Doosan B15 - 20T-5 AC

For use in service manual form SB4176E SB4183E00 Feb. 2005

SERVICE MANUAL CONTENTS NOTICE This form lists the contents of the complete Service Manual for this product. The items listed with form numbers are available and included in the manual. If form numbers 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 SB4183E00 SB2003E00 SB2004E00

DIRVE & CONTROL SYSTEM MicroController Control Systems

SB4177E00

POWER TRAIN Power Train

SB4185E00

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

SB4186E00 SB4187E00 SB4182E00 SB4181E00 SB2143E03

OPERATION & MAINTENANCE Operation & Maintenance Manual Operation & Maintenance Manual

Models ; B15T-5, B18T-5, B20T-5 (AC 36V, 48V) B16X-5, B18X-5, B20X-5 (AC 48V)

SB2339E01 SB2340E01

For use in service manual form SB4176E SB4183E00 Feb. 2005

SERVICE MANUAL CONTENTS NOTICE This form lists the contents of the complete Service Manual for this product. The items listed with form numbers are available and included in the manual. If form numbers 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 SB4183E00 SB2003E00 SB2004E00

DIRVE & CONTROL SYSTEM MicroController Control Systems

SB4177E00

POWER TRAIN Power Train

SB4185E00

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

SB4186E00 SB4187E00 SB4182E00 SB4181E00 SB2143E03

OPERATION & MAINTENANCE Operation & Maintenance Manual Operation & Maintenance Manual

Models ; B15T-5, B18T-5, B20T-5 (AC 36V, 48V) B16X-5, B18X-5, B20X-5 (AC 48V)

SB2339E01 SB2340E01

6%( $XJ   

:$51,1*

6$)(7< :$51,1*

:$51,1*

'RQRWRSHUDWHWKLVPDFKLQHXQOHVV\RXKDYH UHDGDQGXQGHUVWDQGWKHLQVWUXFWLRQVLQ WKH 23(5$725 6*8,'(,PSURSHUPDFKLQH RSHUDWLRQLVGDQJHURXVDQGFRXOGUHVXOW LQ LQMXU\RUGHDWK

7KHSURSHUDQGVDIHOXEULFDWLRQDQGPDLQWHQDQFH IRUWKLVPDFKLQHUHFRPPHQGHGE\'$(:22DUH RXWOLQHG LQ WKH 23(5$7,21  0$,17(1$1&( *8,'(IRUWKLVPDFKLQH ,PSURSHU SHUIRUPDQFH RI OXEULFDWLRQ RU PDLQWHQDQFHSURFHGXUHVLVGDQJHURXVDQGFRXOG UHVXOWLQLQMXU\RUGHDWK5HDGDQGXQGHUVWDQGWKH 23(5$7,21  0$,17(1$1&( *8,'( EHIRUH SHUIRUPLQJDQ\OXEULFDWLRQRUPDLQWHQDQFH

 8VHVWHSVDQGJUDEKDQGOHVLIDSSOLFDEOH ZKHQ PRXQWLQJRUGLVPRXQWLQJDPDFKLQH&OHDQDQ\PXGRU GHEULVIURPVWHSVZDONZD\VRUZRUNSODWIRUPVEHIRUH XVLQJ$OZD\VIDFHPDFKLQHZKHQXVLQJVWHSVODGGHUV DQGZDONZD\V:KHQLWLVQRWSRVVLEOHWRXVHWKH GHVLJQHGDFFHVVV\VWHPSURYLGHODGGHUVVFDIIROGVRU ZRUNSODWIRUPVWRSHUIRUPVDIHUHSDLURSHUDWLRQV

7KH VHUYLFHPDQ RU PHFKDQLF PD\ EHXQIDPLOLDUZLWKPDQ\ RIWKHV\VWHPVRQWKLVPDFKLQH7KLVPDNHVLWLPSRUWDQW WRXVHFDXWLRQZKHQSHUIRUPLQJVHUYLFHZRUN$ NQRZOHGJHRIWKHV\VWHPDQGRUFRPSRQHQWVLV LPSRUWDQWEHIRUHWKHUHPRYDORUGLVDVVHPEO\RIDQ\ FRPSRQHQW

 7RDYRLGEDFNLQMXU\XVHDKRLVWZKHQOLIWLQJ FRPSRQHQWVZKLFKZHLJKNJOE RUPRUH0DNH VXUHDOOFKDLQVKRRNVVOLQJVHWFDUHLQJRRG FRQGLWLRQDQGDUHRIWKHFRUUHFWFDSDFLW\%HVXUH KRRNVDUHSRVLWLRQHGFRUUHFWO\/LIWLQJH\HVDUHQRWWR EHVLGHORDGHGGXULQJDOLIWLQJRSHUDWLRQ

%HFDXVHRIWKHVL]HRIVRPHRIWKHPDFKLQH FRPSRQHQWVWKHVHUYLFHPDQRUPHFKDQLFVKRXOGFKHFN WKHZHLJKWVQRWHGLQWKLV0DQXDO8VHSURSHUOLIWLQJ SURFHGXUHVZKHQUHPRYLQJDQ\FRPSRQHQWV

 7RDYRLGEXUQVEHDOHUWIRUKRWSDUWVRQPDFKLQHV ZKLFKKDYHMXVWEHHQVWRSSHGDQGKRWIOXLGVLQOLQHV WXEHVDQGFRPSDUWPHQWV

)ROORZLQJLVDOLVWRIEDVLFSUHFDXWLRQVWKDWVKRXOGDOZD\V EHREVHUYHG

 %HFDUHIXOZKHQUHPRYLQJFRYHUSODWHV*UDGXDOO\ EDFNRIIWKHODVWWZREROWVRUQXWVORFDWHGDWRSSRVLWH HQGVRIWKHFRYHURUGHYLFHDQGSU\FRYHUORRVHWR UHOLHYHDQ\VSULQJRURWKHUSUHVVXUHEHIRUHUHPRYLQJ WKHODVWWZREROWVRUQXWVFRPSOHWHO\

 5HDG DQG XQGHUVWDQGDOO:DUQLQJSODWHVDQGGHFDOVRQ WKHPDFKLQHEHIRUHRSHUDWLQJOXEULFDWLQJRUUHSDLULQJ WKHSURGXFW  $OZD\VZHDUSURWHFWLYHJODVVHVDQGSURWHFWLYHVKRHV ZKHQZRUNLQJDURXQGPDFKLQHV,QSDUWLFXODUZHDU SURWHFWLYHJODVVHVZKHQSRXQGLQJRQDQ\SDUWRIWKH PDFKLQHRULWVDWWDFKPHQWVZLWKDKDPPHURUVOHGJH 8VHZHOGHUVJORYHVKRRGJRJJOHVDSURQDQGRWKHU SURWHFWLYHFORWKLQJDSSURSULDWHWRWKHZHOGLQJMRE EHLQJSHUIRUPHG'RQRWZHDUORRVHILWWLQJRUWRUQ FORWKLQJ5HPRYHDOOULQJVIURPILQJHUVZKHQZRUNLQJ RQPDFKLQHU\

 %HFDUHIXOZKHQUHPRYLQJILOOHUFDSVEUHDWKHUVDQG SOXJVRQWKHPDFKLQH+ROGDUDJRYHUWKHFDSRUSOXJ WRSUHYHQWEHLQJVSUD\HGRUVSODVKHGE\OLTXLGVXQGHU SUHVVXUH7KHGDQJHULVHYHQJUHDWHULIWKHPDFKLQH KDVMXVWEHHQVWRSSHGEHFDXVHIOXLGVFDQEHKRW  $OZD\VXVHWRROVWKDWDUHLQJRRGFRQGLWLRQDQGEH VXUH\RXXQGHUVWDQGKRZWRXVHWKHPEHIRUH SHUIRUPLQJDQ\VHUYLFHZRUN

 'RQRWZRUNRQDQ\PDFKLQHWKDWLVVXSSRUWHGRQO\E\ OLIWMDFNVRUDKRLVW$OZD\VXVHEORFNVRUMDFNVWDQGV WRVXSSRUWWKHPDFKLQHEHIRUHSHUIRUPLQJDQ\ GLVDVVHPEO\

 5HLQVWDOODOOIDVWHQHUVZLWKVDPHSDUWQXPEHU'RQRW XVHDOHVVHUTXDOLW\IDVWHQHULIUHSODFHPHQWVDUH QHFHVVDU\'RQRWPL[PHWULFIDVWHQHUVZLWK VWDQGDUGQXWVDQGEROWV

 /RZHU WKHIRUNVRURWKHU LPSOHPHQWVWRWKHJURXQG EHIRUHSHUIRUPLQJDQ\ZRUNRQWKHPDFKLQH,IWKLV FDQQRWEHGRQHPDNHVXUHWKHIRUNVRURWKHU LPSOHPHQWVDUHEORFNHGFRUUHFWO\WRSUHYHQWWKHP IURPGURSSLQJXQH[SHFWHGO\

 ,ISRVVLEOHPDNHDOOUHSDLUVZLWKWKHPDFKLQHSDUNHG RQDOHYHOKDUGVXUIDFH%ORFNPDFKLQHVRLWGRHV QRWUROOZKLOHZRUNLQJRQRUXQGHUPDFKLQH

 RI

:$51,1*  'RQRWRSHUDWHDPDFKLQHLIDQ\URWDWLQJSDUWLV GDPDJHGRUFRQWDFWVDQ\RWKHUSDUWGXULQJ RSHUDWLRQ$Q\KLJKVSHHGURWDWLQJFRPSRQHQWWKDW KDVEHHQGDPDJHGRUDOWHUHGVKRXOGEHFKHFNHG IRUEDODQFHEHIRUHUHXVLQJ

 'LVFRQQHFWEDWWHU\DQGGLVFKDUJHDQ\FDSDFLWRUV HOHFWULFWUXFNV EHIRUHVWDUWLQJWRZRUNRQPDFKLQH +DQJ'R1RW2SHUDWHWDJLQWKH2SHUDWRU V &RPSDUWPHQW  5HSDLUVZKLFKUHTXLUHZHOGLQJVKRXOGEH SHUIRUPHGRQO\ZLWKWKHEHQHILWRIWKHDSSURSULDWH UHIHUHQFHLQIRUPDWLRQDQGE\SHUVRQQHODGHTXDWHO\ WUDLQHGDQGNQRZOHGJHDEOHLQZHOGLQJSURFHGXUHV 'HWHUPLQHW\SHRIPHWDOEHLQJZHOGHGDQGVHOHFW FRUUHFWZHOGLQJSURFHGXUHDQGHOHFWURGHVURGVRU ZLUHWRSURYLGHDZHOGPHWDOVWUHQJWKHTXLYDOHQWDW OHDVWWRWKDWRISDUHQWPHWDO

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

 'R QRW GDPDJHZLULQJGXULQJUHPRYDORSHUDWLRQV 5HLQVWDOOWKHZLULQJVRLWLVQRWGDPDJHGQRUZLOOLW EHGDPDJHGLQRSHUDWLRQE\FRQWDFWLQJVKDUS FRUQHUVRUE\UXEELQJDJDLQVWVRPHREMHFWRUKRW VXUIDFH'RQRWFRQQHFWZLULQJWRDOLQHFRQWDLQLQJ IOXLG  %HVXUHDOOSURWHFWLYHGHYLFHVLQFOXGLQJJXDUGVDQG VKLHOGVDUHSURSHUO\LQVWDOOHGDQGIXQFWLRQLQJ FRUUHFWO\EHIRUHVWDUWLQJDUHSDLU,IDJXDUGRUVKLHOG PXVWEHUHPRYHGWRSHUIRUPWKHUHSDLUZRUNXVH H[WUDFDXWLRQ

,IGXVWZKLFKPD\FRQWDLQDVEHVWRVLVSUHVHQWWKHUHDUH VHYHUDOFRPPRQVHQVHJXLGHOLQHVWKDWVKRXOGEH IROORZHG

 $OZD\VVXSSRUWWKHPDVWDQGFDUULDJHWRNHHS FDUULDJHRUDWWDFKPHQWVUDLVHGZKHQPDLQWHQDQFH RUUHSDLUZRUNLVSHUIRUPHGZKLFKUHTXLUHVWKH PDVWLQWKHUDLVHGSRVLWLRQ

D 1HYHUXVHFRPSUHVVHGDLUIRUFOHDQLQJ E$YRLGEUXVKLQJRUJULQGLQJRIDVEHVWRVFRQWDLQLQJ PDWHULDOV

 /RRVHRUGDPDJHGIXHOOXEULFDQWDQGK\GUDXOLF OLQHVWXEHVDQGKRVHVFDQFDXVHILUHV'RQRW EHQGRUVWULNHKLJKSUHVVXUHOLQHVRULQVWDOORQHV ZKLFKKDYHEHHQEHQWRUGDPDJHG,QVSHFWOLQHV WXEHVDQGKRVHVFDUHIXOO\'RQRWFKHFNIRUOHDNV ZLWK\RXUKDQGV3LQKROHYHU\VPDOO OHDNVFDQ UHVXOWLQDKLJKYHORFLW\RLOVWUHDPWKDWZLOOEH LQYLVLEOHFORVHWRWKHKRVH7KLVRLOFDQSHQHWUDWH WKHVNLQDQGFDXVHSHUVRQDOLQMXU\8VHFDUGERDUG RUSDSHUWRORFDWHSLQKROHOHDNV

F )RUFOHDQXSXVHZHWPHWKRGVRUDYDFXXP HTXLSSHGZLWKDKLJKHIILFLHQF\SDUWLFXODWHDLU +(3$ ILOWHU G8VHH[KDXVWYHQWLODWLRQRQSHUPDQHQWPDFKLQLQJ MREV H :HDUDQDSSURYHGUHVSLUDWRULIWKHUHLVQRRWKHUZD\ WRFRQWUROWKHGXVW I &RPSO\ZLWKDSSOLFDEOHUXOHVDQGUHJXODWLRQVIRUWKH ZRUNSODFHIRUH[DPSOHLQWKH86$26+$ UHTXLUHPHQWVDVVHWIRUWKLQ&)5 

 7LJKWHQFRQQHFWLRQVWRWKHFRUUHFWWRUTXH0DNH VXUHWKDWDOOKHDWVKLHOGVFODPSVDQGJXDUGVDUH LQVWDOOHGFRUUHFWO\WRDYRLGH[FHVVLYHKHDWYLEUDWLRQ RUUXEELQJDJDLQVWRWKHUSDUWVGXULQJRSHUDWLRQ 6KLHOGVWKDWSURWHFWDJDLQVWRLOVSUD\RQWRKRW H[KDXVWFRPSRQHQWVLQHYHQWRIDOLQHWXEHRUVHDO IDLOXUHPXVWEHLQVWDOOHGFRUUHFWO\

J )ROORZHQYLURQPHQWDOUXOHVDQGUHJXODWLRQVIRU GLVSRVDORIDVEHVWRV K $YRLGDUHDVZKHUHDVEHVWRVSDUWLFOHVPD\EHLQWKH DLU

 5HOLHYHDOOSUHVVXUHLQDLURLORUZDWHUV\VWHPV EHIRUHDQ\OLQHVILWWLQJVRUUHODWHGLWHPVDUH GLVFRQQHFWHGRUUHPRYHG$OZD\VPDNHVXUHDOO UDLVHGFRPSRQHQWVDUHEORFNHGFRUUHFWO\DQGEH DOHUWIRUSRVVLEOHSUHVVXUHZKHQGLVFRQQHFWLQJDQ\ GHYLFHIURPDV\VWHPWKDWXWLOL]HVSUHVVXUH

RI

6%( $XJ 

6SHFLILFDWLRQV 72548( 63(&,),&$7,216

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

0(75,&1876$1'%2/76 7+5($' 6,=( PP

67$1'$5'72548( 1 P

0



0



0



0



0



0



0



0



0



0



“ “ “  “  “  “  “  “  “  “ 

OE IW          

“ “ “ “ “ “ “ “ “ “

         

0(75,&7$3(5/2&.678'6 7+5($' 6,=( PP

67$1'$5'72548( 1 P

0



0



0



0



0



0



0



0



0



“ “ “ “ “ “ “ “ “

OE IW





































 RI

“ “ “ “ “ “ “ “ “

        

67$1'$5'72548()25,1&+)$67(1(56 ([FHSWLRQVWRWKHVHWRUTXHVDUHJLYHQLQWKH6HUYLFH 0DQXDOZKHUHQHHGHG

,1&+1876$1'%2/76 7+5($' 6,=( LQFK

67$1'$5'72548( 1 P

























































“ “ “ “ “ “ “ “ “ “ “ “ “ “



OE IW 





















































“ “ “ “ “ “ “ “ “ “ “ “ “ “

             

,1&+7$3(5/2&.678'6 7+5($' 6,=( LQFK

67$1'$5'72548( 1 P





















































“ “ “ “ “ “ “ “ “ “ “ “ “



OE IW 

















































 RI

“ “ “ “ “ “ “ “ “ “ “ “ “

    

       

25,1*)$&(6($/),77,1*6 25,1*)$&(6($/),77,1*

25,1**5229(

25,1*)$&(6($/187

675$,*+77+5($'25,1* 3257),77,1*(1'

25,1*

,'$6%

675$,*+77+5($'25,1* ),77,1*)2525,1*)$&( 6($/),77,1*21/< 7+5($' 6,=( LQFK

67$1'$5'72548( OE  IW 1 P





















































“ “ “ “ “ “ “ “ “ “ “ “ “

 

“OE  LQ

“OE  LQ













































“ “ “ “ “ “ “ “ “ “ “

  

       

25,1*)$&(6($/),77,1*187 7+5($' 6,=( LQFK

67$1'$5'72548( 1 P

































“ “ “ “ “ “ “ “

OE IW

































 RI

“ “ “ “ “ “ “ “

       

),77,1*,167$//$7,21  3XWORFNQXW EDFNXSZDVKHU DQG2ULQJVHDO  DVIDUEDFNRQILWWLQJERG\ DVSRVVLEOH+ROG WKHVHFRPSRQHQWVLQWKLVSRVLWLRQ7XUQWKHILWWLQJ LQWRWKHSDUWLWLVXVHGRQXQWLOEDFNXSZDVKHU MXVW PDNHVFRQWDFWZLWKWKHIDFHRIWKHSDUWLWLVXVHGRQ

+ 37.6 V

Table 2 : Case of an 36V system

EE code disappears only after active directional switch is turned off.

BATTERY CHARGE LEVEL Discharged battery 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % Full charged battery

Time meter or, otherwise, odometer Steering angle Maintenance time expiry, indicated by warning symbol Slow speed operation, indicated by Lift truck speed level, range from 0 (NO speed) to 9 (MAXIMUM speed) segment, as in symbol Battery level, indicated by a 9 segments symbol.

Table 3: Case of a 48V system

In following Table 1, you can read the generic relation between battery charge level and number of visualized bars . See Table 2 in case of an 36V system and Table 3 in case of a 48V system. Display signals with alarm code EL the fact battery is completely discharged.

G

BATTERY CHARGE LEVEL Discharged battery 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % Full charged battery

99

BATTERY VOLTAGE [V] Voltage < 45.6 V 45.6 V ~ 46.4 V 46.4 V ~ 47.0 V 47.0 V ~ 47.6 V 47.6 V ~ 48.2 V 48.2 V ~ 48.7 V 48.7 V ~ 49.2 V 49.2 V ~ 49.7 V 49.7 V ~ 50.1 V 50.1 V ~ 50.4 V Voltage > 50.4 V

G

Otherwise symbol indicates, as usual, selected operating mode.

Lift truck operation mode Pressing E-S-H button, you can set energetic operating mode for your system.

Notice:As usual, if lift truck is moving, symbol indicates speed level. Notice: If active mode is one of L1, L2 or L3 limitations and you change operating mode (from PROGRAMMABLE WORKING to ES-H), software automatically sets operating mode to economic one.

This function is enabled using EYE menu named Calibration – ESH, to select desired operating mode. In particular you can choose between E-S-H or PROGRAMMABLE WORKING : - Pressing E-S-H (economic, standard, high) button, you change energetic mode and update related parameters with a value, corresponding to selected operating mode, that operator can’t modify. - Pressing PROGRAMMABLE WORKING you can manage 3 further options (limit 1, limit 2, and limit 3). You can set parameters value, that are expressed in per cent of high energetic mode; changing active limitation (among L1, L2 or L3), related per cent data are used to calculate actual parameters value.

Alarm message, indicated by an alpha-numerical code in the display area where usually lift truck speed appears. See Table 5 for the meaning of alarm codes. Over-temperature alarm, indicated by the warning light In case the temperature of power transistors exceeds the warning limit, alarm code and relative light blink. Moreover, in case temperature exceeds the alarm limit, (or it stays between the two thresholds for 30 s or more), the symbols stop blinking and became still.

Notice:Percent values can be modified only with EYE Calibration – E-S-H menu.

Hour meter separation point, usually blinking, stops in following cases: - Seat switch open. - Serial communication between display and control unit not active - Main breaker open

Notice:Pressing PROGRAMMABLE WORKING you can manage economic, standard or high operating mode too. COMPACT display shows different symbols in function of selected energetic mode:

Turning your lift truck on, some alphanumeric codes, visible for 3 seconds, appear where usually is visualized speed indicator symbol; those codes help to identify system in use (see Table 6). Where usually is visualized hour meter, on left side appears feed voltage in VDC, and on right side, maximum weight industrial truck can lift, expressed in quintals.

- E-S-H management disabled: no symbol visualised. - E-S-H management enabled: active mode is indicated by symbol - PROGRAMMABLE WORKING management enabled: in case you have chosen one of L1, L2 or L3 operating modes, and lift truck is stopped, one of the segments of speed indicator symbol (see Table 4 ) blinks to show selected energetic mode DISPLAY VISUALISATION (from symbol left side) 1st segment 5th segment 9th segment

SYSTEM IN USE 4 Wheels (BX) 3 Wheels (BT) Table 6

OPERATINGMODE L1 (Limit 1) L2 (Limit 2) L3 (Limit 3)

Table 4 : selected energetic mode

G

100

CODE C0 C1

G

ALARM CODE F F0 F1 F2 F3 F4 F5 F6 F7 F8 F9 FA Fc Fd FE FH FL E1 E2 E3 E4 E5 E6 EE EL EE (flashing) A AL 17 60 77 78 79 80 81 82 83 84

LED Indicators

ALARM DESCRIPTION Wrong eeprom + watch dog timer Maximum battery voltage Minimum battery voltage Pedal trimmer fault Drive right module desat/overcurrent Drive left module desat/overcurrent Pump module Desat/overcurrent Drive right motor current offset Drive left motor current offset Pump motor current offset Steer sensor fault 5V encoders not ok Drive right motor Encoder Left right motor Encoder 24V out not ok 12V out not ok Pump inputs on at start Drive right module Overtemperature Drive left module Overtemperature Pump module overtemperature Drive right motor Overtemperature Drive left motor Overtemperature Pump motor Overtemperature Wrong start Low battery voltage Seat switch opened Alarm on pre-charge circuit of internal capacitors Key retention Main breaker fault Battery / inverter mismatch Wrong right traction motor thermal probe Wrong left traction motor thermal probe Wrong pump motor thermal probe Wrong right traction module thermal probe Wrong left traction module thermal probe Wrong pump module thermal probe CRC fault Bank CRC restored

On left side, COMPACT display has four LED indicators which, when switched on, give information as follows: Alarm message; red colour LED Message of lamps; green colour LED (future) Indicator lights activated; green colour LED (future) Low oil level of the brakes; red colour LED (future)

Notice:Alarm LED

- Display normally working: LED lights up briefly switching on /off your system - Display not communicating with control board: after 3 seconds from the moment in which the communication stops, alarm LED brightens - Display board microprocessor not working: alarm LED brightens.

G G G G G G G G G G G G G G G G G G G G G G G G G G

Table 5 : Meaning of alarm codes

G

is managed as follows:

101

G

Display Keys Utilization As you can see in Fig.1, on right side of display front there are four keys: E-S-H, UP (TURTLE), DOWN and ENTER. The function of each of them is described as follows:

E-S-H key With this key, you can modify the device operating condition, in a circular sequence, as described in Table 7 :

ENTER key 1. When you switch your device on, this key, pressed for 3 consecutive seconds, allows entering both to parameter calibration and to diagnostic mode. 2. During usual operations, this key, pressed for 3 consecutive s, allows you to access merely to diagnostic mode.

Current Working Condition

Remember that if the display is operating in diagnostic mode during typical operations, you can exit this procedure pressing once ENTER key. Moreover, ENTER key is used to confirm the new value of the parameter in calibration procedure.

Economic (E)

Standard (S)

Standard (S)

High (H)

High (H) Limitation 1 (L1)

Limitation 1 (L1) Limitation 2 (L2)

Limitation 2 (L2)

Limitation 3 (L3)

Limitation 3 (L3)

Economic (E)

Table 7

Notice: You can modify system operating modes only after enabling their management with EYE applicative software.

UP key 1. Pressing of this key, in calibration and diagnostic mode, you increase the number of the parameter displayed. 2. In calibration phase, you increase the numeric value of the parameter displayed.

Notice: Pressing this key when you are in diagnostic mode you can see a circular list of 10 latest alarms.

TURTLE key Remember that pressing this key you can toggle between slow running and normal working condition (if the lift truck is already in speed limitation mode).

DOWN key 1. Pressing of this key, in calibration and diagnostic mode, you decrease the number of the parameter displayed. 2. In calibration phase, you decrease the numeric value of the parameter displayed.

G

Working Condition After the Key Pressure

102

G

The parameter number (blinking) appears on the display area usually reserved to lift truck speed and alarm codes, and its value is shown in the timemeter area. Moreover, appear a number of segments proportional to the parameter value.

Parameter Calibration This chapter describes the way to adjust the main operating parameters of the system. You inhibit the access to this menu with EYE submenu named “Lift truck setup”. To calibrate your parameters, read following instructions:

If you see that the numeric data have been modified in the time meter area, it means that the value of the chosen parameter has really been updated into control board memory.

To enter calibration mode: 1. Switching on your system, press ENTER key until a blinking “0” (zero) appears. 2. Press UP key: the entry to the chosen calibration mode is indicated by “C”; this symbol persists until the first parameter will be selected.

Notice: Remember that parameter values can be modified only by discrete increments. See Table 8 for the list of all adjustable parameters and relative minimum available variations.

Notice: If calibration procedure is not enabled using EYE “Lift truck setup” menu, UP key pressure has no effect. Notice: You can exit this operating mode only switching off your system. To execute the calibration: 1. Select parameter 10 using UP and DOWN keys, and confirm your choice pressing ENTER key. 2. Use UP and DOWN keys to set at 4 the value of this parameter, and confirm with ENTER key. 3. Repeat the above operations to fix parameter 17 value at 6 Notice: it doesn’t matter if you first modify parameter 10 and then 17, or vice versa. Only after this procedure, you allow operator to change the value of other parameters: 1. Select the parameter to change, using UP or DOWN key; press ENTER to confirm. 2. Now adjust the value of the selected parameter with UP and DOWN keys; confirm your choice typing ENTER key.

G

103

G



G

No 5 6 9 10 11 12 13

Parameter Deceleration steering ramp 1 Deceleration steering ramp 2 Battery reset value First parameter for calibration enable Seat switch delay Chat time Hydro time

Unit rpm/s rpm/s V*10

Minimum 10 1 464

14

Maintenance time inserting enable

17 18 19 20 23 24 26 32 33 34 41 42 43 44 46 47 48 49 50 51 52 53 59 61 62 63 64 65 66 67 68 69 70 71 72 73

Second parameter for calibration enable Steering clockwise Steering anticlockwise Steering middle Minimum accelerator Maximum accelerator Stop on slop timer Maximum lift Minimum lift Middle lift Drive maximum current Forward maximum speed Reverse maximum speed Drive limitation maximum speed High lift 1 switch drive max speed Steer limitation maximum speed Acceleration ramp Inversion ramp Release ramp Pedal brake ramp Creep speed Diameter of drive tyres Partial release ramp Lift maximum current Auxiliary maximum current Lift maximum speed Tilt speed AUX 1 speed AUX 2 speed AUX 3 speed Lift minimum speed High lift 1 switch lift max speed Hydro speed Hydro idle speed Pump acceleration ramp Pump deceleration ramp

s s s

1 3 10

3 9 6 9 10 20 Disable = 0 (Default) Enable = 1

500 500 500 200 3,000 1 3,000 0 1,000 20 1,000 1,000 500 400 400 400 400 400 400 100 300 10 20 10 1,500 500 500 500 500 500 500 400 200 1,000 1000

1,200 11,500 10,300 11,500 6,300 11,500 1,000 4,500 5,000 12,000 5 10 11,500 12,000 1,000 12,000 2,750 12,000 100 100 4,500 4,500 4,500 4,500 2,000 2,500 2,000 4,500 1,000 2,000 1,100 2,000 1,300 2,000 900 2,000 1,200 2,000 300 2,000 451 600 50 500 100 100 65 100 2,950 4,500 900 2,000 900 2,800 900 2,800 900 2,800 700 1,500 500 4500 500 800 300 500 7,000 10,000 7000 10000 Accelerator signal 1 = E mode, 2 = S mode, 3 = H mode Disable = 0 (Default) Enable = 1 Normal = 0 (Default) British unit = 1 5 8 Disable = 0 Enable = 1 (Default) Timer meter = 0 (Default) Odometer = 1 0 10000

93

Power mode (E-S-H, limitations)

digit

94

Slow speed

digit

95

British unit

digit

96

Display brightness

digit

97

E-S-H enable

digit

98

Time meter / Odometer on display

digit

99

Maintenance time

digit mV mV mV mV mV s mV mV mV % rpm rpm rpm rpm rpm rpm/s rpm/s rpm/s rpm/s rpm mm rpm/s % % rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm/s rpm

h

104

0

0

Default 800 6 470

Maximum 5000 10 501

Variation 10 1 1 1 1 1 1

1 10 10 10 10 10 1 10 10 10 1 50 50 50 50 50 10 10 10 10 1 10 1 1 50 50 50 50 50 50 50 10 10 10 10

1

100

G



G

No 5 6 9 10 11 12 13

Parameter Deceleration steering ramp 1 Deceleration steering ramp 2 Battery reset value First parameter for calibration enable Seat switch delay Chat time Hydro time

Unit rpm/s rpm/s V*10

Minimum 10 1 344

14

Maintenance time inserting enable

17 18 19 20 23 24 26 32 33 34 41 42 43 44 46 47 48 49 50 51 52 53 59 61 62 63 64 65 66 67 68 69 70 71 72 73

Second parameter for calibration enable Steering clockwise Steering anticlockwise Steering middle Minimum accelerator Maximum accelerator Stop on slop timer Maximum lift Minimum lift Middle lift Drive maximum current Forward maximum speed Reverse maximum speed Drive limitation maximum speed High lift 1 switch drive max speed Steer limitation maximum speed Acceleration ramp Inversion ramp Release ramp Pedal brake ramp Creep speed Diameter of drive tyres Partial release ramp Lift maximum current Auxiliary maximum current Lift maximum speed Tilt speed AUX 1 speed AUX 2 speed AUX 3 speed Lift minimum speed High lift 1 switch lift max speed Hydro speed Hydro idle speed Pump acceleration ramp Pump deceleration ramp

s s s

1 3 10

3 9 6 9 10 20 Disable = 0 (Default) Enable = 1

500 500 500 200 3,000 1 3,000 0 1,000 20 1,000 1,000 500 400 400 400 400 400 400 100 300 10 20 10 1,500 500 500 500 500 500 500 400 200 1,000 1000

1,200 11,500 10,300 11,500 6,300 11,500 1,000 4,500 5,000 12,000 5 10 11,500 12,000 1,000 12,000 2,750 12,000 100 100 3,800 3,800 3,800 3,800 2,000 2,500 2,000 3,800 1,000 2,000 1,100 2,000 1,300 2,000 900 2,000 1,200 2,000 300 2,000 451 600 50 500 100 100 65 100 2,950 4,500 900 2,000 900 2,800 900 2,800 900 2,800 700 1,500 500 4500 500 800 300 500 7,000 10,000 7000 10000 Accelerator signal 1 = E mode, 2 = S mode, 3 = H mode Disable = 0 (Default) Enable = 1 Normal = 0 British unit = 1 (Default) 5 8 Disable = 0 Enable = 1 (Default) Timer meter = 0 (Default) Odometer = 1 0 10000

93

Power mode (E-S-H, limitations)

digit

94

Slow speed

digit

95

British unit

digit

96

Display brightness

digit

97

E-S-H enable

digit

98

Time meter / Odometer on display

digit

99

Maintenance time

digit mV mV mV mV mV s mV mV mV % rpm rpm rpm rpm rpm rpm/s rpm/s rpm/s rpm/s rpm mm rpm/s % % rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm/s rpm

h

105

0

0

Default 800 6 356

Maximum 5000 10 373

Variation 10 1 1 1 1 1 1

1 10 10 10 10 10 1 10 10 10 1 50 50 50 50 50 10 10 10 10 1 10 1 1 50 50 50 50 50 50 50 10 10 10 10

1

100

G

Sensor Initial Setting

Default Setting

In case that initial settings of sensors are not performed accordingly, the machine performance can be lowered. So, in the following cases, initial setting for each sensor should be done to secure the correct machine performance.

It is also possible to update the parameters with default values. As for the procedure explained below, use UP, DOWN and ENTER keys to set parameter 10 value to 5 and parameter 17 value to 2. Once more, the order you adopt to change the two parameters is not important. The loading of default data is indicated by the symbols d S (default set);

- Replacing Logic - Updating flash memory(Update EEPROM) or Resetting EEPROM - Replacing or adjusting Sensor - Default Setting

Notice: All parameters whose value is related to selected energetic operating mode (economic, standard, high, limitation 1, limitation 2, limitation 3) are updated with default values corresponding to the active one. Pressing E-S-H key on display, and selecting a different working mode, you immediately change the value of all parameters related. Such parameters, as well as their default values, are listed in Table 10 (*)

STEERING SENSOR (parameter 13): Enter diagnostic mode to visualize steering sensor voltage. Minimum value calibration: turn wheels completely on left and read sensor voltage value from display; enter calibration mode and set parameter 19 to the value measured. Maximum value calibration: turn wheels completely on right and read sensor voltage value from display; enter calibration mode and set parameter 18 to the value measured.

Parameter Central value calibration: put wheels straight and read sensor voltage value from display; enter calibration mode and set parameter 20 to the value measured.

Maximum drive current Maximum forward speed [rpm] Maximum reverse speed [rpm] Acceleration proportional to load Drive acceleration ramp [rpm/s] Lift maximum current Maximum lift speed [rpm] Drive inversion ramp [rpm/s] Drive release ramp [rpm/s]

ACCELERATOR SENSOR (parameter 11): Enter diagnostic mode to visualize speed sensor voltage. Minimum value calibration: read from display sensor voltage corresponding to start switch closure (when all segments dedicated to speed level visualisation are active); enter calibration mode and set parameter 23 to the value measured. Maximum value calibration: read sensor voltage value from display, with pedal completely pressed; enter calibration mode and set parameter 24 to the value measured. LIFT LEVER SENSOR (parameter 5): Enter diagnostic mode to visualize lift lever voltage. Minimum value calibration: read from display sensor voltage with lift lever released; enter calibration mode and set parameter 33 to the value read.

Standar d Mode

Hige Mode

62

76

100

3000

3500

4500

3000

3500

4500

20

20

20

700

800

1150

70

80

100

2500

2750

2950

600

900

1200

600

850

1000

Table 10 (*) Its values are actually implemented into the software of BX20 48 V lift truck

Notice: Once default data have been loaded, if you further need to modify parameters value, you have to switch your system off, before entering calibration mode again.

Maximum value calibration: read from display sensor voltage with lift lever completely pressed; enter calibration mode and set parameter 32 to the value measured. Central value calibration: enter calibration mode and modify parameter 34.

G

Econom ic Mode

Notice: Parameter 94 is visualized only in case ES-H management procedure is enabled with relative EYE software calibration menu.

106

G

Diagnostic Mode This operating mode enables you to test main analogical and digital signals managed by your system. Enter diagnostic mode if you are switching on your lift truck: 1. Press ENTER key (for 3 consecutive seconds) until the symbol “0” lights up. 2. Press DOWN key to enter diagnostic mode; the symbol “d” is visualized and it persists until the first parameter has been selected. Enter diagnostic mode if you are working as usual with your lift truck: 1. Press ENTER key (for 3 consecutive seconds) until symbol “d” appears; it will persist as long as the first parameter has been selected. After diagnostic operation mode has been enabled, you can choose the parameter you want to analyse using UP and DOWN keys (parameter number increases using UP key and decreases with DOWN key). Here, in Table 11, you have a list of the parameters you can analyze with their respective displaying order :

G

107

G

List of diagnostic Parameter No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

G

Description Right traction motor speed Right traction motor speed reference Left traction motor speed Left traction motor speed reference Lift voltage Battery voltage Right traction motor power module temperature Pump motor power module temperature Pump motor speed Pump motor speed reference Accelerator potentiometer voltage Accelerator second potentiometer voltage Steering sensor voltage Left traction motor power module temperature Right traction motor phase current U Right traction motor phase current V Right traction motor phase current W Left traction motor phase current U Left traction motor phase current V Left traction motor phase current W Pump motor phase current U Pump motor phase current V Pump motor phase current W Right traction motor temperature Left traction motor temperature Pump motor temperature Seat switch hour meter Drive motor hour meter Pump motor hour meter Seat switch Park brake switch Start switch Reverse traction direction switch Forward traction direction switch Pedal brake switch 3 / 4 wheels selection switch Side shift switch Auxiliary 2 function switch High lift switch Tilt switch Main breaker command 5V out 12V out 24V out Buzzer command Fans command

108

Unit [rpm] [rpm] [rpm] [rpm] [mV] [V½10] [¶C / ¶F] [¶C / ¶F] [rpm] [rpm] [mV] [mV] [mV] [¶C / ¶F] [A rms] [A rms] [A rms] [A rms] [A rms] [A rms] [A rms] [A rms] [A rms] [¶C / ¶F] [¶C / ¶F] [¶C / ¶F] [h] [h] [h] [digit] [digit] [digit] [digit] [digit] [digit] [digit] [digit] [digit] [digit] [digit] [digit] [digit] [mV] [digit] [digit] [digit]

G

In diagnostic mode selected parameter is visualized as follows: 1. In the area dedicated to speed and alarm signals, appears parameter number ( flashing) 2. Its actual value is displayed in the area reserved to the time meter.

Accessing Stored Error Codes The B18X series of remembers the last 10 error codes. This is case the truck has had an intermittent problem, but the operator cannot remember which code appeared on the display. Also by analyzing the contents of the last 10 error codes, it may be possible to determine what sort of application the truck has been working in.

In particular, if the selected parameter is: Analogue input: Instrument panel shows the parameter value, expressed in the unit of Table 11

The stored error codes are accessed at diagnostic mode by using E-S-H button.

Digital input: if the command activated by the operator corresponds to the parameter selected, the value of the quantity is visualized.

1. Access the diagnostic mode.

Other way the symbol E (error) appears, except in following case: 1. Seat switch active, for any selected digital input.

2. Press E-S-H button. And then, the stored error code will be shown with SMU hours, if any.

To exit diagnostic mode, type ENTER key again.

3. By pressing UP or DOWN key, more error codes can be shown.

Notice: If an alarm occurs when diagnostic mode is enabled, and the system is working as usual, display returns automatically to its typical visualization mode. However you can enter diagnostic mode again, pressing ENTER key (for 3 consecutive s), until the last parameter displayed before exiting is visualized.

4. Pressing again E-S-H key, you return to diagnostic mode.

If the selected parameter is a temperature, also thermal alarm symbol is visualized.

G

109

G

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

It can be run from a PC with serial or USB (1.x o2.x) port. Connection between PC and Main harness’s Serial Communication connector is characterized by a 38,4 kBaud/s Baud-rate. User can communicate with lift truck during working operations, and can analyse on line main electrical variables value/ status. EYE software interface is user friendly and intuitive: it guides the operator through the process of parameter setting and is an effective data analysis instrument, helping to identify faults and causes of malfunctioning. Following functions are in particular very useful: 1. Diagnostic: User can receive relevant control data from the main board (such as current, voltage, rpm, temperatures etc ) evaluating lift truck performance and detecting any faulty circuit 2. Calibration: User can transmit parameters and settings to the truck in order to tune its performance. 3. Flash memory software update

G

110

G

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

G

111

G

PC-Controller Communication

General Information G

Connect serial port of PC and harness with picture below.

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

Serial port

USB port

4. Graphic card 1Mb 5. Windows 98SE/NT/XP/ME/2000 6. 1024x768 resolution video adapter G G

Recommanded Requirements G 1. 2. 3. 4. 5. 6. G

G

1GHz Pentium class or higher microprocessor 512Mb of RAM Serial port or USB port Graphic card 2Mb Windows 98SE/NT/XP/ME/2000 1024x768 resolution video adapter

112

G

Installation G To install EYE software, complete following steps: 1. Check computer requirements 2. Start Setup.exe application 3. Select destination path then press FINISH 4. At the end press OK and then reboot 5. You can create a short-cut of EYE.exe on desktop If there is an old release installed, you must uninstall it. To uninstall you must execute Setup.exe application from CD and confirm any step

G

113

G

Features G If EYE software installation is successful, starting the application from Windows “Programs” Menu, or using shortcut on desktop (Fig.1), you can access main menu (Fig.2).

Fig.1: Short-cut

Date: xx-xx-xx (Software version) Fig.2: Main menu – operator mode

To quit application or exit a submenu, press ESC key or select Exit menu. In case of any problems, refer to section 4 “TROUBLESHOOTING”.

WARNING Some menus, items or calibration parameters described in this manual are optional lift truck functions: so they could be not implemented.

G

114

G

Main Menu On left side, there are some notes about software release, operating mode and serial communication setting. Below lift-truck picture, there are actual active alarms (code level and description); In case of more alarms with the same priority level, the first occurred is visualized. In operator mode, you can access following menus: 1. “Setup” 2. “Test” 3. “Data logging” 4. “Password” 5. “About” Even before starting of serial communication between lift truck and PC (Fig.3), you can access “Setup”, “Password” and “About” menus (Fig.4). In such a case some data field are missing. In case of faults during a serial communication data flow, any submenu is aborted and main menu front panel is reinitialized.

Fig.3: operator mode – serial communication faulty

Fig.4: About menu

G

115

G

Password Insertion G G G G G G G G G G G G G Fig.5: Password insertion

Selecting Password mode from menu-bar, you can access Supervisor mode (Fig.6) inserting the correct password (Fig.5). Contact EYE software developer to know correct password.

Fig.6: main menu – supervisor mode

In case wrong password insertion (Fig.7), following message becomes visible:

Fig.7: unauthorized user

G G

116

G

In Supervisor mode, you can access these further menus: 1. “Calibration” 2. “Flash” “Password” menu disappears from menu-bar. In case of faulty serial communication, main menu front panel is reinitialized as follows (Fig.8):

WARNING “PANEL BLANK” message is used to distinguish case of not programmed flash memory, so Flash menu is obviously active.

Fig.8: supervisor mode – communication faulty

G You can select active menus directly from main panel menu bar (any greyed menu is not accessible in that moment); you can also access present sub panels with a further selection by a pop-up menu (Fig.9)

G G G G G G G G G G Fig.9: Submenu selection

G

117

G

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

Submenus Print function is accessible from many of listed submenus: you can send active front panel image to printer or save it on file; in that case destination directory is \EYE\ images. BEWARE: if more than one window is in use, only the one relative to the inner submenu is active and all others work in background. If you select a non active window, you can’t communicate\ interact with inverter panel.

G

118

G

Configuration Menu (Setup)

Fig.10: Setup menu

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

G

119

G

Test This pop-up menu includes of following subjects: 1. “Drive” (Fig.11) 2. “Pump” (Fig.12) 3. “Battery” (Fig.13) 4. “Timers” (Fig.14)

Drive (Traction)

Fig.11: Drive menu

Following items appear in Drive menu front panel: 1. Accelerator pedal voltage 2. Pedal brake pressure (in bar) 3. Drive motors phase currents: you can select current phase from pop-up menu 4. Both modules temperature: you can select measure unit between °C and °F. Temperature above 60°C is signalled by a red colour; temperature above 90°C is signalled by a flashing display. 5. Steering angle in percent, using following criteria: 6. 0% steering completely on left 7. 50% straight wheels 8. 100% steering completely on right 9. Steering sensor voltage 10. Request RPM and motor speed for both motors, with an arrow signalling direction 11. Both motors temperature: you can select measure unit between °C and °F. In case of an overheating alarm, the corresponding green led becomes red. 12. Active output command status 13. Steering switch status 14. Customizable input switch status 15. Start, forward and reverse switches status 16. Drive motors encoder diagnostic leds, both for A and B channel 17. Pedal brake, hand brake and seat switches status

G

120

G

Pump

Fig.12: Pump menu

G Following items appear in Pump menu front panel: 1. Voltage on lift command circuit 2. Hydraulic lift circuit pressure 3. Pump motor current : you can select current phase from pop-up menu 4. Module temperature: you can select measure unit between °C and °F. Temperature above 60°C is signalled by a red colour; temperature above 90°C is signalled by a flashing display. 5. Request RPM and motor speed, with an arrow signalling direction 6. Motor temperature: you can select measure unit between °C and °F. In case of an overheating alarm, the green led becomes red 7. Electrovalves output status 8. Customizable input switches status 9. Tilt, lift and high lift digital input status 10. Encoder diagnostic leds, both for A and B

G

121

G

Battery

Fig.13: Battery menu

G Following items appear in Battery menu front panel: 1. Battery and inverter voltages 2. Battery charge level 3. Code, description and level of active more serious alarm for both microprocessors; if there is more than one alarm of same level, the latest is visualized. 4. There is a chronological list of latest 10 alarms, with code, description, time and temperature. First listed alarm is the first occurred. Temperature value is obviously referred to faulty module or faulty motor (if there are no faulty modules or motors, this is a no meaning data field). With “Reset alarms” menu, you can reset alarm list.

G

122

G

Timers

Fig.14: Timers menu

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

G

123

G

Calibration G For safety, you can access all calibration menus only in Supervisor mode and with park brake on. A confirmation is asked to quit a calibration menu without saving changes. You can’t set a value out of fixed limits: the message “OUT OF LIMIT” signals a case like that. By a pop-up menu, you can access following calibration functions: 1. “Battery“: Battery reset voltage calibration (Refer to page 125) 2. “Timers“: Timers calibration (Refer to page 126) 3. “Steering“: Steering sensor (Refer to page 127) 4. “Pedal“: Pedal accelerator calibration (Refer to page 128) (**) 5. “Lift“: Lift calibration (Refer to page 129) 6. “ESH“: E/S/H parameters calibration and limits (Refer to page 130) 7. “Steering parameters“: Steering parameters calibration (Refer to page 132) 8. “Program service“: Program service interval setting (Refer to page 133) 9. “Drive motor“: Drive motors parameters calibration (Refer to page 134) 10. “Pump motor“: Pump motors parameters calibration (Refer to page 135) 11. “Critical height switches“: Speed limits calibration in case of critical height (Refer to page 136) 12. “Weight sensor“: Weight sensor calibration (Refer to page 137) (*) 13. “Cab lift“: Cab lift speed calibration (Refer to page 138) (*) 14. “Timer reset“: Timers meters reset (Refer to page 139) 15. “Truck setup“: Some lift truck parameters setup (Refer to page 140) (*) 16. “Backing mode“: Slow mode calibration (Refer to page 141) (*) 17. “Load eeprom default“: EEPROM configuration (Refer to page 142) 18. “Paramters image”: Parameter store or Restore. (Refer to page 143) (*): Optional menu (**): Menu present in standard or optional version

G

124

G

Battery reset voltage calibration

Fig.15: Battery reset menu

In that menu front panel, you can find following data about battery reset voltage: description, actual value, new value you want to set, measure unit, default value, minimum and maximum settable values. You can execute following operations: Load default value: 1. Press DEFAULT button ; NEW data field will be automatically updated with default value 2. Press SAVE button and confirm; OLD data field too will be updated Change actual value: 1. Insert changed value in NEW data field 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field initial value is restored. Discard changes: 1. Press CANCEL button; initial value will be restored in NEW data field 2. Press SAVE button and confirm; OLD data field too is restored with initial value G G

G

125

G

Timers calibration

Fig.16: Timers calibration menu

G In that menu front panel, you can find following data about timer parameters: description, actual value, new value you want to set, measure unit, default value, minimum and maximum settable values. You can execute following operations: Load default value: 1. Press DEFAULT button ; NEW data fields will be automatically updated with default value 2. Press SAVE button and confirm; OLD data fields too will be updated Change actual value: 1. Insert changed value in NEW data field 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field initial value is restored. Discard changes: 1. Press CANCEL button; initial values will be restored in NEW data fields 2. Press SAVE button and confirm; OLD data fields too are restored with initial values

G

G

126

G

Steering sensor calibration

Fig.17: Steering calibration menu

There are following data about steering parameters: description, actual value, measure unit, default values, minimum and maximum settable values. Pressing SAVE button, selected parameter VALUE data field is updated with steering sensor actual voltage. You can execute following operations: Load default value: 1. Press DEFAULT button; VALUE data fields will be automatically updated with default values Change parameters value: 1. Select ANTICLOCK parameter 2. Turn steering completely anticlockwise 3. Press SAVE button and confirm 4. Select CLOCK parameter 5. Turn steering completely clockwise 6. Press SAVE button and confirm 7. Select MIDDLE parameter 8. Put wheels straight ahead 9. Press SAVE button and confirm Discard changes: 1. Press CANCEL button; initial value will be restored in VALUE data fields If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any lift truck fault.

G

127

G

Accelerator pedal calibration Standard version

Fig.18: Menù di calibrazione del pedale

There are following data about accelerator parameters: description, actual value, measure unit, default values, minimum and maximum settable values. Pressing SAVE button, selected parameter VALUE data field is updated with pedal sensor actual voltage. You can execute following operations: Load default value: 1. Press DEFAULT button; VALUE data field will be automatically updated with default value Change parameters value: 1. Select MIN ACCELERATOR parameter 2. Slowly press accelerator pedal until START switch turns on 3. Press SAVE button and confirm 4. Select MAX ACCELERATOR parameter 5. Press completely accelerator pedal 6. Press SAVE button and confirm Discard changes: 1. Press CANCEL button; initial value will be restored in VALUE data fields If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any lift truck fault. In this window front panel there are 3 green leds, expressing actual state of forward, reverse and start switches.

Optional version There is a second pedal sensor. Calibration procedure is like standard one, except that START led present (Fig.18) turns ON only after software verifies that the voltages on both pedal sensors are equal to Vmin + 0,5 V voltage, obtained slowly pressing accelerator pedal.

G

128

G

Lift calibration

Fig.19: Lift sensor calibration menu

There are following data about lift parameters: description, actual value, measure unit, default values, minimum and maximum settable values. Pressing SAVE button, selected parameter VALUE data field is updated with lift sensor actual voltage. You can execute following operations: Load default value: 1. Press DEFAULT button; VALUE data fields will be automatically updated with default values Change parameters value: 1. Select MIN LIFT parameter 2. Release lift command lever 3. Press SAVE button and confirm 4. Select MAX LIFT parameter 5. Press completely lift command lever 6. Press SAVE button and confirm 7. Select MIDDLE LIFT parameter 8. Press lift command lever to select start acceleration point for pump motor 9. If lift sensor actual value is inside permitted range, press SAVE button and confirm Discard changes: 1. Press CANCEL button; VALUE data fields will be restored with initial values If selected parameter value is out of permitted voltage range, you cannot calibrate it; in such a case check for any lift truck fault.

G

129

G

E/S/H parameters and L1, L2, L3 limits calibration

Fig.20: E/S/H calibration menu

In that menu front panel, you can find following data about E/S/H parameters: description, actual value, new value you want to set, measure unit, default values for E, S, and H operating mode, settable per cent values for parameters in L1,L2,L3 operating mode You can execute following operations: Select default value: 1. Press DEFAULT button ; NEW data field will be automatically updated with default value 2. Press SAVE button and confirm; OLD data field too will be updated Change actual value: 1. Insert changed value in NEW data field 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field initial value is restored. Discard changes: 1. Press CANCEL button; NEW data fields will be restored with initial values 2. Press SAVE button and confirm; OLD data fields too are restored with initial values This calibration procedure is optional, and you can enable/disable it with the ESH button. In any case, you can disable limits calibration section (L1, L2 and L3 parameters) with PROGRAMMABLE WORKING button. N.B.: if “programmable working” section is disabled, and you select one of L1, L2 or L3 operating modes, a message will advise user and E operating mode will be forced . With E_S_H, pop-up menu you can select one of lift truck possible energetic operating modes (Economic, Standard and High); selected operating mode default values are so loaded on characteristic parameters. The message in Fig. 21 appears if you have selected a different energetic mode using Compact display; pressing OK button, parameters are updated loading new values from control board.

G

130

G

G G G G G G G G G G Fig.21: Parameters externally changed

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

Fig.22: Percent parameters menu

In that menu front panel, there are data about L1, L2 and L3 parameters: description, measure unit, modifiable values expressed in per cent, minimum and maximum settable values. You can execute following operations: Change actual value: 1. Insert new value 2. Confirm If actually selected operating mode percent values are now modified, exiting to ESH calibration menu, user can load new default values. Every parameter per cent value is referred to High mode data.

G

131

G

Steering parameters calibration

Fig.23: Steering parameters calibration menu

In that menu front panel, you can find following data about steering parameters: description, actual value, new value you want to set, measure unit, default values minimum and maximum settable values. You can execute following operations: Select default value: 1. Press DEFAULT button ; NEW data fields will be automatically updated with default value 2. Press SAVE button and confirm; OLD data fields too will be updated Change actual value: 1. Insert changed value in NEW data field 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field initial value is restored. Discard changes: 1. Press CANCEL button; NEW data fields will be restored with initial values 2. Press SAVE button and confirm; OLD data fields too are restored with initial values

G

132

G

Program service calibration

Fig. 24: "Program service" menu

G To modify assistance interval, you have to enable apposite function. Change actual value: 1. Set button INCREASE properly to select if increase or decrease service interval 2. Change assistance interval value using HOURS INCREASE pop-up menu 3. Press SAVE AND EXIT button and confirm

G

133

G

Drive motor parameters calibration

Fig.25: Drive motors calibration

In that menu front panel, you can find following data about drive motor parameters: description, actual value, new value you want to set, measure unit, default values minimum and maximum settable values, actual value in percent. You can execute following operations: Select default value: 1. Press DEFAULT button; NEW data fields will be automatically updated with default value 2. Press SAVE button and confirm; both OLD data fields and first 3 parameters will be updated Change actual value: 1. Insert changed value in NEW data field (or modify one of first 3 parameters) 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field (or one of first 3 parameters) initial value is restored. Discard changes: 1. Press CANCEL button; NEW data fields will be restored with initial values 2. Press SAVE button and confirm; OLD data fields and first 3 parameters are restored with initial values First 3 parameters, for their particular meaning, are visualized and managed in a more user friendly way.

G

134

G

Pump motor parameters calibration

Fig.26: Pump motor calibration menu

In that menu front panel, you can find following data about pump motor parameters: description, actual value, new value you want to set, measure unit, default values minimum and maximum settable values, actual value in percent. You can execute following operations: Select default value: 1. Press DEFAULT button; NEW data fields will be automatically updated with default value 2. Press SAVE button and confirm; OLD data fields will be updated Change actual value: 1. Insert changed value in NEW data field 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field initial value is restored. Discard changes: 1. Press CANCEL button; NEW data fields will be restored with initial values 2. Press SAVE button and confirm; OLD data fields are restored with initial values

G

135

G

Critical height: speed limits calibration(Optional Menu)

Fig.27: Maximum speed calibration menu

You can set maximum speed of pump and drive motors in case of a fork height superior to critical one (that condition is signalled by two switches present on lift truck forks) In that menu front panel, you can find following data about critical maximum speeds: description, actual value, new value you want to set, measure unit, default values minimum and maximum settable values, actual value in percent. You can execute following operations: Select default value: 1. Press DEFAULT button; NEW data fields will be automatically updated with default value 2. Press SAVE button and confirm; OLD data fields will be updated Change actual value: 1. Insert changed value in NEW data field 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field initial value is restored. Discard changes: 1. Press CANCEL button; NEW data fields will be restored with initial values 2. Press SAVE button and confirm; OLD data fields are restored with initial values

G

136

G

Weight sensor calibration (Optional Menu)

Fig.28: Fork weight calibration menu

In that menu front panel, you can find following data about parameters: description, actual value, measure unit, default values, minimum and maximum settable values. Pressing SAVE button, visualized pressure value is saved on actually selected parameter. You can execute following operations: Select default value: 1. Press DEFAULT button; VALUE data fields will be automatically updated with default value Calibrate weight sensor: 1. Select NO LOAD parameter 2. Hoist lift truck forks till 50 cm height 3. Wait for 5 s 4. Press SAVE button and confirm to record weight sensor reading in case of no load on forks 5. Put on lift truck forks a known value load 6. Select LOAD parameter 7. Set, in weight data field, lifted load value 8. Hoist lift truck forks till 50 cm height 9. Wait for 5 s 10. Press SAVE button and confirm to record weight sensor reading in case of known load on forks Discard changes: 1. Press CANCEL button; VALUE data fields will be restored with initial values

G

137

G

Cab lift speed calibration (Optional Menu)

Fig.29: Cab lift calibration menu

In that menu front panel, you can find following data about cab lift speed: description, actual value, new value you want to set, measure unit, default values minimum and maximum settable values. You can execute following operations: Select default value: 1. Press DEFAULT button; NEW data field will be automatically updated with default value 2. Press SAVE button and confirm; OLD data field will be updated Change actual value: 1. Insert changed value in NEW data field 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field initial value is restored. Discard changes: 1. Press CANCEL button; NEW data field will be restored with initial values 2. Press SAVE button and confirm; OLD data field are restored with initial values

G

138

G

Timers reset

Fig.30: Timers reset menu

In that menu you can reset timers signalling lift truck working hours; remember that if you press that button, a double confirmation is necessary. This menu is use possibility developer.

G

139

G

Lift truck setup (Optional Menu)

Fig.31: Lift truck setup menu

In that menu front panel, you can find following data: parameters description, actual status (ON or OFF), new status you want to set, and default status. You can execute following operations: Select default value: 1. Press DEFAULT button; NEW data fields will be automatically updated with default status 2. Press SAVE button and confirm; OLD data fields will be updated Change actual value: 1. Insert changed status in NEW data field 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field initial status is restored. Discard changes: 1. Press CANCEL button; NEW data fields will be restored with initial status 2. Press SAVE button and confirm; OLD data fields are restored with initial status

G

140

G

Backing mode parameters calibration (Optional Menu)

Fig.32: Backing mode calibration menu

In that menu front panel, you can find following data about backing mode parameters: description, actual value, new value you want to set, measure unit, default values minimum and maximum settable values. You can execute following operations: Select default value: 1. Press DEFAULT button; NEW data field will be automatically updated with default value 2. Press SAVE button and confirm; OLD data field will be updated Change actual value: 1. Insert changed value in NEW data field 2. Press SAVE button and confirm; in case of good result, OLD data field is updated. Otherwise an error is signaled and NEW data field initial value is restored. Discard changes: 1. Press CANCEL button; NEW data field will be restored with initial values 2. Press SAVE button and confirm; OLD data field are restored with initial values

G

141

G

Eeprom reset menu That menu has two important functions: 1. In case of Eeprom alarm, you have to use complete EEPROM reset procedure. 2. If you have updated flash memory software, and you want to load default Eeprom configuration, you have to use complete Eeprom reset; to maintain already calibrated values you can use partial EEPROM reset procedure. Pay attention that using complete reset procedure you loose already calibrated values. Both procedures, in any case, don’t modify timers value and alarm history. Partial EEPROM reset: 1. Press PARTIAL LOAD EEPROM button 2. Give a confirmation to load default values

Fig. 33: Eeprom configuration menu

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

Fig. 34: Further confirmation

G

142

G

Parameters Image menu

Fig 35: Parameters image menu

In that menu, You can store and restor about calibration parameters except Lift, pedal, steering setting valure. Parameter Store 1. Press Export button 2. Store calibration parameters Parameter Restore (other trucks) 1. Press Import button 2. Restore calibration parameters

G

143

G

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

Fig. 36: Data logging menu

Data acquisition procedure is following: 1. Select Nmax, the number of variables you want to save 2. Select the variables whose value you want to record, with apposite pop-up menu 3. You can modify sampling period, expressed in seconds. 4. Pressing START button, saving procedure begins; in that phase you can’t modify acquisition parameters During acquisition procedure (Fig. 37), following data are visualized: 1. A led signals saving instant 2. A gauge scans time between 2 saving instants 3. Indication of number of saved frames 4. Flashing message SAVING… To stop saving procedure you can press START button, or simply exiting the menu.

G

144

G

Fig. 37: Data logging menu – saving mode

Logging.out file format is: FIRST ROW: name of NMAX variables to be saved followed by saving date and time; SUCCESSIVE ROWS: NMAX recorded values separated by space.

G

145

G

Flash

Fig. 38: Flash programming phase

To upgrade main controller software, with Flash menu (Fig. 36) follow these steps: 1. Disable all commands 2. Verify if C:\SOURCE_FILE directory exists (otherwise create it) 3. Source directory must contain only 2 source files 4. Select FLASH item from menu-bar 5. Give confirmation to start programming phase 6. In case of troubles with source files, (missing files, wrong version,...) there will be an error message and flash memory will not programmed . 7. After a synchronization phase, flash programming will start; a bar gives the percent indication of already programmed memory. 8. In case of problems with serial communication, there will be an error message and flash programming phase will be stopped. 9. After traction micro successful programming, begins pump micro programming phase (step 7 and 8) 10. A message will signal the end of programming phase, and its result; give confirmation to exit the menu. See troubleshooting section in case of any error. NOTE: If programming phase fails after synchronization, panel has to be programmed with correct software before being used. Enforce necessarily following item after Flash. 1. Click the total load EEPROM of LOAD EEPROM DEFAULT MENU 2. Re-set the lift, pedal, steering sensor

G

146

G

Troubleshooting of Eye Program Generality

Flash Programmation G If panel programming phase fails, when you try to load source files: 1. Verify if c:\source_file directory exists 2. Verify if c:\source_file directory contains only 2 source files 3. Be sure that source files are the ones provided by DHIM’s Homepage.

Often you can solve problems reading error messages and following suggestions.

Software Installation In case of failed EYE software installation, follow these steps: 1. Verify if your PC complies minimal requirements 2. Be sure of having PC administrator rights 3. Close all active applications and disable antivirus before installation 4. Verify installation, step by step

If you program memory successfully, but inverter doesn’t work correctly: 1. Be sure that source files are the ones provided by S.M.E

In case of successful installation, if application has a runtime error: 1. Verify if your PC complies minimal requirements 2. Turn off PC and try again after turning it on 3. Uninstall and install again EYE software

In case of transmission error: 1. Verify system ground connections 2. Control serial connection cable: you must use a shielded one 3. Verify if serial port works correctly 4. Verify if there are any active commands

Serial Communication

Other Problems

If application doesn’t work and message “not connected” appears: 1. Verify system ground connections 2. Verify if inverter panel works correctly 3. Control serial connection cable: you must use a shielded one 4. Verify if serial port works correctly 5. Use Setup menu to verify serial port configuration 6. Verify no other applications serial port

Application works slowly: 1. Verify if your PC complies minimal requirements Application doesn’t work properly: 1. Verify if your PC complies minimal requirements Text and ”objects” on main panel are not centred: 1. Verify if your PC complies minimal requirements 2. Don’t modify window size Monitor doesn’t display correctly text and “objects” 1. Verify if monitor refresh frequency is at least 75Hz 2. Verify if your PC complies minimal requirements

G

147

G

Appendix A : 48[V] Parameter List

G

No

Parameter No

Parameter

Parameter Description

1

5

Deceleration steering ramp 1

2

6

Deceleration steering ramp 2

3

9

Battery reset value

4

11

Seat switch delay

5

12

Chat time

6

13

Hydro time

as high it is as quickly the truck decreases its speed if the truck driver is turning the wheel quickly as high it is as quickly the truck decreases its speed in relation to the drive speed of truck. This parameter increases the deceleration ramp while the driver is steering at high speed. Minimum battery voltage necessary to reset battery discharged voltage alarm Time interval between seat switch opening and drive and pump motors stopping Time delay between last command given to a drive or pump motor and chat mode signalling Time interval when pump motor works (with hydro speed) after the end of a command

7

14

8

18

9

19

10

20

11

23

12

24

13

26

14

32

Maximum lift

15

33

Minimum lift

16

34

Middle lift

17

41

18

42

19

43

20

44

21

46

Maintenance time inserting enable Steering clockwise Steering anticlockwise Steering middle Minimum accelerator Maximum accelerator Stop on slop timer

Drive maximum current Forward maximum speed Reverse maximum speed Drive limitation maximum speed High lift 1 switch drive max speed

Maintenance time inserting enable Steering sensor voltage with wheels turned on left Steering sensor voltage with wheels turned on right Steering voltage with wheels straight ahead Accelerator sensor voltage with pedal released Accelerator sensor voltage with pedal completely pressed Without stepping on pedal brake, time that is doing stop in slope Lift sensor voltage with lift lever completely pressed Lift sensor voltage with lift lever released Lift lever potentiometer voltage to which the lifting becomes proportional to the shift of the lever Drive motors maximum current (expressed in per cent of high energetic mode value) Maximum forward lift truck speed with no speed limitation (no alarms present and turtle not active) Maximum reverse lift truck speed with no speed limitation (no alarms present and turtle not active)

Unit

Mini mum

Def ault

Maxi mum

Varia tion

rpm/s

10

800

5000

10

rpm/s

1

6

10

1

V*10

464

470

501

1

s

1

3

9

1

s

3

6

9

1

s

10

10

20

1

Disable = 0 (Default) Enable = 1

digit

mV

500

1,200

11,500

10

mV

500

10,300

11,500

10

mV

500

6,300

11,500

10

mV

200

1,000

4,500

10

mV

3,000

5,000

12,000

10

s

1

5

10

1

mV

3,000

11,500

12,000

10

mV

0

1,000

12,000

10

mV

1,000

2,750

12,000

10

%

20

100

100

1

rpm

1,000

4,500

4,500

50

rpm

1,000

4,500

4,500

50

Maximum lift truck speed with speed limitation (turtle active)

rpm

500

2,000

2,500

50

Maximum lift truck speed when forks high is more than critical one

rpm

400

2,000

4,500

50

148

G

No

G

Parameter No

Parameter Steer limitation maximum speed Acceleration ramp Inversion ramp Release ramp Pedal brake ramp

Parameter Description

Unit

Mini mum

Def ault

Maxi mum

Varia tion

Maximum speed reference in the angle in which the internal wheel is mechanically still.

rpm

400

1,000

2,000

50

Lift truck acceleration with accelerator pedal pressed

rpm/s

400

1,100

2,000

10

Lift truck deceleration in inversion

rpm/s

400

1,300

2,000

10

rpm/s

400

900

2,000

10

rpm/s

400

1,200

2,000

10

rpm

100

300

2,000

1

mm

300

451

600

rpm/s

10

50

500

10

Pump motor maximum current with lift function active

%

20

100

100

1

Pump motor maximum current with lift lever released

%

10

65

100

1

rpm

1,500

2,950

4,500

50

rpm

500

900

2,000

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

Minimum lift speed

rpm

500

700

1,500

50

Maximum pump motor speed with forks above the critical height

rpm

500

500

4500

50

rpm

400

500

800

10

rpm

200

300

500

10

rpm/s

1,000

7,000

10,000

10

Pump motor deceleration after the end of a command

rpm

1000

7000

10000

10

Power mode setting up state

digit

Accelerator signal 1 = E mode, 2 = S mode, 3 = H mode

22

47

23

48

24

49

25

50

26

51

27

52

Creep speed

28

53

Diameter of drive tyres

Drive tyre's diameter

Partial release ramp

Parameter that softens the drive inversion ramp if the traction motors are working with low rpm

29

59

30

61

31

62

32

63

33

64

Tilt speed

34

65

AUX 1 speed

35

66

AUX 2 speed

36

67

AUX 3 speed

37

68

38

69

39

70

40

71

41

72

42

73

43

93

Lift maximum current Auxiliary maximum current Lift maximum speed

Lift minimum speed High lift 1 switch lift max speed Hydro speed Hydro idle speed Pump acceleration ramp Pump deceleration ramp Power mode (E-S-H, limitations)

Lift truck deceleration with accelerator pedal released Lift truck deceleration with pedal brake pressed If the truck speed is greater then this threshold, the speed reference becomes a parabolic function of the accelerator potentiometer voltage.

Maximum lift speed Pump motor speed with lift function active Pump motor speed with lateral shift function (1st auxiliary) active Pump motor speed with 2nd auxiliary function active Pump motor speed with 3rd auxiliary function active

Pump motor speed when steering Pump motor speed with direction command lever not in neutral, acceleration pressed and no pump command active Lift acceleration

149

G

G

No

Parameter No

44

94

Slow speed

45

95

British unit

46

96

Display brightness

47

97

E-S-H enable

48

98

49

99

Parameter

Time meter / Odometer on display Maintenance time

Parameter Description If parameter is set to1, speed limitation is active; otherwise lift truck speed is managed as usual. If parameter is set to 1, values are expressed in British unit, otherwise in international ones. Display's brightness adjustment If this parameter is set to 1, it is possible to change the value of the power mode with the display If parameter is set to 1, odometer indication appears on display ; otherwise display shows the hour meter. Maintenance period decision

150

Unit

Mini mum

Def ault

Maxi mum

Varia tion

digit

Disable = 0 (Default) Enable = 1

digit

Normal = 0 (Default) British unit = 1

digit

0

5

8

1

digit

Disable = 0 Enable = 1 (Default)

digit

Timer meter = 0 (Default) Odometer = 1

h

0

0

10000

100

G

Appendix B : 36[V] Parameter List

G

No

Parameter No

1

Parameter

Parameter Description

5

Deceleration steering ramp 1

2

6

Deceleration steering ramp 2

3

9

Battery reset value

4

11

Seat switch delay

5

12

Chat time

6

13

Hydro time

as high it is as quickly the truck decreases its speed if the truck driver is turning the wheel quickly as high it is as quickly the truck decreases its speed in relation to the drive speed of truck. This parameter increases the deceleration ramp while the driver is steering at high speed. Minimum battery voltage necessary to reset battery discharged voltage alarm Time interval between seat switch opening and drive and pump motors stopping Time delay between last command given to a drive or pump motor and chat mode signalling Time interval when pump motor works (with hydro speed) after the end of a command

7

14

8

18

9

19

10

20

11

23

12

24

13

26

14

32

Maximum lift

15

33

Minimum lift

16

34

Middle lift

17

41

18

42

19

43

20

44

21

46

Maintenance time inserting enable Steering clockwise Steering anticlockwise Steering middle Minimum accelerator Maximum accelerator Stop on slop timer

Drive maximum current Forward maximum speed Reverse maximum speed Drive limitation maximum speed High lift 1 switch drive max speed

Maintenance time inserting enable Steering sensor voltage with wheels turned on left Steering sensor voltage with wheels turned on right Steering voltage with wheels straight ahead Accelerator sensor voltage with pedal released Accelerator sensor voltage with pedal completely pressed Without stepping on pedal brake, time that is doing stop in slope Lift sensor voltage with lift lever completely pressed Lift sensor voltage with lift lever released Lift lever potentiometer voltage to which the lifting becomes proportional to the shift of the lever Drive motors maximum current (expressed in per cent of high energetic mode value) Maximum forward lift truck speed with no speed limitation (no alarms present and turtle not active) Maximum reverse lift truck speed with no speed limitation (no alarms present and turtle not active)

Unit

Mini mum

Def ault

Maxi mum

Vari ation

rpm/s

10

800

5000

10

rpm/s

1

6

10

1

V*10

344

356

373

1

s

1

3

9

1

s

3

6

9

1

s

10

10

20

1

Disable = 0 (Default) Enable = 1

digit

mV

500

1,200

11,500

10

mV

500

10,300

11,500

10

mV

500

6,300

11,500

10

mV

200

1,000

4,500

10

mV

3,000

5,000

12,000

10

s

1

5

10

1

mV

3,000

11,500

12,000

10

mV

0

1,000

12,000

10

mV

1,000

2,750

12,000

10

%

20

100

100

1

rpm

1,000

3,800

3,800

50

rpm

1,000

3,800

3,800

50

Maximum lift truck speed with speed limitation (turtle active)

rpm

500

2,000

2,500

50

Maximum lift truck speed when forks high is more than critical one

rpm

400

2,000

3,800

50

151

G

No

G

Parameter No

Parameter Steer limitation maximum speed Acceleration ramp Inversion ramp Release ramp Pedal brake ramp

Parameter Description

Unit

Mini mum

Def ault

Maxi mum

Vari ation

Maximum speed reference in the angle in which the internal wheel is mechanically still.

rpm

400

1,000

2,000

50

Lift truck acceleration with accelerator pedal pressed

rpm/s

400

1,100

2,000

10

Lift truck deceleration in inversion

rpm/s

400

1,300

2,000

10

rpm/s

400

900

2,000

10

rpm/s

400

1,200

2,000

10

rpm

100

300

2,000

1

mm

300

451

600

rpm/s

10

50

500

10

Pump motor maximum current with lift function active

%

20

100

100

1

Pump motor maximum current with lift lever released

%

10

65

100

1

rpm

1,500

2,950

4,500

50

rpm

500

900

2,000

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

rpm

500

900

2,800

50

Minimum lift speed

rpm

500

700

1,500

50

Maximum pump motor speed with forks above the critical height

rpm

500

500

4500

50

rpm

400

500

800

10

rpm

200

300

500

10

rpm/s

1,000

7,000

10,000

10

Pump motor deceleration after the end of a command

rpm

1,000

7,000

10,000

10

Power mode setting up state

digit

Accelerator signal 1 = E mode, 2 = S mode, 3 = H mode

22

47

23

48

24

49

25

50

26

51

27

52

Creep speed

28

53

Diameter of drive tyres

Drive tyre's diameter

Partial release ramp

Parameter that softens the drive inversion ramp if the traction motors are working with low rpm

29

59

30

61

31

62

32

63

33

64

Tilt speed

34

65

AUX 1 speed

35

66

AUX 2 speed

36

67

AUX 3 speed

37

68

38

69

39

70

40

71

41

72

42

73

43

93

Lift maximum current Auxiliary maximum current Lift maximum speed

Lift minimum speed High lift 1 switch lift max speed Hydro speed Hydro idle speed Pump acceleration ramp Pump deceleration ramp Power mode (E-S-H, limitations)

Lift truck deceleration with accelerator pedal released Lift truck deceleration with pedal brake pressed If the truck speed is greater then this threshold, the speed reference becomes a parabolic function of the accelerator potentiometer voltage.

Maximum lift speed Pump motor speed with lift function active Pump motor speed with lateral shift function (1st auxiliary) active Pump motor speed with 2nd auxiliary function active Pump motor speed with 3rd auxiliary function active

Pump motor speed when steering Pump motor speed with direction command lever not in neutral, acceleration pressed and no pump command active Lift acceleration

152

G

G

No

Parameter No

Parameter

44

94

Slow speed

45

95

British unit

46

96

Display brightness

47

97

E-S-H enable

48

98

49

99

Time meter / Odometer on display Maintenance time

Parameter Description If parameter is set to1, speed limitation is active; otherwise lift truck speed is managed as usual. If parameter is set to 1, values are expressed in British unit, otherwise in international ones. Display's brightness adjustment If this parameter is set to 1, it is possible to change the value of the power mode with the display If parameter is set to 1, odometer indication appears on display ; otherwise display shows the hour meter. Maintenance period decision

153

Unit

Mini mum

Def ault

Maxi mum

Vari ation

digit

Disable = 0 (Default) Enable = 1

digit

Normal = 0 British unit = 1 (Default)

digit

0

5

8

1

digit

Disable = 0 Enable = 1 (Default)

digit

Timer meter = 0 (Default) Odometer = 1

h

0

0

10000

100

G

Appendix C : Error Code List EYE Code

1

2

3

5

6

G

Error Code

Description

F0

Maximum battery voltage

F1

Minimum battery voltage

F2

Pedal trimmer fault

F

Eeprom alarm

A

Pre -charge capacitors low voltage alarm (Capacitors not charged)

Level

Cause

Trohbleshooting

1

Battery voltage, measured by a circuit inside logic, exceeds following levels: 63 V, in case of systems working at 36 V 63 V, in case of systems working at 48 V

1

Battery voltage, measured by an internal circuit, is lower than following levels : 24 V , in case of systems working at 36 V

2

Voltage measured on accelerator circuit exceeds the value calculated averaging calibration and reachable voltages; moreover, start switch seems to be open.

1

6

Eeprom does not work properly, or one of memorised values is out of correct limits. Voltage level of pre charge capacitors is less then 70 % of nominal battery level. It could happen, in example, if the inverter is working with main breaker open. Capacitors voltage decreases cause energy spent to keep motors in motion.

154

1. Such an alarm can be caused also by the presence of regeneration currents; when lift truck is on release or reverse braking ramp, motors work as generators, and battery voltage can exceed overvoltage limit. In a case like that, the battery condition should be verified ( if the battery is new it is necessary to do some charge-discharge cycles before reaching the rating declared by the constructor) or has a high internal resistance. If the case is the second and it is not possible to change the battery, the solution may be to reduce the release and reverse braking ramp. 2. Incorrect wiring to battery positive or negative terminals. 3. Verify if battery is still in good conditions. 4. Replace the logic. 1. Incorrect wiring to battery, or corroded positive or negative terminals; 2. Verify battery conditions: if the electrolyte inside is partially exhausted, an under voltage alarm can sometimes be detected from the controller; even in case of low battery charge ( 37.6 V

81 82 83 84 A A

A A

Table 2 : Case of an 36V system

A

BATTERY CHARGE LEVEL Discharged battery 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % Full charged battery

BATTERY VOLTAGE [V] Voltage < 45.6 V 45.6 V ÷ 46.4 V 46.4 V ÷ 47 V 47 V ÷ 47.6 V 47.6 V ÷ 48.2 V 48.2 V ÷ 48.7 V 48.7 V ÷ 49.2 V 49.2 V ÷ 49.7 V 49.7 V ÷ 50.1 V 50.1 V ÷ 50.4 V Voltage > 50.4 V

E1 E2 E3 E4 E5 E6 EE EE (FLASI NG)

Table 3: Case of a 48V system

G

39

Contraction CONTACTOR FAULT

77

Table 1 : Case of a generic system

Description

P-MOTOR ENCODER R-M TEMP SENSOR L-M TEMP SENSOR P-M TEMP SENSOR

Wrong right traction motor thermal switch Wrong left traction motor thermal switch Wrong pump motor thermal probe Wrong right traction module thermal probe Wrong left traction module thermal probe Wrong pump module thermal probe CRC fault Bank CRC restored Capacitors not charged : fast charge Trans.precharge in short/Cap. too charged Capacitors not charged : slow charge Capacitors not charged : time out Capacitors not charged Drive right module Overtemperature Drive left module Overtemperature Pump module Overtemperature Drive right motor Overtemperature Drive left motor Overtemperature Pump motor Overtemperature Wrong start

TIME OUT CHARGE CAP NOT CHARGED R-INV OVERTEMP L-INV OVERTEMP P-INV OVERTEMP R-MOTOR OVERTEMP L-MOTOR OVERTEMP P-MOTOR OVERTEMP WRONG START

Seat switch

SEAT SW OPEN

R-INV T SENSOR

L-INV T SENSOR P-INV T SENSOR CRC FAULT CRC RESTORED FAST CHARGE TOO CHARGED CAP SLOW CHARGE

Operation Section

EL F F F F0 F1 F2 F3 F4 F5 F6 F7 F8

Low battery voltage Eeprom WD Timer/Enable micro signals Serial communication Maximum battery voltage Minimum battery voltage Pedal trimmer fault Drive right module Desat/overcurrent Drive left module Desat/overcurrent Pump module Desat/overcurrent Drive right motor current Offset Drive left motor current Offset Pump motor current Offset

F9

Steer sensor fault

FA

5V encoders not ok Drive right motor Encoder Drive left motor Encoder 24V out 12V out not ok Pump input on at the start

Fc Fd FE FH FL

expressed in per cent of high energetic mode; changing active limitation (among L1, L2 or L3), related per cent data are used to calculate actual parameters value.

LOW BATT VOLT EEPROM FAULT WD TIMER FAULT COMM FAULT

NOTE: Percent values can be modified only with EYE Calibration – E-S-H menu.

MAX BATT VOLT MIN BATT VOLT

NOTE: Pressing PROGRAMMABLE WORKING you can manage economic, standard or high operating mode too.

ACCEL FAULT R-INVERTER FAULT L-INVERTER FAULT P-INVERTER FAULT R-MOTOR I OFFSET L-MOTOR I OFFSET P-MOTOR I OFFSET STEER SENSOR OUT 5V NOT OK R-MOTOR ENCODER L-MOTOR ENCODER 24V NOT OK 12V NOT OK

COMPACT display shows different symbols in function of selected energetic mode: - E-S-H management disabled: no symbol visualised. - E-S-H management enabled: active mode is indicated by symbol (Type1)

(Type2)

- PROGRAMMABLE WORKING management enabled: in case you have chosen one of L1, L2 or L3 operating modes, and lift truck is stopped, one of the segments of speed indicator symbol (see Table 5 ) blinks to show selected energetic mode

PUMP SIGN ON

DISPLAY VISUALISATION (from symbol left side) 1st segment 5th segment 9th segment

Lift truck operation mode

(Type1)

Pressing E-S-H button, you can set energetic operating mode for your system.

OPERATINGMODE L1 (Limit 1) L2 (Limit 2) L3 (Limit 3)

Table 5 : selected energetic mode Otherwise symbol indicates, as usual, selected operating mode.

(Type2)

This function is enabled using EYE menu named Calibration – ESH, to select desired operating mode. In particular you can choose between E-S-H or PROGRAMMABLE WORKING :

(Type1)

(Type2)

- Pressing E-S-H (economic, standard, high) button, you change energetic mode and update related parameters with a value, corresponding to selected operating mode, that operator can’t modify. - Pressing PROGRAMMABLE WORKING you can manage 3 further options (limit 1, limit 2, and limit 3). You can set parameters value, that are

G

NOTE: as usual, if lift truck is moving, symbol indicates speed level. (Type1)

(Type2)

40

Operation Section

NOTE: if active mode is one of L1, L2 or L3 limitations and you change operating mode (from PROGRAMMABLE WORKING to ES-H), software automatically sets operating mode to economic one.

82 83 84

Over-temperature alarm, indicated by the warning light In case the temperature of power transistors exceeds the warning limit, alarm code and relative light blink. Moreover, in case temperature exceeds the alarm limit, (or it stays between the two thresholds for 30 s or more), the symbols stop blinking and became still.

Alarm message, indicated by an alpha-numerical code in the display area where usually lift truck speed appears. See Table 6 for the meaning of alarm codes. Table 6 : Meaning of alarm codes. ALARM ALARM DESCRIPTION CODE F Wrong eeprom + watch dog timer F0 Maximum battery voltage F1 Minimum battery voltage F2 Pedal trimmer fault F3 Drive right module desat/overcurrent F4 Drive left module desat/overcurrent F5 Pump module Desat/overcurrent F6 Drive right motor current offset F7 Drive left motor current offset F8 Pump motor current offset F9 Steer sensor fault FA 5V encoders not ok Fc Drive right motor Encoder Fd Left right motor Encoder FE 24V out not ok FH 12V out not ok FL Pump inputs on at start E1 Drive right module Overtemperature E2 Drive left module Overtemperature E3 Pump module overtemperature E4 Drive right motor Overtemperature E5 Drive left motor Overtemperature E6 Pump motor Overtemperature EE Wrong start EL Low battery voltage EE Seat switch opened (flashing) Alarm on pre - charge circuit of A internal capacitors AL Key retention 17 Main breaker fault 60 Battery / inverter mismatch Wrong right traction motor thermal 77 probe Wrong left traction motor thermal 78 probe 79 Wrong pump motor thermal probe Wrong right traction module thermal 80 probe Wrong left traction module thermal 81 probe

G

Wrong pump module thermal probe CRC fault Bank CRC restored

Hour meter separation point, usually blinking, stops in following cases: - Seat switch open. - Serial communication between display and control unit not active - Main breaker open Turning your lift truck on, some alphanumeric codes, visible for 3 seconds, appear where usually is visualized speed indicator symbol; those codes help to identify system in use (see Table 7). Where usually is visualized hour meter, on left side appears feed voltage in VDC, and on right side, maximum weight industrial truck can lift, expressed in quintals. SYSTEM IN USE

CODE

BT (3WHEEL)

C1

Table 7

LED Indicators On left side, COMPACT display has four LED indicators which, when switched on, give information as follows: Alarm message; red color LED Message of lamps; green color LED (OPTION) Indicator lights activated; green color LED (OPTION) Low oil level of the brakes; red color LED (Type1)

(Type2)

41

Operation Section

Seat Belt warning (Option) : red color LED for 10 seconds. NOTE: Alarm LED

is managed as follows:

- Display normally working: LED lights up briefly switching on /off your system - Display not communicating with control board: after 3 seconds from the moment in which the communication stops, alarm LED brightens - Display board microprocessor not working: alarm LED brightens.

No Alarm, No Movement (OPTION) When select the direction lever for forward or reverse direction, in case the drive motor does not move even if press on accelerator, it is that service brake operates. Confirm whether service brake switch is acted.

G

42

Operation Section

Front and Rear Floodlights Switch

Tilt Steering Column

Located on the right side of the instrument panel, below the display panel.

Located on the lower front of the steering column. To adjust the steering column, raise the handle(1) and move the steering column to the desired position. Release the handle and the steering column will remain in the desired position.

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.

Seat Adjustment Adjust the seat at the beginning of each shift or when changing operators.

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.

Adjust the seat to allow full travel of all pedals with the operator seated against the seat back. The seat must be adjusted with the operator seated.

Horn Button

Move the lever to adjust the seat forward or backward. Release the lever. Move the seat slightly to lock it.

Located in the center of the steering wheel. Push in on the horn button to sound the horn.

G

43

Operation Section

Emergency Switch (If Equipped)

OFF - Push the emergency switch button to disconnect the electrical circuits. (It must be done after the key switch is turned off) ON - Pull the emergency switch button to connect the electrical circuit.

G

44

Operation Section

Lift Truck Controls

Service Brake Pedal

Parking Brake Lever NOTICE Do not engage the parking brake while the lift truck is moving unless an emergency arises. The use of the parking brake as a service brake in regular operation will cause severe damage to the parking brake system.

Service Brake - The service brake pedal is located on the floor of the operator’s compartment. Depress the service brake pedal to slow or stop the lift truck. Drive circuit will be interrupted while the pedal is depressed. Release the service brake pedal to allow the lift truck to move.

Parking Brake - The parking brake lever is located on the left side of the cowl. Parking Brake Engaged - Pull the parking brake lever up, which will engage the interlock switch that shuts off power to the drive motor. Parking Brake Disengaged - Push the parking brake lever down to release the parking brake.

G

45

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.

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.

Push down the pedal to increase travel speed. If the accelerator pedal is depressed before the key switch is turned to the ON position, the lift truck will not move until the pedal is released and depressed again.

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. When the operator raises off the seat (seat switch opens) while the lift truck is in motion, the drive

This film shows the function of the brake and accelerator pedals.

G

46

Operation Section

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.

Tilt Control Lever

Lift Control Lever

The forks’ tilt control is located at the operator’s right side front. The tilt control lever is the lever at the center. Tilt Forward - Push the lever forward smoothly to tilt the forks forward. 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.

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.

Tilt Back- Pull the lever back smoothly to tilt the forks back.

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.

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.

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.

G

47

Operation Section

Sideshift Attachment Control (If Equipped)

The sideshift attachment control is located at the operator’s right side front. The sideshift attachment control lever is the lever at the right. Sideshift Left - Push the lever forward smoothly to shift the carriage to the left. Sideshift Hold - Release the sideshif attachment lever. The lever will return to the center(hold) position and sideshifting action will stop. Sideshift Right - Pull the lever back smoothly to shift the carriage to the right.

NOTE: To prevent a sudden change of position of the load, operate all lift, tilt and attachment controls smoothly.

G

48

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.

8

7

6 9

3

6. Inspect the tires and wheels for proper inflation, cuts, gouges, foreign objects and loose or missing nuts.

2

7. Inspect the overhead guard for damage, loose or missing mounting bolts.

1 8. Inspect the hydraulic system for leaks, worn hoses or damaged lines. 9. Inspect the drive axle housing and the ground for oil leaks.

1. Inspect the operator’s compartment for looseitems and clean any mud or debris from the floor plates for safe footing. 2. Inspect the instrument panel for damage to the indicator display. 3. Test the horn and other safety devices for proper operation.

10 4

5

10. Disconnect the battery. Raise the lever bracket assembly to the full upright position. Tilt the steering column to the full upright position.

Batteries give off flammable fumes that can explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Always wear protective glasses when working with batteries.

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.

G

49

Operation Section

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.

11. Release the battery restraint lever in front of battery cover. Raise the seat and cover assembly. 12. Inspect the battery compartment for loose connections and frayed cables. 13. Observe the battery electrolyte level for proper level. Lower the seat and cover assembly and the lever bracket assembly and connect the battery to the lift truck. Secure the battery restraint properly.

Personal injury may occur from accidents caused by improper seat adjustment. Always adjust the operator’s seat before operating the lift truck. Seat adjustment must be done at the beginning of each shift and when operators change.

16. With the seat switch closed and the directional lever in NEUTRAL, turn the key switch ON. Observe the battery discharge indicator. Type1

14. Position the seat by operating the lever and moving the seat forward or backward to a comfortable position.

G

50

Operation Section

Type2

17. Make sure the battery is charged before operating the lift truck. A fully charged battery will cause “9 Segments” to be displayed on the BDI display.

Better Battery Performance NOTICE The lift truck operator must not start 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. 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.

G

51

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 4. Push down on the service brake pedal and release the parking brake.

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.

1. Adjust the operator’s seat. 2. Fasten the seat belt (if equipped).

5. Turn the key switch ON. Raise the attachments to the travel position.

3. Move the directional control lever into the NEUTRAL position, if it is not already in this position.

6. Move the directional control lever to the desired direction of travel.

G

52

Operation Section

11. Hold the accelerator pedal down until the lift truck nearly comes to a complete stop. Release the accelerator pedal.

7. Release the service brake pedal.

12. Push down on the service brake pedal to bring the lift truck to a complete stop and hold it. 13. To change direction, continue to push down on the accelerator pedal until the desired travel speed in the opposite direction is obtained. 14. 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 the service brake pedal, and bring the lift truck to a smooth stop.

8. Push down on the accelerator pedal to reach the travel speed. Release the pedal to decrease travel speed. 9. Electrical braking (plugging) can be used to slow or stop the lift truck or to change the lift truck direction of travel. See the section below, “Eletrical Braking (Plugging)” for an explanation of electrical braking.

10. Move the directional control lever to the opposite direction of lift truck travel.

G

53

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 dirve 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.

G

54

Operation Section

Operating Techniques NOTE: The illustrations used here are typical examples and may not look exactly like to your particular lift truck.

Inching into Loads

Lifting the Load

1. Move the lift truck slowly forward into position and engage the load. Lift truck should be square with load. The forks should be spaced evenly between pallet stringers and as far apart as the load will permit.

1. Lift the load carefully and tilt the mast back a short distance. 2. Tilt the mast further back to cradle the load.

2. Move the lift truck forward until the load touches the carriage.

3. Operate the lift truck in reverse until the load is clear of the other loads. 4. Lower the load to the travel position before turning or traveling. The forklift truck must not be used to push loads or other vehicles. Only the moving equipment supplied or the rear hook for towing must be used.

G

55

Operation Section

Traveling

Turning

Whether you are traveling with or without a load, keep the fork as low as possible, while still maintaining good clearance above the floor.

1. 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. 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.

NOTE: The MicroCommand control uses the steer wheel angle signals to adjust drive motor speeds to match the steering cramp angle. With steer wheel cramp angles of 20° or more, the MicroCommand control limits drive motor speed to both drive motors. Limiting motor speed when turning reduces lift truck rotational speed while maintaining traction and power to both drive wheels.

3. Travel in reverse with bulky loads. This gives you better vision.

G

56

Operation Section

Unloading

3. As the steer wheel angle increases, the inside drive motor speed is progressively slowed down with respect to the outside drive motor speed. It is essentially switched OFF when the steer wheel cramp angle is 45°.

1. Move the lift truck into the unloading position. 2. Do not tilt the mast forward until it is directly over the unloading area.

Do not tilt the mast forward with the load unless directly over the unloading area, even if the power is off.

4. At a steer wheel cramp angle of 75°, the inside drive motor rotation is reversed and its speed will progressively increase as the cramp angle increases. 5. At a steer wheel cramp angle of 90°, the inside drive motor rotation, in reverse, is as fast as the outside drive motor rotation in forward. This causes the lift truck to turn about a point midway between the two drive tires.

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.

G

57

Operation Section

Lifting Drums or Round Objects

1. Block the drums or round objects. Tilt the mast forward and slide the fork tips along the floor to get under the load.

2. Tilt the mast back slightly until the load is cradled on the forks before lifting. 3. Lift the load to the travel position.

G

58

Operation Section

Parking the Lift Truck NOTICE Parking or storage of electric lift trucks outdoor can cause lift truck system damage or failure. Park or store all electric lift trucks inside a building to protect electrical system from moisture damage.

3. Engage the parking brake.

When leaving the operator’s station, park the lift truck in authorized areas only. Do not block traffic. Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor. Block the drive wheels when parking on an incline.

4. Tilt the mast forward and lower forks to the ground.

1. Apply the service brake to stop the lift truck.

5. Turn key switch to OFF and remove the key.

2. Move the directional control lever into NEUTRAL.

G

59

Operation Section

6. Disconnect the battery. 7. Block the wheels if parking on an incline.

Parking Alarm Warning (If Equipped) G When leaving the operator’s station without engaging the parking brake, warning buzzer is acted.

G

60

Operation Section

Lift Fork Adjustment When adjusting the fork spread, be careful not to pinch your hand between forks and the carriage slot.

Hook-on type Fork

1. Move up the hook pin to the free position in each fork to side the fork on the carriage bar. 2. Adjust the forks in the position most appropriate for the load and as wide as possible for load stability. 3. When adjusting the forks, make sure that the weight of the load is centered on the truck. 4. After adjustment, set the fork locks to keep the forks in place.

Make sure the forks are locked before carrying a load.

G

61

Operation Section

Storage Information Before Storage When storing the lift truck for an extended period of time, take the following measures to ensure that it can be returned to operation with minimal service. 1. After every part is washed and dried, the machine should be housed in a dry building. Never leave it outdoors. In case it has to be left outdoors, lay wooden boards on the ground, park the machine on the boards and cover it with canvas, etc. 2. Lubricate, grease and replace oil before storage. 3. Apply a thin coat of grease to exposed hydraulic cylinder piston rods. 4. Cover the battery after removing terminals, or remove it from the machine and store it separately.

During Storage Drive the truck for a short at least once a month. This coats moving part surfaces with a new film of oil. Charge the battery at this same time.

After Storage After storage(when it is kept without cover or rustpreventive 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 any accumulated water. 2. Wipe off grease from hydraulic cylinder piston rod. 3. Measure specific gravity and check that the battery is charged. 4. Drive at low speed to make sure moving parts in drive gear boxes are well oiled.

G

62

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

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.

NOTICE

NOTICE

Improper lifting or tiedowns can allow load to shift and cause injury and/or damage.

Obey all state and local laws governing the weight, width and length of a load. Observe all regulations governing wide loads.

1. Weight and instructions given herein apply to lift trucks as manufactured by DAEWOO. 2. Use properly rated cables and slings for lifting. Position the crane for level lift truck lift.

NOTICE 3. Spreader bar widths should be sufficient to prevent contact with the lift truck.

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.

G

63

Operation Section

Towing Information Consult your DAEWOO Lift Truck dealer for towing a disabled lift truck. Personal injury or death could result when towing a disabled lift truck incorrectly. Block the lift truck wheels to prevent movement before releasing the brakes. The lift truck can roll free if it is not blocked. Follow the recommendations below to properly perform the towing procedure. The towing instructions given here are for moving a disabled lift truck only a short distance at low speed [no faster than 1.2 mph (2 km/h)] to a convenient location for repair. These instructions are for emergencies only. If long-distance moving is required, always haul the lift truck. 1. Release the parking brake.

You must provide shielding on the towing lift truck to protect the operator if the tow line or bar should break.

NOTICE Release the parking brake to prevent excessive wear and damage to the parking brake system.

Do not allow an operator to sit on the lift truck being towed unless the steering and braking can be controlled. The operator on the towed lift truck must always steer in the direction of the tow line pull.

2. Release the service brake pedal.

Inspect the tow line or bar and make sure it is in 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 times the gross weight of the towing lift truck.

3. Turn the key switch OFF.

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.

6. Remove any wheel blocks. Tow the lift truck slowly. Do not tow any faster than 2 km/h (1.2 mph).

4. Disconnect the battery. 5. Fasten the tow bar to the lift truck.

Use gradual and smooth lift truck movement. Moving the lift truck quickly could overload the tow line or bar and cause it to break.

Be sure all necessary repairs and adjustments 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.

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 rolling uncontrolled. The requirements of each towing situation will be affected by many conditions. Minimum towing lift truck capacity is required on smooth, level surfaces, while maximum capacity is needed on inclines or on poor surface conditions.

G

64

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for inspection, maintenance and repair of lift truck forks. It also provides general information on the design and application of forks and the common cause of fork failures.

Users may also refer to the International Organization For Standardization-ISO Technical Report 5057-Inspection and Repair of Fork Arms and ISO Standard 2330-Fork Arms-Technical Characteristics and Testing.

Lift truck forks can be dangerously weakened by improper repair or modification. They can also be damaged by the cumulative effects of age, abrasion, corrosion, overloading and misuse.

While there are no specific standards or regulations in the United States, users should be familiar with the requirements for inspection and maintenance of lift trucks as provided by the 29 Code Federal Register 1910.178 Powerd Industrial Truck, and ANSI/ASME Safety Standard(s) B56.1, B56.5 or B56.6 as applicable to the type of machine(s) in use.

A 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. z

A fork rated at 1500 pounds at 24 inch load center will be stamped 1500 X 24.

z

A fork rated at 2000 kg at 600 mm load center will be stamped 2000 X 600.

The manufacturer identification and year and date of manufacture is also usually shown. Some countries have standards or regulations which apply specifically to the inspection and repair of forks.

G

65

Maintenance Section

Causes of Fork Failure

z

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.

Improper Modification or Repair Fork failure can occur as a result of a field modification involving welding, flame cutting or other similar processes which affect the heat treatment and reduces the strength of the fork. In most cases, specific processes and techniques are also required to achieve proper welding of the particular alloy steels involved. Critical areas most likely to be affected by improper processing are the heel section, the mounting components and the fork tip.

z

Wear Forks are constantly subjected to abrasion as they slide on floors and loads. The thickness of the fork blade is gradually reduced to the point where it may not be capable of handling the load for which it was designed.

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.

z

Stress Risers 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.

Bent or twisted forks are much more likely to break and cause damage or injury. They should be removed from service immediately.

Overloading

Fatigue

Extreme overloading can cause permanent bending or immediate failure of the forks. Using forks of less 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.

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. 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.

G

Repetitive Overloading

66

Maintenance Section

Fork Inspection

First Installation 1. Inspect forks to ensure they are the correct size for the truck on which they will be used. Make sure they are the correct length and type for the loads to be handled. If the forks have been previously used, perform the “12 Month Inspection”. If the forks are rusted, see “Maintenance and Repair”. 2. Make sure fork blades are level to each other within acceptable tolerances. See “Forks, Step 4,” in the “2000 Service Hours or Yearly” in “Maintenance Intervals”

Establish a daily and 12 month inspection routine by keeping a record for the forks on each lift truck. Initial information should include the machine serial number on each the forks are used, the fork manufacturer, type, original section size, original length and capacity. Also list any special characteristics specified in the fork design.

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

z

Actual wear conditions, such as percent of original blade thickness remaining.

z

Any damage, failure or deformation which might impair the use of the truck.

z

1. Visually inspect forks for cracks, especially in the heel section, around the mounting brackets, and all weld areas. Inspect for broken or jagged fork tips, bent or twisted blades and shanks. 2. Make sure positioning lock is in place and working. Lock the forks in position before using the truck. See “2000 Service Hours or Yearly” in “Maintenance Intervals”.

Note any repairs or maintenance.

An ongoing record of this information will help in identifying proper inspection intervals for each operation, in identifying and solving problem areas and in anticipating time for replacement of the forks.

G

3. Remove all defective forks from service.

67

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 recomendations. Most repairs or modifications should be done only by the original manufacturer of the forks or an expert knowledgeable of the materials, design, welding and heat treatment process. 2. The following repairs or modifications SHOULD NOT be attempted. z Flame cutting holes or cutouts in fork blades. z

z z

Welding on brackets or new mounting hangers. Repairing cracks or other damage by welding. Bending or resetting.

3. The following repairs MAY be performed. z

z

z

z

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.

G

68

Maintenance Section

Tire Inflation Information Tire Inflation

Tire Shipping Pressure Size

18 X 7-8

Ply Rating or Strength Index B15/18T-5 16

Shipping Pressure kPa psi 1000

145

The inflation pressures shown in the following chart are cold inflation shipping pressures for tires on DAEWOO lift trucks. The operating inflation pressure is based on the weight of a ready-to-work lift truck without attachments, at rated payload, and in average operating conditions. Pressures for each application may vary and should always be obtained you’re your tire supplier.

Personal injury or death could result when tires are inflated incorrectly. Use a self-attaching inflation chuck and stand behind the tread when inflating a tire.

Tire Inflation Pressures Adjustment

Proper inflation equipment, and training in using the equipment, are necessary to avoid overinflation. A tire blowout or rim failure can result from improper or misused equipment.

A tire inflation in a warm shop area, 18°C to 21°C (65°F to 70°F), will be underinflated if the lift truck works in freezing temperatures. Low pressure shortens the life of a tire.

NOTICE Set the tire inflation equipment regulator at no more than 140 kPa(20 psi) over the recommended tire pressure.

G

69

Maintenance Section

Torque Specifications 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.

Torque for Standard Bolts, Nuts and Taperlock Studs NOTICE

NOTE: Use only metric tools on most hardware for proper fit. Other tools could slip and possibly cause injury.

The following charts give general torques for bolts, nuts and taperlock studs of SAE Grade 5 or better quality.

Torque for Standard Hose Clamps - Worm Drive Band Type

Torques for Bolts and Nuts With Standard Threads Thread Size Inch 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2

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.

Clamp Width 16 mm (.625 inch) 13.5 mm (.531 inch) 8 mm (.312 inch)

Clamp Width

16 mm (.625 inch) 13.5 mm (.531 inch) 8 mm (.321 inch)

Initial Installation Troque on New Hose N•m1 lb•in 7.5 ± 0.5 65 ± 5 4.5 ± 0.5

40 ± 5

0.9 ± 0.2 8±2 Reassembly or Retightening Troque on existing hose N•m1 lb•in 4.5 ± 0.5 40 ± 5 3.0 ± 0.5

25 ± 5

0.7 ± 0.2

6±2

11 Newton meter (N•m) is approximately the same as 0.1 kg•m.

11 Newton meter (N•m) is approximately the same as 0.1 kg•m.

G

Standard Bolt & Nut Troque N•m1 lb•ft 12±4 9±3 25±7 18±5 45±7 33±5 70±15 75±11 100±15 75±11 150±20 110±15 200±25 150±18 360±50 270±37 570±80 420±60 875±100 640±75 1100±150 820±110 1350±175 1000±130 1600±200 1180±150 2000±275 1480±200

70

Maintenance Section

Torques for Taperlock Studs Thread Size Inch 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2

Torque for Metric Fasteners

Standard Taperlock Stud Torque N•m1 Ib•ft 8±3 6±2 17±5 13±4 35 + 5 26±4 45 ±10 33 ±7 65 ±10 48 ±7 110±20 80 ±15 170±30 125 ±22 260 ±40 190 ±30 400 ±60 300 ±45 500 ±70 370 ±50 650 ±80 480 ±60 750 ±90 550 ±65 870 ±100 640 ±75

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. 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.

11 Newton meter (N•m) is approximately the same as0.1 kg•m.

METREC ISO2 THREAD Thread Size Standard Torque Metric N•m1 Ib•ft M6 12±4 9±3 M8 25±7 18±5 M10 55±10 41 ±7 M12 95 ±15 70 ±11 M14 150±20 110 + 15 M16 220 ±30 160±22 M20 450 ±70 330 ±50 M24 775 ±100 570 ±75 M30 1600 ±200 1180±150 M36 2700 ±400 2000 ±300 11 Newton meter (N•m) is approximately the same as 0.1 kg•m. 2ISO-International Standard Organization.

G

71

Maintenance Section

Lubricant Specifications Lubricant Information

Hydraulic Oil

Some classifications and abbreviations we use in this section follow S.A.E. (Society of automotive Engineers) J754 nomenclature and others follow S.A.E. J183. All MIL specifications are U.S.A. Military. Recommended oil viscosities are given in the“Lubricant Viscosities” chart later in this section of the manual. Greases are classified according to the National Lubricating Grease Institute (NLGI) based on ASTM D217-68 worked Penetration characteristics which give a defined consistency numbel.

The following commercial classifications can be used in the hydraulic system. 䳜ISO 6743/4 HM 䳜AFNOR NFE 48-603 HM 䳜DIN 51524 TEIL 2 H-LP 䳜HAGGLUNDS DENISON HFO-HF2 䳜CINCINNATI P68, 69, 70

Chain and Linkage Oils (DEO or EO)

Viscosity : ISO VG 32 These oils should have antiwear, antifoam, antirust and antioxidation additives for heavy duty use as stated by the oil supplier. ISO viscosity grade of 32 would normally be selected.

NOTICE Correct Hydraulic Oil should be used to achieve maximum life and performance from hydraulic system components. The following hydraulic Oil is recommended in most hydraulic and hydrostatic systems.

Use following engine oils are recommended for use on chains and linkages. χ䳜European oil specification CCMC D3.

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.

䳜API Specification CD, CD/SF, CE 䳜Military specifications MIL-L-2104D or E

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.

G

72

Maintenance Section

Drive Axle Lubricant

Lubricating Grease (MPGM)

Select an oil that meets below specifications

Use Multipurpose Molybdenum Grease (MPGM) for all lubrication points. If MPGM grease can not be used, a multipurpose type grease which contains 3% to 5% molybdenum disulfide can be used.

Universal Transmission Tractor Oil (UTTO) The following UTTO products are authorized for use. TOTAL

TRANSMISSION MP

MOBIL

MOBIL FLUID, 422 MOBIL FLUID 425

MOTUL

TRM 97

OPAL

NLGI No.2 grade is suitable for most temperatures. Use NLGI No.1 or No.0 grade for extremely low temperature.

Brake Fluid

OPAL FLUID TA/HIS

Located on the left side of the cowl. Use heavy duty hydraulic brake fluid certified by the oil supplier to meet ISO 6743/4 HM, ISO VG 10 latest revision. TOTAL

Azolla ZS 10

AGIP

Acer 10

BP

Spindurn 10

ELF

Spinelf 10

ESSO

Nuto H 10 Spinesso 10

FINA

Hydran 10

SHELL

73

HLP 10

CALTEX

MOBIL

G

Energol HP 10

Velocite oil No. 5 Velocite oil E Tllvs oil C10 Morlina 10

Maintenance Section

Battery Discharge Indicator Type2

The battery discharge indicator should be observed frequently before and during operation. Type1

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.

Type2

To prevent over-discharge, the lift interrupt should not be reset by disconnecting and reconnecting the battery. If the batteries are weak, have them charged or replaced. The batteries should not be discharged below 80% of the full charge as indicated by their specific gravity. This specification varies with different battery manufacturers. See the manufacturer’s specifications for specific gravity at 80% discharge. If information is not available from the battery supplier, use 1.140 specific gravity level.

A fully charged battery will cause a “9 segments” to be displayed on the LCD display. As the battery is discharged, the LCD display will count down, 9, 8, 7, and etc., until “EL” is displayed. When the battery reaches 80% discharge level, the Micro-Controller will cause the LCD display to continuously index through the entire range (1 through 9 segments ) to signal that the battery is discharged and lift interrupt is imminent. Type1

G

74

Maintenance Section

Battery

When using pressure air for cleaning purposes, wear a protective face shield and protective clothing. Maximum air pressure must be below 207 kPa (30 psi).

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.

Do not smoke near batteries that are being stored or when checking the electrolyte level.

Batteries that have been fully charged should have a tag attached for identification.

Electrolyte is an acid solution and can cause personal injury. Avoid contact with skin and eyes.

A battery should be recharged in 8 to 12 hours after being discharged, depending on the charger type, then allowed to cool and stabilize 4 to 8 hours. Repeated undercharging must be prevented because it can damage the battery.

Maximum life and performance of lift truck batteries is dependent on the operator, battery charging, maintenance and service.

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.

Most dirt and dust picked up by the battery can usually be blown off with low pressure compressed air. However, if cells are overfilled and electrolyte collects on the covers, the top of the battery will stay wet. If necessary, clean the top of the battery with a solution of baking soda and hot water.

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%.

NOTICE Vent caps must be tight to prevent soda solution from entering battery cells.

To make the solution, add 0.5 kg (1 lb) of baking soda to 4 liters (1 gallon) of water. Use a brush having flexible bristles. Apply the soda solution to the top of the battery until the cleaning action of the soda stops.

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 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.

G

75

Maintenance Section

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.

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 an authorized personnel only. Do not attempt to open or dismantle a battery or a cell.

Battery condition is important for a long life. The elecrolyte level should be maintained at the recommended levels and the battery should be kept clean and dry. “Washing down” batteries at different time periods will reduce the chance of “grounds” caused by electrolyte spills and corrosion. If done often enough, just washing with water alone will eliminate the need for using baking soda. If not, a solution of baking soda and water must be used to wash battery at different time periods. Add water at regular intervals. Enough water should be added to bring the electrolyte approximately 13.0 mm (.50 inch) above the plates. This is a simple matter with the use of an automatic cell filler, which shows a light when the correct level has been reached. Water should always be added before charging to be sure thorough mixing with acid when gassing occurs near the end of charging period. Use distilled water or have the water supply analyzed. Charge batteries correctly. It is important that all batteries should be charged according to the manufacturer’s instructions. Most of the charging equipment is fully automatic and should be checked periodically. Never operate the lift truck with a fully discharged battery because this will damage the battery. When charging, proper provision must be made for venting of the charging gases. Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed. When a battery charger operates correctly and brings a good battery up to full charge, the current readings will level to the “finish rate.” The charging voltage will stabilize, the specific gravity will stop rising and normal gassing can be seen.

G

76

Maintenance Section

Cold Storage Applications Type2

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.

Observe the battery discharge indicator frequently.

Battery

Hydraulic System

There is a reduction in battery capacity in cold storage applications. For this reason, it is important to : 1. Be sure the battery is completely charged at the start of each work cycle. 2. If possible, keep the lift truck in a warm storage area when it is not in use. 3. Do not store a discharged battery at below freezing temperature. Type1

Drain the hydraulic system and fill it with SAE 5. MIL-H-5606A hydraulic oil

Lift Chains 1. Remove the chains Clean them in a nonflammable cleaning solvent. 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.

G

77

Maintenance Section

3. Put MPGM grease on the chains at one-week intervals. 4. Check chains very carefully for wear on the link plate edges, caused when they run over the sheaves. Check the chains regularly for cracked links, loss of shape in the holes, and corrosion.

G

78

Maintenance Section

Lubricant Viscosities and Refill Capacities Lubricant Viscosities

Refill Capacities REFILL CAPACITIES-(APPROXIMATE) Compartment or Liter U.S. Imperi System s Gal al Gal Hydraulic & Power 18 5 4.5 Steering System Drive Axle Housing 1.1 0.29 0.23 Brake Reservoir 0.6 0.16 0.13

LUBRICANT VISCOSITIES FOR AMBIENT (OUTSIDE) TEMPERATURES Compartme Oil °C nt Viscositie Min Max or System s ISO VG -30 +20 22 Hydraulic and Power ISO VG -20 +30 Steering 32 System ISO VG -10 +40 ISO 6743/4 46 HM ISO VG 0 +50 68 SA E API 10 -20 +22 *Drive Axle CD/ W Housing TO-2 SA E +10 +50 30 *Brake Reservoir

ISO VG 10

-30

+50

°F Min

Max

-22

+68

-4

+86

+14 +104 +32 +122 -4

+72

+50 +122 -22

+122

* For the detailed information about the lubricant specifications, see “Lubricant Specifications” section. The SAE grade number indicates the viscosity of oil A proper SAE grade number should be selected according to ambient temperature.

G

79

Maintenance Section

Maintenance Intervals Every 500 Service Hours or 3 Months 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.

Tilt Cylinders - Check, Adjust, Lubricate ............ 101 Crosshead Rollers - Inspect............................... 102 Mast Hinge Pins - Lubricate ............................... 103 Steering Mechanism - Lubricate......................... 103 Drive Axle Oil - Change...................................... 103 Overhead Guard - Inspect.................................. 103 Control Panel - Clean, Inspect ........................... 104 Directional Lever – Check .................................. 105

NOTICE Careless disposal of waste oil can harm the environment and can be dangerous to persons. Always dispose of waste oil to an authorized personnel only.

G

Every 1000 Service Hours or 6 Months Drive Axle Oil - Change...................................... 106 Drive and Pump Motor - Clean, Inspect ............. 106 Tires and Wheels - Inspect, Check .................... 108 Lift Chains - Test, Check, Adjust......................... 109

When Required Self Diagnostics - Test .......................................... 81 Compact Display Keys.......................................... 81 Carriage Roller Extrusion – Adjust........................ 86 Power Modules – Discharge................................. 87 Fuses - Replace.................................................... 88 Seat - Lubricate .................................................... 88

G

G

G

Every 10 Service Hours or Daily

Every 2500 Service Hours or 15 Months

Walk-Around Inspection - Inspect......................... 89 Mast Channels - Lubricate.................................... 91 Battery - Check, Exchange, Charge ..................... 91 Indicator - Check................................................... 93 Tires and Wheels - Inspect ................................... 94 Back-up Alarm (If Equipped) - Test....................... 94

Hydraulic Oil - Check, Change............................116

Every 2000 Service Hours or Yearly Steer Wheel Bearings - Reassemble .................. 111 Fork - Inspect ......................................................113 Air Breather - Change .........................................115

G

First 50 - 100 Service Hours or a Week Drive Axle Oil – Change........................................ 95 G

First 250 Service Hours or a Month Hydraulic Return Filter - Change .......................... 96

Every 250 Service Hours or Monthly Brake Oil Level - Check ........................................ 97 Drive Axle Oil Level - Check ................................. 97 Parking Brake - Test ............................................. 98 Hydraulic Oil Level - Check .................................. 98 Wheel Bolts - Check ............................................. 99 Mast, Carriage, Lift Chains & Attachmemts - Inspect, Lubricate ............................................................... 99

G

80

Maintenance Section

When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Self Diagnostics - Test

Compact Display Keys Type1

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. Type2

1. Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor.

As you can see in Fig. on right side of display for type1 or type2 there are four keys: E-S-H, UP (TURTLE), DOWN and ENTER.

2. Block the drive wheels.

The function of each of them is described as follows:

3. Release the parking brake.

ENTER key 1. When you switch your device on, this key, pressed for 3 consecutive seconds, allows entering both to parameter calibration and to diagnostic mode. 2. During usual operations, this key, pressed for 3 consecutive s, allows you to access merely to diagnostic mode. Remember that if the display is operating in diagnostic mode during typical operations, you can exit this procedure pressing once ENTER key.

4. Move the directional control lever to NEUTRAL. 5. Move the key switch to OFF.

G

81

Maintenance Section

Moreover, ENTER key is used to confirm the new value of the parameter in calibration procedure.

Run Time Diagnostic Type1

UP key 1. Pressing of this key, in calibration and diagnostic mode, you increase the number of the parameter displayed. 2. In calibration phase, you increase the numeric value of the parameter displayed.

TURTLE key Remember that pressing this key you can toggle between slow running and normal working condition (if the lift truck is already in speed limitation mode).

Type2

DOWN key 1. Pressing of this key, in calibration and diagnostic mode, you decrease the number of the parameter displayed. 2. In calibration phase, you decrease the numeric value of the parameter displayed. 3. "3. way of shifting from the visualization of "time meter" and "odometer": you can do it by pressing the "DOWN ARROW" button of Compact display for 1 second in succession during normal working of the display. "

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

E-S-H key

Enter diagnostic mode if you are switching on your lift truck:

With this key, you can modify the device operating condition, in a circular sequence, as described in Table 7 : CURRENT WORKING CONDITION Economic (E) Standard (S) High (H) Limitation 1 (L1) Limitation 2 (L2) Limitation 3 (L3)

1. Press ENTER key (for 3 consecutive s) until the symbol “0” lights up. 2. Press DOWN key to enter diagnostic mode; the symbol “d” is visualized and it persists until the first parameter has been selected.

WORKING CONDITION AFTER THE KEY PRESSURE Standard (S) High (H) Limitation 1 (L1) Limitation 2 (L2) Limitation 3 (L3) Economic (E)

Enter diagnostic mode if you are working as usual with your lift truck: 1. Press ENTER key (for 3 consecutive s) until symbol “d” appears; it will persist as long as the first parameter has been selected. After diagnostic operation mode has been enabled, you can choose the parameter you want to analyse using UP and DOWN keys (parameter number increases using UP key and decreases with DOWN key).

Table 7 NOTE: You can modify system operating modes only after enabling their management with EYE applicative software.

G

82

Maintenance Section

Here, in Table 11, you have a list of the parameters you can analyze with their respective displaying order :

G

83

Maintenance Section

G

PARAMETER NUMBER

PARAMETER DESCRIPTION

1

Right traction motor speed [rpm]

2

Right traction motor speed reference [rpm]

3

Left traction motor speed [rpm]

4

Left traction motor speed reference [rpm]

5

Lift voltage [mV]

6

Battery voltage [V·10]

7

Right traction motor power module temperature [ºC / °F]

8

Pump motor power module temperature [ºC / °F]

9

Pump motor speed [rpm]

10

Pump motor speed reference [rpm]

11

Accelerator potentiometer voltage [mV]

12

Accelerator second potentiometer voltage [mV]

13

Steering sensor voltage [mV]

14

Left traction motor power module temperature [ºC / °F]

15

Right traction motor phase current U [A rms]

16

Right traction motor phase current V [A rms]

17

Right traction motor phase current W [A rms]

18

Left traction motor phase current U [A rms]

19

Left traction motor phase current V [A rms]

20

Left traction motor phase current W [A rms]

21

Pump motor phase current U [A rms]

22

Pump motor phase current V [A rms]

23

Pump motor phase current W [A rms]

24

Right traction motor temperature [ºC / °F]

25

Left traction motor temperature [ºC / °F]

26

Pump motor temperature [ºC / °F]

27

Seat switch hour meter [h]

28

Drive motor hour meter [h]

29

Pump motor hour meter [h]

30

Seat switch[digit]

31

Park brake switch [digit]

32

Start switch [digit]

33

Reverse traction direction switch [digit]

34

Forward traction direction switch [digit]

35

Pedal brake switch [digit]

84

Maintenance Section

36

3 / 4 wheels selection switch [digit]

37

Auxiliary 1 function (side shift) switch[digit]

38

Auxiliary 2 function switch [digit]

39

High lift switch [digit]

40

Tilt switch [digit]

41

Main breaker command [digit]

42

5V out [digit]

43

12V out [mV]

44

24V out [digit]

45

Buzzer command [digit]

46

Fans command [digit]

Table 11 : List of accessible parameters in diagnostic mode (from 1th to 46th)

G

85

Maintenance Section

In diagnostic mode selected parameter is visualized as follows:

Carriage Roller Extrusion – Adjust 1. Set the mast vertical.

- In the area dedicated to speed and alarm signals, appears parameter number( flashing)

2. Lower the carriage completely.

- Its actual value is displayed in the area reserved to the time meter.

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.

In particular, if the selected parameter is: Analogue input: COMPACT display shows the parameter value, expressed in the unit of Table 11 Digital input: if the command activated by the operator corresponds to the parameter selected, the value of the quantity is visualized. Other way the symbol e (error) appears, except in following case: - Seat switch active, for any selected digital input.

4. Measure the distance from the bottom of the inner upright to the bottom of carriage bearing.

To exit diagnostic mode, type ENTER key again. NOTE: If an alarm occurs when diagnostic mode is enabled, and the system is working as usual, display returns automatically to its typical visualization mode. However you can enter diagnostic mode again, pressing ENTER key (for 3 consecutive s), until the last parameter displayed before exiting is visualized.

5. The measurement (A) must be as follows in Chart below. Height of carriage roller extrusion (A)

If the selected parameter is a temperature, also thermal alarm symbol is visualized.

G

86

STD mast

FF mast

FFT mast

-6

8

8

Maintenance Section

Power Modules – Discharge

Personal injure could result if power modules have not been discharged properly. Battery voltage and high amperage are present. The power modules must be discharged before any contact with the electrical control system is made. Before touching any electrical components, remove rings, watches and other metallic objects from the hands and arms, then discharge the power modules.

2. Open the hood.

3. Before touching any electrical components, the power modules must be discharged. Put a 90 ohm, modules watt resistor in position bewtten the terminals as shown. Hold the resistor in this position for approximately ten seconds. This will discharge the power modules.

The power modules are located in the control panel at the rear of the lift truck.

4. Perform any necessary maintenance and repair at this time. 5. Close the hood. 6. Connect the battery.

1. Disconnect the battery.

G

87

Maintenance Section

Fuses - Replace

Seat - Lubricate

The fuses are located in the control panel and fuse box at the rear of the lift truck. They protect the electrical system from damage caused by overloaded circuits. Change a fuse if the element separates. If the element of a new fuse separates, have the circuit checked and repaired.

NOTICE Replace fuses with the same type and size only. Otherwise, electrical damage can result. If it is necessary to replace fuses frequently, an electrical problem may exist. Contact your DAEWOO Lift Truck dealer.

Check the operation of the seat adjusters. Make surethat the seat slides freely on its track. Lightly oil the seat slider tracks.

Horn DC/DC converter Lights(1) Lights(2) Fan Key

- 10 amps - 10 amps - 10 amps - 10 amps - 10 amps - 10 amps

Main Fuse - 700 amps

G

88

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 Iindicator display. 3. Test the horn and other warning devices for proper operation.

7. Inspect the overhead guard for damage, loose or missing mounting bolts.

4. Inspect the mast and lift chains for wear, broken links, pins and loose rollers. 5. Inspect the carriage, forks or attachments for wear, damage and loose or missing bolts.

8. Inspect the hydraulic system for leaks, worn hoses or damaged lines.

G

89

Maintenance Section

12. Move the directional lever to NEUTRAL.

9. Inspect the drive axle housing and the ground for oil leaks. Refer to “Drive Axle Oil” in “Every 1000 Service Hours or 6 Months” section, if an oil leak is found.

13. Turn the key switch to ON. Type1 10. Adjust the operator’s seat.

Type2 11. Adjust the steering wheel to a comfortable position.

G

90

Maintenance Section

14. Check the LCD display for battery discharge status. A fully charged battery will be displayed on the LCD display.

Battery - Check, Exchange, Charge

15. Check the operation of parking brake, service brake, controls and other devices that may be equipped on your lift truck.

Battery Access Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor.

Mast Channels - Lubricate

1. Disconnect the battery. 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.

2. Tilt the steering column to the full upright position and move the seat fully rearward. 3. Release the hood latch lever which retain the seat and battery cover.

4. Raise the seat and battery cover.

G

91

Maintenance Section

3. Check the specific gravity of the battery. If the specific gravity reading is below 1.150, the battery must be charged.

Check Electrolyte

NOTICE The battery should not be used if a difference in specific gravity between two cells is greater than .020. If this condition exists, the battery should be put on an equalization charge. If this does not correct the condition, consult your battery supplier. 4. Check the electrolyte level of all cells. Maintain the electrolyte level about 13 mm (.50 inch) above the plates. Add water as needed. Use only distilled water. Add water before charging the battery.

1. Inspect the battery compartment for loose connections, frayed cables and properly secured battery restraint.

5. Lower the seat and battery cover. To closed position and secure with the latch on the front of the cover.

2. Clean the top of the battery. If necessary, clean the top of the battery with a solution of baking soda and hot water.

6. Connect the battery. NOTICE

Battery Exchanging 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 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 and secure with the latch on the front of the cover. 9. Adjust the seat position.

G

92

Maintenance Section

Battery Charging

When charging, proper provision must be made for venting of the charging gases. Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed. With Battery Installed in Lift Truck 3. Move the directional control lever to the NEUTRAL position.

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. 3. When the battery is fully charged, disconnect the battery from the battery charger. 4. Connect the battery to the lift truck. 5. Lower the seat and battery cover to closed position and secure with the latch on the front of the cover. 6. Adjust the seat position

4. Close the seat switch. Type1

Indicator - Check

Type2

1. Turn the key switch to ON.

5. Check the indicator LCD display for the discharge state of the battery.

2. Engage the parking brake.

G

93

Maintenance Section

Tires and Wheels - Inspect

Inflate the tires, if necessary. See “Tire Inflation Information” section of this manual. Inspect tires and valve stems for wear, cuts, gouges and foreign objects.

Back-up Alarm (If Equipped) - Test

Check all components carefully and replace any cracked, badly worn, damaged and severely rusted or corroded parts with new parts of the same size and type. If there is any doubt, replace with new parts. Do not, under any circumstances, attempt to rework, weld, heat or braze any rim components.

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.

Check Inflation Pressure (If equipped with pneumatic tires)

Measure the tire air pressure on each tire.

G

94

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 After the first 50 ~ 100 hour of operation, subsequently after every 500 hours or 3 months.

4. Fill the drive axle housing with oil through air breather plug hole(ཛ) , the accurate amount of oil is defined by the opening of level checking plug(ཛྷ). 5. Maintain the oil level.

Park the lift truck level, with the parking brake engaged and directional control lever in NEUTRAL. 1. Raise the mast and block in place.

6. Screw the level checking plug(ཛྷ) and air breather in with the seal ring.

2. Turn the key switch to OFF.

7. Raise the mast and remove the blocking.

3. Unscrew oil air - breather (Oil filling plug) (1), level checking plug (2) and remove the drain plug (3). Allow the oil to drain.

G

95

Maintenance Section

First 250 Service Hours or a Month You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Hydraulic Return Filter - Change

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Park the lift truck level with the forks lowered, parking brake engaged, directional lever in NEUTRAL and the key switch to OFF.

1. Loosen the bolts of the hydraulic tank top plate assembly.

2. Remove the return filter by hand and discard it. 3. Install a new filter assembly. 4. Install the tank top plate assembly and fasten the bolts.

G

96

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

Drive Axle Oil Level - Check

G The brake system reservoir is located at the right side of the steering column.

1. Park the lift truck on a level surface. Raise the high enough to gain access to the housing level/fill plugs.

1. Remove the filler cap. 2. Use blocking to secure the carriage in this position.

2. Maintain the brake fluid level in the brake system reservoir. 3. Clean and install the filler cap.

3. Remove the housing level/fill plugs. Maintain lubricant level to the bottom of the plug opening. Install the level/fill plugs. 4. Remove blocking. Lower the carriage.

G

97

Maintenance Section

Parking Brake - Test

Hydraulic Oil Level - Check

NOTE: Be sure area around the lift truck is clear of personnel and obstructions. 1. Drive the lift truck with a rated load up a 15% incline.

To prevent personal injury, the operator must be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move. 1. Operate the lift truck for a few minutes to warm the oil. 2. Park the lift truck level, with the forks lowered, mast tilted back (all cylinders retracted), parking brake engaged, directional control lever in NEUTRAL, and the key switch to OFF. 3. Open the hood. 4. Remove the dipstick 5. Maintain the oil level to the full mark on the breather/dipstick. 2. Halfway up the incline, stop the lift truck by applying the service brakes.

6. Install the dipstick. 7. Install the access cover.

3. Engage the parking brake. 4. Release the service brake. If the parking brake has the correct adjustment, the lift truck will be held in place. NOTE: The lift truck may move slightly while the parking brake is engaging. 5. If the parking brake does not hold, adjust the parking brake lever screw.

G

98

Maintenance Section

Wheel Bolts - Check

Mast, Carriage, Lift Chains & Attachmemts - Inspect, Lubricate

Steer Wheels

1. Operate the lift, tilt and attachment controls. Listen for unusual noises. These may indicate a need for repair.

1. Inspect tightness of wheel nuts in a sequence opposite each other 113 N•m (85 lb•ft).

Drive Wheels

2. Inspect for loose bolts and nuts on the carriage and load backrest. Remove any debris from the carriage and mast. 2. Inspect tightness of wheel nuts in a sequence opposite each other to 140 N•m (105 lb•ft) for the cushion tire In case of the solid softer tire, tighten the nuts 180 N•m (135 lb•ft).

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.

G

99

Maintenance Section

5. Raise and lower the carriage a few times to work lubricant into the chain links.

NOTICE Lubricate chains more frequently than normal where the atmosphere can cause corrosion to components, or when lift truck must work in rapid lift cycles.

6. Inspect the chain anchors and individual links for lwear, loose pins or cracked leaves. NOTE: Have all reparis and adjustments made as required.

G

100

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 Pivot Eyes - Check, Lubricate

Tilt Cylinders - Check, Adjust, Lubricate Chassis Pivot Eyebolts - Lubricate

1. Lubricate the mast pivot eyes, one fitting on each side of the mast. 1. Remove floor plates.

2. Check the mast pivot eye pins for loose retainer bolts and wear. 2. Lubricate pivot eyebolts, one fitting on each tilt cylinder.

Cylinder Rod Extension - Adjust

3. Check the pivot eye pins for loose retainer bolts and wear.

G

1. Tilt the mast to the full forward position.

101

Maintenance Section

Crosshead Rollers - Inspect 1. Operate the mast through a lift cycle. Watch the chains move over the crosshead rollers. Make sure the chain is tracking over the rollers properly.

2. Measure the extended length of the cylinder rods from the cylinder housing to the pivot eye. The cylinder rods must be within 3.18 mm (.125 inch) of each other. 3. To adjust the cylinder rod extension, loosen bolt. Typical example

4. Turn the cylinder rod in or out of pivot eye to obtain the proper adjustment. Turning the rod into pivot eye shortens the stroke. Turning the rod out of pivot eye lengthens the stroke.

2. Check for damaged crosshead rollers, guards and retainer rings.

5. Tighten bolt to a torque of 95 ±15 N•m (70 ±10 lb•ft). Check the cylinder rods again for even travel. 6. With the mast at the tilt back position, install shims as required to permit no gap between pivot eye and spacer, so the mast does not twist at full tilt back position.

G

102

Maintenance Section

Mast Hinge Pins - Lubricate

Steering Mechanism - Lubricate

Lubricate two fittings

Lubricate one fitting

1. Lower the forks and tilt the mast forward.

Lubricate fitting on steer axle.

Drive Axle Oil - Change See topic, “Drive Axle Oil - Change” in “First 50 – 100 Service Hours or a Week”.

Overhead Guard - Inspect

2. Lubricate the mast hinge pins. One fitting on each side of the mast. Total of two fittings.

Look for any loose or damaged bolts. Replace damaged bolts or missing bolts with original equipment part only. Retighten bolts to a torque of 60 ±10 N•m (45 ± 7 lb•ft). Check the overhead guard for bent or cracked sections. Repair if needed.

G

103

Maintenance Section

Control Panel - Clean, Inspect Pressure air can cause personal injury.

Park the lift truck level, with the forks lowered, parking brake engaged, directional control lever in NEUTRAL, and the key switch to OFF.

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. Open the hood.

2. 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 Power Modules must be discharged before any contact with the control panel is made. Personal injury could result if it has not been discharged properly.

3. Inspect all wiring for loose connections, frayed cables and loose mounting bolts. 4. Inspect the fuses for looseness, corrosion and broken connections.

G

104

Maintenance Section

Directional Lever – Check

5. Close the hood and connect the battery. Check the tightness of the directional lever mounting bracket. Adjust if needed. Check for ease of movement of directional lever. Adjust if needed. Check for loose wiring. Secure wiring if needed.

G

105

Maintenance Section

Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Drive Axle Oil - Change B15/18/20T-2 (36V) Only See topic, “Drive Axle Oil - Change” in “First 50 – 100 Service Hours or a week”.

Drive and Pump Motor - Clean, Inspect 4. Fasten lift chains, of equal length, in lift openings in the front of the lift truck. 5. Slowly lift the front of the lift truck, until the drive wheels are just off the ground. 6. Put stands under the frame. Remove the tension on the lift chains. 7. Remove the battery. 8. Remove the floor plate. 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. 3. Remove the battery. See topic, “Battery” in “Every 10 Service Hours or Daily” section of this manual.

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.

G

106

Maintenance Section

. Battery voltage and high amperage are present. The Power Module must be discharged before any contact with the control panel is made. Personal injury could result if it has not been discharged properly.

10. Operate the drive motor slowly. Blow off the drive motor END SHIELD with 205 kPa (30 psi) maximum air pressure, until dust is removed from the motor.

Typical example

11. Install the floor plate. 12. Slowly lift the front of the lift truck and remove the stands. Lower the lift truck to the floor. Remove the chains. 13. Install and connect the battery. Lower the battery cover and adjust the seat.

G

107

Maintenance Section

Tires and Wheels - Inspect, Check

Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while servicing tires and rims, the assemblies could burst with explosive force and cause serious physical injury or death. Follow carefully the specific information provided by your tire serving man or dealer.

Do NOT inflate a tire that has been run while flat or underinflated, without first checking to make sure the locking ring on the wheel is not damaged and is in position. When tires are changed be sure to clean all rim parts, and if necessary, repaint to stop detrimental effects of corrosion. Sand blasting is recommended for removal of rust. Check all components carefully and replace any cracked, badly worn, damaged and severely rusted or corroded parts with new parts of the same size and type. If there is any doubt, replace with new parts. Do not, under any circumstances, attempt to rework, weld, heat or braze any rim components.

Inspect tires for wear, cuts, gouges and foreign objects. Look for bent rims and correct seating of locking ring. If equipped with pneumatic tires, check tires for proper inflation. See topic, “Tire Infaltion Pressure.” To inflate tires always use a clip-on chuck with minimum 60 cm (24 inches) length of hose to an inline valve and gauge. Always stand behind the tread of the tire, NOT in front of the rim. Lift truck capacity is dependent on tire type. Your lift truck dealer should be consulted for possible down ratings when pneumatic tires are used to replace solid (cushion) tires.

1. Install drive wheel. Install two nuts opposite each other (180°). 2. Install the remaining nuts. Tighten all nuts in a crisscross sequence opposite each other (180°) to 140 ± 25 N•m (105 ± 20 lb•ft) for the cushion for the solid softer tire or (180°) to 180 ± 25 N•m (135 ± 20 lb•ft) for the solid softer tire. 3. Reverse the lifting procedure for the front of the lift truck and lower it to the ground.

G

108

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 wear. Inspect to be sure that chain link pins do not extend outside of the link hole. If any single link pin is extended beyond its connecting corresponding link, it should be suspected of being broken inside of its link hole. Lift chains are required to check for wear about every 1,000 service hours or 6 months.

Typical example

Chain wear test is a measurement of wear of the chain links and pins. Take the following steps to check chain wear.

Lift the carriage and the mast high enough for getting tension on lift chains. Check the chains, and make sure the tension is the same. Lift chains are required to check for equal tension about every 1,000 service hours or 6 months.

1. Lift the mast and carriage enough for getting ension on lift chains.

Personal injury can be caused by sudden movement of the mast and carriage. Keep hands and feet clear of any parts that can move.

Lift Chain Adjustment Typical example 2. Measure precisely ten links of chain distance at the center of pins in millimeter. 3. Calculate chain wear rate*. 4. If the chain wear rate is 2% or more, replace the lift chain. * Chain wear rate (%) =

Typical example for carriage equal tension

- Pitch** X 10 ( Actual measurement )x100 Pitch** X 10

If the tension is not the same on both chains, take the procedure as follows.

**Chain Pitch = 15.88 mm(0.63 in)

NOTE: If carriage height is not correct, make adjustments by following procedures.

G

109

Maintenance Section

Carriage Chain Adjustment

Mast Chain Adjustment - FF,FFT Mast

Make sure that carriage height is correct. If correct, adjust the chain for equal tension. If not, adjust the chain for correct carriage height by adjusting anchor nuts(1),(2). NOTE: See the previous section, “Carriage Roller Extrusion” in “When Required”. for proper height of carriage. 1. Fully lower the carriage and tilt mast forward or lift the carriage and put blocks under the carriage to release the tension from the lift chains.

Typical example for FF mast

2. Loosen nut(1) and adjust nut(2) to get proper distance from bottom of inner upright to the bottom of carriage bearing.

Typical example for FFT mast Make sure that mast height is correct. If correct, adjust chain for equal tension. If not, adjust mast chain for correct mast height by adjusting anchor nuts(3),(4).

Typical example for carriage chain of STD mast

NOTE: See the previous section, “Carriage Roller Extrusion” in “When Required”. for proper inner mast height. 1. Lift the inner mast and put blocks under the inner mast to release the tension from the lift chains. 2. Loosen nut(3) and adjust nut(4) to make inner mast rail flush with outer mast rail bottom. Typical example for carriage chain of FF,FFT mast 3. Make adjustment anchor nuts(3),(4) for equal chain tension.

3. Make adjustment anchor nut(1),(2) for equal chain tension. 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.

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.

G

110

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

2. Remove wheel nuts (1). Remove steer wheel (2). 1. Turn steer wheel 90° with lug nuts exposed.

3. Remove the cover. Bend lockwasher tab back and remove locknut (3). Remove the lockwasher, washer and spacers. Remove the hub group seal and the bearings.

NOTE: When lifting the rear of the lift truck, apply the parking brake and block the drive tires. Using two equal length chains, place chain hooks under counterweight lip, at each end of the steer wheel opening or a hydraulic floor jack and a block of wood in the center of the wheel opening. Raise the lift truck slowly and block under the counterweight at the outer ends. Lower the lift truck on the blocking.

5 4

4. Inspect the bearings and the seal for wear or damage. Replace if necessary. Reassemble the bearing. Install bearing (4) and seal (5). Lubricate seal lip (5) lightly with bearing lubricant.

G

111

Maintenance Section

6 8 7

3

5. Install hub group(6) . Pack area (7) with bearing lubricant. Install bearing (8). Install the spacers, washer, lockwasher and locknut (3). Hand tighten the locknut.

6. Install the steer wheel. Put two nuts opposite each other (144°) in B15/18/20T-2(36V) or (180°) in B13/15/18/20T-2(48V). Tighten both. Install all remaining nuts. Tighten all nuts in a crisscross sequence opposite each other (144°) to a torque of 140±25 N•m (105±20 lb•ft) in B15/18/20T- 2(36V) or (180°) to 180±25 N•m (135±20 lb•ft) in B13/15/18/20T-2(48V).

7. While rotating the wheel, tighten the locknut to 34 N•m (24 lb•ft). Loosen the nut completely. Tighten the nut again to a torque of 11±3 N•m (8±2 lb•ft) and lock within this range. Install the cover. 8. Raise the lift truck and remove the blocking. Lower the lift truck to the floor.

G

112

Maintenance Section

exceeds 93 degrees or deviates by more than 3 degrees from an original angle other than 90 degrees, as may be found in some special appli- cation forks.

Fork - Inspect

Forks should be inspected, at a minimum, every 12 months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked every six months.

3. Check the straightness of the upper face of blade (D) and the front face of shank (E) with a straight edge.

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.

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").

Forks with cracks should be removed from service. "Wet Test" magnetic particle inspection is gener- ally preferred due to its sensitivity and the ease of interpreting the results. Portable equipment is usually recommended so it can be moved to the lift truck. Inspectors should be trained and qualified in accordance with The American Society for Non Destructive Testing, Level II Qualifications.

4. Check the difference in height of one fork tip to the other when mounted on the fork carrier. A difference in fork tip height can result in uneven support of the load and cause problems with entering loads. The maximum recommended difference in fork tip elevation (F) is 6.5 mm (0.25") for pallet forks and 3 mm (0.125") for fully tapered forks. The maximum allowable difference in fork tip eleva- tion between the two or more forks is 3 percent of blade length (L). Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DAEWOO Lift Truck Dealer for further information.

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)

G

113

Maintenance Section

at both ends of the carriage and in the path of the bottom fork hook. The load backrest extension may be used in place of the stop blocks in some cases. Shaft mounted forks may use set collars or spac- ers on the shaft to either side of the fork. They may also use U bolts, pins, or similar devices which engage the fork through the top structure of the carriage.

5. Check the fork blade (J) and shank (H) for wear with special attention to the heel (G). The fork should be withdrawn from service if the thickness is reduced to 90 percent or less of the original thickness. Fork blade length may also be reduced by wear, especially on tapered forks and platens. Remove the forks from service when the blade length is no longer adequate for the intended loads.

8. Check fork markings (N) for legibility. Renew markings as required to retain legibility.

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.

9. a. Lift the mast and operate the tilt control lever, until the top surface of the forks is parallel with the floor. Place two straight bars that are the same width as the carriage, across the forks as shown. b. Measure the distance from the bottom of each end of the two bars to the floor. The forks must be parallel within 3 mm (.12 in) for Full Tapered and Polished (FTP) forks, all other forks 6.4 mm (.25 in), for their complete length.

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.

c. Put one fork, one third from the tip, under a fixture that will not move. Then operate the tilt control with caution until the rear of the truck lifts just off the floor. Follow the same proce- dure with the second fork. Repeat Step a.

When adjusting the fork spacing, the forks are prevented from sliding off the end of the carriage by stop blocks. These stop blocks are

G

114

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 hood. 2. Install a new air breather.

3. Close the hood.

G

115

Maintenance Section

Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures.

Hydraulic Oil - Check, Change

4. Remove the dipstick/filler cap assembly. 5. Fill the hydraulic tank. See topic, “Refill Capacities”. Install the dipstick /filler cap assembly.

1. Operate the lift truck a few minutes to warm the oil. Park the lift truck level, with the forks lowered, parking brake engaged, directional lever in NEUTRAL and the key switch to OFF.

6. Turn the key switch to ON and close the seat switch. Operate the hydraulic controls and steering system through a few cycles, to fill the filter and lines. 7. Check for oil leaks. 8. Retract all cylinders. 9. Turn the key switch to OFF. 10. Maintain the oil level to the FULL mark on the dipstick. Add oil if necessary.

2. Remove the hydraulic tank drain plug. Allow the oil to drain. Clean and install the plug. 3. Open the hood.

G

116

Environment Section

Environment Protection When servicing this lift truck, use an authorized servicing area and an approved container to collect coolant, oil, fuel, grease, electrolyte and any other potential environmental pollutant before any lines, fittings or related items are disconnected or removed. After servicing, dispose of those materials in an authorized place and container. When cleaning the lift truck, be sure to use an authorized area.

G

117

Index Section

Index A

DOWN key ........................................................... 82 Drive and Pump Motor - Clean, Inspect .............. 106 Drive Axle Lubricant ............................................. 73 Drive Axle Oil - Change ............................... 103,106 Drive Axle Oil – Change ....................................... 95 Drive Axle Oil Level - Check ................................. 97 Drive Wheels ........................................................ 99 During Storage ..................................................... 62

Accelerator Pedal ................................................. 46 After Storage......................................................... 62 Air Breather - Change ......................................... 115 Attachment Abbreviations (Includes Special Forks) ............................................................................. 36 Avoiding Lift Truck Tipover ................................... 20

B

E

B15/18/20T-2 (36V) Only .................................... 106 Back-up Alarm (If Equipped) - Test....................... 94 Battery ............................................................. 75,77 Battery - Check, Exchange, Charge...................... 91 Battery Access...................................................... 91 Battery Charging................................................... 93 Battery Discharge Indicator................................... 74 Battery Disconnect Before Servicing Warning ........ 9 Battery Exchanging............................................... 92 Battery Restraint Warning....................................... 8 Before Operating the Lift Truck ............................. 49 Before Storage...................................................... 62 Bent or Twisted Forks ........................................... 66 Better Battery Performance .................................. 51 Brake Fluid ........................................................... 73 Brake Oil Level - Check ........................................ 97

Electrical Braking (Plugging)................................. 54 Emergency Switch (If Equipped)........................... 44 Environment Management...................................... 3 Environment Protection ...................................... 117 E-S-H key ............................................................. 82 Every 10 Service Hours or Daily ........................... 89 Every 1000 Service Hours or 6 Months .............. 106 Every 2000 Service Hours or Yearly................... 111 Every 250 Service Hours or Monthly .................... 97 Every 2500 Service Hours or 15 Months ............ 116 Every 500 Service Hours or 3 Months ................ 101

F Fatigue ................................................................. 66 Film for Function of Pedals (If Equipped).............. 46 First 250 Service Hours or a Month ...................... 96 First 50 - 100 Service Hours or a Week ................ 95 First Installation .................................................... 67 Foreword ................................................................ 2 Fork - Inspect...................................................... 113 Fork Inspection ..................................................... 67 Front and Rear Floodlights Switch........................ 43 Fuses - Replace ................................................... 88

C Capacity Chart ...................................................... 32 Capacity Chart – With Side Shifter........................ 33 Carriage Chain Adjustment................................. 110 Carriage Roller Extrusion – Adjust ........................ 86 Causes of Fork Failure.......................................... 66 Chain and Linkage Oils (DEO or EO) ................... 72 Chassis Pivot Eyebolts - Lubricate...................... 101 Check Electrolyte.................................................. 92 Check for Equal Tension..................................... 109 Check Inflation Pressure (If equipped with pneumatic tires) .................................................... 94 Cold Storage Applications..................................... 77 Compact Display Keys.......................................... 81 Control Panel - Clean, Inspect ............................ 104 Crosshead Rollers - Inspect................................ 102 Cylinder Rod Extension - Adjust ......................... 101

G General Hazard Information ................................. 10

H Hook-on type Fork ................................................ 61 Horn Button .......................................................... 43 How to Survive in a Tipover.................................. 27 Hydraulic Oil ......................................................... 72 Hydraulic Oil - Check, Change............................ 116 Hydraulic Oil Level - Check .................................. 98 Hydraulic Return Filter - Change .......................... 96 Hydraulic System.................................................. 77

D Daily Inspection .................................................... 67 Directional Control Lever ...................................... 46 Directional Lever – Check................................... 105 Display Segments................................................. 38

G

118

Index Section

N

I

No Alarm, No Movement (OPTION....................... 42 No Riders Warning ................................................. 8 Noise .................................................................... 31 Noise and Vibration .............................................. 31

Identification, Lift Capacity and Attachment Plate . 35 Important Safety Information................................... 4 Improper Modification or Repair............................ 66 Inching into Loads................................................. 55 Index................................................................... 118 Indicator - Check................................................... 93 Inspection, Maintenance and Repair of Lift Truck Forks..................................................................... 65

O Operating Techniques .......................................... 55 Operation................................................................ 3 Operation Information ........................................... 11 Operator Restraint System (If Equipped) .............. 16 Operator’s Station and Monitoring Systems.......... 37 Operator’s Warning and Identification Plate.......... 35 Operator’s Warning Plate ..................................... 35 Overhead Guard - Inspect .................................. 103 Overloading .......................................................... 66

K Key Switch............................................................ 37

L LED Indicators ...................................................... 41 Lift Chain Adjustment.......................................... 109 Lift Chain Wear Test ........................................... 109 Lift Chains........................................................ 11,77 Lift Chains - Test, Check, Adjust......................... 109 Lift Control Lever .................................................. 47 Lift Fork Adjustment .............................................. 61 Lift Truck Capacity Rating..................................... 35 Lift Truck Controls................................................. 45 Lift Truck Operation .............................................. 52 Lifting Drums or Round Objects ............................ 58 Lifting the Load ..................................................... 55 Literature Information.............................................. 2 Lubricant Information ............................................ 72 Lubricant Specifications ........................................ 72 Lubricant Viscosities ............................................. 79 Lubricant Viscosities and Refill Capacities............ 79 Lubricate one fitting ............................................ 103 Lubricate two fittings ........................................... 103 Lubricating Grease (MPGM) ................................. 73

P Parking Alarm Warning (If Equipped) ................... 60 Parking Brake - Test............................................. 98 Parking Brake Lever ............................................. 45 Parking the Lift Truck............................................ 59 Power Modules – Discharge................................. 87 Prepare for the Self Diagnostic - Test................... 81 Refill Capacities.................................................... 79

R Run Time Diagnostic 82 S Safety .................................................................. 2,5 Safety Rules ......................................................... 22 Seat - Lubricate .................................................... 88 Seat Adjustment ................................................... 43 Seat Switch .......................................................... 37 Self Diagnostics - Test.......................................... 81 Serial Number....................................................... 34 Serial Numbers Locations..................................... 34 Service Brake Pedal ............................................. 45 Shipping ............................................................... 63 Sideshift Attachment Control (If Equipped) ........... 48 Specifications ....................................................... 28 Steer Wheel Bearings - Reassemble.................. 111 Steer Wheels ........................................................ 99 Steering Mechanism - Lubricate ......................... 103 Storage Information .............................................. 62

M Machine Lifting and Tiedown Information.............. 63 Maintenance ........................................................... 3 Maintenance and Repair....................................... 68 Maintenance Information ...................................... 13 Maintenance Intervals........................................ 3,80 Mast Abbreviations ............................................... 36 Mast Chain Adjustment - FF,FFT Mast ............... 110 Mast Channels - Lubricate .................................... 91 Mast Hinge Pins - Lubricate................................ 103 Mast Pivot Eyes - Check, Lubricate .................... 101 Mast, Carriage, Lift Chains & Attachmemts - Inspect, Lubricate............................................................... 99 Monitoring Systems Indicator................................ 38

T 12 Months Inspection ........................................... 68 Tilt Control Lever .................................................. 47

G

119

Index Section

Tilt Cylinders - Check, Adjust, Lubricate ............. 101 Tilt Steering Column ............................................. 43 Tire Inflation.......................................................... 69 Tire Inflation Information ....................................... 69 Tire Inflation Pressures Adjustment ...................... 69 Tire Shipping Pressure ......................................... 69 Tires and Wheels - Inspect ................................... 94 Tires and Wheels - Inspect, Check ..................... 108 Torque for Metric Fasteners.................................. 71 Torque for Standard Bolts, Nuts and Taperlock Studs .................................................................... 70 Torque for Standard Hose Clamps - Worm Drive Band Type ............................................................ 70 Torque Specifications ........................................... 70 Torques for Bolts and Nuts With Standard Threads ............................................................................. 70 Torques for Taperlock Studs................................. 71 Towing Information ............................................... 64 Transportation Hints ............................................. 63 Traveling............................................................... 56 Turning ................................................................. 56 TURTLE key ......................................................... 82

U Unloading ............................................................. 57 UP key .................................................................. 82 Use following engine oils are recommended for use on chains and linkages. ........................................ 72

W Walk-Around Inspection........................................ 49 Walk-Around Inspection - Inspect ......................... 89 Warning Signs and Labels ...................................... 5 Wheel Bolts - Check ............................................. 99 When Required..................................................... 81 G

G

120

DAEWOO HEAVY INDUSTRIES & MACHINERY LTD. AROUND THE WORLD ̻ : Sales office

ൢ : Parts depot

ED U.K. (Northhampton, UK) EDSA (Frameries, Belgium)

ED France (Paris France)

DMV (Dusseldorf, Germany)

ED Italy (Milano, Italy)

DWYC Beijing (China) DWYC (Yantai, China)

DHIAC (Cleveland, USA)

H.Q. (Seoul, Korea)

(Atlanta, Georgia) DWYC Shanghai (China)

DME (Sao Paulo, Brazil)

Head Office Hwasu-Dong 7-11, Dong-Gu, Incheon, Korea. Tel : 82-32-760-1114 Fax : 82-32-762-1546

Seoul Office 8th floor Daewoo Heavy Industries & Machinery Bidg, 14-34, Youido-Dong, Youngdungpo-Gu, Seoul, Korea Tel : 82-2-2167-3511 Fax : 82-2-2167-3530

NORTH AMERICA Daewoo Heavy Industries America Corp. 2905 Shawnee Industrial Way, Suwanee, Georgia 30024, U.S.A. Tel : 1-770-831-2200 Fax : 1-770-831-0480

Daewoo Heavy Industries America Cleveland Office 4350 Renaissance Parkway, Warrensville Heights, OH44128, U.S.A. Tel : 1-216-595-1212 Fax : 1-216-595-1214

SOUTH AMERICA Daewoo Maquinas E Equipamentos Ltda AV Tres Andradas 819-jd. Piratininga-CEP 06230-050-Osasco-SP-Brazil Phone : 55-11-3686-0177 Fax : 55-11-3686-0970

Daewoo Maschinen Vertriebs Gmbh Vertrieb Gabelstapler Hans-Bockler strasse 29, D-40764,Langenfeld-Fuhrkamp, Germany Tel : 49-2173-8509-91 Fax : 49-2173-8509-80

Euro Daewoo S.A 1A Rue, Achille Degrace, 7080 Frameries, Belgium Tel : 32-65-61-3245 Fax : 32-65-67-6622

Euro Daewoo France S.A Ave Du Bois De La Pie 33-49 Zac Paris Nordii BP 50069,95947 Roissy Cdg Cedex Paris, FRANCE Tel : 33-1-48-63-1533 Fax : 33-1-48-63-0045

Euro Daewoo Italy S.A Via Flume,13 I-20059 Vimercate(MI),ITALY Tel : 39-039-6083202 Fax : 39-039-6083210

ASIA & OCEANIA Daewoo Heavy Industries Yantai Co.,Ltd E-10,Wuzhishan Road,Eco.& Tech, Development Zone, Yantai, Shandong, China Tel : 86-535-639-9150 Fax : 86-535-638-2004

Daewoo Heavy Industries Yantal Co.,Ltd

EUROPE

No.21 Xiao Yun Road Dong sanhuan beilu, chaoyang District, Beijing, China(100027) Tel : 86-10-6462-3181 ext)301 Fax : 86-10-6462-3278

Euro Daewoo U.K. Ltd

Daewoo Heavy Industries Yantai Co.,Ltd

12 Kildey Road Brackmills Industrial Estates Northhampton NN4 7BK, U.K. Tel : 44-1604-825600 Fax : 44-1604-825650

Room c,14F, Zhaofeng Universe Building 1800 Zhongshan W.Road Shanghai, Chain(200233) Tel : 86-21-6440-1821 Fax : 86-21-6640-0842