called the center of gravity or CG. If the object is uniform, its geometric center will coincide with its CG. If it is not uniform, the CG could be at a point outside of the object. When the lift truck picks up a load, the truck and load have a new combined CG. These same factors are also important for unloaded lift trucks. They tip over sideways easier than a loaded lift truck carrying its load in the lowered position.

- 20 -

Safety Section

Lift Truck Stability Base

capacity load shown on the nameplate is for a standard lift truck with standard backrest, forks and mast, and having no special-purpose attachment. In addition, the capacity load assumes that the load center is no further from the top of the forks than it is from the face of the backrest. If these conditions do not exist, the operator may have to reduce the safe operating load because the truck stability may be reduced. The lift truck should not be operated if its capacity/nameplate does not indicate capacity load. NOTE: If the load is not uniform, the heaviest portion should be placed closer to the backrest and centered on the forks.

For the lift truck to be stable (not tip over forward or to the side), the CG must stay within the area of the lift truck stability base – a triangular area between the front wheels and the pivot of the steer wheels. If the CG moves forward of the front axle, the lift truck will tip forward. If the CG moves outside of the line on either side of the stability base, the lift truck will tip to the side.

NOTICE 1. Capacity/Nameplates originally attached to forklifts sold by DAEWOO shall not be removed, altered or replaced without DAEWOO’s approval.

WARNING 2. DAEWOO assumes no responsibility for lift trucks placed in service without a valid DAEWOO Nameplate.

Dynamic forces (braking, acceleration, turning) also affect stability and can produce tipover even when the CG is within the stability triangle.

3. If necessary to change your specification, contact your DAEWOO lift truck dealer.

Capacity Load (Weight and Load Center)

The capacity load of the lift truck is shown on the capacity/nameplate riveted to the truck. It is determined by the weight and load center. The load center is determined by the location of the CG of the load. The load center shown on the nameplate is the horizontal distance from the front face of the forks, or the load face of an attachment, to the CG of the load. The location of the CG in the vertical direction is the same as the horizontal dimension. Remember that, unless otherwise indicated, the - 21 -

Safety Section

Safety Rules

Do not operate a lift truck unless you are in the operator's seat. Keep arms, legs and head inside the confines of the operator's area. Keep hands and feet out of the mast assembly.

Only properly trained and authorized personnel should operate forklift trucks. Wear a hard hat and safety shoes when operating a lift truck. Do not wear loose clothing.

Do not start, stop, turn or change direction suddenly or at high speed. Sudden movement can cause the lift truck to tip over. Slow the speed of your truck and use the horn near corners, exits, entrances, and near people.

Inspect and check the condition of your forklift truck using the operator's check list before starting work. Immediately report to your supervisor any obvious defects or required repairs.

Do not operate your truck in unauthorized areas. Know your forklift truck and think safety. Do not compromise safety. Follow all safety rules and read all warning signs.

Never operate a lift truck with wet hands or shoes. Never hold any controls with grease on your hands. Your hands or feet will slide off of the controls and cause an accident.

- 22 -

Safety Section

Do not raise anyone on the forks of your lift truck unless using an approved safety cage. Do not let other people ride on the truck. Lift trucks are designed to carry loads, not people.

Do not overload. Always handle loads within the rated capacity shown on the capacity plate. Do not add extra counterweight to the truck. An overload can cause the truck to roll over and cause injury to personnel and damage to the lift truck.

Do not operate your truck without the load backrest extension and overhead guard. Keep the load against the backrest with the mast tilted backward

Do not drive on soft ground. Observe all signs, especially those on maximum permitted floor loadings, elevator capacities and clearance heights. Handle loads carefully and check them closely for stability and balance.

Do not lift or move loads that are not safe. Do not pick up an off center load. Such a load increases the possibility of a tipover to the side. Make sure loads are correctly stacked and positioned across both forks. Always use the proper size pallet. Position the forks as wide as possible under the load. Position loads evenly on the forks for proper balance. Do not lift a load with one fork.

Do not drive on slippery surfaces. Sand, gravel, ice or mud can cause a tipover. If unavoidable, slow down.

- 23 -

Safety Section

Do not permit anyone to stand or walk under the load or lifting mechanism. The load can fall and cause injury or death to anyone standing below.

Do not elevate the load with the mast tilted forward. Do not tilt the elevated loads forwards. This will cause the lift truck to tip over forward.

Look out for overhead obstructions when raising or stacking loads. Do not travel with a raised load. Do not travel with the mast raised. The lift truck can roll over and cause injury or death to you or other personnel.

Do not jump off if your truck starts to tip over. Stay in your seat to survive.

Go up ramps in forward direction and down ramps in reverse direction when moving loads. Never elevate a load with the forklift truck on an incline. Go straight off and straight down. Use an assistant when going up or down a ramp with a bulky load.

Do not move loose loads that are higher than the load backrest. Be alert for falling loads when stacking. Travel with the load tilted back and the forks as low as possible. This will increase stability to the truck and load and permit better visibility for you.

- 24 -

Safety Section

Do not stack or turn on ramps. Do not attempt to pick-up or deposit a load unless the lift truck is level. Do not turn on or drive across an incline.

Do not drive in forward direction when loads restrict your visibility. Operate your lift truck in reverse to improve visibility except when moving up a ramp.

Be careful when operating a lift truck near the edge of a loading dock or ramp. Maintain a safe distance from the edge of docks, ramps and platforms. Always watch tail swing. The truck can fall over the edge and cause injury or death.

Do not go over rough terrain. If unavoidable, slow down. Cross railroad tracks slowly and diagonally whenever possible. A railroad crossing can give a loaded forklift truck a real jolt. For smoother crossing, cross the railroad diagonally so one wheel crosses at a time.

Do not operate on bridge plates unless they can support the weight of the truck and load. Make sure that they are correctly positioned. Put blocks on the vehicle you enter to keep it from moving.

Avoid running over loose objects. Look in the direction of travel. Look out for other persons or obstructions in your path of travel. An operator must be in full control of his lift truck at all times.

- 25 -

Safety Section

Do not operate your truck close to another truck. Always keep a safe distance from other trucks and make sure there is enough distance to stop safely. Never overtake other vehicles.

Park your lift truck in authorized areas only. Fully lower the forks to the floor, put direction lever in NEUTRAL position, engage the parking brake, and turn the key to the OFF position. Remove the key and put blocks behind the wheels to prevent the truck from rolling. Shut off your forklift truck when leaving it unattended. Check the condition of your forklift truck after the day's work.

Do not use your lift truck to push or tow another truck. Do not let another push or tow your truck. If a truck will not move, call a service technician.

Forklift trucks may only be refueled at specially reserved locations. Switch off the engine when refueling. Smoking and handling of naked flames during refueling are strictly prohibited. This prohibition also applies during the changing of the LPG (liquefied propane gas) tank. Mop up spilt fuel and do not forget to close the fuel tank before restarting the engine. - 26 -

Safety Section

How to Survive in a Tipover WARNING

Brace your feet and keep them within the operator’s compartment.

In the event of a tipover, the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided. Always use operator restraint system.

Lean away from the direction of fall.

DON’T jump.

Lean forward.

Hold on tight.

- 27 -

General Section

Specifications CHARACTERISTICS 1 2 3 4 5 6 7

Manufacturer Model Capacity Load center Power type Operator type Tire

9 10 12 13

Lift with STD two-stage mast Fork carriage Fork

at rated load center distance Electric,Diesel,Gasoline,LP-Gas Stand-on, Driver-seated P=pneumatic,E=elastic,C=cushion DIMENSIONS maximum fork height with rated load free lift ISO Class lengthXwidthXthickness

LB/kg inch/mm

inch/mm inch/mm

fork spacing (minimumXmaximum) 14 15 16 17 18 19 20 21 22 23 23a

Tilt of mast

Overall dimensions

forward/backward length to fork face width mast lowered height mast extended height overhead guard height seat height

STD Tire

Outside turning radius Load moment constant (from front wheel to fork face) Aisle 90º stacking Aisle 90º intersecting PERFORMANCE travel, loaded/unloaded

36V

Speeds

lift, loaded/unloaded

36V

lowering, loaded/unloaded

36V

26 28 30

Max. Drawbar pull Max. gradeability

at 1mph, loaded at 1mph, loaded

32 33

WEIGHT Total weight (with weight of battery) Axle load with load

front/rear

without load

35 36 37 38 39

Tires

CHASSIS number of front/rear Size

Wheelbase Tread

distance front/rear

40 41 42 43

Ground clearance Service brake Parking brake

at the lowest point at center of wheelbase

44 45 46 47 48 54 57 58

Battery Electric motor Speed control Relief pressure Noise level

front/rear

inch mm inch mm deg inch/mm inch/mm inch/mm inch/mm inch/mm inch/mm inch/mm inch/mm inch/mm inch/mm Mile/h km/h ft/m mm/s ft/m mm/s LB/kg % LB/kg LB kg LB kg

front rear STD Tire loaded

DRIVE Type Voltage/capacity(5 hours) Weight(minimum) Drive motor (1 HR Rating) Hydraulic motor (20% Duty) with electric drive system/attachment Leq@operator's ear-empty travel

- 28 -

36V 36V

inch/mm inch mm inch/mm mm

V/AH LB/kg hp/kw hp/kw Type psi dB(A)

General Section

DHI&M BC15S 3000/1360 24/610 Electric Driver-seated C

DHI&M BC18S 3500/1590 24/610 Electric Driver-seated C

DHI&M BC20SC 4000/1810 24/610 Electric Driver-seated C

1 2 3 4 5 6 7

130/3300 5.1/130 II 1.4X4X41 35X100X1050 9.4X35.6 240X905 6/5 76.2/1935 37.2/945 83.9/2130 171.1/4345 85.2/2165 43.3/1100 66.5/1690 15.5/394 82.0/2085 63.1/1605

130/3300 5.3/135 II 1.5X4X41 40X100X1050 9.4X35.6 240X905 6/5 77.2/1960 39.0/991 83.9/2130 171.1/4345 85.2/2165 43.3/1100 67.5/1715 15.7/399 83.2/2115 63.6/1615

9 10 12

8.1/8.5 13.1/13.7 72.8/110 370/560 98.4/88.6 500/450 2376/1080 13

7.9/8.5 12.7/13.6 67.0/110 340/560 98.4/88.6 500/450 2486/1130 12

7.7/8.3 12.4/13.4 63.0/110 320/560 98.4/88.6 500/450 2486/1130 11

6989/3170 8715/1580 3953/717 2985/4004 1354/1816

7628/3460 9760/1726 4427/783 3075/4553 1395/2065

8047/3650 10395/2060 4715/935 2738/5309 1242/2408

2/2 18X6X12.1 14X5X10 48.0/1220 31 / 31 787 / 787 3.0/75 3.7/93 foot/hyd hand/mechanical

2/2 18X6X12.1 14X5X10 48.0/1220 31 / 31 787 / 787 3.0 / 75 3.7 / 93 foot/hyd hand/mechanical

2/2 18X7X12.12 14X5X10 48.0/1220 32 / 31 813 / 787 3.0 / 75 3.7 / 93 foot/hyd hand/mechanical

35 36 37 38

40 41 42 43

lead-acid 36/880 1850/839 10.1/7.5 10.1/7.5 TR chopper 2880/2020 68

lead-acid 36/880 1850/839 10.1/7.5 10.1/7.5 TR chopper 3130/2020 68

44 45 46 47 48 54 57 58

- 29 -

13 14 15 16 17 18 19 20 21 22 23 23a 24 25 26 28 30

33 34

General Section

Capacity Chart – without Sideshifter NARROW TREAD STD, FFL

FFT

BC15S

MODEL

A. 4000 – 4500mm MAST B. 4750mm MAST C. 5000mm MAST D. 5500mm MAST E. 6000mm MAST

A. 2700 – 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000 – 4500mm MAST B. 4750mm MAST C. 5000mm MAST D. 5500mm MAST E. 6000mm MAST

A. 2700 – 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000 – 4500mm MAST B. 4750mm MAST C. 5000mm MAST D. 5500mm MAST E. 6000mm MAST

BC20SC

BC18S

A. 2700 – 4000mm MAST B. 4500mm MAST

- 30 -

General Section

Capacity Chart – without Sideshifter WIDE TREAD STD, FFL

FFT

BC15S

MODEL

A. 4000 - 4500mm MAST B. 4750 - 5000mm MAST C. 5500mm MAST D. 6000mm MAST

A. 2700 – 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000mm MAST B. 4500 - 4750mm MAST C. 5000mm MAST D. 5500mm MAST E. 6000mm MAST

A. 2700 - 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

BC20SC

BC18S

A. 2700 – 4500mm MAST

- 31 -

General Section

Capacity Chart – with Hook-On type Sideshifter NARROW TREAD STD, FFL

FFT

BC15S

MODEL

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

A. 2700 – 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

A. 2700 - 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

BC20SC

BC18S

A. 2700 - 4000mm MAST B. 4500mm MAST

- 32 -

General Section

Capacity Chart – with Hook-On type Sideshifter WIDE TREAD STD, FFL

FFT

BC15S

MODEL

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

A. 2700 – 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

BC20SC

BC18S

A. 2700 - 4000mm MAST B. 4500mm MAST

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

A. 2700 - 3700mm MAST B. 4000mm MAST C. 4500mm MAST

- 33 -

General Section

Capacity Chart – with Integral type Sideshifter NARROW TREAD STD, FFL

FFT

BC15S

MODEL

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

A. 2700 - 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

A. 2700 - 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

BC20SC

BC18S

A. 2700 – 4000mm MAST B. 4500mm MAST

- 34 -

General Section

Capacity Chart – with Hook-On type Sideshifter WIDE TREAD STD, FFL

FFT

BC15S

MODEL

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

A. 2700 - 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

A. 2700 - 3700mm MAST B. 4000mm MAST C. 4500mm MAST

A. 4000mm MAST B. 4500 mm MAST C. 4750mm MAST D. 5000mm MAST E. 5500mm MAST F. 6000mm MAST

BC20SC

BC18S

A. 2700 – 4000mm MAST B. 4500mm MAST

- 35 -

General Section

Noise and Vibration Noise Noise Level [Unit: dB(A)]

Sound Pressure Level at Operator’s ear (Leq.)

Model

Sound Pressure Level at By-stander position (AS 3713)

AS 3713

prEN 12053

Drive-By

Lifting Mode

64.0

65.0

63.0

57.0

BC15S, BC18S, BC20SC

* Test Model: BC20SC

Vibration (weighted overall value) Measuring Place [Unit: m/sec2] Model

Seat

Steering Wheel

Floor Plate

0.11

0.13

0.12

BC15S, BC18S, BC20SC * Test course: Concrete road

- 36 -

General Section

Serial Number Serial Number Locations For quick reference, record your lift truck's serial numbers in the spaces provided below the photographs.

Drive Motor Serial Number

Lift Truck Serial Number

Hydraulic/Power Steering Motor Serial Number

- 37 -

General Section

Operator’s Warning and Identification Plate Familiarize yourself with the information on the ldentification, Lift Capacity and Attachment Plates. Do not exceed allowable lift truck working capacity load ratings.

Operator’s Warning Plate

Identification, Lift Capacity and Attachment Plate Lift Truck Capacity Rating DO NOT exceed allowable lift truck working capacity load ratings. The capacity of the lift truck is given by weight and distance to the load center. For example: a capacity of 1200 kg (2640 lb) at 600 mm (24in) means that the lift truck can lift 1200 kg (2640 lb) if the load center is 600 mm (24 in) from both the vertical and horizontal faces of the forks.

Located on the right side of the operator’s seat on the battery cover.

Before attempting to lift any load, ensure that the weight and load center combination is within the capacity of the lift truck as shown on the capacity rating plate. To determine the load center measure the distance from the face of the carriage to the gravitational center of the load. The rated capacity on the plate refers to the capacity of the lift truck as it left the factory. Subsequent changes of any form to the equipment or battery can alter the lift truck’s rating. The rated capacity of the lift truck applies to operating conditions where the lift truck is on level ground. The capacity of the lift truck is reduced on inclines.

Mast Abbreviations STD

- Standard Mast (single inner member, low free lift).

- Full Free Mast [single inner member, with high free duplex or multiple cylinder(s)].

FFT

- Triple Lift Mast (two inner members with either low or full free lift). QUAD - Quadruple(Quad) Mast(three inner - 38 -

General Section

members). SPEC - Special Mast, such as non-telescopic or double mast, not within the other classifications. NOTE : When only a mast-type is listed on the identification plate, a standard carriage and forks are used.

- Special Carriage-increased width, height or outreach.

SSS

- Shaft-type Sideshift Carriage.

HSS

- Hook-type Side Carriage(ITA).

- Special Counterweight.

- Special Forks.

NOTE : Numbers following this abbreviation indicate number and/or length of forks. SS

- SWS-Sideshift-Swing Shift.

RAM

- Ram or Boom

ROTC - Rotating Carriage. DBCBH - Double Cube Block Handler HFP

- Hydraulic Fork Positioner, Non Sideshift.

- Crane Arm or Crane Boom.

- Tire Handler.

CTH

- Container Top Handler.

CSH

- Container Side Handler

- Load Push Device, Non Sideshift.

LPP

- Load Push-Pull Device, Non Sideshift.

- General Clamp (other than Bale, Carton or Roll).

- Bale Clamp.

CC RC

- Carton Clamp. - Roll Clamp.

- Load Stabilizer.

- Log Handler.

PWH

- Pulp Wood Handler.

SS-ST - Sideshift-Side Tilt Carriage.

Attachment Abbreviations (includes Special Forks) SC

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Operation Section

Operator’s Station and Monitoring Systems Read and understand the “Safety”, “Operation” and “Maintenance” sections before operating the lift truck.

Key Switch

Seat Switch

The key switch is located on the right side of the steering column.

The seat switch is located under the operator’s seat. OPEN - When the operator’s seat is in the up position the electrical circuits are disconnected.

OFF - Turn the key switch to OFF (1) to disconnect the electrical circuits. ON - Turn the key switch the ON (2) to connect the electrical circuits. If the key switch is left in the ON position when the operator leaves the lift truck, the LCD display will show a flashing “EE”.

CLOSE - When the operator’s seat is in the down position (operator seated) the electrical circuits are connected. The power steering pump motor is activated when the key switch is turned to ON and the seat switch is closed.

The power steering pump motor is activated when the key switch is turned to ON and the seat switch is closed.

Monitoring Systems Indicator

NOTE: The power steering pump motor will shut off if the directional lever is left in NEUTRAL and no control levers are actuated for approximately six seconds. The motor will be turned on when any control lever is used.

Located on the middle of the console cover panel. The symbols shown on the instrument panel identify different features of the lift truck. The symbol for each feature is identified and an explanation of the function and location is described on the following pages.

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Operation Section

Run Time Diagnostics

Power On Indicator

While operating the lift truck, diagnostic checks are constantly being made. The LCD display is used to indicate the following discrepancies from normal operation.

When the key switch is on and the seat switch is open an “EE” will flash on the display. This is to remind the operator to turn the key switch OFF when leaving the lift truck.

Battery Discharge Indicator with Interrupt

Static Return to Off

If the directional control lever is placed in forward or reverse and/or the accelerator is depressed before both the key switch is turned to ON and the seat switch is closed, an “EE” will be shown on the display and the lift truck will not operate. The directional control lever must be returned to neutral and/or the accelerator released before the lift truck will operate.

Indicates the battery state of charge, as shown by the LCD display on the instrument panel. A fully charged battery will cause a “6” segments displayed on the display. As the battery is discharged, the LCD display will count down 6,5,4,3 etc, until “EL” is displayed. When “1 segment” is flashed the battery has reached 80% discharge level, the Micro-Controller will cause the display to continuously index through the entire range to signal, to the operator, that the battery is discharged and lift interrupt is imminent. If the warning is ignored lift interrupt will prevent the lift and tilt from operating and a “EL” (zero) will be flashed on the display.

On performance modes it is necessary to release the park brake to clear the “EE” from the display.

Replacement of the discharged battery will reset the lift interrupt and normal operation will resume again.

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Operation Section

Fault Detection Circuit

Over Temperature

During lift truck operation the drive hydraulic pump circuits are continuously monitored for power circuit failure. Additional drive and pump circuit components are tested each time the key switch is turned on. Should a fault be detected, the lift truck will shut off and the display will alternately flash “F” and a code.

If the control panel or motors should overheat, The high temperature symbol will be shown on the LCD display. Lift truck performance will be reduced until operating temperatures return to normal. When this occurs, the lift truck should be parked and permitted to cool.

The “F” plus code indicates the component failure. (Codes are listed on the schematic diagram on the inside of the control panel door and in the service manuals.)

NOTE : Refer to the “Test and Adjusting” section of the Service Manual or contact your DAEWOO Lift Truck dealer.

Self-Diagnostics Indicator

No LCD Display

The LCD display is also used as an indicator for the self-diagnostics system built into the “MicroController.” A service mechanic can completely troubleshoot the electrical functions without additional diagnostic equipment. See the topic “Self-Diagnostics” in the Maintenance Section of this manual for further information on your particular model for self-diagnostics. Brief instructions are also printed on the wiring diagram and schematic, located on the back side of the control panel cover.

If the LCD display does not show any indication when the key switch is on and the seat switch is closed, the line fuse and key fuse should be checked. NOTE : The LCD display indicates the lift truck discrepancies described, but will automatically return to the battery discharge with interrupt function when the problem is corrected.

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Operation Section

Motor Brushes Wear Indicator

Service Hour Meter

The “E1” or “E2” code is displayed when the motor brushes are worn and need to be replaced. Replace the brushes to reduce the risk of armature damage from overworn brush.

Located on the RIGHT side of cowl. Indicates the total number of hours the lift truck has operated. Use it to determine service intervals.

Front and Rear Floodlights Switch

Parking Brake Indicator

Located on the right side of the instrument panel below the display panel. OFF - Push down on the left side of the switch to turn both front and rear flood lights off. Front Floodlights - Push down on the right side of the switch, to the first position, to turn the front floodlights on.

The LCD below parking brake symbol will be lit when the park brake is applied.

Front and Rear Floodlights - Push down on the right side of the switch, to the second position, to turn both the front and rear floodlights on. The rear floodlights are optional.

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Operation Section

Horn Button

Seat Adjustment Adjust the seat at the beginning of each shift or when changing operators. Adjust the seat to allow full travel of all pedals with the operator seated against the seat back. The seat must be adjusted with the operator seated.

Located in the center of the steering wheel. Push in on the horn button to sound the horn.

Tilt Steering Column

Move the lever to adjust the seat forward or backward. Release the lever. Move the seat slightly to lock it.

Located on the lower front of the steering column. To adjust the steering column, raise the handle and move the steering column to the desired position. Release the handle and the steering column will remain in the desired position.

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Operation Section

Lift Truck Control Service Brake Pedal

Parking Brake NOTICE Do not engage the parking brake while the lift truck is moving unless an emergency arises. The use of the parking brake as a service brake in regular operation will cause severe damage to the parking brake system.

Service Brake - The service brake pedal is located on the floor of the operator’s compartment. Depress the service brake pedal to slow or stop the lift truck. Release the service brake pedal to allow the lift truck to move. Parking Brake - The parking brake lever is located on the left side of the cowl.

Parking Brake Engaged - Pull the parking brake lever back, which will engage the interlock switch that shuts off power to the drive motor.

Parking Brake Disengaged - Push the parking brake lever forward to release the parking brake.

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Operation Section

Accelerator Pedal

Directional Control Lever

NOTICE The service brake and accelerator pedals should not be used at the same time, except for emergency situations. Use of both the brake and accelerator pedals at the same time may cause the drive motor to overheat.

Forward - Push the lever forward. The lift truck will move forward. Neutral - Move the lever to center position. The lift truck should not move when lever is in neutral. If the operator leaves the seat, or turns the key switch off, the lever must be returned to NEUTRAL. The lift truck will not move until accelerator pedal is released and lever is returned to NEUTRAL.

Accelerator Pedal - The accelerator pedal is located on the floor of the operator’s compartment. Push down the pedal to increase travel speed.

NOTE : Wait Mode of Operation-This condition will go into effect when the following occurs. The seat switch is closed, key switch is on and the directional control lever is left in NEUTRAL for more than five seconds, with no operator input to any control.

If the accelerator pedal is depressed before the key switch is turned to the ON position, the lift truck will not move until the pedal is released and depressed again.

The line contactor will open and the power steering motor will turn off to conserve energy. The lift truck will remain in this mode until the operator moves the directional control lever, pushes on the accelerator pedal and/or moves any control valve lever.

Release the pedal to decrease travel speed.

Film For function of pedals (if equipped)

Reverse - Pull the lever toward the operator. The lift truck will move in reverse. NOTE : The directional control lever can be used for electrical braking(plugging). To slow or stop the lift truck when traveling in either direction, move the directional control lever to the opposite direction of travel while keeping the accelerator depressed. The lift truck will slow to a complete stop and then accelerate in the opposite direction.

This plate shows the function of the brake and accelerator pedals.

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Operation Section

When the operator raises off the seat (seat switch opens) while the lift truck is in motion, the drive motor will lose power. When this occurs, release the accelerator, close the seat switch (operator seated), move the directional control lever to NEUTRAL and then to desired direction of travel. Push down on the accelerator.

Lift Control Lever

Directional Steering Controls

The forks’ lift control is located at the operator’s right side front. The lift control lever is the lever at the left. Lower - Push the lever forward smoothly to lower the lift forks.

Hold - Release the lift lever. The lever will return to the center (hold) position and the forks will remain in the position they are in.

The directional steering of the lift truck is controlled by the steering wheel. The direction the steering wheel is turned is the direction that the lift truck will turn. Left Turn - Move the steering wheel in a counterclockwise direction to steer the lift truck to the left. The further the steering wheel is turned in a counterclockwise direction the sharper the truck will turn left.

Raise - Pull the lever back smoothly to raise the lift forks.

NOTE : To prevent a sudden change of position of the load, operate all lift, tilt and attachment controls smoothly.

Right Turn - Move the steering wheel in a clockwise direction to steer the lift truck to the right. The further the steering wheel is turned in a clockwise direction the sharper the truck will turn right

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Operation Section

Sideshift Attachment Control (If Equipped)

Tilt Control Lever

The forks’ tilt control is located at the operator’s right side front. The tilt control lever is the lever at the center.

The sideshift attachment control is located at the operator’s right side front. The sideshift attachment control lever is the lever at the right.

Tilt Forward - Push the lever forward smoothly to tilt the forks forward.

Sideshift Left - Push the lever forward smoothly to shift the carriage to the left.

Hold - Release the tilt lever. The lever will return to the center(hold) position and the forks will remain in the position they are in.

Sideshift Hold - Release the sideshif attachment lever. The lever will return to the center(hold) position and sideshifting action will stop.

Tilt Back- Pull the lever back smoothly to tilt the forks back.

Sideshift Right - Pull the lever back smoothly to shift the carriage to the right.

NOTE : To prevent a sudden change of position of the load, operate all lift, tilt and attachment controls smoothly. Never tilt an elevated load forward past vertical.

NOTE : To prevent a sudden change of position of the load, operate all lift, tilt and attachment controls smoothly.

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Operation Section

Before Operating the Lift Truck Walk - Around Inspection For your own safety and maximum service life of the lift truck, make a thorough walk-around inspection before mounting the lift truck or starting to move it. Look for such items as loose bolts, trash build-up, oil leaks, condition of tires, mast, carriage, forks or attachments.

6. Inspect the tires and wheels for proper inflation, cuts, gouges, foreign objects and loose or missing nuts. 7. Inspect the overhead guard for damage, loose or missing mounting bolts. 8. Inspect the hydraulic system for leaks, worn hoses or damaged lines. 1. Inspect the operator’s compartment for loose items and clean any mud or debris from the floor plates for safe footing.

9. Inspect the drive axle housing and the ground for oil leaks.

2. Inspect the instrument panel for damage to the indicator display. 3. Test the horn and other safety devices for proper operation.

10. Disconnect the battery. Tilt the steering column to the full upright position. Release the battery restraint lever in front of battery cover. 11. Raise the seat and cover assembly. 4. Inspect the mast and lift chains for wear, broken links, pins and loose rollers. 5. Inspect the carriage, forks or attachments for wear, damage and loose or missing bolts.

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Operation Section

12. Inspect the battery compartment for loose connections, frayed cables.

WARNING Personal injury may occur from accidents caused by improper seat adjustment. Always adjust the operator’s seat before operating the lift truck.

13. Observe the battery electrolyte level for proper level. Lower the seat and cover assembly and connect the battery to the lift truck. Secure the battery restraint properly.

Seat adjustment must be done at the beginning of each shift and when operators change.

WARNING Batteries give off flammable fumes that can explode.

15. Adjust the steering wheel to comfortable position. Grasp the steering wheel and raise the handle to release the steering column. PULL the steering column BACK or PUSH FORWARD to obtain the most comfortable position. RELEASE the knob and make sure the steering column is locked in this position.

Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Always wear protective glasses when working with batteries.

16. With the seat switch closed and the directional lever in NEUTRAL, turn the key switch ON. Observe the battery discharge indicator. 14. Position the seat by operating the lever and moving the seat forward or backward to a comfortable position.

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Operation Section

Better Battery Performance NOTICE The lift truck operator must not start his shift with a battery that has been taken off a charger too soon. A battery should never be disconnected from a charge until the charge cycle has been completed. The batteries that have been fully charged should have a tag attached for identification.

17. Make sure the battery is charged before operating the lift truck. A fully charged battery will cause “6” to be displayed on the BDI display.

In Operation, a battery should be discharged then recharged in 8 to 12 hours, depending on the charger type. Then, they should be allowed to cool and stabilize 4 to 8 hours. Repeated undercharging must be prevented. It can damage the battery. If there is an indication of low battery operation, the lift truck operator should return the lift truck to the battery charging area.

NOTE : Refer to the Maintenance Section of this guide for additional battery exchanging and charging information.

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Operation Section

Lift Truck Operation Be sure no one is working on or near the lift truck. Keep the lift truck under control at all times. Reduce speed when maneuvering in tight quarters or when braking over a rise. Do not allow the lift truck to overspeed downhill. Use the service brake pedal to reduce speed when traveling down hill. NOTICE Do not move directional control lever from one direction to the other (plug) when the drive wheels are off the ground and rotating at full speed. Damage can occur to the control panel.

5. Turn the key switch to the ON position. Raise the attachments to the travel position.

1. Adjust the operator’s seat. 2. Fasten the seat belt (If Equipped).

6. Move the directional control lever to the desired direction of travel.

3. Move the directional control lever into the NEUTRAL position, if it is not already in this position.

7. Release the service brake pedal.

4. Push down on the service brake pedal and release the parking brake.

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Operation Section

11. Push down on the service brake pedal to bring the lift truck to a complete stop and hold it.

8. Push down on the accelerator pedal to reach the travel speed. Release the pedal to decrease travel speed.

12. To change direction, continue to push down on the accelerator pedal until the disired travel speed in the opposite direction is obtained. 13. Do not use electrical braking (plugging) to stop the lift truck where the stopping distance is too short. Instead, release the accelerator pedal, push down on service brake pedal, and bring the lift truck to a smooth stop.

9. Move the directional control lever to the opposite direction of lift truck travel. 10. Hold the accelerator pedal down until the lift truck nearly comes to a complete stop. Release the accelerator pedal.

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Operation Section

Electrical Braking (Plugging)

Electrical braking uses the drive motor’s own power to slow, stop or change direction when traveling in either direction. It is a more gradual type of stop, compared to using the service brakes. Electrical braking can be used for normal operation where there is adequate time and distance to stop safely. Electrical braking should NOT be used for sudden or emergency stops. To start electrical braking, move the directional control lever to the opposite direction while keeping the accelerator pedal depressed. The lift truck drive control senses that the motors are turning opposite to the vehicle direction of travel and immediately goes into the plugging mode. Motor rotation is retarded at a predetermined rate by electrical braking (plugging). If the accelerator pedal is kept depressed, the drive control will slow the lift truck to a complete stop and then accelerate in the opposite direction.

NOTICE Do not move directional control lever from one direction to the other (plug) when the drive wheels are off the ground and rotating at full speed. Damage can occur to the control panel.

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Operation Section

Operating Techniques NOTE : The illustrations used here are typical examples and may not look exactly like your particular lift truck.

Inching into Loads

Lifting the Load

1. Move the lift truck slowly forward into position and engage the load. Lift truck should be square with load and forks should be spaced evenly between pallet stringers and as far apart as load will permit.

1. Lift the load carefully and tilt the mast back a short distance. 2. Tilt the mast further back to cradle the load.

2. Move the lift truck forward until the load touches the carriage.

3. Operate the lift truck in reverse until the load is clear of the other loads. 4. Lower the load to the travel position before turning or traveling.

CAUTION The forklift truck must not be used to push loads or other vehicles. Only the moving equipment supplied or the rear hook for towing must be used.

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Operation Section

Turning

Traveling Whether you are traveling with or without a load, travel with the fork as low as possible, while still maintaining good clearance above the floor.

1. When turning sharp corners, keep close to the inside corner. Begin the turn when the inside drive wheel meets the corner. 1. Carry the load as low as possible, but maintain clearance.

2. When turning in narrow aisles, keep as far from the stockpile as possible when making a turn into the aisle. Allow for counterweight swing. 2. On grades, alway travel with the load on the “uphill” side, as shown above.

3. Travel in reverse with bulky loads. This gives you better vision.

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Operation Section

Unloading

Lifting Drums or Round Objects

1. Move the lift truck into the unloading position.

1. Block the drums or round objects. Tilt the mast forward and slide the fork tips along the floor to get under the load.

2. Do not tilt the mast forward until it is directly over the unloading area.

WARNING Do not tilt the mast forward with the load unless directly over the unloading area, even if the power is off.

2. Tilt the mast back slightly until the load is cradled on the forks before lifting. 3. Lift the load to the travel position.

3. Deposit the load and back away carefully to free the forks. 4. Lower the carriage and forks to either travel position or park position.

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Operation Section

Parking the Lift Truck NOTICE Parking or storage of electric lift trucks outdoor can cause lift truck system damage or failure. Park or store all electric lift trucks inside a building to protect electrical system from moisture damage. 3. Engage the parking brake. When leaving the operator’s station, park the lift truck in authorized areas only. Do not block traffic. Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor. Block the drive wheels when parking on an incline.

4. Tilt the mast forward and lower forks to the floor.

1. Apply the service brake to stop the lift truck.

5. Turn key switch to OFF and remove the key. 6. Disconnect the battery

2. Move the NEUTRAL.

directional

control

lever

into

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Operation Section

7. Block the wheels if parking on an incline.

WARNING Blocking the wheels will prevent unexpected lift truck movement, which could cause personal injury.

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Operation Section

Lift Fork Adjustment WARNING When adjusting the fork spread, be careful not to pinch your hand between forks and the carriage slot.

Hook-on type Fork

1. Move up the hook pin to the free position in each fork to slide the fork on the carriage bar. 2. Adjust the forks in the position most appropriate for the load and as wide as possible for load stability. 3. When adjusting the forks, make sure that the weight fo the load is centered on the truck. 4. After adjustment, set the hook pins to keep the forks in place.

WARNING Make sure the forks are locked before carrying a load.

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Operation Section

Storage Information Before Storage To place the machine in storage for an extended period of time, the following measures must be taken to ensure that it can be returned to operation with minimal service. 1. After every part is washed and dried, the machine should be housed in a dry building. Never leave it outdoors. In case it has to be left outdoors, lay wooden boards on the ground, park the machine on the boards and cover it with canvas, etc. 2. Lubricate, grease and replace oil before storage. 3.

Apply a thin coat of grease surface(hydraulic piston rods.)

to metal

4. Cover batteries after removing terminals, or remove them from the machine and store separately.

During Storage Drive the truck for a short while once a month so that new oil film will be coated over movable parts and component surfaces. Charge the battery at the same time.

After Storage After storage (when it is kept without cover or rust preventive operation once a month is not made), you should apply the following treatment before operation. 1. Remove the drain plug on hydraulic tank and drain mixed water. 2. Wipe off grease from hydraulic cylinder piston rod. 3. Measure specific gravity and check that battery is charged. 4. Drive at low speed to make sure inside of transfer is well oiled.

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Operation Section

Transportation Hints

6. Disconnect the battery.

Shipping

7. Block the tires and secure the lift truck with tiedowns.

Check travel route for overpass clearances. Make sure there is adequate clearance if the lift truck being transported is equipped with a high mast, overhead guard or cab.

Machine Lifting and Tiedown Information

NOTICE

To prevent the lift truck from slipping while loading, or shifting in transit, remove ice, snow or other slippery material from the loading dock and the truck bed before loading.

Improper lifting or tiedowns can allow load to shift and cause injury and/or damage.

1. Weight and instructions given herein apply to lift trucks as manufactured by DAEWOO.

NOTICE Obey all state and local laws governing the weight, width and length of a load. Observe all regulations governing wide loads.

2. Use properly rated cables and slings for lifting. Position the crane for level lift truck lift. 3. Spreader bar widths should be sufficient to prevent contact with the lift truck.

NOTICE Remove ice, snow or other slippery material from the shipping vehicle and the loading dock.

4. Use the tiedown locations provided for lift truck tiedown. Check the state and local laws governing weight, width and length of a load. Contact your DAEWOO Lift Truck dealer for shipping instructions for your lift truck.

1. Always block the trailer or the rail car wheels before loading the lift truck. 2. Position the lift truck on the trailer or the rail car. 3. Apply the parking brake and place the transmission control in NEUTRAL. 4. Tilt the mast forward and lower forks to the floor. 5. Turn key switch OFF and remove the key.

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Operation Section

rolling uncontrolled.

Towing Information Personal injury or death could result when towing a disabled lift truck incorrectly.

The requirements of each towing situation will be affected by many conditions. Minimum towing lift truck capacity is required on smooth, level surfaces, while maximum capacity is needed on inclines or on poor surface conditions.

Block the lift truck wheels to prevent movement before releasing the brakes. The lift truck can roll free if it is not blocked.

Consult your DAEWOO Lift Truck dealer for towing a disabled lift truck.

WARNING

Follow the recommendations below to properly perform the towing procedure. The towing instructions given here are for moving a disabled lift truck only a short distance at low speed [no faster than 1.2 mph (2 km/h)] to a convenient location for repair. These instructions are for emergencies only. If long-distance moving is required, always haul the lift truck. You must provide shielding on the towing lift truck to protect the operator if the tow line or bar should break. 1. Release the parking brake.

Do not allow an operator to sit on the lift truck being towed unless the steering and braking can be controlled.

NOTICE Release the parking brake to prevent excessive wear and damage to the parking brake system.

The operator on the towed lift truck must always steer in the direction of the tow line pull. Inspect the tow line or bar and make sure it is in good condition and has enough strength for the towing situation involved. For a disabled lift truck stuck in mud or when towing on a grade, use a towing line or bar with a strength of at least 1.5 timesthe gross weight of the towing lift truck.

2. Release the service brake pedal. 3. Turn the key switch OFF. 4. Disconnect the battery.

Keep the tow line angle to a minimum. Do not exceed a 30° angle from the straight-ahead position. Connect the tow line as low as possible on the lift truck being towed.

5. Fasten the tow bar to the lift truck. 6. Remove any wheel blocks. Tow the lift truck slowly. Do not tow any faster than 2 km/h (1.2 mph).

Use gradual and smooth lift truck movement. Moving the lift truck quickly could overload the tow line or bar and cause it to break.

WARNING

Normally, the towing lift truck should be at least as large as the disabled lift truck. It should have enough brake capacity, weight, and power to control both lift trucks for the grade and distance involved. A larger towing lift truck or additional lift trucks connected to the rear could be required to provide sufficient control and braking when moving a disabled lift truck downhill. This will prevent it from

Be sure all necessary repairs and adjustments have been made before a lift truck that has been towed to a service area is put back into operation. Personal injury or death could result.

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Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for inspection, maintenance and repair of lift truck forks. It also provides general information on the design and application of forks and the common cause of fork failures.

Users may also refer to the International Organization For Standardization-ISO Technical Report 5057-Inspection and Repair of Fork Arms and ISO Standard 2330-Fork Arms-Technical Characteristics and Testing. While there are no specific standards or regulations in the United States, users should be familiar with the requirements for inspection and maintenance of lift trucks as provided by the 29 Code Federal Register 1910.178 Powered Industrial Truck, and ANSI/ASME Safety Standard(s) B56.1, B56.5 or B56.6 as applicable to the type of machine(s) in use.

Lift truck forks can be dangerously weakened by improper repair or modification. They can also be damaged by the cumulative effects of age, abrasion, corrosion, overloading and misuse. A fork failure during use can cause damage to the equipment and the load. A fork failure can also cause serious injury. A good fork inspection and maintenance program along with the proper application can be very effective in preventing sudden on the job failures. Repairs and modifications should be done only by the fork manufacturer or a qualified technician who knows the material used and the required welding and heat treatment process. Users should evaluate the economics of returning the forks to the manufacturer for repairs or purchasing new forks. This will vary depending on many factors including the size and type of fork. Forks should be properly sized to the weight and length of the loads, and to the size of the machine on which they are used. The general practice is to use a fork size such that the combined rated capacity of the number of forks used is equal to or greater than the “Standard (or rated) Capacity” of the lift truck. The individual load rating, in most cases, will be stamped on the fork in a readily visible area. This is generally on the top or side of the fork shank. • A fork rated at 1500 pounds at 24 inch load center will be stamped 1500X24. • A fork rated at 2000 kg at 600 mm load center will be stamped 2000X600. The manufacturer identification and year and date of manufacture is also usually shown. Some countries have standards or regulations which apply specifically to the inspection and repair of forks. - 64 -

Maintenance Section

• Repetitive Overloading

Causes of Fork Failure Improper Modification or Repair

Repetitive cycling of loads which exceeds the fatigue strength of the material can lead to fatigue failure. The overload could be caused by loads in excess of the rated fork capacity and by use of the forks tips as pry bars. Also, by handling loads in a manner which causes the fork tips to spread and the forks to twist laterally about their mountings.

Fork failure can occur as a result of a field modification involving welding, flame cutting or other similar processes which affect the heat treatment and reduces the strength of the fork. In most cases, specific processes and techniques are also required to achieve proper welding of the particular alloy steels involved. Critical areas most likely to be affected by improper processing are the heel section, the mounting components and the fork tip.

• Wear Forks are constantly subjected to abrasion as they slide on floors and loads. The thickness of the fork blade is radually reduced to the point where it may not be capable of handling the load for which it was designed.

Bent or Twisted Forks Forks can be bent out of shape by extreme overloading, glancing blows against walls or other solid objects or using the fork tip as a pry bar.

• Stress Risers

Bent or twisted forks are much more likely to break and cause damage or injury. They should be removed from service immediately.

Scratches, nicks and corrosion are points of high stress concentration where cracks can develop. These cracks can progress under repetitive loading in a typical mode of fatigue failure.

Fatigue

Overloading

Parts which are subjected to repeated or fluctuating loads can fail after a large number of loading cycles even though the maximum stress was below the static strength of the part.

Extreme overloading can cause permanent bending or immediate failure of the forks. Using forks of less capacity than the load or lift truck when lifting loads and using forks in a manner for which they were not designed are some common causes of overloading.

The first sign of a fatigue failure is usually a crack which starts in an area of high stress concentration This is usually in the heel section or on the fork mounting. As the crack progresses under repetitive load cycling, the load bearing cross section of the remaining metal is decreased in size until it becomes insufficient to support the load and complete failure occurs. Fatigue failure is the most common mode of fork failure. It is also one which can be anticipated and prevented by recognizing the conditions which lead up to the failure and by removing the fork service prior to failing.

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Maintenance Section

First Installation

Fork Inspection

1. Inspect forks to ensure they are the correct size for the truck on which they will be used. Make sure they are the correct length and type for the loads to be handled. If the forks have been previously used, perform the “12 Month Inspection”. If the forks are rusted, see “Maintenance and Repair”. Establish a daily and 12 month inspection routine by keeping a record for the forks on each lift truck.

2. Make sure fork blades are level to each other within acceptable tolerances. See “Forks, Step 4,” in the “2000 Service Hours or Yearly” in “Maintenance Intervals”

Initial information should include the machine serial number on each the forks are used, the fork manufacturer, type, original section size, original length and capacity. Also list any special characteristics specified in the fork design.

3. Make sure positioning lock is in place and working Lock forks in position before using truck. See “Forks, Step 7”, in the “2000 Service Hours or Yearly” in “Maintenance Intervals”.

Record the date and results of each inspection, making sure the following information is included.

Daily Inspection

• Actual wear conditions, such as percent of original blade thickness remaining.

1. Visually inspect forks for cracks, especially in the heel section, around the mounting brackets, and all weld areas. Inspect for broken or jagged fork tips, bent or twisted blades and shanks.

• Any damage, failure or deformation which might impair the use of the truck. • Note any repairs or maintenance.

2. Make sure positioning lock is in place and working. Lock the forks in position before using the truck. See “2000 Service Hours or Yearly” in “Maintenance Intervals”.

An ongoing record of this information will help in identifying proper inspection intervals for each operation, in identifying and solving problem areas and in anticipating time for replacement of the forks.

3. Remove all defective forks from service.

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Maintenance Section

With the fork restrained in the same manner as its mounting on the lift truck, apply the test load twice, gradually and without shock. Maintain the test for 30 seconds each time.

12 Months Inspection Forks should be inspected, at a minimum, every 12 months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked every six months. See “Forks” in the “2000 Service Hours or Yearly” in “Maintenance Intervals.”

Check the fork arm before and after the second application of the test load. It shall not show any permanent deformation. Consult the fork manufacturer for further information as may be applicable to the specific fork involved. Testing is not required for repairs to the positioning lock or the markings.

Maintenance and Repair 1. Repair forks only in accordance with the manufacturer’s recommendations. Most repairs or modifications should be done only by the original manufacturer of the forks or an expert knowledgeable of the materials, design, welding and heat treatment process. 2. The following repairs or modifications SHOULD NOT be attempted. • Flame cutting holes or cutouts in fork blades. • Welding on brackets or new mounting hangers. • Repairing cracks or other damage by welding. • Bending or resetting. 3. The following repairs MAY be performed. • Forks may be sanded or lightly ground, to remove rust, corrosion or minor defects from the surfaces. • Heel sections may be ground with a carbon stone to remove minor surface cracks or defects. Polish the inside radius of the heel section to increase the fatigue life of the fork. Always grind or polish in the direction of the blade and shank length. • Repair or replace the positioning locks on hook type forks. • Repair or replace most fork retention devices used with other fork types. 4. A fork should be load tested before being returned to service on completion of repairs authorized and done in accordance with the manufacturer’s recommendations. Most manufacturers and standards require the repaired fork to be tested with a load 2.5 times the specified capacity and at the load center marked on the fork arm.

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Maintenance Section

Torque Specifications Torque for Standard Bolts, Nuts and Taperlock Studs

Metric Hardware - This lift truck is almost totally metric design. Specifications are given in metric and U.S. Customary measurement. Metric hardware must be replaced with metric hardware. Check parts books for proper replacement.

NOTICE The following charts give general torques for bolts, nuts and taperlock studs of SAE Grade 5 or better quality.

NOTE : Use only metric tools on most hardware for proper fit. Other tools could slip and possibly cause injury.

Torques for Bolts and Nuts with Standard Threads

Torque for Standard Hose Clamps - Worm Drive Band Type

Thread Size NOTICE The following chart gives the torques for initial installation of hose clamps on new hoses and for reassembly or retightening of hose clamps on existing hose.

Initial Installation Torque on New Hose Clamp Width 1 lb·in N·m 16 mm (.625 inch) 7.5 ± 0.5 65 ± 5 13.5 mm (.531 inch) 4.5 ± 0.5 40 ± 5 8 mm (.312 inch) 0.9 ± 0.2 8±2 Reassembly or Retightening Torque on Clamp Width existing hose N·m1 lb·in 16 mm (.625 inch) 4.5 ± 0.5 40 ± 5 13.5 mm (.531 inch) 3.0 ± 0.5 25 ± 5 8 mm (.312 inch) 0.7 ± 0.2 6±2 1 1 Newton meter (N•m) is approximately the same as 0.1 kg•m.

Standard Bolt & Nut Torque

Inch

N·m1

lb·ft

1/4

12 ± 4

9±3

5/16

25 ± 7

18 ± 5

3/8

45 ± 7

33 ± 5

7/16

70 ± 15

50 ± 11

1/2

100 ± 15

75 ± 11

9/16

150 ± 20

110 ± 15

5/8

200 ± 25

150 ± 18

3/4

360 ± 50

270 ± 37

7/8

570 ± 80

420 ± 60

875 ± 100

640 ± 15

1 1/8

1100 ± 150

820 ± 10

1 1/4

1350 ± 175

1000 ± 130

1 3/8

1600 ± 200

1180 ± 150

1 1/2

2000 ± 275

1480 ± 200

1 Newton meter (N•m) is approximately the same as 0.1 kg•m.

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Maintenance Section

Torques for Taperlock Studs Thread Size

Torque for Metric Fasteners

Standard Taperlock Stud

NOTICE Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or incorrect fasteners will cause lift truck damage or malfunction and may even result in personal injury.

Torque

Inch

N·m

lb·ft

1/4

8±3

6±2

5/16

17± 5

13 ± 4

3/8

35 ± 5

26 ± 4

7/16

45 ±10

33 ± 7

1/2

65 ±10

48 ± 7

5/8

110 ± 20

80 ± 15

3/4

170 ± 30

125 ± 22

7/8

260 ± 40

190 ± 30

400 ± 60

300 ± 45

1 1/8

500 ± 70

370 ± 50

1 1/4

650 ± 80

480 ± 60

1 3/8

750 ± 90

550 ± 65

1 1/2

870 ± 100

640 ± 75

Original fasteners removed from the lift truck should be saved for reassembly whenever possible. If new fasteners are needed, they must be of the same size and grade as the ones that are being replaced. The material strength identification is usually shown on the bolt head by numbers.(8.8, 10.9, etc.) The following chart gives standard torques for bolts and nuts with Grade 8.8.

NOTE : Metric hardware must be replaced with metric hardware. Check parts book for proper replacement.

1 Newton meter (N•m) is approximately the same as0.1 kg•m.

METRIC ISO THREAD Thread Size

Standard Torque

Metric

N·m1

lb·ft

12 ± 4

9±3

25 ± 7

18 ± 5

M10

55 ± 10

41 ± 7

M12

95 ± 15

70 ± 11

M14

150 ± 20

110 ± 15

M16

220 ± 30

160 ± 22

M20

450 ± 70

330 ± 50

M24

775 ± 100

570 ± 75

M30

1600 ± 200

1180 ± 150

M36

2700 ± 400

2000 ± 300

1 Newton meter (N•m) is approximately the same as 0.1 kg•m. 2 ISO-International Standard Organization.

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Maintenance Section

Battery Discharge Indicator The batteries should not be discharged below 80% of the full charge as indicated by their specific gravity. This specification varies with different battery manufacturers. See the manufacturer’s specifications for specific gravity at 80% discharge. If information is not available from the battery supplier, use 1.140 specific gravity level.

The battery discharge indicator should be observed frequently before and during operation.

A fully charged battery will cause a “6 segments” to be displayed on the LCD display. As the battery is discharged, the LCD display will count down, 6, 5, 4, and etc., until “EL” is displayed. When the battery reaches 80% discharge level, the Micro-Controller will cause the LCD display to continuously index through the entire range (1 through 6 segments) to signal that the battery is discharged and lift interrupt is imminent. If the warning is ignored, lift interrupt will prevent the hydraulic pump motor from operating and an “EL” will be displayed on the LCD display. To prevent over-discharge, the lift interrupt should not be reset by disconnecting and reconnecting the battery. If the batteries are weak, have them charged or replaced.

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Maintenance Section

Low battery operation must be prevented. Operation with a low battery may cause damage to the battery. Low battery operation will cause higher than normal current in the electrical system. This can damage contactor tips or shorten motor brush life.

Battery WARNING When using pressure air for cleaning purposes, wear a protective face shield and protective clothing. Maximum air pressure must be below 207 kPa (30 psi).

Batteries that have been fully charged should have a tag attached for identification. A battery should be recharged in 8 to 12 hours after being discharged, depending on the charger type, and then allowed to cool and stabilize 4 to 8 hours. Repeated undercharging must be prevented because it can damage the battery.

Do not smoke near batteries that are being stored or when checking the electrolyte level. Electrolyte is an acid solution and can cause personal injury. Avoid contact with skin and eyes.

A battery requires an equalizing charge at least once every 20 normal charge/discharge cycles. This helps correct and prevent unequal cell specific gravity (SG) readings. An “equalizing charge” is a cycle charge with modification, given usually at an interval to bring all cells up to a state of equal charge. An equalizing charge usually adds three to four more hours to the cycle charge, at a low finish rate. It is usually given when the specific gravity (SG) of electrolyte has a variation of more than 20 points (.020) from cell to cell, after a regular cycle charge.

Maximum life and performance of lift truck batteries is dependent on the operator, battery charging, maintenance and service. Most dirt and dust picked up by the battery can usually be blown off with low pressure compressed air. However, if cells are overfilled and electrolyte collects on the covers, the top of the battery will stay wet.

A “cycle charge” will completely recharge the battery. The typical cycle charge for a fully discharged battery usually is an eight-hour charge. The battery must be recharged before it has been discharged over 80% of the rated capacity of the battery. The work shift of the lift truck can be planned so the battery will not be discharged more than 80%.

If necessary, clean the top of the battery with a solution of baking soda and hot water. NOTICE Vent caps must be tight to prevent soda solution from entering battery cells.

A battery should never be left in a discharged state because of sulfate formation. This reduces battery life drastically. To extend life always recharge the battery without delay after it has been discharged.

Repeated over discharging of the battery will damage the cells, which will shorten battery life and increase operating cost. Battery life (number of cycles) decreases as the depth of discharge increases. The estimated life of the battery discharged to 80% will be approximately twice as long as if it were discharged 100%.

After cleaning action has stopped, rinse the batteries thoroughly with water. Dry the batteries with low air pressure. The lift truck operator must not start his shift with a battery that has been taken off a charger too soon. Batteries are designed to be charged and allowed to cool and stabilize. A battery should never be disconnected from a charger until the charge cycle has been completed.

The battery’s maximum temperature is critical. The electrolyte temperature should never exceed 43°C (110°F) either while operating or charging. If higher temperatures are maintained through use or abuse, reduced battery service life can be expected. - 71 -

Maintenance Section

Battery condition is important for a long life. The electrolyte level should be maintained at the recommended levels and the battery should be kept clean and dry. “Washing down” batteries at different time periods will reduce the chance of “grounds” caused by electrolyte spills and corrosion. If done often enough, just washing with water alone will eliminate the need for using baking soda. If not, a solution of baking soda and water must be used to wash battery at different time periods. Add water at regular intervals. Enough water should be added to bring the electrolyte approximately 13.0 mm (.50 inch) above the plates. This is a simple matter with the use of an automatic cell filler, which shows a light when the correct level has been reached. Water should always be added before charging to be sure thorough mixing with acid when gassing occurs near the end of charging period. Use distilled water or have the water supply analyzed. Charge the batteries correctly. It is important that all batteries should be charged according to the manufacturer’s instructions. Most of the charging equipment is fully automatic and should be checked periodically. Never operate the lift truck with a fully discharged battery because this will damage the battery. When a battery charger operates correctly and brings a good battery up to full charge, the current readings will level to the “finish rate.” The charging voltage will stabilize, the specific gravity will stop rising and normal gassing can be seen.

NOTICE • DISPOSAL OF OLD BATTERY Careless disposal of a battery can harm the environment and can be dangerous to persons. Always dispose of a battery to authorized personnel only. Do not attempt to open or dismantle a battery or a cell.

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Maintenance Section

Lubricant Specifications

Hydraulic Oils (HYDO)

Lubricant Information Certain abbreviations follow S.A.E. J754 nomenclature and some classifications follow S.A.E. J183 abbreviations. The MIL specifications are U.S.A. Military Specifications. The recommended oil viscosities can be found in the “Lubricant Viscosities” chart in this publication.

Chain and Linkage Oils (DEO or EO) The following commercial classifications can be used in the hydraulic system. • ISO 6743/4 • AFNOR NFE 48-603 • DIN 51524 TEIL 2 • HAGGLUNDS DENISON • CINCINNATI

HM HM H-LP HFO-HF2 P68, 69, 70

Viscosity: ISO VG 32

Use the following engine oils recommended for use on chains and linkages.

These oils should have antiwear, antifoam, antirust and antioxidation additives for heavy duty use as stated by the oil supplier. ISO viscosity grade of 32 would normally be selected.

• European oil specification CCMC D3. • API Specification CD, CD/SF, CE • Military specifications MIL-L-2104D or E

NOTICE Make-up oil added to the hydraulic tanks must mix with the oil already in the systems. Use only petroleum products unless the systems are equipped for use with special products. If the hydraulic oil becomes cloudy, water or air is entering the system. Water or air in the system will cause pump failure. Drain the fluid, retighten all hydraulic suction line clamps, purge and refill the system. Consult your DAEWOO Lift Truck dealer for purging instructions.

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Maintenance Section

Hydraulic Brake Fluid

Drive Axle Oil NOTE: Failure to follow the recommendation will cause shortened life due to excessive gear wear. The API CD/TO-2 specification or MIL-L-2104D, E or F oils could be used.

Lubricating Grease (MPGM) Use multipurpose Molybdenum Grease (MPGM) for all lubrication points. If MPGM grease can not be used, multipurpose type grease which contains 3% to 5% molybdenum disulfide can be used.

Use heavy duty hydraulic brake fluid certified by the oil supplier to meet ISO 6743/4 HM, ISO VG 10 latest revision.

NLGI No.2 grade is suitable for most temperatures. Use NLGI No.1 or No.0 grade for extremely low temperature.

TOTAL

Azolla ZS 10

AGIP

Acer 10

Energol HP 10 HLP 10

CALTEX

Spindurn 10

ELF

Spinelf

ESSO

Nuto H 10 Spinesso 10

FINA

Hydran 10

MOBIL SHELL

- 74 -

Velocite oil No.5 Velocite oil E Tllvs oil C 10 Morlina 10

Maintenance Section

Cold Storage Applications

Hydraulic System

When an electric lift truck is operated in cold storage applications, at temperatures as low as -20°C (-4°F), the battery capacity is decreased. Operation at cold temperatures can also cause mechanical failures, short circuits and too much wear due to the formation of ice crystals. The direct cause of these problems is the extreme changes in temperature in combination with humidity in the air which can result in condensation. To protect the electric lift truck’s components and decrease the effects of the cold temperature, perform the following items before you put the lift truck to work in cold storage applications.

Drain the hydraulic system and fill it with SAE 5, or MIL-H-5606E hydraulic oil

Lift Chains Battery

There is a reduction in battery capacity in cold storage applications. For this reason, it is important to:

Remove the chains. Clean nonflammable cleaning solvent.

them

2. Put the chains in molybdenum disulfide (MPGM) grease for one hour. Then, before installation, hang the chains, where they will not move, for three hours.

a. Be sure the battery is completely charged at the start of each work cycle. b. If possible, keep the lift truck in a warm storage area when it is not in use. c. Do not store a discharged battery at below freezing temperature.

3. Put MPGM grease on the chains at one-week intervals. 4. Check chains very carefully for wear on the link plate edges, caused when they run over the sheaves. Check the chains regularly for cracked links, loss of shape in the holes, and corrosion. Observe the battery discharge indicator frequently.

- 75 -

Maintenance Section

Chassis

Put molybdenum disulfide (MPGM) grease in all the grease fittings.

- 76 -

Maintenance Section

Lubricant Viscosities and Refill Capacities Lubricant Viscosities

Refill Capacities

LUBRICANT VISCOSITIES FOR AMBIENT (OUTSIDE) TEMPERATURES Compartment or System Hydraulic and Power Steering System ISO 6743/4 HM

Drive Axle Housing API CD/TO-2

Brake Reservoir ISO 6743/4 HM

REFILL CAPACITIES (APPROXIMATE) Compartment

Oil °C Viscosities Min Max

°F Min Max

ISO VG 22

-30

+20

-22

+68

ISO VG 32

-20

+30

-4

+86

ISO VG 46

-10

+40

+14 +104

ISO VG 68

+50

+32 +122

Liters

U.S. Gal

5.28

Drive Axle Housing

5.0

1.32

Brake Reservoir

0.6

0.16

or System

SAE 10W

-20

+22

-4

SAE 30

+10

+50

+50 +122

ISO VG 10

-20

+30

-4

Hydraulic & Power Steering System

+72

- 77 -

Maintenance Section

Every 250 Service Hours or Monthly

Maintenance Intervals

Brake Oil Level - Check....................................102 Parking Brake - Test, Adjust .............................102 Drive Axle Oil Level - Check .............................104 Mast Carriage, Chains and Attachments - Inspect, Adjust, Lubricate ..............................................105 Hydraulic Oil Level - Check ..............................106 Wheel Bolt & Nut - Check for Tightness............106

NOTICE All maintenance and repair, except every 10 service hours or daily, on the lift truck must be performed by qualified and authorized personnel only.

Every 500 Service Hours or 3 Months NOTICE

Quick Reference to Maintenance Schedule ................................. 79

Mast Hinge Pin - Lubricate ...............................107 Tilt Cylinders - Check, Adjust, Lubricate............107 Crosshead Roller - Check.................................108 Directional Control Lever - Check .....................109 Drive Axle Oil - Change ....................................109 Overhead Guard - Inspect ................................109 Steering Mechanism - Lubricate .......................109 Control Panel - Clean, Inspect ..........................110

When Required

Every 1000 Service Hours or 6 Months

Self Diagnostics - Test ....................................... 80 Head Capacitor - Discharge ............................... 91 Brushes - Check, Replace.................................. 92 Fuses - Replace................................................. 93 Seat - Lubricate ................................................. 94 Carriage Roller Extrusion - Adjust ...................... 94

Drive Motor - Clean, Inspect .............................111 Hydraulic Pump Motor - Clean, Inspect.............113 Hydraulic Return Filter - Change.......................114 Lift Chains – Test, Check, Adjust ......................115

Every 10 Service Hours or Daily

Steer Wheel Bearings - Reassemble ................117 Drive Wheel Bearings - Reassemble ................119 Forks - Inspect .................................................119 Air Breather......................................................122

Careless disposal of waste oil can harm the environment and can be dangerous to persons. Always dispose of waste oil to authorized personnel only.

Every 2000 Service Hours or Yearly

Walk - Around Inspection - Inspect..................... 95 Mast Channels - Lubricate ................................. 97 Battery - Check, Exchange, Change .................. 97 Indicator - Check................................................ 99 Back - up Alarm (If Equipped) - Test................... 99

Every 2500 Service Hours or 15 Months Hydraulic Oil - Check, Change..........................123

First 50 - 100 Service Hours or a Week Drive Axle Oil - Change.................................... 100

First 250 Service Hours or a Month Hydraulic Return Filter - Change ...................... 101

- 78 -

Maintenance Section

Air Breather

Change

122

Back-up Alarm(If Equipped)

Test

Battery Brake Oil Level Brushes Carriage Roller Extrusion Control Panel

Check, Exchange, Charge Check Check, Replace Adjust Clean, Inspect

Crosshead Rollers Directional Control Lever Drive Axle Oil Drive Axle Oil Level Drive Axle Oil Drive Motor Drive Wheel Bearings Forks Fuses Head Capacitor Hydraulic Oil Hydraulic Oil Level

Check Check Change Check Change Clean, Inspect Reassemble Inspect Replace Discharge Check, Change Check

99 97 102 92 94 110 108 109 100 104 109 111 119 119 93 91 123 106

Clean, Inspect

113

Change Change Check Test, Check, Adjust

101 114 99 115

Hydraulic Power Steering Pump Motor Hydraulic Return Filter Hydraulic Return Filter Indicator Lift Chains Mast Carriage, Chains & Attachments Mast Channels Mast Hinge Pins Overhead Guard Parking Brake Seat Self Diagnostics

Inspect, Adjust, Lubricate

105

Lubricate Lubricate Inspect Test, Adjust Check, Lubricate Test

Steer Wheel Bearings Steering Mechanism Tilt Cylinders Walk-Around Inspection

Reassemble Lubricate Check, Adjust, Lubricate Inspect

Wheel Bolt & Nut

Inspect

97 107 109 102 94 80 117 109 107 95 106

- 79 -

2500 Service Hours or 15 Months

2000 Service Hours or a Year

1000 Service Hours or 6 Months

500 Service Hours or 3 Months

250 Service Hours or a Month

EVERY

10 Service Hours or a Day

PAGE

250 Service Hours or a Month

SERVICES

When Required

ITEMS

50-100 Service Hours or a Week

FIRST

Quick Reference to Maintenance Schedule

O O O O O

O O O O

O O

O O O

O O

O O O

Maintenance Section

When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Self Diagnostics - Test Prepare for the Self - Diagnostic Test

The Micro-Controller has a built-in diagnostic system to provide aid in rapid troubleshooting of lift truck problems. NOTE: Make sure the battery is fully charged before any of the following tests are made. After the self-diagnostics tests have been started, the procedure does not have to be completed. At any point the procedure can be interrupted, and the lift truck made ready for operation.

4. Move the directional control lever to NEUTRAL. 5. Move the key switch to OFF.

1. Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor.

6. Disconnect the battery.

2. Block the drive wheels. 3. Release the parking brake.

7. Remove the control panel cover.

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Maintenance Section

WARNING Personal injury could result if head capacitor has not been discharged properly. Battery voltage and high amperage are present. The HEAD capacitor must be discharged before any contact with the electrical control system is made. Before touching any electrical components, remove rings, watches and other metallic objects from the hands and arms, and then discharge the HEAD capacitor.

10. Loosen the four screws to remove the logic unit cover.

11. Toggle the diagnostic switch from the “Run” to the “Diagnostic” position. 8. Discharge the head capacitor. See topic “Head Capacitor” in this section.

12. Connect the battery. 9. Disconnect line fuse to prevent lift truck movement.

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Maintenance Section

13. Turn the key switch to ON. If the line fuse has not been disconnected the LCD display will show a “d”. Further testing is not possible until the line fuse is disconnected.

An “A0” will be displayed, in the LCD, if the logic module circuitry is correct. An “F” will be displayed, in the LCD, if a failure is detected. A “d” will be displayed, in the LCD, if the line fuse has not been disconnected.

Perform the Self-Diagnostic Tests The tests will be performed in order. The LCD display will advance one number upward, upon the successful completion of each test. If the test detects a failure, the number will not advance. See the “Service Manual” testing and adjusting section of “Lift Trucks Micro- Controller Control System” to see if the failed component should be replaced or repaired.

Seat Switch

A test that failed can be bypassed to test remaining components by moving the diagnostic toggle switch from “Diagnostic” to “Run” and back to “Diagnostic”. The tests are performed as follows: Close the seat switch by depressing the seat and then release.

Logic Module Circuitry

The logic module circuitry will be automatically checked if the line fuse has been disconnected.

The seat is depressed, the LCD display “A1”. And the seat is released, the LCD display “A0”. If still “A0” or “A1”, failure has been detected.

- 82 -

Maintenance Section

Direction Selector

Lift Switch

Move the directional control lever from NEUTRAL to reverse to forward and back to NEUTRAL.

Pull the lift control lever to maximum lift position and then release.

The directional control lever is reverse, the LCD display “A2”. And the directional control lever is neutral, the LCD display “A0”. If still “A0” or “A2”, a failure has been detected. The directional control lever is forward, the LCD display “A3”. And the directional control lever is neutral, the LCD display “A0”. If still “A0” or “A3”, a failure has been detected. The LCD displays the speed that the lift lever is set to. As lever is pulled back, 1 through 3 will be shown. And the lift control lever is released, the LCD display “A0”. If still “A0”, a failure has been detected.

- 83 -

Maintenance Section

Tilt and Auxiliary Switches

With the auxiliary control lever in maxmum position, the LCD will display “A7” and “A0” when the lever is released. If still “A0” or “A7”, a failure has been detected.

Pull the tilt lever to maximum position and then release.

Parking Brake Switch

With the tilt control lever in maximum position, the LCD will display “A6” and “A0” when the lever is released. If still “A0” or “A6”, a failure has been detected.

Pull the parking brake lever to maximum position and the release.

Pull the auxiliary control lever to maximum position and then release. If there is no auxiliary control lever, skip to next procedure.

With the parking brake lever in maximum position, the LCD will display “A9” and “A0” when the lever is released. If still “A0” or “A9”, a failure has been detected. - 84 -

Maintenance Section

Accelerator Control

Contactor Test Switch

Depress the accelerator pedal fully and then

Move the DIAG/RUN/SETUP switch from DIAG to RUN and then back to DIAG position.

release.

The LCD display “AC” and then contactors are activated in order. (Line contactor →bypass contactor →forward direction contactor→reverse direction contactor)

When the accelerator pedal is depressed, the speed symbols are increase from 0 to 10 on the LCD. When the accelerator pedal is released, the speed symbols are decrease to 0. If the speed symbols are not full on the LCD, a failure has been detected.

- 85 -

Maintenance Section

Reverse Direction Contactor (Right Side) This completes the self-diagnostics tests. Turn the key switch to the OFF position and disconnect the battery. NOTE: If the lift truck still has a problem after the Self- Diagnostic tests have been completed, see the Service Manual or contact your DAEWOO Lift Truck dealer for additional information.

3. Connect line fuse.

1. Move the diagnostic switch to the "Run" position.

4. Install the control panel cover. 5. Connect the battery.

2. Install the logic unit cover.

- 86 -

Maintenance Section

Diagnostic tests Diagnostic procedure is essentially the same as the standard model's, but contains some additional tests. Refer to the following table, and previous text and pictures to determine correct diagnostic procedure. Step 1 2

Procedure

Display status

Circuit

Active

Turn key switch on with

Internal circuit

battery connected

Fuse removal

Depress the seat and then release

Seat switch

Normal

A0 A1

Lift switch

1,2,3

Tilt switch

Release the park brake lever and move 3

the directional lever to reverse then to neutral

4 5 6

Move the directional lever to forward then to neutral Pull the lift lever to maximum position and then release Pull the tilt lever to maximum position and the release Pull the auxiliary lever to maximum

Directional switch

position

Auxiliary switch

and then release 8 9

Pull enough the parking brake lever and

Parking brake switch

then release Depress

the

accelerator

pedal

maximum and then release

Accelerator control

Accelerator Speed symbol

Contactors 10

Move the DIAG/RUN/SETUP switch RUN

Line → Bypass

position and then back to DIAG position

→ Fwd →

Pull the tilt lever and then release

The end of the diagnostics

Rev

See “Store error codes”

Error Codes E

- 87 -

Maintenance Section

Stored error Codes

Error Codes Erasing

The logic card will remember up to 25 of the last error codes. This is useful in case the truck has an intermittent problem, or thermal condition, and the operator cannot remember what exactly happened. By analyzing the contents of the last 25 Error codes, one may recall the last thermal conditions or error codes that have appeared on the display. These error codes are accessed at the end of self-diagnostics, by using the following procedure.

To erase all of the error codes, the following procedures are used at the start of self-diagnostics. 1. Move the direction control lever to the reverse and the DIAG/RUN/SETUP switch to the DIAG position. 2. Turn on the key switch and wait until display shows a solid "8b", then move the DIAG/RUN/SETUP switch to the SETUP position and back to DIAG two times.

1. Access the self diagnostics procedure as previously described. 2. Either step through the diagnostic procedure, or override each test by moving the DIAG/RUN/SETUP switch from DIAG to RUN and back to DIAG until the contactor testing is complete.

3. Wait until the display show "A1", the display indicates that all error codes have been erased.

3. Cycle the DIAG/RUN/SETUP switch once more, and cycle through the contactor testing again. After the reverse contactor (left side) drops out, now the display will indicate a "Pd" (flashing).

To save service records, the following procedures are used at the end of self-diagnostics and service record are numbers between 1-9.

Service Records Saving

1. Move the direction control lever to the forward position after accessing the error codes and displaying "E".

The error codes can now be accessed one at a time by moving the TILT lever to maximum and then back to NEUTRAL position. This will display the most recent error code. By cycling the lever more times, more error codes will appear on the display, up to a total of twenty five. When the display shows a solid "E", it indicates that all of the error codes have been displayed. It is also possible that all error codes may be the same, and the display will not change between lever cycles.

2. Display shows a solid "8d" move the DIAG/Run/ SETUP switch to the Setup position and back to DIAG two times. 3. When the display shows "E"(flashing), a service record has been saved.

- 88 -

Maintenance Section

Programmable or Settable Feature The logic card contains a number of features which are either settable or programmable. The following is a list of the features, however the "Service Manual" or your DAEWOO dealer should be consulted in determining which options may be beneficial to the application.

PROGRAM FEATURE

DESCRIPTION

Creep speed

Steering duty

Electrically assisted braking

Discharged battery reset value

Top travel speed

Not used

Wait timer

Discharged battery drive speed

Acceleration travel speed time

Excessive traction motor current

Battery type selection

Maximum idle speed

Maximum lift 1. speed

Maximum lift 2. speed

Maximum tilt speed

Maximum Aux speed

HYD. Ramp timer

Possible Stored Error The following are the possible error codes stored in memory. Most error codes are identical to the one displayed during RUN. See "Service Manual" for further explanation and troubleshooting of any of the following error codes.

ERROR CODES

DESCRIPTION

Excessive drive motor current

Don't use

Drive circuit problem

Pump circuit problem

Drive and pump circuit problem

Drive circuit problem

Pump circuit problem

Drive and pump circuit problem

- 89 -

Maintenance Section

ERROR CODES

DESCRIPTION

Pump shunt field problem

Battery mismatch

Drive motor brush problem

Pump motor brush problem

Steering Pressure switch circuit problem

Drive or (and) Pump Motor brush problem

Controller thermal problem

Drive motor thermal problem

Battery lock-out

Pump motor thermal problem

Non Stored Error The following are error codes not stored in memory. Most error codes are identical to the one displayed during RUN. See "Service Manual" for further explanation and troubleshooting of any of the following error codes.

ERROR CODES EE "EE" (Flashing)

DESCRIPTION Static return to off error (SRO error) Seat circuit problem

General Displaying Codes The following are the general displaying codes and indicate any operation status

GENERAL CODES

DESCRIPTION

System normal operation

Wait operation

The end of the diagnostics

8b/A0 8d/8d (Flashing)

Error Code Erase (Preparation/Completion) Service Record Save (Preparation/Completion)

- 90 -

Maintenance Section

Head Capacitor - Discharge

2. Remove the control panel cover.

Before touching any electrical components, remove rings, watches and other metallic objects from the hands and arms, and then discharge the HEAD capacitor.

3. Before touching any electrical components, the HEAD capacitor must be discharged. Put a 150 ohm, 24 watt resistor in position between the terminals of the HEAD capacitor as shown. Hold the resistor in this position for approximately ten seconds. This will discharge the capacitor.

The head capacitor is located in the control panel at the rear of the lift truck.

4. Perform any necessary maintenance and repair at this time. 5. Install the control panel cover. 6. Connect the battery.

1. Disconnect the battery.

- 91 -

Maintenance Section

Brushes - Check, Replace NOTICE Refer to “Drive Motor” and/or “Hydraulic Pump Motor” section in “Every 1000 Service Hours or 6 Months” section of “Maintenance Intervals” if brush wear is suspected.

Do NOT let the seating stone stay in contact with the commutator for too long. It will cause more wear than necessary to the brushes and the commutator.

Brush Seating 1. All new drive and hydraulic motor brushes must be seated. For drive motor brush seating, lift the front of the lift truck until the drive wheels are off the floor and free to turn. Put adequate stands under the frame to support the lift truck. NOTICE Do NOT move the directional control lever from one direction to the other when the drive wheels are off the ground and rotating at full speed.

4. Check the contact surface of the brushes. At least 85% of the brush contact surface must show contact with the commutator. If necessary repeat the seating procedure.

Damage can be caused to the control panel.

NOTE: Do NOT use a brush seating stone that is shorter than 63.5 mm (2.50 inch).

WARNING Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

2. Use a brush seating stone for drive and hydraulic motors. 3. Put the seating stone in position on the commutator. Operate the motor slowly and move the seating stone from side to side, at the back edge of the brushes for a short time. This will take the shine off the commutator and seat the brushes.

5. While operating the motor slowly, blow out all of the abrasive grit and dust with 205 kPa (30 psi) air pressure.

- 92 -

Maintenance Section

Fuses - Replace

Horn-10 amps The fuses are located in the control panel at the rear of the lift truck.

Control Panel (1)-10 amps (Key Switch Circuit) Fuses - They protect the electrical system from damage caused by overloaded circuits. Change a fuse if the element separates. If the element of a new fuse separates, have the circuit checked and repaired.

Control Panel (2)-10 amps (Shunt Field circuit)

NOTICE Replace fuses with the same type and size only. Otherwise, electrical damage can result. If it is necessary to replace fuses frequently, an electrical problem may exist. Contact your DAEWOO Lift Truck dealer.

Main Fuse - 675 amps

Lights (If Equipped) - 10 amps (not shown) Light fuses are located on the right side of cowl.

- 93 -

Maintenance Section

Carriage Roller Extrusion - Adjust

Seat - Lubricate

1. Set the mast vertical. 2. Lower the carriage completely. 3. On full free lift and full free triple lift models, the bottom of the inner mast must be flush with the bottom of the stationary mast.

Check the operation of the seat adjusters. Make sure that the seat slides freely on its track. Lightly oil the seat slider tracks.

4. Measure the distance from the bottom of the inner upright to the bottom of carriage bearing. 5. The measurement (A) must be as follows in Chart below. Height of carriage roller extrusion (A)

- 94 -

STD mast

FF mast

FFT mast

-6

Maintenance Section

Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Walk - Around Inspection – Inspect

6. Inspect the tires, valve stems and wheels for cuts, gouges, foreign objects and loose or missing nuts. Refer to “Tires and Wheels” in “Every 10 Service Hours or Daily” section, if repairs or replacement is necessary.

1. Inspect the operator’s compartment for loose item and clean any mud or debris from the floor plates. 2. Inspect the instrument panel for damage to the indicator display. 3. Test the horn and other warning devices for proper operation.

7. Inspect the overhead guard for damage, loose or missing mounting bolts.

4. Inspect the mast and lift chains for wear, broken links, pins and loose rollers.

8. Inspect the hydraulic system for leaks, worn hoses or damaged lines.

5. Inspect the carriage, forks or attachments for wear, damage and loose or missing bolts.

9. Inspect the drive axle housing and the ground for oil leaks. Refer to “Drive Axle Oil Level-Check” in “Every 250 Service Hours or Monthly” section, if an oil leak is found. - 95 -

Maintenance Section

10. Adjust the operator’s seat.

12. Move the directional lever to NEUTRAL.

11. Adjust the steering wheel to a comfortable position.

13. Turn the key switch to ON.

14. Check the LCD display for battery discharge status. A fully charged battery will be displayed on the LCD display. 15. Check the operation of parking brake, service brake, controls and other devices that may be equipped on your lift truck.

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Maintenance Section

Mast Channels - Lubricate

3. Release the battery restraint lever in front of the battery cover. The channels on the roller-type mast require a break-in period. Apply a light film of lubricant on the channels where the rollers ride. This will prevent metal peel until the rollers set a pattern.

Battery - Check, Exchange, Change Battery Access Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor.

4. Raise the seat and battery cover.

Check Electrolyte

1. Disconnect the battery. 2. Tilt the steering column to the full upright position.

1. Inspect the battery compartment for loose connections, frayed cables. 2. Clean the top of the battery. If necessary, clean the top of the battery with a solution of baking soda and hot water.

- 97 -

Maintenance Section

Battery Exchanging NOTICE Vent caps must be tight to prevent soda solution from entering battery cells.

NOTE: Batteries should be changed, water added and charged only in areas where proper protective and ventilation facilities are provided.

A clean battery top is essential to avoid conductive paths on higher voltage batteries.

1. Refer to “Battery Access” topic for battery access.

To make the solution, add 0.5 kg (1 lb) of baking soda to 4 liters (1 gallon) of water. Use a brush having flexible bristles. Apply the soda solution to the top of the battery until the cleaning action of the soda stops. After cleaning action has stopped, rinse the batteries thoroughly with water. Dry the batteries with low air pressure.

2. Cover the battery with hinged battery cover or with plywood. 3. Install insulated battery tree and hoist, of sufficient capacity, to the battery. 4. Remove the battery. Recharge the battery. 5. Install a fully charged battery. 6. Remove the battery tree. Remove hinged battery cover or plywood from the top of the battery. 7. Connect the battery. 8. Lower the seat and battery cover to closed position and secure battery restraint on the front of the cover.

3. Check the specific gravity of the battery. If the specific gravity reading is below 1.150, the battery must be charged.

9. Adjust the seat position. Battery Charging With Battery Installed in Lift Truck

NOTICE The battery should not be used if a difference in specific gravity between two cells is greater than .020. If this condition exists, the battery should be put on an equalization charge. If this does not correct the condition, consult your battery supplier.

1. Refer to “Battery Access” topic for battery access. 2. Connect the battery to the charger and charge the battery. Observe safety warnings for charging batteries.

4. Check the electrolyte level of all cells. Maintain the electrolyte level about 13 mm (.50 inch) above the plates. Add water as needed. Use only distilled water. Add water before charging the battery.

3. When the battery is fully charged, disconnect the battery from the battery charger. 4. Connect the battery to the lift truck.

5. Lower the seat and battery cover. Secure battery restraint properly on the front of the cover.

5. Lower the seat and battery cover to closed position and secure battery restraint on the front of the cover.

6. Connect the battery.

6. Adjust the seat position. - 98 -

Maintenance Section

Indicator - Check

5. Check the indicator LCD display for the discharge state of the battery. 1. Turn the key switch to ON.

Back - up Alarm (If Equipped) - Test

2. Engage the parking brake.

With the key switch on, apply the service brake and move the directional control lever into REVERSE. The alarm should start to sound immediately. It will continue to sound until the directional control lever is moved to NEUTRAL or FORWARD.

3. Move the directional control lever to the NEUTRAL position. 4. Close the seat switch.

- 99 -

Maintenance Section

First 50 - 100 Service Hours or a Week You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Drive Axle Oil - Change

7. Fill the drive axle housing with sufficient fresh oil through the drive axle housing level/fill plug opening until it reaches the bottom of the hole. See the section, “Lubricant the Viscosities” and “Refill Capacities” for the type and amount of oil to use.

Park the lift truck on a level surface, parking brake applied, transmission in neutral.

8. Screw the oil filling plug in with the seal ring. 9. Remove the wood blocking and Lower the carriage.

1. Raise the carriage high enough to access the drive axle housing level/fill plug with breather. 2. Block the bottom of the carriage with a block of wood to hold the carriage in the raised position. 3. Turn the ignition switch OFF. 4. Place an appropriate container under the axle to catch the oil as it drains. Remove the drive axle housing drain plug.

10. Operate the lift truck for a few minutes and check oil level again. See the topic, “Drive Axle Oil Level - Check” in “Every 250 Service Hours or Monthly” section.

5. Allow the oil to drain completely out. Discard the old oil according to local regulations. 6. Clean and reinstall the drive axle housing drain plug.

- 100 -

Maintenance Section

First 250 Service Hours or a Month You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. 5. Insert a new filter element into the filter housing.

Hydraulic Return Filter - Change

6. Inspect the filter housing gasket. Replace if necessary.

WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

7. Apply a small amount of clean oil to the filter element seal and housing seal. 8. Install the filter housing with filter to the housing base.

Park the lift truck level with the forks lowered, parking brake engaged, directional lever in NEUTRAL and the key switch to OFF.

9. Install the battery. 10. Turn the key switch ON with the seat switch closed, and operate the hydraulic controls, and the steering system, through a few cycles to fill the lines. Look for oil leaks.

1. Remove the battery.

11. Retract all cylinders. Turn the key switch to OFF and check the oil level. Maintain the oil level to the FULL mark on the dip stick/filler cap assembly.

2. Remove mounting bolts and filter housing.

3. Remove and discard filter element from filter housing. 4.

Clean the filter housing nonflammable solvent.

with

clean,

- 101 -

Maintenance Section

Every 250 Service Hours or Monthly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Brake Oil Level – Check

Parking Brake - Test, Adjust NOTE: Be sure area around the lift truck is clear of personnel and obstructions. 1. Drive the lift truck with a rated load up a 15% incline.

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.

The brake system reservoir is located at the left side of the steering column. 1. Remove the filler cap. 2. Maintain the brake fluid level to the fluid level mark on the brake system reservoir. 3. Clean and install the filler cap.

2. Halfway up the incline, stop the lift truck by applying the service brakes.

3. Engage the parking brake. 4. Release the service brake.

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Maintenance Section

If the parking brake has the correct adjustment, the lift truck will be held in place. NOTE: The lift truck may move slightly while the parking brake is engaging. 5. If the parking brake does not hold, adjust the parking brake lever screw. Adjust - Parking Brake 1. Park the lift truck level, with the forks lowered and the parking brake engaged.

6. Remove ten lock wire (4) from bolt (5). Turn the adjusting nut (5) counterclockwise to increase the clearance. Turn the adjusting nut (5) clockwise to decrease the clearance. Recheck the clearance at location (3). Readjust if necessary. Install lock wire (4) on bolt (5).

2. Move the directional control lever into NEUTRAL and turn key switch to OFF and remove the key. 3. Block the drive wheels and release the parking brake. 4. Remove the battery and the floor plate under the battery.

7. Measure the length of spring (6). Maintain 70± 5mm (2.76±.02 inch) with locknut (7) and adjusting nut (8) included. Loosen the locknut (7) and turn adjusting nut (8) counterclockwise to increase length and clockwise to decrease the length. Tighten the locknut (7).

5. Measure the clearance between brake drum (1) and the lining of the strap assembly (2) at location (3). Maintain 0.25 to 0.50 mm (.010 to .020 inch) clearance between the brake drum and the lining of the strap assembly at location (3).

NOTE: Be sure the shoulder of the cable (9) is seated against the strap assembly (2).

- 103 -

Maintenance Section

Drive Axle Oil Level - Check Park the lift truck on a level surface. Apply the parking brake. Place the directional control lever in NEUTRAL.

8. Engage the parking brake. Measure the clearance between the bracket assembly (10) and the leg of the strap assembly (2). Maintain 6 mm (.24 inch) maximum clearance. 9. Release the parking brake. Check that the parking brake foot pedal is in the full OFF position and the leg of the strap assembly (2) and the stop bolts (11) are in contact. Loosen the locknuts (12) and adjust stop bolts (11), if necessary. Tighten the locknuts (12).

1. Raise the carriage high enough to access the level/fill plug. 2. Block the bottom of the mast with a block of wood to hold the carriage in the raised position.

10. Install the floor plate and the battery.

3. Turn the ignition switch OFF.

4. Remove the level/fill plug. The oil level should reach the bottom of the hole. Maintain the oil level, to the bottom of the hole. 5. Clean off the level/fill plug and put it back in place. 6. Remove the wood blocking and lower the load backrest.

- 104 -

Maintenance Section

5. Raise and lower the carriage a few times to work lubricant into the chain links.

Mast Carriage, Chains and Attachments Inspect, Adjust, Lubricate

NOTICE Lubricate chains more frequently than normal where the atmosphere can cause corrosion to components, or when lift truck must work in rapid lift cycles.

1. Operate the lift, tilt and attachment controls. Listen for unusual noises. These may indicate a need for repair.

6. Inspect the chain anchors and individual links for wear, loose pins or cracked leaves. NOTE: Have all repairs and adjustments made as required.

2. Inspect for loose bolts and nuts on the carriage and load backrest. Remove any debris from the carriage and mast. 3. Inspect the forks and attachments for free operation and damage. Have repairs made if needed.

4. Brush in a film of oil on all links of the chain.

- 105 -

Maintenance Section

Hydraulic Oil Level - Check

Wheel Bolt & Nut - Check for Tightness Steer Wheels

1. Operate the lift truck for a few minutes to warm the oil. 2. Park the lift truck level, with the forks lowered, mast tilted back (all cylinders retracted), parking brake engaged, directional control lever in NEUTRAL, and the key switch to OFF.

Typical example

1. Inspect tightness of wheel nuts in a sequence opposite each other 135 N•m (100 lb•ft) Drive Wheels 3. Remove the left floor plate. 4. Remove the dipstick 5. Maintain the oil level to the full mark on the dipstick. 6. Install the dipstick. 7. Install the floor plate. 2. Inspect tightness of wheel bolts in a sequence opposite each other to 135 N•m (100 lb•ft)

- 106 -

Maintenance Section

Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Mast Hinge Pin - Lubricate

Tilt Cylinders - Check, Adjust, Lubricate Chassis Pivot Eyebolts – Lubricate 1. Lubricate two fittings for the pivot eyebolts, one on each tilt cylinder.

Typical Example

1. Lower the forks and the carriage.

2. Check the pivot eye pins for loose retainer bolts and wear.

Mast Pivot Eyes - Lubricate

2. Lubricate the two fittings for the mast hinge pins, one on each side of the mast.

Typical Example

1. Lubricate two fittings for the mast pivot eyes, one on each side of the pin. 2. Check the pivot eye pins for loose retainer bolts and wear.

- 107 -

Maintenance Section

Cylinder Rod Extension - Adjust

Crosshead Rollers - Check

NOTE: The following description is for forward tilt. For cylinder rod back tilt, the collar should be stationary by the tilt eye. If it is not, the O-ring inside the collar may need to be replaced. To adjust back tilt, spacers must be added or removed.

1. Operate the mast through a lift cycle. Watch the chains move over the crosshead rollers. Make sure the chain is tracking over the rollers properly.

Typical Example Typical Example

2. Check for damaged crosshead rollers, guards and retainer rings.

1. Check to make sure the tilt cylinders extend and retract evenly. 2. If one cylinder continues to move after the other cylinder has stopped in full forward or backward tilt, an adjustment must be made to one cylinder. 3. To adjust the cylinder rod extension, move the spacer to the rear and loosen the pinch bolt on the clevis. 4. Turn the cylinder rod in or out of the clevis to obtain the proper adjustment. Turning the rod into the clevis shortens the stroke. Turning the rod out of the clevis lengthens the stroke. 5. Tighten the pinch bolts to a torque of 95±15 N•m (70±10 lb• ft). Check the cylinder rods again for even travel.

- 108 -

Maintenance Section

Directional Control Lever - Check

Overhead Guard - Inspect

Check the tightness of the directional lever mounting bracket. Adjust if needed. Check for ease of movement of directional lever. Adjust if needed. Check for loose wiring. Secure wiring if needed.

Look for any loose or damaged bolts. Replace damaged bolts or missing bolts with original equipment part only. Retighten bolts to a torque of 100±15 N•m (75±11 lb•ft). Check the overhead guard for bent or cracked sections. Repair if needed.

Drive Axle Oil - Change See topic, “Drive Axle Oil - Change” in “First 50-100 Service Hours or a week”.

Steering Mechanism - Lubricate

Lubricate 2 fittings.

- 109 -

Maintenance Section

Control Panel - Clean, Inspect

WARNING

Park the lift truck level, with the forks lowered, parking brake engaged, directional control lever in NEUTRAL, and the key switch to OFF.

Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.

Disconnect the battery.

The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

1. Remove the access cover.

WARNING

3. Clean the control panel with 205 kPa (30 psi) maximum air pressure, until dust is removed from the control panel.

Battery voltage and high amperage are present. The HEAD capacitor must be discharged before any contact with the control panel is made.

4. Check movement of contactors and inspect contactor tips for burning or pitting. Replace if needed.

Personal injury could result if it has not been discharged properly.

5. Inspect all wiring for loose connections, frayed cables and loose mounting bolts. 6. Inspect the fuses for looseness, corrosion and broken connections.

2. Discharge the head capacitor. See “Head Capacitor” in “When Required” section of this manual. 7. Install the access cover and connect the battery.

- 110 -

Maintenance Section

Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Drive Motor - Clean, Inspect

8. Unlatch and remove the commutator screen cover. 1. Disconnect the battery.

9. Connect the battery. Turn the key switch to ON and apply pressure to the seat switch.

2. Block the steer wheels.

NOTICE Do not move directional lever from one direction to the other when the drive wheels are off the ground and rotating. Damage can be caused to the control panel.

WARNING Battery voltage and high amperage are present. The HEAD capacitor must be discharged before any contact with the control panel is made. Personal injury could result if it has not been discharged properly.

3. Fasten lift chains, of equal length, in lift openings in the front of the lift truck. 4. Slowly lift the front of the lift truck, until the drive wheels are just off the ground. 5. Put stands under the frame. Remove the tension on the lift chains.

10. Operate the drive motor slowly. Blow off the drive motor brush area with 205 kPa (30 psi) maximum air pressure, until dust is removed from the motor.

6. Remove the battery. See topic, “Battery” in “Every 10 Service Hours or Daily” section of this manual.

11. Release the pressure on the seat. Turn the key switch to OFF. Disconnect the battery.

7. Remove the floor plate.

- 111 -

Maintenance Section

Typical example

12. Remove the brush retainer clip by pushing down and in toward the brush to release it from the brush holder. Then, pull out on the clip to remove it.

14. To replace the brushes, loosen the retaining screws (1) and disconnect the wires (2). Remove the brushes from the holders. 15. Connect the wires on the new brushes. Install the brushes in the holders. 16. Install the brush retainer clips. Make sure the brushes move freely in the holder. 17. Seat the new brushes. See “Brushes” in “When Required” section of this manual.

Typical example

13. Remove the brush from the holder. Measure the length of the brush on the longest side. Ensure that all brushes move freely in their holders. Use compressed air until all brushes are free to move.

Type of Motor

Change Brush if Length is Less Than

Minimum Allowable Brush 1 Length Limit

Drive Motor

22 mm (.87 in)

20 mm (.79 in)

Typical example

18. Install the commutator screen cover. 19. Install the floor plate. 20. Slowly lift the front of the lift truck and remove the stands. Lower the lift truck to the floor. Remove the chains.

When the minimum brush length is less than the dimension shown, replace all brushes. When the brush is used beyond this dimension, motor damage could result.

21. Install and connect the battery. Lower the battery cover and adjust the seat. NOTE: To check the brush wear indicator wiring, connect one end of a jumper wire to the negative (-) side of the battery and touch the other end of the wire to the brush wear indicator terminal on the side of the motor.

- 112 -

Maintenance Section

Hydraulic Pump Motor - Clean, Inspect 1. Disconnect the battery. 2. Open the right side cover.

6. Operate the hydraulic pump motor slowly. Blow off the hydraulic pump motor brush area with 205 kPa (30 psi) maximum air pressure, until dust is removed from the motor. 3. Unlatch and remove the commutator screen cover.

7. Release the pressure on the seat. Turn the key switch to OFF. Disconnect the battery.

4. Connect the battery.

8. Remove the brush retainer clip by pushing down and in toward the brush to release it from the brush holder. Then, pull out on the clip to remove it.

5. Turn the key switch to ON and apply pressure to the seat switch.

Typical example

9. Remove the brush from the holder. Measure the length of the brush on the longest side.

- 113 -

Maintenance Section

Ensure that all brushes move freely in their holders. Use compressed air until brushes are free to move. Type

Motor Hyd. Motor

Change Brush if

Minimum

Length is Less

Allowable Brush

Than

Length Limit1

22 mm (.87 in)

20 mm (.79 in)

When the minimum brush length is less than the dimension shown, replace all brushes. When the brush is used beyond this dimension, motor damage could result.

14. Install the commutator screen cover. 15. Close the right side cover. 16. Install and connect the battery. NOTE: To check the brush wear indicator wiring, connect one end of a jumper wire to the negative (-) side of the battery and touch the other end of the wire to the brush wear indicator terminal on the side of the motor.

Hydraulic Return Filter - Change

Typical example

See topic “Hydraulic Return Filter - Change” in “First 250 Service Hours or a Month.”

10. Replace the brushes by loosening the retaining screws (1) and disconnect the wires (2). Remove the brushes from the holders. 11. Connect the wires on the new brushes. Install the brushes in the holders. 12. Install the brush retainer clips. Make sure the brushes move freely in the holder. 13. Seat the new brushes. See “Brushes” in “When Required” section of this manual.

- 114 -

Maintenance Section

Check for Equal Tension

Lift Chains - Test, Check, Adjust Lift Chain Wear Test Inspect the part of the chain that is normally operated over the cross head roller. When the chain bends over the roller, the movement of the parts against each other causes wears. Inspect to be sure that chain link pins do not extend outside of the link hole. If any single link pin is extended beyond its connecting corresponding link, it should be suspected of being broken inside of its link hole. Lift chains are required to check for wear about every 1,000 service hours or 6 months.

Typical example

Chain wear test is a measurement of wear of the chain links and pins. Take the following steps to check chain wear.

WARNING Personal injury can be caused by sudden movement of the mast and carriage. Keep hands and feet clear of any parts that can move.

1. Lift the mast and carriage enough for getting tension on lift chains.

Lift Chain Adjustment

Typical example

2. Measure precisely ten links of chain distance at the center of pins in millimeter.

Typical example for carriage equal tension

3. Calculate chain wear rate*.

If the tension is not the same on both chains, take the procedure as follows.

4. If the chain wear rate is 2% or more, replace the lift chain.

NOTE: If carriage height is not correct, make adjustments by following procedures.

* Chain wear rate (%) Actual measurement - Pitch** X 10 = ×100 Pitch** X 10

Carriage Chain Adjustment Make sure that carriage height is correct. If correct, adjust the chain for equal tension. If not, adjust the chain for correct carriage height by adjusting anchor nuts (1), (2).

** Chain Pitch = 15.88 mm (0.63 in)

- 115 -

Maintenance Section

NOTE: See the previous section, “Carriage Roller Extrusion” in “When required” for proper height of carriage.

Mast Chain Adjustment - FF, FFT Mast

1. Fully lower the carriage and tilt mast forward or lift the carriage and put blocks under the carriage to release the tension from the lift chains. 2. Loosen nut(1) and adjust nut(2) to get proper distance from bottom of inner upright to the bottom of carriage bearing.

Typical example for FF mast

Typical example for carriage chain of STD mast

Typical example for FFT mast

Make sure that mast height is correct. If correct, adjust chain for equal tension. If not, adjust mast chain for correct mast height by adjusting anchor nuts (3), (4). NOTE: See the previous section, “Carriage Roller Extrusion” in “When Required” for proper inner mast height.

Typical example for carriage chain of FF, FFT mast

1. Lift the inner mast and put blocks under the inner mast to release the tension from the lift chains.

3. Make adjustment anchor nut (1), (2) for equal chain tension.

2. Loosen nut (3) and adjust nut (4) to make inner mast rail flush with outer mast rail bottom.

4. Set the mast vertical and raise the carriage and check equal chain tension. If not equal, repeat the same procedure as step 1 through step 3.

3. Make adjustment anchor nuts (3), (4) for equal chain tension. 4. Raise the inner mast and check equal chain tension. If not equal, repeat the same procedure as step 1 through step 3.

5. Put LOCTITE No. 242 Tread lock on the threads of the anchor nuts (1), (2) after the adjustment is completed.

5. Put LOCTITE No. 242 tread lock on the threads of the anchor nuts (3), (4) after the adjustment is completed.

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Maintenance Section

Every 2000 Service Hours or Yearly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Steer Wheel Bearings - Reassemble

4. Remove the outer wheel bearing. Inspect the bearing for damage and wear. Replace if needed.

1. Block the drive wheels. Raise the steer wheels off the ground. Block the lift truck up with blocking under the frame and steer axle.

5. Remove the wheel assembly. 6. Examine the seal for damage and wear. Replace the seal, if necessary.

2. Remove the hub cap.

3. Remove the locknut, lock washer and flat washer.

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Maintenance Section

7. Remove the inner bearing. Inspect the bearing for damage and wear. Replace if needed.

12. Install the outer wheel bearing.

8. Clean and lubricate the steering knuckle. 9. Assemble the inner and outer bearing.

13. Install the flat washer, lock washer and locknut. 14. Tighten the locknut to 135 N•m (100 lb•ft), while turning wheel hub to seat the bearing. 10. Install the inner bearing.

15. Loosen the locknut. Torque the locknut to 50±5 N•m (35±4 lb•ft). Bend the lock washer tang to secure locknut. 16. Bend the lock washer tang to secure locknut. 17. Install the hub cap. 18. Raise the lift truck and remove the blocking. Lower the lift truck to the ground.

11. Install the wheel assembly on the steering knuckle.

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Maintenance Section

Forks - Inspect

Drive Wheel Bearings - Reassemble Consult your DAEWOO lift truck dealer for the proper wheel bearing reassembling procedure. Reassembling of bearings and adjustment procedure must be made by a trained mechanic or dealer personnel.

Forks should be inspected, at a minimum, every 12 months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked every six months.

1. Inspect the forks carefully for cracks. Special attention should be given to the heel section (A), all weld areas and mounting brackets (B). Inspect the top and bottom hooks on forks used on hook type carriages and tubes on shaft mounted forks.

Forks with cracks should be removed from service. “Wet Test” magnetic particle inspection is generally preferred due to its sensitivity and the ease of interpreting the results. Portable equipment is usually recommended so it can be moved to the lift truck.

1. Apply Loctite No.271 Thread Lock to threads of spindle bolts. Torque for bolts that hold spindle to drive axle housing is 100.5 ± 12.3 N•m (74.2 ± 9.1 lb•ft).

Inspectors should be trained and qualified in accordance with The American Society for Non-Destructive Testing, Level II Qualifications.

2. Tighten nut slowly until torque required to turn bearings is 10.8 ± 2.0 N•m (8.0 ± 1.5 lb•ft). 3. Apply Loctite No.271 Thread Lock to threads of stopping bolts. Torque for bolts that hold nut and

Contact your local DAEWOO Lift Truck Dealer for further information.

plate is 9.8 ± 2.0 N•m (7.2 ± 1.5 lb•ft). 4. Apply Loctite No.271 Thread Lock to threads of drive shaft bolts. Torque for bolts that hold drive shaft to hub is 71 ± 12 N•m (52.5 ± 9 lb•ft).

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Maintenance Section

2. Check the angle between the upper face of the blade and the front face of the shank. The fork should be withdrawn from service if angle (C) exceeds 93 degrees or deviates by more than 3 degrees from an original angle other than 90 degrees, as may be found in some special application forks.

4. Check the difference in height of one fork tip to the other when mounted on the fork carrier. A difference in fork tip height can result in uneven support of the load and cause problems with entering loads. The maximum recommended difference in fork tip elevation (F) is 6.5 mm (0.25”) for pallet forks and 3 mm (0.125”) for fully tapered forks. The maximum allowable difference in fork tip elevation between the two or more forks is 3 percent of blade length (L). Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference.

3. Check the straightness of the upper face of blade (D) and the front face of shank (E) with a straight edge. The fork should be withdrawn from service if the deviation from straightness exceeds 0.5 percent of the length of the blade and/or the height of the shank respectively 5 mm/1000 mm (0.18”/36”). 5. Check the fork blade (J) and shank (H) for wear with special attention to the heel (G). The fork should be withdrawn from service if the thickness is reduced to 90 percent or less of the original thickness. Fork blade length may also be reduced by wear, especially on tapered forks and platens. Remove the forks from service when the blade length is no longer adequate for the intended loads.

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Maintenance Section

6. Check the fork mountings (K) for wear, crushing and other local deformation, which can cause excessive side to side wobble of the forks. Excessive clearance on hook type forks may allow them to fall from the carrier. Forks which show visible signs of such damage should be removed from service.

8. Check fork markings (N) for legibility. Renew markings as required to retain legibility.

7. Check the positioning lock and other fork retention devices to make sure they are in place and working. Hook type forks use a spring loaded pin (M), located in the top hook, to engage notches in the top carriage bar to hold the fork in place. 9. a. Lift the mast and operate the tilt control lever, until the top surface of the forks is parallel with the floor. Place two straight bars that are the same width as the carriage, across the forks as shown.

When adjusting the fork spacing, the forks are 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.

9. b. Measure the distance from the bottom of each end of the two bars to the floor. The forks must be parallel within 3 mm (.12 in) for Full Tapered and Polished (FTP) forks, all other forks 6.4 mm (.25 in), for their completer length.

Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork. They may also use U bolts, pins, or similar devices which engage the fork through the top structure of the carriage.

9. c. Put one fork, one third from the tip, under a fixture that will not move. Then operate the tilt control with caution until the rear of the truck lifts just off the floor. Follow the same procedure with the second fork. Repeat Step a.

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Maintenance Section

Air Breather - Change Park the lift truck level, with the forks lowered, parking brake engaged, directional lever in NEUTRAL and the key switch to OFF. 1. Open the floor plate. 2. Remove and discard the air breather.

4. Install a new air breather. 6. Close the floor plate.

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Maintenance Section

Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Hydraulic Oil - Check, Change

1. Operate the lift truck a few minutes to warm the oil. Park the lift truck level, with the forks lowered, parking brake engaged, directional lever in NEUTRAL and the key switch to OFF.

4. Remove the dipstick and the strainer. Wash them in clean, nonflammable solvent and dry them. 5. Install the strainer. Fill the hydraulic tank. See “Refill Capacities.” Install the dipstick. 6. Turn the key switch to ON and close the seat switch. Operate the hydraulic controls and steering system through a few cycles, to fill the filter and lines. 7. Check for oil leaks. 8. Retract all cylinders. 9. Turn the key switch to OFF. 10. Maintain the oil level to the FULL mark on the dipstick. Add oil if necessary.

2. Remove the hydraulic tank drain plug. Allow the oil to drain. Clean and install the plug. 3. Remove the floor plate.

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Environment Section

Environment Protection When servicing this lift truck, use an authorized servicing area and an approved container to collect coolant, oil, fuel, grease, electrolyte and any other potential environmental pollutant before any lines, fittings or related items are disconnected or removed. After servicing, dispose of those materials in an authorized place and container. When cleaning the lift truck, be sure to use an authorized area.

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Index Section

Index

Crushing or Cutting Prevention...........................13

Daily Inspection..................................................66 Directional Control Lever ....................................46 Directional Control Lever - Check .....................109 Directional Steering Controls ..............................47 Drive Axle Oil .....................................................74 Drive Axle Oil - Change ....................................100 Drive Axle Oil - Change ....................................109 Drive Axle Oil Level - Check .............................104 Drive Motor - Clean, Inspect .............................111 Drive Wheel Bearings - Reassemble ................119 Drive Wheels....................................................106 During Storage...................................................61

Accelerator Pedal .............................................. 46 After Storage ..................................................... 61 Air Breather - Change ...................................... 122 Apply Parking Brake Warning............................... 8 Attachment Abbreviations (includes Special Forks)..................................... 39 Avoiding Lift Truck Tipover................................. 20

B Back - up Alarm (If Equipped) - Test................... 99 Batteries ............................................................ 14 Battery............................................................... 71 Battery............................................................... 75 Battery - Check, Exchange, Change .................. 97 Battery Access................................................... 97 Battery Charging................................................ 98 Battery Discharge Indicator ................................ 70 Battery Discharge Indicator with Interrupt ........... 41 Battery Disconnect Before Servicing Warning ...... 8 Battery Exchanging............................................ 98 Battery Restraint Warning .................................... 6 Before Operating the Lift Truck .......................... 11 Before Operating the Lift Truck .......................... 49 Before Starting the Lift Truck.............................. 11 Before Storage................................................... 61 Bent or Twisted Forks ........................................ 65 Better Battery Performance................................ 51 Brake Oil Level - Check ................................... 102 Brushes - Check, Replace.................................. 92 Burn Prevention ................................................. 14

E Electrical Braking (Plugging)...............................54 Environment Management....................................3 Environment Protection ....................................124 Every 10 Service Hours or Daily .........................78 Every 10 Service Hours or Daily .........................95 Every 1000 Service Hours or 6 Months...............78 Every 1000 Service Hours or 6 Months.............111 Every 2000 Service Hours or Yearly ...................78 Every 2000 Service Hours or Yearly .................117 Every 250 Service Hours or Monthly...................78 Every 250 Service Hours or Monthly.................102 Every 2500 Service Hours or 15 Months.............78 Every 2500 Service Hours or 15 Months...........123 Every 500 Service Hours or 3 Months.................78 Every 500 Service Hours or 3 Months...............107 12 Months Inspection .........................................67

Fatigue...............................................................65 Fault Detection Circuit ........................................42 Film For function of pedals (if equipped) .............46 Fire or Explosion Prevention...............................15 First 250 Service Hours or a Month ....................78 First 250 Service Hours or a Month ..................101 First 50 - 100 Service Hours or a Week ..............78 First 50 - 100 Service Hours or a Week ............100 First Installation ..................................................66 Fluid Penetration ................................................13 Foreword..............................................................2 Fork Inspection...................................................66 Forks - Inspect .................................................119 Front and Rear Floodlights Switch ......................43 Fuses - Replace .................................................93

Capacity Chart – with Hook-On type Sideshifter . 32 Capacity Chart – with Hook-On type Sideshifter . 33 Capacity Chart – with Hook-On type Sideshifter . 35 Capacity Chart – with Integral type Sideshifter ... 34 Capacity Chart – without Sideshifter................... 30 Capacity Chart – without Sideshifter................... 31 Carriage Roller Extrusion - Adjust ...................... 94 Causes of Fork Failure....................................... 65 Center of Gravity (CG) ....................................... 20 Chain and Linkage Oils (DEO or EO) ................. 73 Chassis.............................................................. 76 Chassis Pivot Eyebolts – Lubricate .................. 107 Check Electrolyte............................................... 97 Cold Storage Applications.................................. 75 Control Panel - Clean, Inspect.......................... 110 Crosshead Rollers - Check .............................. 108 - 125 -

Index Section

Load Backrest Must Be In Place Warning .............7 Lubricant Information..........................................73 Lubricant Specifications......................................73 Lubricant Viscosities...........................................77 Lubricant Viscosities and Refill Capacities ..........77 Lubricating Grease (MPGM)...............................74

G General.............................................................. 15 General Hazard Information ................................. 9 General Warnings to Operator ............................. 6

Hard Placement Warning ..................................... 7 Head Capacitor - Discharge ............................... 91 Hook-on type Fork ............................................. 60 Horn Button ....................................................... 44 How to Survive in a Tipover ............................... 27 Hydraulic Brake Fluid......................................... 74 Hydraulic Oil - Check, Change ......................... 123 Hydraulic Oils (HYDO) ....................................... 73 Hydraulic Pump Motor - Clean, Inspect ............ 113 Hydraulic Return Filter - Change ...................... 101 Hydraulic System............................................... 75

Machine Lifting and Tiedown Information............62 Maintenance ........................................................3 Maintenance and Repair ....................................67 Maintenance Information ....................................13 Maintenance Intervals ..........................................3 Maintenance Intervals ........................................78 Mast Abbreviations.............................................38 Mast Carriage, Chains and Attachments - Inspect, Adjust, Lubricate ..............................................105 Mast Chain Adjustment - FF, FFT Mast ............116 Mast Channels - Lubricate..................................97 Mast Hinge Pin - Lubricate ...............................107 Mast Pivot Eyes - Lubricate ..............................107 Monitoring Systems Indicator..............................40 Motor Brushes Wear Indicator ............................43 Mounting and Dismounting .................................11

I Identification, Lift Capacity and Attachment Plate38 If Optional Suspension Seat (weight adjusting type) Equipped ........................................................... 18 Important Safety Information ................................ 4 Improper Modification or Repair ......................... 65 Inching into Loads.............................................. 55 Index ............................................................... 125 Indicator - Check................................................ 99 Inspection, Maintenance and Repair of Lift Truck Forks ................................................................. 64

N No LCD Display..................................................42 No Riders Warning...............................................7 No Standing on Forks Warning, No Standing under Forks Warning......................................................7 Noise .................................................................36 Noise and Vibration ............................................36

Key Switch......................................................... 40

Oils ....................................................................14 Operating Techniques ........................................55 Operating the Lift Truck ......................................11 Operation .............................................................2 Operation Information.........................................11 Operator Restraint System(If Equipped) ...............2 Operator Restraint System(If Equipped) .............16 Operator’s Station and Monitoring Systems ........40 Operator’s Warning and Identification Plate ........38 Operator’s Warning Plate ...................................38 Over Temperature..............................................42 Overhead Guard - Inspect ................................109 Overhead Guard Must Be In Place Warning .........8 Overloading........................................................65

L Lift Chain Adjustment....................................... 115 Lift Chain Wear Test ........................................ 115 Lift Chains ......................................................... 75 Lift Control Lever ............................................... 47 Lift Fork Adjustment ........................................... 60 Lift Truck Capacity Rating .................................. 38 Lift Truck Control ............................................... 45 Lift Truck Operation ........................................... 52 Lift Truck Parking............................................... 12 Lift Truck Stability .............................................. 20 Lift Truck Stability Base...................................... 21 Lifting Drums or Round Objects ......................... 57 Lifting the Load .................................................. 55 Lines, Tubes and Hoses .................................... 16 Literature Information........................................... 2 - 126 -

Index Section

Parking Brake .................................................... 45 Parking Brake - Test, Adjust............................. 102 Parking Brake Indicator...................................... 43 Parking the Lift Truck ......................................... 58 Power On Indicator ............................................ 41 Pressure Air....................................................... 13

Torques for Bolts and Nuts with Standard Threads...............................................68 Torques for Taperlock Studs ..............................69 Towing Information.............................................63 Training Required To Operate or Service Warning5 Transportation Hints ...........................................62 Traveling ............................................................56 Turning...............................................................56

Refill Capacities................................................. 77 Run Time Diagnostics........................................ 41

Unloading...........................................................57

Vibration (weighted overall value).......................36

Safety .................................................................. 2 Safety .................................................................. 5 Safety Rules ...................................................... 22 Seat - Lubricate ................................................. 94 Seat Adjustment ................................................ 17 Seat Adjustment ................................................ 44 Seat Switch........................................................ 40 Self Diagnostics - Test ....................................... 80 Self-Diagnostics Indicator................................... 42 Serial Number.................................................... 37 Serial Number Locations.................................... 37 Service Brake Pedal .......................................... 45 Service Hour Meter............................................ 43 Shipping ............................................................ 62 Sideshift Attachment Control (If Equipped) ......... 48 Specifications .................................................... 28 Stability and Center of Gravity............................ 20 Starting the Lift Truck......................................... 11 Static Return to Off ............................................ 41 Steer Wheel Bearings - Reassemble................ 117 Steer Wheels ................................................... 106 Steering Mechanism - Lubricate....................... 109 Storage Information ........................................... 61

W Walk - Around Inspection....................................49 Walk - Around Inspection - Inspect .....................95 Warning Signs and Labels....................................5 Warning Signs and Labels..................................16 Wheel Bolt & Nut - Check for Tightness............106 When Required ..................................................78 When Required ..................................................80 With Battery Installed in Lift Truck.......................98

T Table of Contents ................................................ 1 Tilt Control Lever ............................................... 48 Tilt Cylinders - Check, Adjust, Lubricate ........... 107 Tilt Steering Column .......................................... 44 Tire Information.................................................. 15 Torque for Metric Fasteners ............................... 69 Torque for Standard Bolts, Nuts and Taperlock Studs ................................................................. 68 Torque for Standard Hose Clamps - Worm Drive Band Type ......................................................... 68 Torque Specifications ........................................ 68

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