Professional Documents
Culture Documents
form SB4176E
SB4183E00
Feb. 2005
TITLE
Service Manual Contents
Safety
Torque Specifications
FORM NUMBER
SB4183E00
SB2003E00
SB2004E00
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
SB2339E01
SB2340E01
TITLE
Service Manual Contents
Safety
Torque Specifications
FORM NUMBER
SB4183E00
SB2003E00
SB2004E00
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
SB2339E01
SB2340E01
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SB4177E00
Feb. 2005
SB4145E00
Jun. 2004
Specifications
Systems Operation
Testing & Adjusting
MicroController Control Systems
B15T-5, B18T-5, B20T-5 (AC 36V/48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
for Electric Lift Trucks
Index
Specifications
Instrument Panel
Systems Operation
Eye Software Interface
General Information .................................................13
Advantage of AC motor.........................................13
Basic ITC ..............................................................16
Comparison between AC and DC motor...............13
ITC system characteristics....................................16
Main ITC(Intelligent Torque Control) features .......15
Glossary ................................................................... 11
Installation and Wiring..............................................17
Accessory Circuits ................................................26
General .................................................................17
Hydraulic Pump Motor Circuit ...............................25
K1 connector: list of all terminals ..........................19
System Circuit.......................................................23
Thermal protection circuit......................................26
Features .................................................................114
General Information................................................112
Installation ..............................................................113
Main Menu..............................................................115
Calibration ...........................................................124
Configuration Menu (Setup) ................................119
Data Logging.......................................................144
Flash ...................................................................146
Not Actual Software / Eeprom Crc Fault..............118
Password Insertion..............................................116
Submenus ...........................................................118
Test......................................................................120
Appendix
Appendix A : 48[V] Parameter List..........................148
Appendix B : 36[V] Parameter List .........................151
Appendix C : Error Code List..................................154
Appendix D : Contraction for dot matrix display......160
1. Alarm Code .....................................................160
2. Calibration Code .............................................161
3. Diagnostic Code..............................................162
Specifications
G
Component Measurements
SPECIFICATIONS
Multimeter Setting
Results
Resistance
+BATT
Each U,V,W
Resistance
-BATT
Each U,V,W
Resistance
U Termina
V Terminal
Resistance
U Termina
W Terminal
Resistance
V Termina
W Terminal
Controller AS Specification
BATTERY VOLTAGE
24-60 V
325 A
400 A
SWITCHING FREQUENCY
3-6-9 KHz
EFFICIENCY
95 %
PROTECTION LEVEL
MECHANICAL SIZE
IP51
580x248x187
WEIGHT
24 Kg
VIBRATION
TEMPERATURE RANGE
- 30 C + 40 C
100C
Complies with EN 1175-1 EN 12895-1
MAIN CONTACTOR
250A
MAIN FUSE
KEY FUSE
700A
10A
5 KW
POWER
12 KW
VOLTAGE
32 V
VOLTAGE
30.5 V
CURRENT
157 A
CURRENT
335 A
RATED SPEED
1500 RPM
RATED SPEED
2200 RPM
MAXIMUM SPEED
4500 RPM
MAXIMUM SPEED
4500 RPM
FREQUENCY
Cos G
75 Hz
0,72
FREQUENCY
Cos G
SERVICE
S2 60'
SERVICE
INSULATION CLASS
PROTECTION DEGREE
BEARINGS
WEIGHT
INSULATION CLASS
IP 10
PROTECTION DEGREE
6206 2RS
38.5 Kg
BEARINGS
WEIGHT
73 Hz
0.84G
S3 15%
F
IP 20
6206 2RS
43.5 Kg
TYPE B
Fuses
NOTE: Apply a small amount of D557047 Thermal Joint Compound on control panel plate and mating surface
prior to assembly. Communication cables assembly with power units and logic control unit uses the micro
screw driver(2.5*100mm)
Communication cable's assembly with Power Unit and Logic Control Unit uses Micro Screw Driver
(1) Logic Control Unit. Use a socket wrench(7mm) to hold bolts
(2) Left Drive Motor Power Unit. Use a hex bit socket(5mm) wrench(100mm) or L-wrench to hold bolts
(3) Pump Motor Power Unit
(4) Right Drive Motor Power Unit
(5) FUSE. Use a socket wrench(13mm) and a wrench(13mm) to hold bolts
(6) Line Contactor
(7) Bus Bar. Use a socket wrench(13mm) and a socket wrench(17mm) to hold bolts
10
Systems Operation
Glossary
NAME
DESCRIPTION
Accelerator
A device that converts mechanical movement into a analog voltage pattern to the
logics for variable drive motor speed.
The unit of measurement of current flow. The amount of current that one volt can
push through a resistance of one ohm.
Analog to Digital
Converter
A device that converts an analog voltage into a pattern of digital HIGH and LOW
voltage signals.
Battery
BDI
Bus Bar
Capacitor
Circuit
A way for current to go from the positive (+) side of an electrical power source to the
negative (-) side of an electrical power source. This can be through wires and
electrical components.
Coil
Connector
Part of a wire assembly or harness that connects with another wire assembly or
harness. Used for ease of assembly and disassembly.
Contactor Assembly
Contactor Coil
The portion of a switch, relay or contactor where the circuit can be opened or closed.
Current
Current Limit
The maximum allowable armature current of a stalled drive motor during pulsing.
Digital Signal
Diode
A semiconductor device that allows current to flow in one direction, from the anode to
the cathode.
Display
Electrically trying to rotate the drive motor opposite to the direction of truck
movement.
Fuse
A component in an electrical circuit that will open the circuit if too much current goes
through it.
Harness
Heat Sink
Indicator
LCD that gives an indication of some vehicle condition when it turns on or flashes.
LCD
The main printed circuit board containing a microprocessor and circuits to condition
the voltage signals that go into or come out of the logics. It electronically monitors
and controls the truck's functions.
11
NAME
DESCRIPTION
Microprocessor
Normal Condition
Words used with a switch or relay. Their normal condition is their condition when they
are not controlled by the application of force, temperature, pressure, or electricity.
MOSFET
Ohm
The unit of measurement of resistance. The amount of resistance that will let one volt
push only one ampere of current through it.
ON-Time
Open Circuit
Overload
Plugging
A portion of electrical braking where the generated current is directed back through
the armature.
Relay
Resistor
A component made of a material that has a specific resistance to the flow of current.
Rotor
Schematic
Short Circuit
Socket
The female contact of a connector that slips over a male contact (pin) of another
connector.
Solid State
Stator
Switch
Systems
The electrical components, circuits, and connections that deliver power to perform
specific tasks.
Terminal
Thermal Sensor
Volt
The unit of measurement of electromotive force. One volt is the force needed to
make one ampere of current flow through one ohm of resistance in a circuit.
Watt
The unit of measurement of power. The amount of power used when one volt pushes
one ampere of current through a resistance of one ohm. The result of amperes
(current) multiplied by volts (voltage) is watts (power).
Wire
A conductor used to provide a path for current to flow to and from electrical
components.
Wiring Diagram
A drawing using visual representation of components the way they actually look. It is
used to show the locations of components and the connections between them.
Zener Diode
12
General Information
Advantage of AC motor
DC Motor system
Little components
More complex
Decreasing price
Increasing price
More reliable
Less reliable
Practically
maintenance free
Continuous
maintenance to brushes
High speed
Low speed
High torque
performance at high
speed
Low torque
performance at high
speed
High braking
performance at high
speed
Poor braking
performance at high
speed
Safer
Less safe
Controller Characteristics
AC Motor systems
9
10 No auxiliary contactor
Complex controller
13
DC Motor system
Simple controller
Presence of auxiliary
contactors
11
4 quadrants
continuous transition
12
Poor regulation
14
Instrument Panel
15
Basic ITC
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
G
G
G
G
G
16
17
18
Use
Name
K1 1
IN
K1 2
OUT
IN
A
K1 3
K1 4
IN
D
START signal
N.O. with internal pull-up and Vmax(in)=24V
K1 5
IN
A
accelerator pedal 2
potentiometer
K1 6
IN
D
K1 7
IN
D
seat switch
K1 8
IN
D
K1 9
IN
D
K1 10
IN
A
accelerator pedal 1
potentiometer
+ 12 V supply
K1 11
OUT
-Battery
+ 24 V supply
K1 12
IN/OUT
D
K1 13
IN
A/D
not used
OUT
+ 5 V encoder supply
OUT
GND
K1 14
K1 15
Function
K1 16
IN
D
K1 17
IN
D
K1 18
OUT
K1 19
OUT
OUT
A
not used
K1 20
19
Pin
number
Use
Name
Function
OUT
D
not used
K1 21
K1 22
IN
+ battery
K1 23
IN
K1 24
IN
A/D
not used
K1 25
IN
D
not used
K1 26
IN
A
not used
K1 27
IN
A
not used
K1 28
IN
D
PHASE B of pump
motor encoder
K1 29
IN
D
PHASE A of pump
motor encoder
K1 30
IN
D
Not used;
PHASE A of an optional encoder
IN/OUT
A/D
Not used;
PHASE B of an optional encoder
K1 31
K1 32
IN
D
Asynchronous RS232
serial RX input
K1 33
IN
D
OUT
OUT
K1 36
OUT
A
not used
K1 37
OUT
D
not used
IN
AUX 2
IN
not used
K1 34
K1 35
K1 38
K1 39
K1 40
IN
A/D
20
Pin
number
Use
K1 41
IN
D
not used
K1 42
IN
A
not used
K1 43
IN
A
not used
K1 44
IN
D
not used
K1 45
IN
D
not used
K1 46
IN
D
K1 47
IN
A/D
Not used
K1 48
IN
D
K1 49
IN
A/D
Not used
K1 50
IN
A
K1 51
IN
A
Not used
K1 52
IN
A
Not used
K1 53
OUT
D
buzzer command
K1 54
IN
D
tilt switch
IN
D
Not used;
PHASE B of an optional
encoder
IN
D
K1 57
IN
D
AUX1
K1 - 58
IN
A/D
K1 59
IN
A/D
K1 - 60
IN
A/D
K1 55
K1 56
Name
Function
21
Pin
number
Use
K1 - 61
IN
A/D
K1 62
K1 63
Name
Function
Not in use
IN
A
OUT
D
Not used;
Electrovalve (or alike) command
OUT
D
Not used;
Electrovalve (or alike)
command
K1 65
OUT
D
Not used;
Electrovalve (or alike)
K1 66
OUT
D
Not used;
Electrovalve (or alike)
K1 67
OUT
A
Not used
K1 68
OUT
D
Not used;
Electrovalve (or alike)
K1 64
NOTES:
D
NOTICE
Remember the controller contains ESD(Electro
Static dischange) sensitive components.
Use appropriate precautions in connecting,
disconnecting and handling it.
22
System Circuit
Power Circuit
23
Actuation Circuit
24
Location Components
1
Location Components
(1) Valve control card.
25
Accessory Circuits
Control Panel
Horn Circuit
Drive Motor
If the drive motor overheats a thermal sensor
mounted in the stator coil of drive motor will warn at
a predetermined temperature (155C). If reach in
overheating temperature, the Instrument Panel will
display a Run Time diagnostic symbol and E4, E5.
To decrease the amount of current allowed to flow
through the drive motor, the logics will reduce the
speed. When the drive motor cools off, the truck will
return to normal operation. Drive system
acceleration performance and top travel speed is
affected by an overheated drive motor. MOTOR
TEMPERATURE will be stored for Drive Motor
overheating in memory.
The 12 volt output of the converter is protected
against short circuits and overloading by an internal
15 amp current limit circuit. A fuse on the converter
protects it from reverse connection of the battery
voltage.
26
Battery Tests
A weak battery can cause or contribute to problems
in the Logic Control Board and power circuits. Verify
the battery is good before investigating other
possibilities.
Hydrometer Test
2
1
27
Battery Maintenance
Visual Checks
28
29
Programmable Parameters
Adjustable Parameters Description
The possibility of interfacing by PC with the system
allows to have an exhaustive real time analysis of
the system working and of the condition of its
components; moreover, you can choose among a
wide range of parameters in order to reach the
optimum operating of the system in compliance with
your needs.
Adjustable parameters are listed below, divided by
functional groups, both for a 36 V and a 48 V
system. We briefly explain whats the meaning of
each programmable parameter, and which is the
effect of its changes in lift truck performance.
30
<48V SYSTEM>
Drive Motor
Parameter
No
5
Deceleration
steering ramp 1
Deceleration
steering ramp 2
26
41
Stop on slop
timer
Drive maximum
current
42
Forward
maximum speed
43
Reverse
maximum speed
44
46
47
48
49
50
Parameter
Drive limitation
maximum speed
Critical height
drive maximum
speed (optional)
Steer limitation
maximum speed
Drive
acceleration
ramp
Drive inversion
ramp
Drive release
ramp
Unit
Mini
mum
Def
ault
Maxi
mum
Varia
tion
rpm/s
10
800
5000
10
rpm/s
1000
10
20
100
100
rpm
1,000
4,500
4,500
50
rpm
1,000
4,500
4,500
50
rpm
500
2,000
2,500
50
rpm
400
2,000
4,500
50
rpm
400
1,500
4,500
50
rpm/s
400
1,150
2,000
10
rpm/s
400
1,200
2,000
10
rpm/s
400
900
2,000
10
rpm/s
400
1,000
2,000
10
rpm
100
300
2,000
mm
300
451
600
rpm/s
10
50
500
Parameter Description
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.
Without stepping on pedal brake, time that is
doing stop in slope
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)
Maximum lift truck speed with speed
limitation (turtle active)
51
52
Creep speed
53
Diameter of drive
tyres
59
Partial release
ramp
93
Power mode
(E-S-H, limitations)
94
Slow speed
95
British unit
96
Display brightness
97
E-S-H enable
98
Time meter /
Odometer on
display
31
10
digit
digit
Disable = 0, Enable = 1
digit
digit
digit
Disable = 0, Enable = 1
digit
Unit
Mini
mum
Def
ault
Maxi
mum
Varia
tion
mV
200
1,000
4,500
10
mV
3,000
5,000
12,000
10
mV
200
1,000
12,000
10
mV
2,000
7,500
12,000
10
mV
500
1,200
11,500
10
mV
3,000
11,500 12,000
10
mV
500
10,030 11,500
10
mV
500
6,300
11,500
10
Parameter Description
Unit
Mini
mum
Def
ault
Maxi
mum
Varia
tion
rpm
1,500
3,200
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
rpm
500
700
1,500
50
rpm
400
500
800
10
rpm
200
300
500
10
rpm/s
1,000
7,000
10,000
10
rpm
1000
7000
10000
10
20
100
100
10
62
100
rpm
500
500
4500
50
Parameter
Parameter Description
Accelerator pedal
minimum value
Accelerator pedal
maximum value
Lift sensor
minimum value
Pump Motor
Parameter
No
70
Lift maximum
speed
Tilt speed
Lateral shift (AUX
1 function) speed
AUX 2 function
speed
AUX 3 function
speed
Lift minimum
speed
Hydro speed
71
63
64
65
66
67
68
72
73
61
62
69
Parameter
Pump
acceleration ramp
Pump
deceleration ramp
Lift maximum
current
Auxiliary
maximum current
High lift 1 switch
lift max speed
Lift acceleration
Pump motor deceleration after the end of a
command
Pump motor maximum current with lift
function active
Pump motor maximum current with lift lever
released
Maximum pump motor speed with forks
above the critical height
32
Timers
Parameter
No
Parameter
Parameter Description
Unit
Mini
mum
Def
ault
Maxi
mum
Varia
tion
10
10
20
Parameter Description
Unit
Mini
mum
Def
ault
Maxi
mum
Varia
tion
V*10
464
470
501
Parameter
Parameter Description
Unit
Maintenance time
Maintenance time
inserting enable
Mini
mum
0
Def
ault
0
11
12
Chat time
13
Hydro time
Battery
Parameter
No
9
Parameter
Battery reset
value
Program Service
Parameter
No
99
14
33
h
digit
Maxi Varia
mum tion
10000 100
Disable = 0, Enable = 1
<36V SYSTEM>
Drive Motor
Parameter
No
5
Deceleration
steering ramp 1
Deceleration
steering ramp 2
26
41
Drive maximum
current
42
Forward
maximum speed
43
Reverse
maximum speed
44
46
47
48
49
50
Parameter
Drive limitation
maximum speed
Critical height
drive maximum
speed (optional)
Steer limitation
maximum speed
Drive acceleration
ramp
Drive inversion
ramp
Drive release
ramp
Parameter Description
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.
Without stepping on pedal brake, time that is
doing stop in slope
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)
Maximum lift truck speed with speed
limitation (turtle active)
Maximum lift truck speed when forks high
is more than critical one
Maximum speed reference in the angle in
which the internal wheel is mechanically still.
Lift truck acceleration with accelerator pedal
pressed
Lift truck deceleration in inversion
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.
51
52
Creep speed
53
Diameter of drive
tyres
59
93
94
Slow speed
95
British unit
96
Display
brightness
97
E-S-H enable
98
Time meter /
Odometer on
display
34
Unit
Mini
mum
Def
ault
Maxi
mum
Vari
ation
rpm/s
10
800
5000
10
rpm/s
1000
10
20
100
100
rpm
1,000
3,800
3,800
50
rpm
1,000
3,800
3,800
50
rpm
500
2,000
2,500
50
rpm
400
2,000
3,800
50
rpm
400
1,500
3,800
50
rpm/s
400
1,150
2,000
10
rpm/s
400
1,200
2,000
10
rpm/s
400
900
2,000
10
rpm/s
400
1,000
2,000
10
rpm
100
300
2,000
mm
300
451
600
rpm/s
10
50
500
10
digit
digit
Disable = 0, Enable = 1
digit
digit
digit
Disable = 0, Enable = 1
digit
Parameter
Accelerator pedal
minimum value
Accelerator pedal
maximum value
Lift sensor
minimum value
Lift sensor middle
value
Steering sensor
minimum value
Lift sensor
maximum value
Steering sensor
maximum value
Steering sensor
middle value
Unit
Mini
mum
Def
ault
Maxi
mum
Varia
tion
mV
200
1,000
4,500
10
mV
3,000
5,000
12,000
10
mV
200
1,000
12,000
10
mV
2,000
7,500
12,000
10
mV
500
1,200
11,500
10
mV
3,000
11,500 12,000
10
mV
500
10,030 11,500
10
mV
500
6,300
11,500
10
Parameter Description
Unit
Mini
mum
Def
ault
Maxi
mum
Varia
tion
rpm
1,500
3,200
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
rpm
500
700
1,500
50
rpm
400
500
800
10
rpm
200
300
500
10
rpm/s
1,000
7,000
10,000
10
rpm
1,000
7,000
10,000
10
20
100
100
10
62
100
rpm
500
500
4500
50
Parameter Description
Accelerator sensor voltage with pedal
released
Accelerator sensor voltage with pedal
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
Steering sensor voltage with wheels turned
on left
Lift sensor voltage with lift lever completely
pressed
Steering sensor voltage with wheels turned
on right
Pump Motor
Parameter
No
70
Lift maximum
speed
Tilt speed
Lateral shift (AUX
1 function) speed
AUX 2 function
speed
AUX 3 function
speed
Lift minimum
speed
Hydro speed
71
63
64
65
66
67
68
72
73
61
62
69
Parameter
Pump acceleration
ramp
Pump deceleration
ramp
Lift maximum
current
Auxiliary
maximum current
High lift 1 switch
lift max speed
Lift acceleration
Pump motor deceleration after the end of a
command
Pump motor maximum current with lift
function active
Pump motor maximum current with lift lever
released
Maximum pump motor speed with forks
above the critical height
35
Timers
Parameter
No
Parameter
11
12
Chat time
13
Hydro time
Parameter Description
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
Unit
Mini
mum
Def
ault
Maxi
mum
Varia
tion
10
10
20
Battery
Parameter
No
9
Parameter
Parameter Description
Unit
Mini
mum
Def
ault
Maxi
mum
Vari
ation
Battery reset
value
V*10
344
356
373
Parameter
Parameter Description
Unit
Maintenance time
Maintenance time
inserting enable
Mini
mum
0
Def
ault
0
Program Service
Parameter
No
99
14
36
h
digit
Maxi Vari
mum ation
10000 100
Disable = 0, Enable = 1
ECONOMIC MODE
STANDARD MODE
HIGH MODE
62
76
100
3000
3500
4500
3000
3500
4500
20
20
20
700
800
1150
600
900
1200
600
850
1000
75
80
100
2500
2750
2950
ECONOMIC MODE
STANDARD MODE
HIGH MODE
62
76
100
2800
3300
3800
2800
3300
3800
20
20
20
700
900
1100
700
900
1100
700
900
1200
75
80
100
1600
2500
2950
In case of 36 V system:
PARAMETER
Maximum drive current
37
Buzzer Management
G
When switching on the key, in case an hydraulic
command is active, the lift, lateral shift, tilt and
auxiliary functions are disabled.
38
Alarm List
NOTICE
If more than one faulty condition is detected,
Compact displays shows alarm code referring to
the most serious one (the one characterized by
lower alarm level).
39
Eeprom alarm
1.
2.
3.
4.
1.
2.
3.
4.
40
41
42
1.
2.
3.
4.
43
1.
2.
3.
4.
44
Wrong start
1. Eye alarm code: 64
2. Eye alarm code: EE
3. Alarm level: warning; main breaker is opened
and pump and drive motors are stopped.
4. Alarm cause: when you start working, you find
accelerator pedal pressed or a forward/ reverse
switch active.
Encoder alarm
45
1.
2.
3.
4.
46
47
48
PROBLEM 1
Central Vehicle Monitoring System (CVMS) does not work,
with no lift truck operation.
POSSIBLE CAUSE
Battery polarity not correct on control panel;
Key fuse open circuit; Key switch defect; Logics
CHECKS
With battery connected, check control panel battery connections for correct polarity.
Positive battery connected to line fuse and negative battery connected to B - on controller.
If correct
If not correct
No continuity
Less than
Battery voltage
Battery
Voltage
Less than
Battery voltage
Replace logics.
Replace horn or
check the battery.
Replace key switch or repair broken wire
#23 between key switch and K1-23.
49
Repair or replace
open wire
PROBLEM 2
CVMS does not work at all, lift truck operation normal.
If only part of CVMS works.
POSSIBLE CAUSE
Open circuit from K1-11 to CVMS connector PIN 8;
Open circuit from K1-15 to CVMS connector PIN 7;
CVMS defect.
CHECKS
Make sure CVMS connector is connected to CVMS.
If connected
If not connected
0 volts
50
PROBLEM 3
Display portion of the CVMS seems random or wrong.
Lift truck operation normal.
POSSIBLE CAUSE
Connection defect; Wiring defect; Logics defect;
Display defect.
CHECKS
Check continuity from logics to CVMS connector
Continuity
No continuity
Shorted
Replace logics.
51
PROBLEM 4
Direction switch circuit defect.
POSSIBLE CAUSE
Direction switch defect; Wiring to direction
switch defect;
CHECKS
Disconnect the battery.
Disconnect K-1 connector.
Check continuity from K1-15 to K1-9 harness connector;
With direction lever in forward should have a closed circuit,
in neutral should be open.
Check OK
Check failed
Check OK
Replace logics.
Check failed
Check failed
52
PROBLEM 5
Lift sensor circuit defect.
POSSIBLE CAUSE
Lift sensor not adjusted properly or defective;
Lift sensor wiring defect; Valve control card (board)
defect; Logics defect.
CHECKS
Retest lift sensor circuit in self diagnostics.
Circuit passes
Diagnostics
Circuit fails
Diagnostics
Replace logics.
0 Volt
NOTE: Before lift truck is placed into operation, connect tilt and auxliary switches and verify proper adjustment.
Refer to Valve Control Card Adjustments.
53
PROBLEM 6
Tilt switch circuit defect.
POSSIBLE CAUSE
Tilt switch defect; Wiring defect; Logics defect.
CHECKS
Disconnect K1 connector. Pull tilt lever to maximum.
Check continuity from K1-54 to K1-15.
Continuity
No continuity
Replace logics.
No continuity
54
No continuity
PROBLEM 7
Auxiliary switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Auxiliary switch defect; Logics defect.
CHECKS
Disconnect K1 connector. Pull auxiliary lever to maximum.
Check continuity from K1-15 to K1-38 or K1-57.
Continuity
Replace logics.
No continuity
Continuity
No continuity
55
No continuity
PROBLEM 8
Park brake switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Park brake switch defect; Logics defect.
CHECKS
Disconnect K1 connector. Release park brake lever.
Check continuity from K1-6 to K1-15.
Continuity
No continuity
Replace logics.
No continuity
No continuity
56
PROBLEM 9
Pedal brake switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Pedal brake switch defect; Logics defect.
CHECKS
Disconnect K1 connector. Push down the brake pedal.
Check continuity from K1-15 to K1-48.
Continuity
No continuity
Replace logics.
No continuity
No continuity
57
PROBLEM 10
Display=E1
The max speed of drive motor is reduced.
POSSIBLE CAUSE
Right drive inverter overtemperature.
Control board failed
CHECKS
Let the truck cool for 15 minutes.
Continuity
Normal
No
58
PROBLEM 11
Display=E2
The max speed of drive motor is reduced.
POSSIBLE CAUSE
Left drive module overtemperature.
Control board failed
CHECKS
Let the truck cool for 15 minutes.
Continuity
Normal
No
59
PROBLEM 12
Display=E3
The max speed of pump motor is reduced.
POSSIBLE CAUSE
Pump module overtemperature.
Control board failed
CHECKS
Let the truck cool for 15 minutes.
Continuity
Normal
No
60
PROBLEM 13
Display=E4
The max speed of drive motor is reduced.
POSSIBLE CAUSE
Right drive motor overtemperature.; Drive
motor thermal sensor defect;
Control board failed
CHECKS
Let the truck cool for 15 minutes.
Continuity
Normal
No
61
PROBLEM 14
Display=E5
The max speed of drive motor is reduced.
POSSIBLE CAUSE
Left drive motor overtemperature.; Drive
motor thermal sensor defect;
Control board failed
CHECKS
Let the truck cool for 15 minutes.
Continuity
Normal
No
62
PROBLEM 15
Display=E6
The max speed of drive motor is reduced.
POSSIBLE CAUSE
Right drive motor overtemperature.; Drive
motor thermal sensor defect;
Control board failed
CHECKS
Let the truck cool for 15 minutes.
Continuity
Normal
No
63
PROBLEM 16
Display=EL
The max speed and max torque of drive &
pump motor is reduced to minimum value.
POSSIBLE CAUSE
Battery discharged; Logic defect
CHECKS
Connect battery, turn on the key switch, close seat switch
And measure voltage from B+ to B- on controller.
Voltage must be greater than 34.5V at 36V system.
Voltage must be greater than 45V at 48V system.
Voltage OK
Voltage low
Check battery
connection ;
Charge or replace battery
Battery voltage
Replace logic
64
PROBLEM 17
Display=EE
No left truck operation
POSSIBLE CAUSE
Static Return to Off(SRO) circuit activated by
Improper operation sequence; Direction switch defect
Accelerator linkage not fully release.
Accelerator control defect; Logic defect.
CHECKS
Check SRO by release of accelerator, release park brake
Move the direction lever to neutral, reselect direction and
Press the accelerator.
No change
Check accelerator,
F/R switch.
If no faulty component is
found, replace logics.
65
PROBLEM 18
Display=EE(Flashing)
No left truck operation
POSSIBLE CAUSE
No operator in seat; Seat switch defect;
Open wire.
CHECKS
Disconnect K1 connector Check continuity from wire #7
to wire #15 .Should be closed circuit when seat is
pressed on and open circuit when seat release.
No continuity
Check OK
Replace logics
Continuity
No continuity
66
PROBLEM 19
Display=F
No lift truck operation
POSSIBLE CAUSE
Improper communication between DSP,
Logic board defect.
CHECKS
Install eye software; pedal, steering, lift resetting.
OK
If not ok
Normal operating.
67
PROBLEM 20
Display=F0,
Lift truck operation.
POSSIBLE CAUSE
Battery voltage exceeds 63V.
Failed logic
CHECKS
Disconnect battery, measure voltage at battery
connector terminal.
More than 63V
Not
Battery discharge
68
PROBLEM 21
Display=F1
Lift truck operation.
POSSIBLE CAUSE
Battery voltage is lower than 24V.
Failed logic
CHECKS
Disconnect battery, measure voltage at battery
connector terminal.
Lower than 24V
Not
Battery charge
69
PROBLEM 22
Display=F2
No lift truck operation.
POSSIBLE CAUSE
Accelerator sensor failure. Accelerator
connector disconnect. Failed logic.
CHECKS
Check Accelerator connector.
Connector
Disconnector
No continuity
70
Connect Accelerator
connector.
PROBLEM 23
Display=F3
No lift truck operation.
POSSIBLE CAUSE
Right drive inverter overcurrent.
(Actual current exceeds limit 340A)
Failed logic board or inverter.
CHECKS
Key switch off and on again.
Display=F3
0 ohm
0 ohm or open
71
PROBLEM 24
Display=F4
No lift truck operation.
POSSIBLE CAUSE
Left drive inverter overcurrent.
(Actual current exceeds limit 340A)
Failed logic board or inverter.
CHECKS
Key switch off and on again.
Display=F4
0 ohm
0 ohm or open
72
PROBLEM 25
Display=F5
No lift truck operation.
POSSIBLE CAUSE
Pump inverter overcurrent.
(Actual current exceeds limit 410A)
Failed logic board or inverter.
CHECKS
Key switch off and on again.
Display=F5
0 ohm
0 ohm or open
73
PROBLEM 26
Display=F6
No lift truck operation.
POSSIBLE CAUSE
Disconnect cable(CN1) from right inverter to
right drive motor; Right inverter defect.
Logic board defect.
CHECKS
Check the cable connecting from right invert to right drive motor.
Connection
Disconnection
Check current of right inverter when you turn on the lift truck.
(You can read temperature measures using COMPACT
display or EYE software.)
Zero current
74
PROBLEM 27
Display=F7
No lift truck operation.
POSSIBLE CAUSE
Disconnect cable(CN2) from left inverter to
Left drive motor; Left inverter defect.
Logic board defect.
CHECKS
Check the cable connecting from left inverter to left drive motor.
Connection
Disconnection
Check current of left inverter when you turn on the lift truck.
(You can read temperature measures using COMPACT
display or EYE software.)
Zero current
75
PROBLEM 28
Display=F8
No lift truck operation.
POSSIBLE CAUSE
Disconnect cable(CN4) from pump inverter to
Pump motor; Pump inverter defect;
Logic board defect.
CHECKS
Check the cable connecting from pump inverter to Pump motor.
Connection
Disconnection
Check current of pump inverter when you turn on the lift truck.
(You can read temperature measures using COMPACT
display or EYE software.)
Zero current
76
PROBLEM 29
Display=F9
The max speed of pump motor is reduced.
POSSIBLE CAUSE
Steering angle sensor fault.
Wiring defect.
CHECKS
Check continuity from K-11(12V) to pin3.; Check continuity from
K-15(Gnd) to pin1.; Check continuity from K-62(out) to pin2.
Check the housing.
No continuity
Continuity
77
PROBLEM 30
Display=FA
No lift truck operation.
POSSIBLE CAUSE
5V Encoder not ok.
Voltage of K1-14 terminal is lower than 4.3V
CHECKS
Measure voltage from K1-14 terminal of encoder to
K1-15(GND) terminal of encoder.
5 voltage
78
PROBLEM 31
Display=Fc
No lift truck operation.
POSSIBLE CAUSE
Right drive motor encoder defect.
An encoder channel is disconnected and
motor is working.
CHECKS
Check right drive motor encoder connection.
If correct
If not correct
If no correct
79
PROBLEM 32
Display=Fd
No lift truck operation.
POSSIBLE CAUSE
Left drive motor encoder fail.
An encoder channel is disconnected and
motor is working.
CHECKS
Check left drive motor encoder connection.
If correct
If not correct
If no correct
80
PROBLEM 33
Display=FH
Lift truck operation.
POSSIBLE CAUSE
12V output not ok.
Voltage of K1-11 terminal is lower than 10.5V.
CHECKS
Measure voltage from K1-11 to K1-15.
12 voltage
81
PROBLEM 34
Display=FL
No lift truck operation.
POSSIBLE CAUSE
Valve control card defect, Lift setting fault.
CHECKS
Key switch on. Seat switch on.
Measure voltage at K1-50
Over minimum setting voltage
No voltage
If not ok
If not ok
82
PROBLEM 35
Display=A
No lift truck operation
POSSIBLE CAUSE
Capacitor discharge; Main contactor fail,
Logic board fail
CHECKS
Key switch off and on again. Key switch off and
measure resistance of the main contactor.
About 85~90
Other resistance
No continuity
Normal
Open
83
PROBLEM 36
Display=60
Lift truck operation
POSSIBLE CAUSE
Battery miss matching;
Logic board fail
CHECKS
Check battery voltage at the each system.
(36V system must use 36V battery, 48V system must
use 48V battery)
OK
If not ok
Replace battery
84
PROBLEM 37
Display=77
Lift truck operation
POSSIBLE CAUSE
Thermal sensor wire of right drive motor open.
Logic board fail
CHECKS
Check continuity from K1-15 to thermal sensor pin1.
Check continuity from K1-58 to thermal sensor pin2.
Continuity
No continuity
85
PROBLEM 38
Display=78
Lift truck operation
POSSIBLE CAUSE
Thermal sensor wire of right drive motor open.
Logic board fail
CHECKS
Check continuity from K1-15 to thermal sensor pin1.
Check continuity from K1-59 to thermal sensor pin2.
Continuity
No continuity
86
PROBLEM 39
Display=79
Lift truck operation
POSSIBLE CAUSE
Thermal sensor wire of right drive motor open.
Logic board fail
CHECKS
Check continuity from K1-15 to thermal sensor pin1.
Check continuity from K1-60 to thermal sensor pin2.
Continuity
No continuity
87
PROBLEM 40
Display=80
Lift truck operation
POSSIBLE CAUSE
Wrong right drive inverter Thermal sensor.
Logic board fail
CHECKS
Check temperature of right drive power unit.
(You can read temperature measures using COMPACT
display or EYE software)
Normal
Abnormal
88
PROBLEM 41
Display=81
Lift truck operation
POSSIBLE CAUSE
Wrong left drive inverter thermal sensor
Logic board fail
CHECKS
Check temperature of left drive inverter.
(You can read temperature measures using COMPACT
display or EYE software)
Normal
Abnormal
89
PROBLEM 42
Display=82
Lift truck operation
POSSIBLE CAUSE
Wrong pump inverter thermal sensor
Logic board fail
CHECKS
Check temperature of pump inverter.
(You can read temperature measures using COMPACT
display or EYE software)
Normal
Abnormal
90
PROBLEM 43
Display=83
No lift truck operation
POSSIBLE CAUSE
Faulty eeprom or mismatching software release
Logic board fail
CHECKS
Restore eeprom with EYE application, Eye software install
Normal
Still problem
91
PROBLEM 44
Display=84
No lift truck operation
POSSIBLE CAUSE
CRC alarm
CHECKS
System turn off/on again.
Eye software reinstall.
Normal
Still problem
92
PROBLEM 45
Display does work normal
Lift truck operation abnormal.
POSSIBLE CAUSE
Encoder defect;
Logic board defect
CHECKS
RPM of defected motor is reducing and current of defected
motor is increasing.
(You can see diagnostic mode of display panel and eye
software.)
OK
If not ok
Replace encoder
93
Hydrometer
Test Equipment
Handheld Multimeter
There are various pieces of electric truck test
equipment that Daewoo recommends for all service
personnel. This equipment is available from a
number of world wide manufactures and local
electronic suppliers. Contact your Daewoo dealer or
the factory for further recommendations.
94
Lift Sensor
4
2
(2) Magnet.
(3) Screw.
NOTICE
Lift sensor may be damaged. Do not allow the
magnet (2) to make contact with the plastic
bracket when the lift lever is activated.
Parking Brake Switch Adjustment
(1) Switch. (2) Plate. (3) Bolts.
95
12. Put the lift truck back in the run mode so the
actual hydraulics can be tested.
14. Pull the lift lever back until the pump motor turns
on. The forks must not move. Adjust P1 so the
motor starts just before the valve opens.
If the valve opens before the motor turns on, adjust
P1 (1) clockwise.
If the motor turns on too far in advance of the valve
opening, adjust P1 (1) counterclockwise.
96
97
Instrument Panel
LCD Instrument panel shows information about
system main analogue and digital parameters,
as follows:
1.
2.
3.
4.
5.
6.
7.
8.
Truck speed
Park brake insertion
Steering angle
Seat switch closure
Maintenance period expiry
Low speed insertion
Battery charge level
Energetic operating mode
98
Instrument Panel
DISPLAY INDICATION
No segments
1 flashing segment
1 segment
2 segments
3 segments
4 segments
5 segments
6 segments
7 segments
8 segments
9 segments
BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery
BATTERY VOLTAGE
[V]
Voltage < 34.5 V
34.5 V ~ 35.1 V
35.1 V ~ 35.5 V
35.5 V ~ 35.9 V
35.9 V ~ 36.2 V
36.2 V ~ 36.5 V
36.5 V ~ 36.8 V
36.8 V ~ 37.1 V
37.1 V ~ 37.4 V
37.4 V ~ 37.6 V
Voltage > 37.6 V
BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery
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
SYSTEM IN USE
4 Wheels (BX)
3 Wheels (BT)
Table 6
OPERATINGMODE
L1 (Limit 1)
L2 (Limit 2)
L3 (Limit 3)
100
CODE
C0
C1
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
Notice:Alarm LED
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
is managed as follows:
101
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
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
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).
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.
102
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:
103
<48V>
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
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
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
digit
94
Slow speed
digit
95
British unit
digit
96
Display brightness
digit
97
E-S-H enable
digit
98
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
104
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
100
<36V>
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
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
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
digit
94
Slow speed
digit
95
British unit
digit
96
Display brightness
digit
97
E-S-H enable
digit
98
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
105
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
100
Default Setting
- Replacing Logic
- Updating flash memory(Update EEPROM) or
Resetting EEPROM
- Replacing or adjusting Sensor
- Default Setting
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]
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
Econom
ic Mode
106
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 :
107
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
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]
[V10]
[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]
109
110
To find further technical data and useful information about EYE software, refer its own user manual.
111
PC-Controller Communication
General Information
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Minimum Requirements
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1. 350MHz Pentium class or higher
microprocessor
2. 128Mb or greater of RAM
3. Serial port or USB port
Serial port
USB port
Recommanded Requirements
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1.
2.
3.
4.
5.
6.
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112
Installation
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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
113
Features
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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
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.
114
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.
115
Password Insertion
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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.
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116
WARNING
PANEL BLANK message is used to distinguish case of not programmed flash memory, so Flash menu is
obviously active.
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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)
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Fig.9: Submenu selection
117
Submenus
Print function is accessible from many of listed submenus: you can send active front panel image to printer or
save it on file; in that case destination directory is <EYE PATH>\EYE\ images.
BEWARE: if more than one window is in use, only the one relative to the inner submenu is active and all others
work in background.
If you select a non active window, you cant communicate\ interact with inverter panel.
118
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From setup menu (Fig.10) you can select communication serial port and image file format used by Print function.
119
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)
120
Pump
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Following items appear in Pump menu front panel:
1. Voltage on lift command circuit
2. Hydraulic lift circuit pressure
3. Pump motor current : you can select current phase from pop-up menu
4. Module temperature: you can select measure unit between C and F.
Temperature above 60C is signalled by a red colour; temperature above 90C 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
121
Battery
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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.
122
Timers
Following items appear in Timers menu front panel: total inverter working hours, drive motor and pump motor hour
meter.
123
Calibration
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For safety, you can access all calibration menus only in Supervisor mode and with park brake on.
A confirmation is asked to quit a calibration menu without saving changes.
You cant set a value out of fixed limits: the message OUT OF LIMIT signals a case like that.
By a pop-up menu, you can access following calibration functions:
1. Battery: Battery reset voltage calibration (Refer to page 125)
2. Timers: Timers calibration (Refer to page 126)
3. Steering: Steering sensor (Refer to page 127)
4. Pedal: Pedal accelerator calibration (Refer to page 128) (**)
5. Lift: Lift calibration (Refer to page 129)
6. ESH: E/S/H parameters calibration and limits (Refer to page 130)
7. Steering parameters: Steering parameters calibration (Refer to page 132)
8. Program service: Program service interval setting (Refer to page 133)
9. Drive motor: Drive motors parameters calibration (Refer to page 134)
10. Pump motor: Pump motors parameters calibration (Refer to page 135)
11. Critical height switches: Speed limits calibration in case of critical height (Refer to page 136)
12. Weight sensor: Weight sensor calibration (Refer to page 137) (*)
13. Cab lift: Cab lift speed calibration (Refer to page 138) (*)
14. Timer reset: Timers meters reset (Refer to page 139)
15. Truck setup: Some lift truck parameters setup (Refer to page 140) (*)
16. Backing mode: Slow mode calibration (Refer to page 141) (*)
17. Load eeprom default: EEPROM configuration (Refer to page 142)
18. Paramters image: Parameter store or Restore. (Refer to page 143)
(*): Optional menu
(**): Menu present in standard or optional version
124
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
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125
Timers calibration
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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
126
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.
127
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.
128
Lift calibration
There are following data about lift parameters: description, actual value, measure unit, default values, minimum
and maximum settable values.
Pressing SAVE button, selected parameter VALUE data field is updated with lift sensor actual voltage.
You can execute following operations:
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.
129
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.
130
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Fig.21: Parameters externally changed
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If PROGRAMMABLE WORKING section is enabled, pressing MODIFY LIMITS button you enter Fig. 22 window;
you can now modify per cent values for L1, L2 and L3 limits, remembering that every single data change require
to be confirmed.
In that menu front panel, there are data about L1, L2 and L3 parameters: description, measure unit, modifiable
values expressed in per cent, minimum and maximum settable values.
You can execute following operations:
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.
131
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
132
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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
133
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.
134
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
135
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
136
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
137
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
138
Timers reset
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.
139
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
140
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
141
142
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
143
Data Logging
With that menu (Fig. 36) you can save on file the values of a certain number of variables with a certain frequency;
the resulting file is logging.out, saved in <EYE PATH>\EYE\out directory.
144
145
Flash
To upgrade main controller software, with Flash menu (Fig. 36) follow these steps:
1. Disable all commands
2. Verify if C:\SOURCE_FILE directory exists (otherwise create it)
3. Source directory must contain only 2 source files
4. Select FLASH item from menu-bar
5. Give confirmation to start programming phase
6. In case of troubles with source files, (missing files, wrong version,...) there will be an error message and flash
memory will not programmed .
7. After a synchronization phase, flash programming will start; a bar gives the percent indication of already
programmed memory.
8. In case of problems with serial communication, there will be an error message and flash programming phase
will be stopped.
9. After traction micro successful programming, begins pump micro programming phase (step 7 and 8)
10. A message will signal the end of programming phase, and its result; give confirmation to exit the menu.
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
146
Flash Programmation
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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 DHIMs Homepage.
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
Serial Communication
Other Problems
147
No
Parameter
No
Parameter
Parameter Description
Deceleration
steering
ramp 1
Deceleration
steering
ramp 2
Battery reset
value
11
Seat switch
delay
12
Chat time
13
Hydro time
14
18
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
Unit
Mini
mum
Def
ault
Maxi
mum
Varia
tion
rpm/s
10
800
5000
10
rpm/s
10
V*10
464
470
501
10
10
20
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
10
mV
3,000
11,500
12,000
10
mV
1,000
12,000
10
mV
1,000
2,750
12,000
10
20
100
100
rpm
1,000
4,500
4,500
50
rpm
1,000
4,500
4,500
50
rpm
500
2,000
2,500
50
rpm
400
2,000
4,500
50
148
No
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
rpm
400
1,000
2,000
50
rpm/s
400
1,100
2,000
10
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
mm
300
451
600
rpm/s
10
50
500
10
20
100
100
10
65
100
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
rpm
500
700
1,500
50
rpm
500
500
4500
50
rpm
400
500
800
10
rpm
200
300
500
10
rpm/s
1,000
7,000
10,000
10
rpm
1000
7000
10000
10
digit
22
47
23
48
24
49
25
50
26
51
27
52
Creep speed
28
53
Diameter of
drive tyres
Partial
release ramp
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)
149
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
digit
Disable = 0
Enable = 1 (Default)
digit
10000
100
No
Parameter
No
Parameter
Parameter Description
Deceleration
steering
ramp 1
Deceleration
steering
ramp 2
Battery reset
value
11
Seat switch
delay
12
Chat time
13
Hydro time
14
18
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
Unit
Mini
mum
Def
ault
Maxi
mum
Vari
ation
rpm/s
10
800
5000
10
rpm/s
10
V*10
344
356
373
10
10
20
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
10
mV
3,000
11,500
12,000
10
mV
1,000
12,000
10
mV
1,000
2,750
12,000
10
20
100
100
rpm
1,000
3,800
3,800
50
rpm
1,000
3,800
3,800
50
rpm
500
2,000
2,500
50
rpm
400
2,000
3,800
50
151
No
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
rpm
400
1,000
2,000
50
rpm/s
400
1,100
2,000
10
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
mm
300
451
600
rpm/s
10
50
500
10
20
100
100
10
65
100
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
rpm
500
700
1,500
50
rpm
500
500
4500
50
rpm
400
500
800
10
rpm
200
300
500
10
rpm/s
1,000
7,000
10,000
10
rpm
1,000
7,000
10,000
10
digit
22
47
23
48
24
49
25
50
26
51
27
52
Creep speed
28
53
Diameter of
drive tyres
Partial
release ramp
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)
152
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
digit
Disable = 0
Enable = 1 (Default)
digit
10000
100
Error
Code
Description
F0
Maximum
battery
voltage
F1
Minimum
battery
voltage
F2
Pedal
trimmer fault
Eeprom
alarm
Pre -charge
capacitors
low voltage
alarm
(Capacitors
not
charged)
Level
Cause
Trohbleshooting
Voltage measured on
accelerator circuit exceeds
the value calculated
averaging calibration and
reachable voltages;
moreover, start switch
seems to be open.
154
EYE
Code
Error
Code
F3
24
F4
Description
right drive
motor power
module
pump motor
power
module
Level
Cause
Trohbleshooting
1
Actual current exceeds
limits 929 A
25
10
11
F5
left drive
motor power
module
Inverter
capacitors
pre -charge
too fast
E3
Pump motor
inverter
overtemper
ature
Capacitors
too charged
on start
155
EYE
Code
12
13
14
Error
Code
EL
E4
E6
15
F6
16
F7
17
17
18
Description
Low battery
alarm
Drive motor
over
temperature
Pump motor
over
temperature
Motor
current
offset alarm
Motor
current
offset alarm
Main
breaker fault
Watchdog
timer alarm
Level
Cause
Trohbleshooting
Overcurrent on main
breaker coil.
Improper communication
between DSPs present on
logic, or/and defective
logic.
156
EYE
Code
19
20
21
22
Error
Code
E5
E1
E2
Description
Drive motor
over
temperature
Right drive
motor
inverter
overtemper
ature
Serial
communicat
ion alarm
Left drive
motor
inverter
overtemper
ature
Level
Cause
Trohbleshooting
Inverter temperature,
measured with a
connector, exceed 100 C,
or is inside [95 C,
100 C] range at least 30
s.
Error in serial
communication between
the two DSP; DSP present
on logic make a mutual
software control, to insure
fast diagnosis of such a
fault.
Inverter temperature,
measured with a connector,
exceed 100 C , or is inside
[95 C, 100 C] range at
least 30 s.
157
EYE
Code
Error
Code
Description
Level
Cause
36
F8
Motor
current
offset alarm
37
FA
Alarm on 5
V encoder
voltage
38
FH
Alarm on 12
V output
voltage
FL
Pump motor
commands
active on
start
50
63
EE
(flash)
Seat switch
open on
start
Trohbleshooting
64
EE
Wrong start
74
Fc
Encoder
alarm
An encoder channel is
disconnected, and motor
is working.
75
Fd
Encoder
alarm
An encoder channel is
disconnected, and motor
is working.
158
EYE
Code
77
77
78
78
79
79
80
80
81
81
82
82
Description
Alarm of
right drive
motor
thermal
connector
Alarm of left
drive motor
thermal
connector
Alarm of
pump motor
thermal
connector
Alarm of
right drive
motor
module
connector
Alarm of left
drive motor
module
connector
Alarm of
pump motor
module
connector
Level
Cause
Trohbleshooting
Temperature difference
between any two of the 3
motors results greater
than 70 C.
Temperature difference
between any two of the 3
inverters results greater
than 70 C.
83
83
CRC fault
alarm
Faulty eeprom or
mismatching software
release.
84
84
Bank CRC
restored
91
98
99
Error
Code
F9
Steering
sensor
alarm
Capacitors
pre -charge
too slow
Capacitors
pre-charge
too slow
Pre-charge capacitors
voltage does not reach the
rated battery voltage
within a limit time, when
you turn on the system.
159
[Description]
Main breaker fault
Battery/inverter mismatch
Pump motor Encoder
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
Seat switch
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
Steer sensor fault
5V encoders not ok
Drive right motor Encoder
Drive left motor Encoder
24V out
12V out not ok
Pump input on at the start
160
[Contraction]
CONTACTOR FAULT
BATT MISMATCH
P-MOTOR ENCODER
R-M TEMP SENSOR
L-M TEMP SENSOR
P-M TEMP SENSOR
R-INV T SENSOR
L-INV T SENSOR
P-INV T SENSOR
CRC FAULT
CRC RESTORED
FAST CHARGE
TOO CHARGED
CAP SLOW CHARGE
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 SW OPEN
LOW BATT VOLT
EEPROM FAULT
WD TIMER FAULT
COMM FAULT
MAX BATT VOLT
MIN BATT VOLT
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
PUMP SIGN ON
2. Calibration Code
[Display Code]
5
6
9
10
11
12
13
14
17
18
19
20
23
24
26
32
33
34
41
42
43
44
45
46
47
48
49
50
51
52
53
59
61
62
63
64
65
66
67
68
69
70
71
72
73
93
94
95
96
97
98
99
[Description]
Deceleration steering ramp 1
Deceleration steering ramp 2
Battery reset value
First parameter for calibration enable
Seat switch delay
Chat time
Hydro time
Maintenance time inserting enable
Second parameter for calibration enable
Steering sensor value : wheels turned on the right
Steering sensor value : wheels turned on the left
Steering sensor value : wheels on straight position
Accelerator pedal minimum value
Accelerator pedal maximum value
Stop on slop timer
Lift sensor maximum value
Lift sensor minimum value
Lift sensor middle value
Drive maximum current
Forward maximum speed
Reverse maximum speed
Drive limitation max speed
Critical weight drive max speed
Critical height drive max speed
Steer limitation drive max speed
Drive acceleration ramp
Drive inversion ramp
Drive release ramp
Pedal brake ramp
Creep speed
Diameter of drive tyres
Partial release ramp
Lift max current
Auxiliary max current
Lift max speed
Tilt speed
Auxiliary 1 function speed
Auxiliary 2 function speed
Auxiliary 3 function speed
Lift min speed
Pump max speed in limiting
Hydro speed
Hydro idle speed
Pump acceleration ramp
Pump deceleration ramp
Power mode (E-S-H, limitations)
Power mode
Slow speed
British unit
Display brightness
Time meter / Odometer on display
Maintenance time
161
[Contraction]
STEERING DECEL1
STEERING DECEL2
BATT RESET VALUE
1ST PASSWARD
SEAT SW DELAY
CHAT TIME
HYDRO TIME
SERVICE TIME ON
2ND PASSWARD
WHEEL TURN RIGHT
WHEEL TURN LEFT
WHEEL STRAIGHT
ACCEL MIN VALUE
ACCEL MAX VALUE
SLOP TIMER
LIFT MAX VALUE
LIFT MIN VALUE
LIFT START VALUE
DRIVE MAX I
FWD MAX SPEED
REV MAX SPEED
D LIMIT MAX SPD
WEIGHT LIMIT SPD
HEIGHT LIMIT SPD
STEER LIMIT SPD
D ACCEL RAMP
D INVERSION RAMP
D RELEASE RAMP
PEDAL BRAKE RAMP
CREEP SPEED
TIRES DIA
PARTIAL RELEASE
LIFT MAX I
AUX MAX I
LIFT MAX SPEED
TILT SPEED
AUX 1 SPEED
AUX 2 SPEED
AUX 3 SPEED
LIFT MIN SPEED
PUMP LIMIT MAX
HYDRO SPEED
IDLE SPEED
PUMP ACCEL RAMP
PUMP DECEL RAMP
USER MODE
E-S-H
CREEP SPEED
BRITISH UNIT
LCD BRIGHTNESS
TIMER-ODOMETER
SERVICE PERIOD
3. Diagnostic Code
[Display Code]
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
[Description]
Right traction motor speed
Right traction motor speed reference
Left traction motor speed
Left traction motor speed reference
Lift lever 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
Right traction motor phase current
Right traction motor phase current
Left traction motor phase current
Left traction motor phase current
Left traction motor phase current
Pump motor phase current
Pump motor phase current
Pump motor phase current
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
Auxiliary 1 switch
Auxiliary 2 switch
High lift switch
Tilt switch
Main breaker command
5V out
12V out
24V out
Buzzer command
Fans command
162
[Contraction]
RIGHT MOTOR SPD
R-MOTOR REF SPD
LEFT MOTOR SPD
L-MOTOR REF SPD
LIFT SENSOR OUT
BATT VOLTAGE
R-INVERTER TEMP
P-INVERTER TEMP
PUMP MOTOR SPD
P-MOTOR REF SPD
ACCEL 1ST OUT
ACCEL 2ND OUT
STEER SENSOR OUT
L-INVERTER TEMP
R-MOTOR I-U
R-MOTOR I-V
R-MOTOR I-W
L-MOTOR I-U
L-MOTOR I-V
L-MOTOR I-W
P-MOTOR I-U
P-MOTOR I-V
P-MOTOR I-W
R-MOTOR TEMP
L-MOTOR TEMP
P-MOTOR TEMP
SEAT H METER
DRIVE H METER
PUMP H METER
SEAT SWITCH
PARK SWITCH
SRART SWITCH
REV SELECT SW
FWD SELECT SW
PEDAL BRAKE SW
3 OR 4 WHEEL
AUX 1 OUTPUT
AUX 2 OUTPUT
HIGH LIFT SWITCH
TILT SWITCH OUT
CONTACTOR
5V OUT
12V OUT
24V OUT
BUZZER
FAN
SB4185E00
Feb. 2005
Specifications
Systems Operation
Testing & Adjusting
Disassembly & Assembly
Lift Trucks Power Train
B15T-5, B18T-5, B20T-5 (AC 36V)
B15T-5, B18T-5, B20T-5 (AC 48V)
B15T-5, B18T-5, B20T-5 (SE 48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
B16X-5, B18X-5, B20X-5 (SE 48V)
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as
shown below.
WARNING
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most
current information available.
Index
Specifications
Brake ......................................................................12
Drive Motor............................................................... 7
Final Drive ................................................................ 9
General Tightening Torques ..................................... 5
Motor and Transmission ..........................................11
Wheel Mounting ......................................................10
Systems Operation
Drive Motor ..............................................................14
Final Drive ...............................................................16
General Information.................................................13
Power Train
Index
Specifications
General Tightening Torques
General tightening torque
for bolts, nuts and taperlock studs
The following charts give the
standard torque values for bolts,
nuts and taperlock studs of SAE
Grade 5 or better quality.
Exceptions are given in other
sections of the Service Manual
where needed.
thread
size
inches
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
standard thread
taperlock stud
standard torque
lbIft
9L3
18 L 5
32 L 5
50 L 10
75 L 10
110 L 15
150 L 20
265 L 35
420 L 60
640 L 80
800 L 100
1000 L 120
1200 L 150
1500 L 200
NIm*
12 L 4
25 L 7
45 L 7
70 L 15
100 L 15
150 L 20
200 L 25
360 L 50
570 L 80
875 L 100
1100 L 150
1350 L 175
1600 L 200
2000 L 275
5/16
3/8
7/16
1/2
5/8
13 L 2
24 L 2
39 L 2
60 L 3
118 L 4
20 L 3
35 L 3
50 L 3
80 L 4
160 L 6
1
5
3
7
1
9
5
3
7
5L2
10 L 3
20 L 3
30 L 5
40 L 5
60 L 10
75 L 10
110 L 15
170 L 20
260 L 30
320 L 30
400 L 40
480 L 40
550 L 50
7L3
15 L 5
30 L 5
40 L 10
55 L 10
80 L 15
100 L 15
150 L 20
230 L 30
350 L 40
400 L 40
550 L 50
650 L 50
750 L 70
1
1-1/8
1-1/4
1-3/8
1-1/2
*1 newton meter(NIm) is approximately the same as 0.1 mkg.
Power Train
Specifications
Metric fasteners
metric ISO thread
thread
size
(mm)
(NIm)*
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
12 L4
25 L7
55 L10
95 L15
150 L20
220 L30
325 L50
450 L70
600 L90
775 L100
1150 L150
1610 L200
2000 L275
2700 L400
torque
(lbIft)
9 L3
18 L5
40 L7
70 L10
110 L15
160 L20
240 L35
330 L50
440 L65
570 L75
840 L110
1175 L150
1450 L200
2000 L300
clamp
width
(NIm)*
7.5 L0.5
(lbIft)
65 L5
4.5 L0.5
0.9 L0.2
40 L5
8 L2
reassembly or
retightening torque
(NIm)*
4.5 L0.5
3.0 L0.5
0.7 L0.2
(lbIft)
40 L5
2 L5
6 L2
Power Train
Specifications
Drive Motor
(AC)
Thermal switch
Warning temperature .......... 155 L 4C (311 L 10F)
Power Train
Specifications
(SE)
Drive Motor
1
New Brush
Thickness B Width B Length
Minimum
Brush Length*
12.5 mm B 32 mm B 35 mm
(.49 in. B 1.25 in. B 1.37 in.)
18 mm
(.70 in.)
New Commutator
Diameter
Minimum
Commutator Diameter**
80 mm
(3.14 in.)
78 mm
(3.07 in.)
Thermal switch
Opening temperature.......... 155 L 4C (311 L 10F)
Power Train
Specifications
Final Drive
5
11
10
E E
(1) Nut. (2) Flat head bolt. (3) Socket head loolt. (4) Socket head bolt. (5) Socket head bolt. (6) Air breather.
(7) Socket head bolt. (8) Plug-oil level. (9) Plug. (10) Drain plug. (11) Socket head bolt.
Power Train
Specifications
Wheel Mounting
2
1
IOPS002I
(1) Nut. (2) Bolt.
Power Train
10
Specifications
IOPS003I
(1) Socket head bolt
Power Train
11
Specifications
Brake
Actuating stroke for the hand brake cable
a. in the operating condition
b. limit of wear
mm
(1) Bleeder port. (2) Brake line (hydraulic line). (3) Brake cable. (a) In the operating condition. (b) Limit of wear.
Power Train
12
Specifications
Systems Operation
General Information
IOPS005S
Power Flow
(1) Final drive. (2) Drive motor.
Power Train
13
Systems Operation
Drive Motor
(AC)
Power Train
14
Systems Operation
(SE)
1
4
10
Drive Motor
(1) Input gear. (2) Brush cover. (3) Thermal switch (thermostat). (4) Commutator. (5) Armature. (6) Field coils.
(7) Frame. (8) Brush holder. (9) Fan. (10) Bearing.
Power Train
15
Systems Operation
Final Drive
11
12
2
3
10
10
13
15
E E
14
(1) Pinion gear. (2) Helical gear. (3) Friction disc carrier. (4) Steel ball. (5) Lever plate. (6) Ring gear. (7) Planetary gear.
(8) Drive shaft. (9) Planetary carrier. (10) Brake cylinder. (11) Transmission housing. (12) Air breather. (13) Piston rod.
(14) Drain plug. (15) Friction and steel plate.
Power Train
16
Systems Operation
WARNING
If an electrical failure or an overload of the motor is
present, personnel must not breathe the toxic fumes
which are a product of the burnt insulation. All power
must be disconnected from the motor before any
inspection is made to find the failure. The area around
the motor must be well ventilated (air flow) and the
motor is to be cooled before any repair work is done.
Water must not be used on any electrical equipment
because of the danger of electric shock. If a fire is
present, disconnect the electrical power and use a
carbon dioxide extinguisher to put the flame out.
Troubleshooting
Visual Checks
Make a visual inspection of the truck to check for
problems. Operate the truck in each direction.
Make a note of the noises that are not normal and
find their source. If the operation is not correct, make
reference to the Check List During Operation for
"Problems" and "Probable Causes".
<AC>
WARNING
NOTICE
To prevent damage to electrical components, make
sure the air line is equipped with a water filter when
they are cleaned with air.
Power Train
17
Probable Cause :
1. Brakes have a defect, cause a resistance(lack of
free movement). Heat increases, which causes the
motor to stall :
Check the brake adjustment according to the
procedures in Testing And Adjusting in the
Vehicle Systems module.
Power Train
18
Probable Cause :
Probable Cause:
3. Dirty motor :
Remove metallic or carbon dust with air
pressure.
4. Wet motor :
To dry the motor, heat it to 90C (194F).
Power Train
19
<SE>
Problem 1 : Drive Motor Will Not Operate.
probable Cause :
1. Switch not closed (battery connector, key switch,
seat switch, direction switch or parking brake
switch) :
Close the switch. If it still does not operate test
for power to the control panel and power flow
through each switch with a voltmeter.
But the service brake switch should be opened.
Power Train
20
Probable Cause :
Probable Cause :
1. Worn brushes:
Replace the brushes. See New Brush Installation
And Brush Inspection in Testing And Adjusting.
NOTICE
Too heavy a load can stall the motor, and result in a
failure to the drive motor.
Power Train
21
Probable Cause :
3. Dirty motor :
Remove metallic or carbon dust with air
pressure.
4. Wet motor :
To dry the motor, heat it to 90C (194F).
Problem 6 : Commutator surface has grooves or
abnormal wear.
Probable Cause :
1. Brushes are worn too low, brush wires caused
arcing on the commutator :
Replace the brushes. See Brush Inspection in
Testing And Adjusting and the method to make
the Brush Life Estimate in Testing And Adjusting.
22
Probable Cause:
Probable Cause:
1. Motor brushes not located in the correct electrical
position (brush neutral settings) :
If the holes in the brush holder are not extended,
make them longer so that brush holder can have
a little rotation. When the holder is in the correct
position, lift truck speed will be the same in both
directions.
Transmission
Probable Cause :
Probable cause :
1. Lock nut loosening :
Check if lock nut and socket head bolt for
stopping lock nut are loosened. Tighten lock nut
and socket head bolt with Loctite No.277.
Probable cause :
23
Probable cause :
Probable cause :
Probable cause :
Probable cause :
Probable cause :
1. Transmission oil level is either too high or too low :
Check oil level.
Power Train
24
Drive Motor
<AC>
Thermal Sensor Tests
Tools Needed
Digital Multimeter Or Equivalent
Power Train
25
Sensor Bearing
Power Train
26
<SE>
Motor Brushes
Brush Inspection
1. Measure the radial length of brush.
1
P0004332
Install Brushes
(1) Brushes.
NOTICE
Installation of the wrong brushes can cause early
motor failure. Always make sure the correct DAEWOO
brushes are installed.
P0004329
Brush Measurement
P0004331
Install Springs
(2) Spring.
Power Train
27
WARNING
NOTICE
Never use air pressure that is more than 205 kPa (30
psi). Make sure the line is equipped with a water filter.
P0004333
Brush Seating
(3) ZLX 0036 Brush seater stone.
NOTICE
Do not let stone(3) stay in contact with the commutator
bar too long. This causes more wear than is necessary
to the brushes and the commutator.
Power Train
28
Ground Test
Armature Tests
Tools Needed
Growler Tester
P0004320
Ground Test.
P0004322
NOTICE
Never use air pressure that is more than 205 kPa (30
psi). Make sure the air line has a water filter.
Power Train
29
P0004321
Open Circuit Test
(1) Armature. (A) Multimeter.
Power Train
30
Commutator Inspection
Surfaces of Commutators that need Replacement
IHPS010P
Grooves on the Commutator Surface
IHPS008P
IHPS011P
Copper Drag on the Commutator Surface
IHPS009P
Threads on the Commutator Surface
Power Train
31
Ground Test
P0004328
Ground Test
(1) Field Terminal. (2) Motor housing.
IHPS012P
Pitch BarMarks on the Commutator Surface
A
1
P0004327
Open Circuit Test
Power Train
32
A
1
EX00005
Brush Test
(1) Test lead.
P0004319
Brush Holder Test
(1) Brush holder. (2) End bell. (A) Multimeter.
Ground Test
EX00006
Ground Test
(1) Armature terminal. (2) Motor housing.
Power Train
33
A
1
P0004325
Open Circuit Test
Ground Test
P0004326
Ground Test
Power Train
34
3
2
IOPS003I
(1) Socket head bolt. (2) Drive motor. (3) Transmission
Power Train
35
Brake
Actuating stroke for the hand brake cable
a. in the operating condition
b. limit of wear
Approx. 0.5L
1 0.35L
2
3
1
IOPS006I
14mm
a(3~5mm)
b(8mm)
(1) Air breather. (2) Sealing washer. (3) Oil level plug.
Power Train
36
Drive Axle
Disassemble Drive Axle
Tools Needed
A B
Bearing Puller
1
6
Start By :
5
IOPD001P
IOPD005P
10
2
3
IOPD002P
10
IOPD006P
IOPD003P
Power Train
37
18
IOPD007P
16
IOPD010P
17
12
15
18
19
13
IOPD008P
12
13
14
14
15
19
IOPD009P
IOPD012P
20
17
18
Power Train
20
IOPD011P
38
21
22
23
IOPD013P
IOPD017P
23
22
26
26
23
21
IOPD014P
IOPD018P
9. Remove three flat head bolts (21), end plat (22) and
three guide washers (23) from housing cover (6).
24
25
26
27
6
6
IOPD015P
IOPD019P
25
24
IOPD016P
26
IOPD020P
Power Train
29
28
27
41
40
30
31
IOPD021P
IOPD024P
15. Remove five steel balls (40) and ball bearing (41)
from housing cover (6).
30
42
43
31
IOPD022P
IOPD025P
31
32
42
29
38
44
33
34
IOPD023P
35
36
37
39
14. Remove pin (32) and split pin (33) from lever
hook (31). Remove wear rings (34), (39), backup
rings (35), (38) and quad rings (36), (37) from
piston rod (29).
Power Train
IOPD026P
40
49
44
45
IOPD027P
52
IOPD030P
50
46
50
47
51
IOPD031P
IOPD028P
48
47
53
46
52
IOPD029P
IOPD032P
Power Train
41
55
52
53
61
60
54
IOPD059P
IOPD035P
63
62
61
56
IOPD033P
IOPD036P
63
62
59
58
57
IOPD037P
61
Power Train
42
Tools Needed
65
67
68
64
IOPD038P
1
1
1
66
IOPD039P
WARNING
Power Train
43
58
65
67
66
59
57
IOPD039P
54
55
52
53
9
IOPD040P
P0004209
IOPD038P
64
68
Power Train
44
50
54
56
IOPD041P
52
51
IOPD043S
IOPD042P
52
Example:
B = 2.58 mm measured at carrier and drive shaft
C = 2.05 mm measured at nut
D = 2.58 - 2.05 - (0 ~ 0.05) = 0.48 0 ~ 0.53 (mm)
Then 0.5 mm thickness of shim pack can be applied.
NOTE: Before determination of the shim pack
thickness, to locate the taper roller bearing of drive
shaft assembly in proper location, tighten the nut (50)
to a torque of 80~110 NIm (59~81 lbIft) with rotating
drive shaft assembly by hand.
Power Train
45
50
IOPD044P
50
52
52
IOPD044P
60
61
62
54
IOPD036P
IOPD045P
62
58
IOPD033P
Power Train
46
49
44
45
IOPD030P
52
50
IOPD027P
42
43
48
IOPD025P
47
46
IOPD029P
46
47
IOPD046P
IOPD028P
Power Train
47
31
32
30
29
38
31
33
34
IOPD023P
35
36
37
39
IOPD022P
22. Assemble pin (32) and split pin (33) into lever
hook (31).
Split pin (33) should be bent enough not to be
removed.
23. Assemble quad rings (36), (37), backup rings
(35), (38) and wear rings (34), (39) into piston rod
(29).
33
30
6
31
IOPD021P
41
40
IOPD024P
29
Power Train
48
25
24
IOPD020P
28
29
27
26
IOPD016P
24
25
26
27
IOPD019P
IOPD015P
30. Install five firiction discs (25) and four steel plate
(26) one by one as shown. Install three springs
(24).
23
26
23
IOPD017P
IOPD048P
Power Train
49
19
21
22
IOPD049P
IOPD012P
20
18
17
17
18
22
22
19
20
IOPD011P
66
34. Assemble sun gear (19), snap ring (18) and snap
ring (17) into helical gear (20). Make the opening
directions of two snap rings opposite.
IOPD050I
IOPD051P
Power Train
50
13
IOPD052P
IOPD004P
2
3
IOPD002P
IOPD005P
12
IOPD008P
41. Install washer (4) and air breather (3) and tighten
air breather to a torque of 70 L 10 NIm (52 L 7
lbIft).
15
13
14
Power Train
51
IOPD001P
Power Train
52
Tool Name
Nut Installer
Illustration
Remark
DAEWOO Tool
No: T126
IOPD053I
DAEWOO Tool
2
No: T127
Bearing Installer
IOPD054I
DAEWOO Tool
3
No: T128
IOPD055I
DAEWOO Tool
4
No: T129
IOPD056I
Power Train
53
Ref. No
Tool Name
Illustration
Remark
DAEWOO Tool
No: T130
IOPD057I
DAEWOO Tool
No: T131
IOPD058I
Power Train
54
SB4186E00
Feb. 2005
Specifications
Systems Operation
Testing & Adjusting
Lift Trucks Vehicle Systems
B15T-5, B18T-5, B20T-5(AC 36V)
B15T-5, B18T-5, B20T-5(AC 48V)
B15T-5, B18T-5, B20T-5(SE 48V)
B16X-5, B18X-5, B20X-5(AC 48V)
B16X-5, B18X-5, B20X-5(SE 48V)
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as
shown below.
WARNING
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most
current information available.
Vehicle Systems
Specifications
Index
Specifications
Priority Valve............................................................10
Sideshift Cylinder.......................................................6
Steering Gear...........................................................11
Steering Wheel ........................................................10
Hydraulic System.....................................................43
Lift Cylinders Air Removal ..................................44
Relief Valve Pressure Check ..............................43
Systems Operation
Troubleshooting .......................................................31
Brake System .....................................................36
Electric Motors ....................................................37
Hydraulic System And Mast ..............................31
Steering System .................................................35
Visual Checks .....................................................31
Vehicle Systems
Index
Specifications
Hydraulic Control Valve
3
2
IHCS101S
AC Type
36 [V]
48 [V]
SE Type
48 [V]
B16X-5, B15T-5
Min. 400 [A] Min. 350 [A] Min. 330 [A]
B18X-5, B18T-5
Max. 420 [A] Max. 370 [A] Max. 350 [A]
B20X-5, B20T-5
L 35 psi
19,800
2,880
19,800
2,880
21,550
3,125
L 350 kPa
L 35 psi
14,000
2,025
Vehicle Systems
Specifications
Hydraulic Pump
Sideshift Cylinder
EHCS002B
EHCS003B
Displacement : 16 cc/rev
Vehicle Systems
Specifications
Lift Cylinders
Full Free Triple Lift and
Full Free Lift Primary
Standard
1
1
Vehicle Systems
Specifications
1
2
Vehicle Systems
Specifications
Tilt Cylinder
Z
X-closed, Y-open
EHCS008B
Cyl. Closed X
Cyl. Open Y
Stroke Z
Forward
Backward
mm
in
mm
in
mm
in
A155319
382
15.0
463
18.2
81
3.2
A155008
396
15.6
463
18.2
67
2.6
A155009
409
16.1
463
18.2
54
2.1
Vehicle Systems
Specifications
Steering Wheel
Priority Valve
EHCS017
Vehicle Systems
10
Specifications
Steering Gear
2
3
VIEW C-C
TIGHTENING SEQUENCE
FOR BOLTS
VIEW B-B
C
5
B
B
C
EHCS018B
Vehicle Systems
11
Specifications
1
2
3
4
5
EHCS015B
Vehicle Systems
12
Specifications
Thermal switch
Warning temperature ..........155 L 4C (311 L 10F)
Vehicle Systems
13
Specifications
(SE)
2
1
EHCS020B
New Brush
Minimum
Minimum
Brush Length *
Commutator Diameter**
12.5 mm B 32 mm B 35 mm
18 mm
78 mm
(.70 in)
(3.07 in)
Vehicle Systems
14
Specifications
Systems Operation
Hydraulic System
IHCS102I
Basic Hydraulic Schematic With Standard Lift
(1) Lift cylinders. (2) Excess flow protector. (3) Sideshift cylinder(option). (4) Flow regulator.
(5) Hydraulic control valve. (6) Tilt cylinders. (7) Relief valve (lift and tilt). (8) Relief valve (sideshift).
(9) Hydraulic oil filter. (10) Hydraulic oil tank. (11) Priority valve. (12) Oil line.
(13) Hydraulic pump. (14) Oil line to steering unit. (15) Oil line.
Vehicle Systems
15
Systems Operation
IHCS103I
Basic Hydraulic Schematic With Full Free Lift Or Full Free Triple Lift
(1) Lift cylinders. (2) Excess flow protector. (3) Sideshift cylinder(option). (4) Flow regulator.
(5) Hydraulic control valve. (6) Tilt cylinders. (7) Relief valve (lift and tilt). (8) Relief valve (sideshift).
(9) Hydraulic oil filter. (10) Hydraulic oil tank. (11) Priority valve. (12) Oil line. (13) Hydraulic pump.
(14) Oil line to steering unit. (15) Oil line. (16) Excess flow protector. (17) Lift cylinder(primary).
Vehicle Systems
16
Systems Operation
Control Valve
Lift Valve Neutral Position
6
7
10
8
ICCS009S
Control Valve for Lift (Shown In NEUTRAL Position)
(1) Spool. (2) Outlet To Head End Of Lift Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring.
Vehicle Systems
17
Systems Operation
Lift Position
6
7
10
8
ICCS010S
Control Valve for Lift (Shown In LIFT Position)
(1) Spool. (2) Outlet To Head End Of Lift Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring.
Vehicle Systems
18
Systems Operation
6
7
10
8
ICCS011S
Control Valve For Lift (Shown In LOWER Postion)
(1) Spool. (2) Outlet To H ead End Of Lift Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Passage For Return Oil. (8) Passage. (9) Chamber. (10) Spring.
Vehicle Systems
19
Systems Operation
13
9
10
14
16
15
11
12
ICCS012S
Tilt Spool In Neutral Position
(1) Spool. (2) Outlet To Rod End Of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil. (6) Chamber.
(7) Outlet To Head End of Tilt Cylinders. (8) Passage For Return Oil. (9) Spring. (10) Spool. (11) Passage. (12) Chamber. (13) Spring.
(14) Orifice. (15) Orifice. (16) Passage.
Oil from lift valve goes to both chamber (6) and (12).
Since spool (1) is in the NEUTRAL position, the only
path the oil can take is from chamber (12) to tank
through passage (11).
The mast can be stopped and held in any position
when the tilt control valve is in neutral. This is
because the flow to and from the tilt cylinders is
stopped by spool (1). In the NEUTRAL position, oil
can not flow from passage (4) to outlet (2) or (7).
Vehicle Systems
20
Systems Operation
13
9
14
10
16
15
11
12
ICCS013S
Tilt Spool In Forward Position
(1) Spool. (2) Outlet to Rod End Of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Outlet To Head End Of Tilt Cylinders. (8) Passage For Return Oil. (9) Spring. (10) Spool. (11) Passage.
(12) Chamber. (13) Spring. (14) Orifice. (15) Orifice. (16) Passage.
Vehicle Systems
21
Systems Operation
13
9
10
14
16
15
11
12
ICCS014S
Tilt Spool In Tilt Back Position
(1) Spool. (2) Outlet To Rod End Of Tilt Cylinders. (3) Load Check Valve. (4) Passage. (5) Inlet Passage For Pump Oil.
(6) Chamber. (7) Outlet To Head End Of Tilt Cylinders. (8) Passage For Return Oil. (9) Spring. (10) Spool. (11) Passage.
(12) Chamber. (13) Spring. (14) Orifice. (15) Orifice. (16) Passage.
Vehicle Systems
22
Systems Operation
Relief Valve
13
14
12
11
IHCS104S
Relief Valve
(7) Passage for return oil. (11) Piston. (12) Dump valve.
(13) Spring chamber. (14) Pilot valve.
Vehicle Systems
23
Systems Operation
Steering System
Hydraulic Operation (Load Sensing Closed Center Steering System)
5
2
T
P
R
LS
13
10
11
12
IBCS036B
Steering System Schematic
(1) Steering Unit. (2) Hose (to hydraulic tank). (3) Priority Valve. (4) Hose (from hydraulic pump). (5) Hose (to control valve).
(6) Hose. (7) Hose. (8) Steering Axle. (9) Check Valve (in steer gear). (10) Hose (from priority valve). (11) Hydraulic Pump.
(12) Hydraulic Tank. (13) Hose (load sensing).
24
Systems Operation
Oil Flow
A
4
PUMP OIL
METERED OIL
RETURN OIL
3 10
11 5
14
15 16
6 7
1
8
9 10 11
IBCS037B
13
9 2
Steering Unit
A. Control valve section. B. Metering section.
(1) Spool. (2) Sleeve. (3) Outlet to tank. (4) Check valve.
(5) Inlet from pump. (6) Rotor. (7) Stator.
(8) Centering springs. (9) Pin. (10) Left turn port.
(11) Right turn port. (12) Body. (13) Drive.
17
IBCS038B
Steering Unit (Shown in RIGHT TURN Position)
(1) Spool. (2) Sleeve. (3) Outlet to tank.
(5) Inlet from pump. (8) Centering springs. (9) Pin.
(10) Left turn port. (11) Right turn port. (13) Drive.
(14) Passage. (15) Passage. (16) Gerotor. (17) Passage.
Vehicle Systems
4 13
12
25
Systems Operation
PUMP OIL
METERED OIL
RETURN OIL
10 11
5
14
15
16
21
18
2
18
19
20
19
9
17
IBCS040B
LEFT TURN
IBCS039B
Vehicle Systems
26
Systems Operation
7
3 10 11
15 16
17
13
EHCS036B
EMERGENCY
EHCS035B
Steering Unit (Shown in Manually Operated Right Turn
Position)
(3) Outlet to tank. (4) Ball check. (10) Left turn port.
(11) Right turn port. (15) Passage. (16) Gerotor.
(17) Passage.
Vehicle Systems
27
Systems Operation
Brake System
1
Master Cylinder
IHCS112P
(1) Master Cylinder Reservoir
5
3
IOCS009I
(3) Brake Cylinder. (4) Piston Rod. (5) Lever Plate.
Vehicle Systems
28
Systems Operation
Electric Motors
Hydraulic Pump Motor
(AC)
Vehicle Systems
29
Systems Operation
(SE)
EHCS039B
Electric Motor
(1) Brush cover. (2) Thermal switch. (3) Motor frame. (4) Brush. (5) Commutator. (6) Armature. (7) Fleld coil. (8) Fan.
Vehicle Systems
30
Systems Operation
Troubleshooting
4. Check all the lift chains and the mast and carriage
welds for wear or damage.
WARNING
1. The pressure of the oil required to open the relief
valve. Relief valve pressures that are too low will
cause a decrease in the lift and the tilt
characteristics of the lift truck. Pressures that are
too high will cause a decrease in the life of hoses
and components.
Performance Test
Visual Checks
Lift, lower, tilt forward and tilt back the forks several
times.
31
Vehicle Systems
32
Probable Cause :
Hydraulic Pump
Probable : Cause :
1. The oil level is low.
5. Oil is dirty.
6. Air leaks into the inlet line.
Vehicle Systems
33
Probable Cause :
Probable Cause :
4. Seal cut on shoulder of pump or keyway during
installation.
Probable Cause :
Problem : The load lowers when the lift spool is
moved from the NEUTRAL position to the RAISE
position.
Probable Cause :
3. There is air leakage in the pump inlet line.
1. There is foreign material in the check valve area.
a. Loose bolts.
b. Defects in suction line.
34
Probable Cause :
1. The springs are broken.
1. The wiper rings show wear and do not remove dirt
and foreign material.
Steering System
Probable Cause :
1. Priority valve (if equipped) releases pressure oil at
a low setting
Probable Cause :
Probable Cause :
Probable Cause :
Probable Cause :
Probable Cause :
Probalble Cause :
1. The cylinder are not in correct alignment.
2. Oil is dirty.
Vehicle Systems
35
Probable Cause :
Probable Cause :
Brake System
Probable Cause :
Probable Cause :
Probable Cause :
Vehicle Systems
36
Parking Brakes
Probable Cause :
Probable Cause :
Electric Motors
Probable Cause :
WARNING
NOTICE
Never use air pressure that is more than 30 psi(205
kPa) and make sure the air line is equipped with a
water filter.
Vehicle Systems
37
(AC)
Problem 1 : Hydraulic pump motor will not
operate.
Probable Cause :
Vehicle Systems
38
Vehicle Systems
39
(SE)
Problem 1 : Hydraulic pump motor will not
operate.
Probable Cause :
1. Bad connections or fuses.
Check battery connections.
Check the key fuse and power steering fuse.
Check the hydraulic pump motor for possible
reasons for a bad fuse.
Some causes are:
a) Operation with too high hydraulic pressures.
b) Operation with too much current draw.
c) Possible short circuit in power unit(Module).
Vehicle Systems
40
41
Probable Cause :
1. Brushes are worn too low, brush wires caused
arcing on commutator.
Inspect the commutator for damage. If the arcing
caused light pitting on commutator, install new
brushes and seat the brushes with the Brush
Seater Stone which will also clean the
commutator surface.
Make another inspection, if there is still pitting,
commutator surface must be machined only to
the minimum diameter as shown is in
Specifications.
2. Dirty motor, and possibly salt water got inside.
Disassemble motor, remove the debris with air
pressure. If necessary, dry the motor with heat to
190C (90F).
Probable Cause :
Vehicle Systems
42
Hydraulic System
2
WARNING
Hydraulic oil, under pressure can remain in the
hydraulic system after the engine and pump have
been stopped. Personal injury can be caused if
this pressure is not released before any work is
done on the hydraulic system. To prevent possible
injury, lower the carriage to the ground, key
switchoff and move control levers to make sure all
hydraulic pressure is released before any fitting,
plug, hose or component is loosened, tightened,
removed or adjusted.
Always move the lift truck to a clean and level
location away from the travel of other machines.
Be sure that other personnel are not near the
machine when engine is running and tests or
adjustments are made.
IHCS105S
Relief Valve Adjustment
(2) Control valve. (3) Screw. (4) Jam nut. (5) Acorn nut.
IHCS113P
Control Valve Pressure Check
(1) Plug (6) Priority Valve.
Vehicle Systems
43
24
EHCS009C
Lift Cylinder Air Removal (FFTL - Secondary Cylinders)
(24) Bleed Screw.
WARNING
The oil will have high pressure present. To prevent
personal injury, do not remove the bleed screws
completely . Keep hands and feet away from any
parts of the truck that move, because the forks will
lower when the bleed screw is loose.
23
EHCS008C
Lift Cylinder Air Removal (FFTL - Primary Cylinder)
(23) Bleed Screw.
Vehicle Systems
44
<BT>
Steering System
Steer Wheel Bearing Adjustment
<BX>
2
1
EHCS033C
Bearing Adjustment
(1) Nut. (2) Lock washer.
EHCS033C
Single wheel
Bearing Adjustment
(1) Nut. (2) Lock washer.
Dual wheel
2. Loosen nut (1) completely. Tighten nut (1) again to
40 L 3 Nm (30 L 2 lbft).
Dual wheel
EHCS034C
Bearing Adjustment
Vehicle Systems
45
WARNING
NOTICE
To prevent damage to the steering pump, keep the oil
level in the hydraulic tank above the outlet to the
pump.
2. Close the seat switch and turn the key switch on.
Add oil immediately to the tank as needed.
NOTICE
Do not hold the steer wheel against its stops for an
extended period of time. This will cause the oil to get
hot and damage the components.
IHCS114P
Hydraulic Steering Gear
(1) "P" port of steering unit.
Vehicle Systems
46
WARNING
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
components are disconnected, make sure all
hydraulic pressure is released in the steering
system. Move the steer wheels to the left and right
and then to the straight forward direction.
Vehicle Systems
47
Brake System
2
IHCS116P
IHCS115P
Reservoir Location
(1) Reservoir.
Vehicle Systems
48
Pedal Adjustment
WARNING
To prevent personal injury, the operator must be
ready to use the service brake if the parking brake
is not adjusted correctly and the lift truck starts to
move.
2. Half way up the incline, stop the lift truck with the
service brakes. Apply the parking brake.
IHCS117P
Vehicle Systems
49
EHCS048B
Vehicle Systems
50
Vehicle Systems
51
(SE)
Motor Brushes
Brush Inspection
EHCS040C
Install Brushes
(1) Brushes.
NOTICE
Installation of the wrong brushes can cause early
motor failure. Always make sure the correct DAEWOO
brushes are installed.
EHCS039C
Brush Measurement
2. Brush measurement :
Install Springs
(2) Spring.
Vehicle Systems
52
WARNING
Wear eye protection when seating, polishing or
cleaning the motor with air pressure. During the
seating and polishing procedure, keep fingers
away from components in rotation. For prevention
of injury to fingers, do not use a commutator
cleaner or brush seater stone that is shorter than
63.5 mm (2.50 in).
Armature Tests
Tools Needed
Digital Multimeter Or Equivalent
Growler Tester
EHCS042C
Brush Seating
(3) Brush seater stone.
EHCS043C
NOTICE
Do not let stone (3) stay in contact with the
commutator bar too long time. This causes more wear
than is necessary to the brushes and the commutator.
Vehicle Systems
53
Ground Test
Commutator Inspection
Surfaces of Commutators that need Replacement
NOTICE
Never use air pressure that is more than 205 kPa
(30psi). Make sure the air line has a water filter.
EHCS045C
Open Circuit Test
(1) Armature.
Vehicle Systems
54
EHCS050B
EHCS052B
EHCS053B
EHCS051B
Pitch Bar-Marks on the Commutator Surface.
Grooves on the Commutator Surface
Vehicle Systems
55
Ground Test
EHCS048C
Ground Test
(1) Field terminal. (2) Motor housing.
EHCS046C
Open Circuit Test
1
A
EHCS047C
Brush Test
(1) Field terminal. (2) Brush leads. (A) Multimeter.
EHCS049C
Brush Holder Test
(1) Brush holder. (2) End bell. (A) Multimeter.
56
Ground Test
EHCS051C
Ground Test
Tools Needed
Digital Multimeter Or Equivalent
EHCS050C
Open Circuit Test
Vehicle Systems
57
Vehicle Systems
58
SB4187E00
Feb. 2005
Disassembly &
Assembly
Lift Trucks Vehicle Systems
B15T-5, B18T-5, B20T-5(AC 36V)
B15T-5, B18T-5, B20T-5(AC 48V)
B15T-5, B18T-5, B20T-5(SE 48V)
B16X-5, B18X-5, B20X-5(AC 48V)
B16X-5, B18X-5, B20X-5(SE 48V)
WARNING
Index
Accelerator Control Switch .......................................19
Assemble Hydraulic Control Valve ...........................11
Brake Master Cylinder..............................................41
Control Panel
AC .........................................................................62
SE .........................................................................63
Counterwieght ..........................................................68
Disassemble & Assemble Brake ..............................42
Disassemble Hydraulic Control Valve.........................8
Drive Motor & Drive Axle ..........................................65
Hood(with seat) Assembly..........................................5
Hydraulic Control Valve ..............................................7
Hydraulic Pump ........................................................17
Hydraulic Pump Motor
AC .........................................................................13
SE .........................................................................15
Link Assemblies........................................................50
Overhead Guard.........................................................6
Primary Lift Cylinder .................................................25
Priority Valve.............................................................40
Secondary Lift Cylinder ............................................22
Spindle-Steer Axle ....................................................57
Standard Lift Cylinder ...............................................20
Steer Axle .................................................................43
Steer Axle .................................................................52
Steer Sensor Group..................................................32
Steer Wheels & Hub.................................................48
Steering Column.......................................................33
Steering Cylinder ......................................................45
Steering Gear ...........................................................35
Steering Knuckles, Kingpins & Bearings ..................50
Steering Wheel .........................................................33
Tilt Cylinder...............................................................28
WARNING
Disconnect batteries before performance of any
service work.
Vehicle Systems
Index
EHCD003C
EHCD001C
EHCD004C
WARNING
The hood and seat assembly can fall when nut (2)
is removed from the support cylinder rod.
To avoid personal injury, support the seat and
hood assembly before removing nut (2).
Vehicle Systems
Overhead Guard
Remove & Install Overhead Guard
IHCD101P
6
3
IHCD102P
Vehicle Systems
WARNING
5. Fill the hydraulic tank to the correct level with fluid.
Refer to the Operation And Maintenance Manual
for further information.
End By :
a. Install the hydraulic control valve switch group.
Start By :
a. Remove hydraulic control valve switch group.
1. Drain the hydraulic tank.
IHCD103P
Vehicle Systems
IHCD107P
10
IHCD105P
IHCD108P
5
2
12
13
IHCD106P
IHCD109P
Vehicle Systems
16
17
18
26
IHCD110P
IHCD112P
28
26
19
24
29
23
27
20
21
25
22
IHCD113P
IHCD111P
30
31
IHCD114P
15. Remove two screws (30) and cap (31) from tilt
section assembly.
Vehicle Systems
15
45
44
14
33
32
34
43
IHCD115P
IHCD118P
16. Remove two screws (32), seal plate (33) and tilt
spool (34).
35
47
45
46
36
37
38
IHCD116P
IHCD119P
22. Remove relief valve (46) and O-ring (47) from the
section assembly (45).
38
40
37
42
41
IHCD117P
19. Remove spring seats (39 and 40), spring (38 and
42) and piston (41).
Vehicle Systems
10
24
NOTICE
Do not use caustic (corrosive) materials to clean any
parts in this valve group. Caustic materials will cause
corrosion and damage to parts.
23
20
21
25
22
1. Make sure all valve parts are clean and free of dirt.
IHCD111P
5
2
17
18
IHCD110P
Vehicle Systems
11
45
47
46
12
13
IHCD119P
IHCD109P
7
8
10
11
1
9
IHCD108P
IHCD105P
10. Install O-ring (8) and plug (7) to the lift section
assembly.
39
38
15. Install the nuts (1) that hold the valve sections
together. Tighten the single top nut to torque of 26
~ 32 Nm (19 ~ 23 lbft) and two bottom nuts to
torque of 24 ~ 29 Nm (18 ~ 21 lbft).
40
37
End By :
42
41
IHCD117P
12
Vehicle Systems
13
Vehicle Systems
14
(SE)
Start By :
a. Raise the hood.
b. Disconnect the battery.
NOTE: For purpose of assembly, put identification
marks on the wires and cables for proper installation.
EHCD045C
End By :
a. Connect the battery.
EHCD046C
Vehicle Systems
15
11
5
EHCD047C
ILCD021P
3
5
ILCD018P
ILCD020P
10
9
Vehicle Systems
16
Hydraulic Pump
Disassemble Hydraulic Pump
Start By :
EHCD053C
3
11
EHCD050C
12
10
EHCD054C
14
13
EHCD051C
EHCD055C
EHCD052C
Vehicle Systems
17
14
13
7
6
EHCD052C
EHCD055C
11
12
10
EHCD051C
9
EHCD050C
EHCD053C
End By :
Vehicle Systems
18
IOCD014P
IOCD011P
IOCD0012P
IOCD013P
Vehicle Systems
19
EHCD101C
1
EHCD099C
EHCD102C
2
EHCD100C
EHCD103C
Vehicle Systems
20
12
9
8
10
EHCD104C
11
EHCD105C
12
9
10
11
8
EHCD105C
EHCD104C
2. Install back up ring (8) and O-ring seal (7) onto the
rod-cover.
5
6
EHCD103C
Vehicle Systems
21
EHCD101C
1
EHCD099C
2
EHCD100C
2
Vehicle Systems
22
3
10
11
EHCD101C
EHCD104C
15
12
13
14
EHCD105C
IOCD015I
8
9
EHCD103C
Vehicle Systems
23
15
12
13
14
EHCD105C
IOCD015I
10
11
EHCD104C
EHCD101C
8
9
EHCD103C
EHCD100C
Vehicle Systems
24
a. remove carriage.
WARNING
Be sure all the pressure in the hydraulic system
has been released before any lines or hoses are
disconnected.
EHCD106C
Start By :
4
5
EHCD108C
Vehicle Systems
25
6
7
EHCD109C
9
EHCD111C
2. Install wiper seal (6). Install the seal with the lip
toward the outside.
EHCD110C
EHCD110C
EHCD111C
5. Remove wiper seal (6), back-up ring (7), Upacking (8) and slide rings (9) from the head
assembly.
Vehicle Systems
26
EHCD109C
1
2
EHCD108C
Vehicle Systems
27
Tilt Cylinder
Remove & Install Tilt Cylinder
NOTE: The procedure for removing and installing
the tilt cylinders is the same for both cylinders.
WARNING
IOCD016P
WARNING
To prevent personal injury, move the control
levers backward and forward to release any
pressure in hydraulic system. Slowly loosen the
cap of the hydraulic tank to release any pressure
in the tank. Be cautious of hot hydraulic oil when
any lines are disconnected in the hydraulic
system.
11
10
EHCD212C
IOCD012P
3. Remove retainer bolt (9) from pin (8). Remove pin (8).
Vehicle Systems
28
Start By :
a. Remove tilt cyliner.
EHCD115C
EHCD113C
NOTICE
Use extra care not to damage the highly finished
surface of the cylinder rod and the bore of the
cylinder body during disassembly and assembly
of the tilt cylinder.
10
5
3
NOTICE
Check the condition of all seals. If any parts are
worn or damaged use new parts for replacement.
EHCD114C
Vehicle Systems
29
11
15
13
12
14
EHCD117C
EHCD118C
15
13
14
11
EHCD118C
12
EHCD117C
16
EHCD119C
Vehicle Systems
30
5
3
10
EHCD116C
EHCD114C
16. Install slipper seal (9) and O-ring seal (10) on the
piston.
EHCD115C
17. Install cylinder rod (7) and shims. Tighten the nut
and bolt on the rod eye to a torque of 95 15 Nm
(70 10 lbft).
EHCD113C
18. Install the spacer (6) with O-ring seal onto the
cylinder rod if needed.
Vehicle Systems
31
(BX)
(BT)
Start By :
End By :
a. Set Sensor Initial setting.
Vehicle Systems
32
Steering Wheel
Steering Column
2
1
3
IOCD020P
2
5
4
EHCD127C
Vehicle Systems
33
8
7
15
9
18
14
17
EHCD128C
12
11
24
25
23
10
13
EHCD133C
EHCD129C
NOTICE
Steering gear (10) and column (12) can separate
after bolts (11) have all been removed, causing
gear (10) to fall. To avoid damaging components,
support the steering gear while removing bolts
(11).
Vehicle Systems
34
Steering Gear
6
10
Start By :
a. Remove steering gear (pump).
4
8
EHCD136C
EHCD134C
Typical Example
12
11
5
4
14
13
EHCD137C
3
EHCD135C
NOTICE
Make a note of the position of special bolt with a
pin. It is locatedmat a mark in line with check
valve.
16
EHCD138C
15
Vehicle Systems
35
16
17
28
27
23
EHCD139C
EHCD142C
21
19
32
2
35
23
33
20
18
34
EHCD140C
EHCD003B
13. Remove plug (31) and spring (32) from the pump
body (2).
14. Remove poppet (34) and relief valve housing (35)
from the pump body.
25
37
36
26
24
EHCD143C
15. Remove plug (36) and washer (37) from the pump
body.
EHCD141C
Vehicle Systems
36
25
26
36
37
24
EHCD143C
EHCD141C
16. Install washer (37) and plug (36) into the pump
body.
32
20. Install dust seal ring (26). Install O-ring seal (24)
with king-ring (25) into pump body (2).
22
21
19
35
33
34
23
20
EHCD003B
18
EHCD140C
17. Install housing (35) and poppet (34) into the pump
body.
NOTICE
For purposes of installation, note that springs (23)
are installed in two stacks of three. Make sure the
curves of the two stacks are in contact and
positioned in the center of spool (17). The notched
side of springs (23) must be positioned toward
sleeve (16).
18. Install spring (32) and plug (31) into pump body
(2). Tighten plug (31) to a torque 11.3 Nm (100
lbin).
17
28
16
27
EHCD142C
23
19. Install washer (28) and plug (27) into pump body
(2) Tighten plugs to a torque 30 Nm (22 lbft).
EHCD139C
37
16
EHCD138C
15
EHCD004B
12
10
11
4
8
EHCD136C
14
13
EHCD137C
NOTICE
Make sure the notch of shaft (7) properly seats on
pin (18) when installed into body (2) and spool (17).
29. Install shaft (7) into body (2) and spool (17).
NOTICE
Gerotor (9) must be aligned with shaft (7) and pin
(18) as shown in the illustration.
Vehicle Systems
38
EHCD005B
NOTICE
To assure proper operation of the pump, make
sure bolts (5) are clean and dry before installing.
Tighten bolts (5) in the sequence shown in the
illustration.
5
4
3
2
EHCD135C
32. Install bolts (5) into cap (4). Tighten bolts (5)
asfollows:
a. Tighten bolts (5) in correct sequence to a first
torque of 14.1 2.8 Nm (125 25 lbin).
b. Tighten bolts (5) in correct sequence to a
second torque of 28.2 2.8 Nm (250 25
lbin).
End By :
a. Install steering pump.
Vehicle Systems
39
Priority Valve
Remove & Install Priority Valve
End By :
Start By :
a. Remove floorplate.
WARNING
Start By :
a. Remove priority valve
NOTE: Mark the positions of all components for
purposes of reassembly.
4
3
EHCD145C
EHCD144C
Vehicle Systems
40
EHCD146C
1
IHCD120P
IHCD121P
Vehicle Systems
41
Master Cylinder
8
4
Start By :
13 3
14
6
12
11 10
42
(BX)
G
Steer Axle
Remove & Install Steer Axle
WARNING
Be sure the pressure in the hydraulic system is
released before any lines or hoses have been
disconnected.
IBCD062C
5. Lower the steer axle onto the bolt heads with the
floor jack.
IBCD061C
5
6
IBCD061C
Vehicle Systems
43
IBCD177C
IBCD062C
NOTE: Use bolts (3) and cap to align steer axle (4)
with the mounting bosses while raising steer axle (4)
into position with the floor jack.
IBCD177C
IBCD063C
Vehicle Systems
44
Steering Cylinder
3
IBCD162C
IBCD064C
IBCD161C
Vehicle Systems
45
9
8
IBCD165C
7
IBCD166C
G
G
G
G
G
G
G
G
G
G
G
G
G IBCD165C
IBCD166C
IBCD164C
Vehicle Systems
46
4
1
IBCD163C
IBCD064C
IBCD162C
IBCD161C
Vehicle Systems
47
IBCD049C
IBCD047C
4
IBCD048C
IBCD051C
Vehicle Systems
48
12
IBCD052C
IBCD055C
10
13. Pack bearing cones (6) and (12), and lubricate the
contact surfaces of the bearing cups with
Multipurpose Grease
14. Reverse the procedures and steps 1 through 12 to
install the steer wheels and bearings.
IBCD053C
10. Remove seal (9) and bearing cup (10) from hub
(7).
11
Vehicle Systems
49
Link Assemblies
Start By:
a. Remove steer wheels
3
2
1
IBCD056C
1
7
3
IBCD058C
6
IBCD057C
Vehicle Systems
50
NOTICE
Check the condition of all seals, bearings and
components. If any parts are worn or damaged use
new parts for replacement.
1
2
IBCD058C
End By:
IBCD059C
IBCD060C
Vehicle Systems
51
(BT)
Steer Axle
Remove & Install Steer Axle
Start By :
a. Remove overhead guard.
b. Remove counterweight.
c. Remove steer sensor group.
IBCD158C
WARNING
Be sure the pressure in the hydraulic system is
released before any lines or hoses have been
disconnected.
IBCD159C
IBCD157C
Vehicle Systems
52
IBCD160C
IBCD161C
End By :
a. Install counterweight.
b. Install overhead guard.
IBCD162C
Vehicle Systems
53
10
IBCD166C
IBCD163C
11
13
12
14
IBCD167C
IBCD164C
16
15
IBCD165C
Vehicle Systems
54
18
15
16
17
IBCD169C
IBCD168C
11
13
18
17
12
14
IBCD167C
IBCD169C
NOTE:
Apply light coat of Loctite NO.592
sealant to outer of seal case.
Vehicle Systems
55
7
3
IBCD167C
IBCD162C
17. Install the cap (9), washers and four bolts (8) to
housing (7). The torque for the bolt (8) is 55 10
Nm (40 7 lbft).
Required Shim=XY
Following is the content of the shim pack.
IBCD164C
SHIM NO
THICKNESS
1
0.05
2
0.13
3
0.80
IBCD161C
IBCD006B
21. Install the top plate (2) and bolt (1). The torque for
the bolt (1) is 45 7 Nm (33 5 lbft).
Vehicle Systems
End By :
a. Install the housing group-steer axle.
56
Spindle-Steer Axle
Remove And Install Spindle-Steer Axle
2
6
IBCD051C
IBCD052C
3
10
IBCD049C
7
IBCD053C
4
IBCD050C
Vehicle Systems
57
11
1
IBCD170C
IBCD054C
16. Install the steer tire (2) and nuts (1). Torque for the
nut (1) is 113 Nm (83 lbft) for unfuion Tire for
solid sokter Tire.
17. Remove the wooden block.
12
IBCD055C
Vehicle Systems
58
IBCD172C
IBCD175C
19. Remove the nut (6) lock washer (5) and washer
(4) from the spindle.
10
IBCD173C
11
IBCD176C
IBCD174C
Vehicle Systems
59
NOTICE
Prepack wheel, actuator bearing and hub with
NLGI NO. 2(GREASE) lubricant.
IBCD174C
10
30. Install the spindle assembly (8) into the beam axle.
11
IBCD176C
IBCD173C
IBCD175C
33. Bend the lock washer (5) to groove of nut (6) and
tighten the nut (6).
Vehicle Systems
60
IBCD171C
2
1
IBCD170C
35. Install the steer tire (2) and nuts (1). Torque for the
nut (1) is 140 Nm (103 lbft).
36. Remove the wooden block.
Vehicle Systems
61
Control Panel
Remove And Install Control Panel
(AC)
WARNING
Battery voltage and high ampere are present.
Injury to personnel is possible. The power unit
must be discharged before any contact with the
control panel is made. Disconnect the battery and
discharge the power unit.
Vehicle Systems
62
(SE)
WARNING
Battery voltage and high ampere are present.
Injury to personnel is possible.
The power unit must be discharged before any
contact with the control panel is made.
Disconnect the battery and discharge the power
unit.
Remove and Install Control Panel
Vehicle Systems
63
Vehicle Systems
64
IOCD029P
2
IOCD027P
IOCD030P
IOCD028P
EHCD189C
Vehicle Systems
65
12
11
13
10
IOCD032P
IOCD031P
12
13
13. Put the drive motor (13) on the drive axle (14) and
install the bolt (12). The torque for the bolt (12) is
55 Nm (41 lbft).
NOTE:
thread.
IOCD032P
11
10
IOCD031P
13
14
IOCD033P
15. Put the drive motor and drive axle assembly (10)
on the frame and install the bolt (11). The torque
for the bolt (11) is 200 Nm (147 lbft). Apply
Loctite NO. 262 on bolt thread.
Vehicle Systems
66
EHCD189C
IOCD028P
16. Install the band (9) and screw on the drive motor.
IOCD030P
IOCD027P
5
1
IOCD029P
17. Install the brake tubes (8), (7) and parking cable
(6) on the drive axle. The torque for the fitting is
50 Nm (37 lbft). Tighten the nut (5).
Vehicle Systems
67
Counterwieght
(BX)
Start By:
(BT)
a. Open hood.
Start By:
2
a. Open hood.
1
2
End By :
a. Close hood.
End By :
a. Close hood.
Vehicle Systems
68
SB4182E00
Feb. 2005
Schematic
Lift Trucks Hydraulic Systems
B15T-5, B18T-5, B20T-5 (AC 36V)
B15T-5, B18T-5, B20T-5 (AC 48V)
B15T-5, B18T-5, B20T-5 (SE 48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
B16X-5, B18X-5, B20X-5 (SE 48V)
10
1
11
13
12
Components
Tilt Cylinder
Hydraulic Filter
Steer Axle
Control Valve
12
13
D500037
11
Lift Cylinder-Primary
10
Flow Protector-Primary
Flow Regulator
Pressure Switch
Steering Unit
Priority Valve
3
Hydraulic Pump
2
Item
14
10
13
11
12
D500038
SB4181E00
Feb. 2005
Schematic
Lift Truck Electric System
B15T-5, B18T-5, B20T-5 (AC 36V/48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
A244902
SB2143E03
Feb.2 0 0 5
G18S-2,
G20SC-2
D18S-2,
D20SC-2
B16X,
B18X,
B20X
B16X-5,
B18X-5,
B20X-5 (AC/SE)
B13T-2,
B15T-2,
B18T-2, B20T-2
B13T-5,
B15T-5,
B18T-5 (AC/SE)
B15S,
B18S
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
IImproper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product will not be damaged or made unsafe by the operation,
lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
Index
Disassembly & Assembly
Forks.........................................................................5
Backrest....................................................................5
Carriage....................................................................6
Mast..........................................................................9
Index
Backrest
Forks
Remove & Install Forks
IBCD501P
2
IDCD001P
IDCD002P
Carriage
Remove & Install Carriage
Start By:
a. Remove forks.
b. Remove backrest.
IBCD504P
1
3
IBCD510P
IBCD503P
End By:
a. Install backrest.
b. Install forks.
Disassemble Carriage
IBCD504P
Start By:
a. Remove carriage.
8. Install stop bolt (7).
Shim stop bolt as required to obtain a 4 to 6 mm
(.157 to .242 in) lap with top carriage stop on the
inner upright.
IBCD571P
IBCD503P
3
IBCD572P
2
1
3
7
4
8
IBCD573P
Part No.
Bearing Size
Bearing O.D.*
D580006
Undersize
D580007
Standard
D580008
Oversize
Assemble Carriage
NOTE : The standard, Full Free Lift and Full Free
Triple Lift carriage load bearings are all adjusted the
same way. The Full Free Triple Lift carriage is shown
in the following illustrations.
To make the carriage clearance adjustments,
carriage must be removed from the mast.
IBCD543P
A
B
5(STD)
3
A
C
5 (FF, FFT)
6
VIEW A-A
C
10
IBCD574P
A
VIEW C-C
IBCD581I
VIEW B-B
Carriage Adjustment
(3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Side-roller bearings. (8) Lower bearings. (9) Pin-adjust.
(10) Bolt. (A) Zero clearance.
(B) 4.0 to 6.0 mm. (.157 to .242 in) clearance.
(C) Minimum clearance. (D) 4.5 L 0.5 mm
Mast
4
IDCD016P
1
2
IBCD511P
IBCD571P
End By:
a. Install carriage, raise the inner mast and insert the
carriage from the bottom of inner mast.
IBCD512P
NOTICE
Place identification marks on all hydraulic connectors
and hoses to assure proper installation. Plug and cap
all hydraulic connectors and hoses to avoid debris and
contamination from entering the system.
2. Disconnect hose(3).
NOTE : For B15/18/20T-2(36V), see article 6 prior to
disconnecting hose (3).
9
6
IBCD513P
WARNING
IBCD502S
6. B15/18/20T-2(36V)
Raise the carriage and mast to open outer lower
part. Remove bolt (9) from the front of mast each
side. Remove bolt (8) from the pit each side.
Disconnect hose (3) of article 2.
103
IBCD582I
IBCD514P
7. B16/18/20X, B13/15/18/20T-2(48V)
Tilt forward mast assembly with the hoist. Remove
bolts (8) from each side.
WARNING
Loosen the tension of straps to be connected with
hoist when mast assembly is tilted forward.
If straps are too tight, mast assembly could slide
off when bolts (7), (8), (10) are removed.
10
Disassemble Mast
Start By:
a. Remove lift chain to be connected primary lift
cylinder.
b. Remove primary lift cylinder.
IBCD518P
3
2
4
IBCD519P
11
15
11
16
6. Remove top cylinder retainer bolts (11) from each
side of the mast.
17
12
16
IBCD524P
15
17
B15/18/20T-2(36V)
IBCD527P
13
17
14
B16/18/20X, B13/15/18/20T-2(48V)
IBCD584I
IBCD526P
12
24
21
24
22
18
23
19
IBCD528P
IBCD534P
20
24
25
IBCD533P
IBCD529P
21
24
IBCD535P
IBCD530P
13
Assemble Mast
NOTE: The standard, Full Free Lift and Full Free
Triple Lift mast load bearings are all adjusted the
same way. The mast shown in the following
illustrations is the Full Free Triple Lift mast.
1. Make sure all parts are clean and free of dirt and
foreign material.
2. Check all parts for damage, use new parts for
replacement.
IBCD541P
NOTICE
When the correct amount of shim has been installed
behind bearings (1) there will be contact (zero clearance)
between the bearings and the inner mast at most narrow
point of mast.
IBCD505S
Mast Adjustment Lower Bearings
(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
IBCD535P
Bearingsize
Bearing O.D.*
D580006
Undersize
D580007
Standard
D580008
Oversize
14
1
4
3
IBCD534P
IBCD533P
IBCD538P
IBCD505S
15
IBCD531P
IBCD534P
IBCD533P
IBCD535P
16
D
E
7
E
F
10
F
7
IBCD506S
8
10
IBCD506S
Mast Adjustment Upper Bearings
(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
17. Install shims (8) behind each pad (7) until there
is 0.80 mm (.031 in) maximum clearance (E)
between the pads and the inner and intermediate
masts with the masts at full extension. Lift by
crane, and pull out intermediate mast from
stationary mast and insert the shims behind each
pad. In case of standard and full free mast, the
pads of stationary upper can be easily extruded
by pulling down the inner mast from the bottom
of stationary mast.
IBCD532P
17
3
IBCD542P
12
11
IBCD505S
Mast Adjustment Lower Bearings
(A) Zero clearance. (B)Minimum clearance. (C)Zero clearance.
(3)Bearing. (4)Bearing. (5)Shims. (6)Shims.
IBCD530P
18. Select lower bearings (3) and (4) from the chart
to obtain minimum clearance (B) between
bearing and channel leg for full channel length.
Use same bearing on left and right side.
Bearing Size
Bearing O.D.*
D580006
Undersize
D580007
Standard
D580008
Oversize
13
IBCD528P
18
14
IBCD529P
15
IBCD526P
16
IBCD527P
19
25
17
IBCD524P
IBCD520P
27
18
26
IBCD519P
20
28
IBCD518P
21
Carriage Adjustment
NOTE: The standard, Full Free Lift and Full Free
Triple Lift carriage load bearings are all adjusted the
same way. The Full Free Triple Lift carriage is shown
in the following illustrations.
D580006
Undersize
D580007
Standard
D580008
Oversize
5(STD)
Bearing O.D.*
Bearing Size
Part No.
C
B
5 (FF, FFT)
VIEW A-A
C
10
A
VIEW C-C
VIEW B-B
IBCD581I
Carriage Adjustment
(3) Upper Bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Side-roller Bearings. (8) Lower Bearings. (9) Pin-adjust.
(10) Bolt. (A) Zero Clearance.
(B) 4.0 to 6.0 mm. (.157 to .242 in) Clearance.
(C) Minimum Clearance. (D) 4.5 L 0.5 mm
22
Chain Adjustments
Chain Adjustment Check
IBCD505P
2
IBCD508P
Chain Adjustment
WARNING
x 100
WARNING
Do not put a lift truck into service if the chain wear
indication is 2% or more. A reading of 2% or more
could cause damage or injury to persons.
IBCD506P
Inner Lift Chains
(1) Chain Anchor Nuts.
23
1. Lift the mast and operate the tilt control lever, until
the top surface of the forks is parallel with the
floor. Place two straight bars, that are the same
width as the carriage, across the forks as shown.
Measure the distance from the bottom of each end
of the two bars to the floor. The forks must be
parallel within 3 mm (.12 in) for Full Tapered and
Polished (FTP) forks, all other forks 6.4 mm (.25
in), for their complete length.
IDCS130S
Forks Parallel Check
(Typical Example)
IBCD585I
24
IDCD009P
Drift Test
The tilt angle of the mast must be checked in the full
tilt back and full tilt forward positions. A tilt indicator
or a protractor can be used to measure the angle.
Both sides of the mast must be checked to make
sure that the mast is not twisted.
WARNING
Personal injury can be caused by sudden movement
of the mast or carriage. Use wood blocks and
clamps to hold the mast in this position. Keep hands
and feet clear of any parts that can move.
25
IBCD513P
Tilt Cylinder Adjustment
(1) Pivot eye. (2) Bolt. (3) Rod.
WARNING
Tilt cylinder pivot eyes can loosen if the torque on
the pivot eye clamping bolt is not tight enough.
This will let the tilt cylinder rod turn in the tilt
cylinder eye. The cylinder rod may twist out of the
pivot eye and the tilt cylinder will be out of
alignment or may let the mast fall and cause
personal injury or damage. When the rod lengths
are made even, the tilt angle differences or the
mast alignment will no longer be a problem.
16mm
EHCS046S
26
3
VIEW A-A
B
B
2
(F)
VIEW B-B
IBCD508S
27
1
IBCD502S
For B15/18/20T-2(36V)
IBCD509S
2
IBCD582I
1
3
IBCD510S
For B15/18S
3. Apply the crean grease to a surface of bearing.
4. Apply Loctite No242 to bolts and tighten with a
torque 180 L 20 NIm (130 L 15 lbIft).
Lift Trucks Mast Systems
28
SB2340E01
Operation &
Maintenance Manual
LIFT TRUCKS
B15T-5, B18T-5, B20T-5 (AC 36V, 48V)
WARNING
Do not start, operate or service this machine unless you have read and understood
these instructions and received proper training.
Unsafe or improper use of the machine may cause serious injury or death.
Operators and maintenance personnel must read this manual and receive training
before operating or maintaining the machine.
This manual should be kept with the machine for reference and periodically
reviewed by the machine operator and by all personnel who will come into contact
with it.
The following warning is provided pursuant to California Health & Safety Code Sections
25247.5 et, seq,
WARNING
California Proposition 65
Engine Exhaust, some of its constituents, and certain vehicle components contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
WASH HANDS AFTER HANDLING.
Table of Contents
Table of Contents
Information Section
Maintenance Section
Foreword ............................................................... 2
Safety Section
Important Safety Information.................................. 4
Safety .................................................................... 5
Warning Signs and Labels .............................. 5
General Hazard Information.......................... 10
Lift Chains..................................................... 11
Operation Information ................................... 11
Maintenance Information .............................. 13
Operator Restraint System (If Equipped) ...... 16
Avoiding Lift Truck Tipover............................ 20
Safety Rules ................................................. 22
How to Survive in a Tipover .......................... 27
G
General Section
Specifications....................................................... 28
Noise and Vibration.............................................. 31
Noise ................................................................... 31
Capacity Chart ..................................................... 32
Capacity Chart With Side Shifter....................... 33
Serial Number...................................................... 34
Serial Numbers Locations.................................... 34
Operators Warning and Identification Plate......... 35
Environment Section
Environment Protection ......................................117
G
Index Section
Index ..................................................................118
WORLDWIDE NETWORK
Operation Section
Operators Station and Monitoring Systems ......... 37
Lift Truck Controls ................................................ 45
Before Operating the Lift Truck ............................ 49
Lift Truck Operation.............................................. 52
Operating Techniques .......................................... 55
Parking the Lift Truck ........................................... 59
Lift Fork Adjustment ............................................. 61
Storage Information ............................................. 62
Transportation Hints............................................. 63
Towing Information............................................... 64
Information Section
Foreword
Safety
Literature Information
contains
lubrication
safety,
operation,
and
maintenance
WARNING
Your DAEWOO truck comes equipped with an
operator restraint system. Should it become
necessary to replace the seat for any reason, it
should only be replaced with another DAEWOO
operator restraint system.
Information Section
Operation
Environment Management
Maintenance
The Maintenance Section is a guide to equipment
care. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items without specific
intervals are listed under "When Required" topics.
Items in the "Maintenance Intervals" chart are
referenced to detailed instructions that follow.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at "Every 500 Service
Hours or 3 Months", also service those items listed
under "Every 250 Service Hours or Monthly" and
"Every 10 Service Hours or Daily".
Safety Section
WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure, work method or operating technique not specifically recommended by DAEWOO
is used, you must be sure that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DAEWOO dealers have the most current
information available.
Safety Section
Safety
WARNING
Improper operation or maintenance could result
in injury or death. Do not operate or work on the
lift truck unless you are properly trained. Read
and understand the Operation and Maintenance
Manual. Additional manuals are available from
DAEWOO Lift Truck dealers.
Safety Section
Safety Section
WARNING
WARNING
Operation without this device in place may be
hazardous.
No hands. Do not place hands in this area. Do
not touch, lean on, or reach through the mast or
permit others to do so.
WARNING
WARNING
IB9O004P
Safety Section
No Riders Warning
WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.
WARNING
Before operating truck, ensure that hood is
securely locked by hood latch, and turn stopper
to locking position. Otherwise, a battery may
come out of a truck in case of tipover. It could
cause the risk of serious injury or death.
Located beside the operator's station.
Safety Section
AC
WARNING
Disconect battery from truck and also discharge
high voltages from capacitor banks with a 150
ohm, 25 watt Resistor before attempting to
service this truck.(B+, B-)
Safety Section
10
Safety Section
Lift Chains
Operation Information
Mounting and Dismounting
Mount and dismount the lift truck carefully.
Clean your shoes and wipe your hands before
mounting.
Use both hands face the lift truck when mounting
and dismounting.
Use the handgrips for mounting and dismounting.
Do not try to climb on or off the lift truck when
carrying tools or supplies.
Make sure the lift truck horn, lights, backup alarm (if
11
Safety Section
12
Safety Section
Maintenance Information
Pressure Air
Pressure air can cause personal injury. When using
pressure air for cleaning, wear a protective face
shield, protective clothing and protective shoes.
Fluid Penetration
Always use a board or cardboard when checking
for a leak. Escaping fluid under pressure, even a
pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid is
injected into your skin, it must be treated by a
doctor familiar with this type of injury immediately.
13
Safety Section
Burn Prevention
Oils
Batteries
Only trained and designated personnel should
inspect, recharge or exchange batteries.
14
Safety Section
Tire Information
15
Safety Section
Make sure that you can read all safety signs. Clean
or replace these if you cannot read the words or
see the pictures. When cleaning the labels use a
cloth, water and soap. Do not use solvent, gasoline,
etc. You must replace a label if it is damaged,
missing or cannot be read. If a label is on a part
that is replaced, make sure a new label is installed
on the replaced part. See you DAEWOO Lift Truck
dealer for new labels.
WARNING
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
could result.
16
Safety Section
WARNING
Do NOT place your hand or fingers under the
seat. Injury may occur as the seat suspension
mechanism moves up and down.
NOTICE
Before getting on the truck, adjust the level of the
suspension using the grip in the rear of the seat.
The "Survive in tipover" warning is located on the
overhead guard. It shows the proper use of the
operator restraint system.
Seat Adjustment
WARNING
When raising and lowering the seat backrest,
avoid placing hand or fingers in the hinge area
indicated by the circle. Injury may occur.
17
Safety Section
Seat Belt
WARNING
Your DAEWOO truck comes equipped with a
DAEWOO operator restraint system. Should it
become necessary to replace the seat for any
reason, it should only be replaced with another
DAEWOO operator restraint system.
18
Safety Section
WARNING
If you fasten the belt across your abdomen, the
belt may injure your abdomen in an accident.
WARNING
Release the Seat Belt
19
Safety Section
tire pressure
20
Safety Section
NOTICE
1. Capacity/Nameplates originally attached to
forklifts sold by DAEWOO shall not be removed,
altered or replaced without Daewoos approval.
2. DAEWOO assumes no responsibility for lift
trucks placed in service without a valid
DAEWOO Nameplate.
3. If necessary to change your specification,
contact your DAEWOO lift truck dealer.
WARNING
Dynamic forces (braking, acceleration, turning)
also affect stability and can produce tipover
even when the CG is within the stability triangle.
21
Safety Section
Safety Rules
22
Safety Section
23
Safety Section
24
Safety Section
25
Safety Section
26
Safety Section
Dont jump.
Lean forward.
Hold on tight.
27
General Section
Specifications
G
1
2
3
4
5
6
7
8
G
9
10
12
13
14
15
16
17
18
19
20
21
22
23
23a
G
CHARACTERISTICS
G
G
G
G
G
at rated load center
G
distance
G
eletric,diesel,gas,Lp-gas
G
stand-on, rider seated
G
P=pneumatic,E=elastic,C=cushion
number of front/rear
DIMENSIONS
maximum fork height with rated
Lift with STD
load
two-stage mast
free lift
Fork carriage
ISO Class
G
thickiness X width X length
Fork
Spacing (Min. X Max.)
G
Tilt of mast
foreward/backward
G
G
length to fork face
G
G
width
G
Overall
mast lowered height
G
dimensions
mast extended height
G
G
overhead guard height
G
G
seat height to SR (daewon sus.)
Outside turning radius
G
Load moment constant (from front wheel to fork face)
Aisle width with pallets 1000X1200 crosswise,
w/clearance
Aisle width with pallets 800X1200 lengthwise,
w/clearance
G
PERFORMANCE
G
24
25
Speeds
lift,loaded/unloaded
26
lowering,loaded/unloaded
30
G
32
33
34
G
35
36
37
38
39
40
41
42
43
G
45
47
54
55
57
G
Manufacturer
Model
Capacity
Load center
Power type
Operator type
Tire
Wheels(x=driven)
G
travel,loaded/unloaded
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
28
G
G
G
lb(kg)
in(mm)
G
G
G
G
G
DAEWOO
B15T-5
3000(1500)
24(500)
electric
rider seated
E,C
2x/2
G
DAEWOO
B18T-5
3500(1750)
24(500)
electric
rider seated
E,C
2x/2
G
mm
3000
3000
mm
G
mm
mm
deg
mm
mm
mm
mm
mm
mm
mm
mm
130
II
35x100x1050
240x905
5/7
1868
1090
2000
4045
2120
919
1492
376
130
II
35x100x1050
240x905
5/7
2001
1090
2000
4045
2120
919
1625
376
36V AC
mm
3194
3327
mm
3318
3451
G
Mph
(km/h)
Fpm
(mm/s)
Fpm
(mm/s)
%
lb(kg)
lb(kg)
lb(kg)
8.7/8.7(14.0/14.0)
8.7/8.7(14.0/14.0)
61/108(310/550)
61/108(310/550)
98/89(500/450)
98/89(500/450)
24/
G G
7024(3186)
23/
G
7297(3310)
9021/1310(4092/594)
3450/3574(1565/1621)
9844/1312(4465/595)
3596/3702(1631/1679)
G G
G
G
G
mm
mm
mm
mm
G
G
G
V/AH
kg
hp(kw)
hp(kw)
Type
Type
psi(kpa)
psi(kpa)
2/2
18X7X12.12
15X6X11.25
1264
902/198
86
100
foot/hyd
hand/mech
G
36/880
700
6.7(5.0)X2
16.1(12.0)
TR Inverter
ODB
2880(19800)
2025(14000)
G
2/2
18X7X12.12
15X6X11.25
1397
902/198
86
100
foot/hyd
hand/mech
G
36/1100
800
6.7(5.0)X2
16.1(12.0)
TR Inverter
ODB
2880(19800)
2025(14000)
General Section
DAEWOO
B20T-5
4000(2000)
24(500)
electric
rider seated
E,C
2x/2
DAEWOO
B15T-5
(1500)
(500)
electric
rider seated
E,C
2x/2
48V AC
DAEWOO
B18T-5
(1750)
(500)
electric
rider seated
E,C
2x/2
DAEWOO
B20T-5
(2000)
(500)
electric
rider seated
E,C
2x/2
1
2
3
4
5
6
7
8
3000
135
II
40x100x1050
240x905
5/7
2006
1090
2000
4050
2120
919
1625
381
3332
3456
3300
130
II
35x100x900
240x905
5/7
1868
1090
2150
4345
1985
919
1492
376
3194
3318
3300
130
II
35x100x900
240x905
5/7
2001
1090
2150
4345
1985
919
1625
376
3327
3451
3300
135
II
40x100x900
240x905
5/7
2006
1119
2150
4350
1985
919
1625
381
3332
3456
9
10
12
14
15
16
17
18
19
20
21
22
23
23a
8.7/8.7(14.0/14.0)
61/108(310/550)
98/89(500/450)
22/
(17.0/17.0)
(400/600)
(500/450)
26/
(17.0/17.0)
(400/600)
(500/450)
25/
(17.0/17.0)
(400/600)
(500/450)
24/
24
25
26
30
8084(3667)
11027/1466(5002/665)
3869/4215(1755/1912)
(3111)
(4054/557)
(1526/1585)
(3236)
(4427/559)
(1592/1644)
(3598)
(4969/629)
(1722/1876)
32
33
34
2/2
18X7X12.12
15X6X11.25
1397
902/198
86
100
foot/hyd
hand/mech
2/2
18x7-8
15x4.5-8
1264
902/167
86
100
foot/hyd
hand/mech
2/2
18x7-8
15x4.5-8
1397
902/167
86
100
foot/hyd
hand/mech
2/2
200x50-10
16x6-8
1397
912/201
86
100
foot/hydaulic
hand/mech
35
36
37
38
39
40
41
42
43
36/1100
1050
6.7(5.0)X2
16.1(12.0)
TR Inverter
ODB
3125(21550)
2025(14000)
48/550
700
(5.0x2)
(12)
TR Inverter
ODB
(19800)
(14000)
48/770
800
(5.0x2)
(12)
TR Inverter
ODB
(19800)
(14000)
48/770
1050
(5.0x2)
(12)
TR Inverter
ODB
(21550)
(14000)
29
13
45
47
54
55
57
General Section
30
General Section
B15T-5
B18T-5
B20T-5
70
31
General Section
Capacity Chart
SOLID SOFTER TIRE
MODEL
STD, FFL
B15T-5 (48V)
kg
1600
1400
1200
1000
800
600
400
kg
A B
C
D E
1600
1400
1200
1000
800
600
400
A B C
D E
F
mm
A. 2000 ~ 4000 mm MAST
B. 4500 mm MAST
C. 5000 mm MAST
D. 5500 mm MAST
kg
B18T-5 (48V)
FFT
1800
1600
1400
1200
1000
800
600
400
mm
A. 3700 ~ 4000 mm MAST
B. 4500 mm MAST
C. 4800 mm MAST
D. 5000 mm MAST
E. 6000 mm MAST
kg
A B C
D
E
F
1800
1600
1400
1200
1000
800
600
400
E. 5500 mm MAST
F. 6000 mm MAST
A B
C D
E
mm
A. 2000 ~ 3700 mm MAST
B. 4000 mm MAST
C. 4500 mm MAST
D. 5000 mm MAST
mm
E. 5500 mm MAST
F. 6000 mm MAST
E. 6000 mm MAST
ID5O0004
B20T-5 (48V)
kg 2000
kg 2000
1800
1600
1400
1200
1000
800
1800
1600
1400
1200
1000
800
500 600 700 800 900 1000 1100 1200
A
B
C
D
E
F
mm
mm
A. 4000 mm MAST
B. 4500 mm MAST
C. 4750 mm MAST
D. 5000 mm MAST
E. 5500 mm MAST
F. 6000 mm MAST
ID5O0007
32
General Section
MODEL
STD, FFL
kg 1600
B15T-5 (48V)
1400
1200
1000
800
600
400
1400
1200
1000
800
600
400
D
E
F
A B C
D
F
mm
kg
B18T-5 (48V)
kg 1600
A B C
1800
1600
1400
1200
1000
800
600
400
mm
A. 3700 ~ 4000 mm MAST
B. 4500 mm MAST
C. 4800 mm MAST
D. 5000 mm MAST
E. 5500 mm MAST
F. 6000 mm MAST
kg
A B C
D
E
F
G
1800
1600
1400
1200
1000
800
600
400
E. 5500 mm MAST
F. 6000 mm MAST
A B C
E
F
mm
A. 2000 ~ 3300 mm MAST
B. 3500 ~ 3700 mm MAST
C. 4000 mm MAST
D. 4500 mm MAS
kg 2000
B20T-5 (48V)
FFT
mm
E. 5000 mm MAST
F. 5500 mm MAST
G. 6000 mm MAST
kg 2000
1800
1600
1400
1200
1000
800
1800
1600
1400
1200
1000
800
500 600 700 800 900 1000 1100 1200
A
B
E. 5500 mm MAST
F. 6000 mm MAST
ID5O0006
C
D
E
F
mm
mm
A. 4000 mm MAST
B. 4500 mm MAST
C. 4750 mm MAST
D. 5000 mm MAST
E. 5500 mm MAST
F. 6000 mm MAST
ID5O0007
33
General Section
Serial Number
Serial Numbers Locations
Both the lift truck and its motors have serial
numbers. You can record them in this manual for
quick reference.
Use the spaces provided below the illustrations.
34
General Section
G
G
G
G
G
G
G
G
G
G
G
G
G
Located on the right side of the operators seat on
the battery cover.
35
General Section
Mast Abbreviations
TH
- Tire Handler.
CTH
CSH
STD
LP
LPP
FF
BC
- Bale Clamp.
CC
- Carton Clamp.
RC
- Roll Clamp.
LS
- Load Stabilizer.
LH
- Log Handler.
PWH
SS-ST
FFT
QUAD
SPEC
SSS
HSS
ISS
CW
- Special Counterweight.
SF
- Special Forks.
- Ram or Boom
ROTC
- Rotating Carriage.
CR
36
Operation Section
Key Switch
Seat Switch
37
Operation Section
Display Segments
Type1
(Type1)
(Type2)
by
(Type1)
(Type2)
38
Operation Section
For type2
The display gives the following contraction on the dot
matrix display about the operating state of the system.
See table 4
DISPLAY INDICATION
No segments
1 flashing segment
1 segment
2 segments
3 segments
4 segments
5 segments
6 segments
7 segments
8 segments
9 segments
Display
Code
BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery
BATTERY CHARGE
LEVEL
Discharged battery
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Full charged battery
17
60
Battery/inverter
mismatch
BATT MISMATCH
76
78
79
80
BATTERY VOLTAGE
[V]
Voltage < 34.5 V
34.5 V 35.1 V
35.1 V 35.5 V
35.5 V 35.9 V
35.9 V 36.2 V
36.2 V 36.5 V
36.5 V 36.8 V
36.8 V 37.1 V
37.1 V 37.4 V
37.4 V 37.6 V
Voltage > 37.6 V
81
82
83
84
A
A
A
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)
39
Contraction
CONTACTOR
FAULT
77
Description
P-MOTOR
ENCODER
R-M TEMP
SENSOR
L-M TEMP
SENSOR
P-M TEMP
SENSOR
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
F9
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
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
(Type2)
PUMP SIGN ON
DISPLAY
VISUALISATION
(from symbol left side)
1st segment
5th segment
9th segment
(Type1)
OPERATINGMODE
L1 (Limit 1)
L2 (Limit 2)
L3 (Limit 3)
(Type2)
(Type1)
(Type2)
(Type2)
40
Operation Section
82
83
84
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
is managed as follows:
42
Operation Section
Seat Adjustment
Adjust the seat at the beginning of each shift or
when changing operators.
Horn Button
43
Operation Section
44
Operation Section
45
Operation Section
Accelerator Pedal
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.
46
Operation Section
47
Operation Section
48
Operation Section
6
9
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.
10
4
49
Operation Section
50
Operation Section
Type2
51
Operation Section
NOTICE
4. Push down on the service brake pedal and
release the parking brake.
52
Operation Section
53
Operation Section
54
Operation Section
Operating Techniques
NOTE: The illustrations used here are typical examples and may not look exactly like to your particular lift
truck.
55
Operation Section
Traveling
Turning
56
Operation Section
Unloading
57
Operation Section
58
Operation Section
59
Operation Section
60
Operation Section
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.
62
Operation Section
Transportation Hints
6. Disconnect the battery.
Shipping
NOTICE
NOTICE
NOTICE
3. Spreader bar widths should be sufficient to
prevent contact with the lift truck.
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.
NOTICE
Release the parking brake to prevent excessive
wear and damage to the parking brake system.
64
Maintenance Section
65
Maintenance Section
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.
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.
Overloading
Fatigue
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
Daily Inspection
67
Maintenance Section
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.
z
z
68
Maintenance Section
18 X 7-8
Ply Rating
or
Strength Index
B15/18T-5
16
Shipping
Pressure
kPa
psi
1000
145
NOTICE
Set the tire inflation equipment regulator at no more
than 140 kPa(20 psi) over the recommended tire
pressure.
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.
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
Nm1
lbin
7.5 0.5
65 5
4.5 0.5
40 5
0.9 0.2
82
Reassembly or
Retightening Troque on
existing hose
Nm1
lbin
4.5 0.5
40 5
3.0 0.5
25 5
0.7 0.2
62
70
Maintenance Section
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.
71
Maintenance Section
Lubricant Specifications
Lubricant Information
Hydraulic Oil
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.
72
Maintenance Section
TRANSMISSION MP
MOBIL
MOTUL
TRM 97
OPAL
Brake Fluid
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
Energol HP 10
Maintenance Section
Type2
74
Maintenance Section
Battery
NOTICE
Vent caps must be tight to prevent soda solution
from entering battery cells.
75
Maintenance Section
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.
76
Maintenance Section
Battery
Hydraulic System
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.
77
Maintenance Section
78
Maintenance Section
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
ISO VG
10
-30
+50
F
Min
Max
-22
+68
-4
+86
+14 +104
+32 +122
-4
+72
+50 +122
-22
+122
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.
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.
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
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.
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.
81
Maintenance Section
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. "
E-S-H key
WORKING
CONDITION AFTER
THE KEY PRESSURE
Standard (S)
High (H)
Limitation 1 (L1)
Limitation 2 (L2)
Limitation 3 (L3)
Economic (E)
Table 7
NOTE: You can modify system operating modes
only after enabling their management with
EYE applicative software.
82
Maintenance Section
83
Maintenance Section
PARAMETER NUMBER
PARAMETER DESCRIPTION
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Seat switch[digit]
31
32
33
34
35
84
Maintenance Section
36
37
38
39
40
41
42
5V out [digit]
43
44
45
46
85
Maintenance Section
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.
86
STD mast
FF mast
FFT mast
-6
Maintenance Section
87
Maintenance Section
Fuses - Replace
Seat - Lubricate
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.
Horn
DC/DC converter
Lights(1)
Lights(2)
Fan
Key
- 10 amps
- 10 amps
- 10 amps
- 10 amps
- 10 amps
- 10 amps
88
Maintenance Section
89
Maintenance Section
Type2
11. Adjust the steering wheel to a comfortable
position.
90
Maintenance Section
Battery Access
Park the lift truck level, with the forks lowered and
the mast tilted forward until the fork tips touch the
floor.
91
Maintenance Section
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.
Battery Exchanging
Vent caps must be tight to prevent soda solution
from entering battery cells.
92
Maintenance Section
Battery Charging
Indicator - Check
Type2
93
Maintenance Section
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.
94
Maintenance Section
4. Fill the drive axle housing with oil through air breather plug hole() , the accurate amount of
oil is defined by the opening of level checking
plug().
5. Maintain the oil level.
6. Screw the level checking plug() and air breather in with the seal ring.
95
Maintenance Section
96
Maintenance Section
G
The brake system reservoir is located at the right
side of the steering column.
97
Maintenance Section
98
Maintenance Section
Steer Wheels
Drive Wheels
99
Maintenance Section
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.
100
Maintenance Section
101
Maintenance Section
102
Maintenance Section
103
Maintenance Section
104
Maintenance Section
105
Maintenance Section
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.
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.
Typical example
107
Maintenance Section
108
Maintenance Section
Typical example
- Pitch** X 10
( Actual measurement
)x100
Pitch** X 10
109
Maintenance Section
110
Maintenance Section
5
4
111
Maintenance Section
6
8
7
112
Maintenance Section
Fork - Inspect
113
Maintenance Section
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.
114
Maintenance Section
115
Maintenance Section
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.
117
Index Section
Index
A
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
118
Index Section
O
Operating Techniques .......................................... 55
Operation................................................................ 3
Operation Information ........................................... 11
Operator Restraint System (If Equipped) .............. 16
Operators Station and Monitoring Systems.......... 37
Operators Warning and Identification Plate.......... 35
Operators 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
119
Index Section
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
120
: 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
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
EUROPE