Service Manual Contents Notice: For Use in Service Manual Form SB4080E SB4081E00 D e C - 2 0 0 2

For use in service manual
form SB4080E
SB4081E00
Dec. 2002
SERVICE MANUAL CONTENTS
NOTICE
This form lists the contents of the complets Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers listed with mark (*) are, they are not available for the initial
release of the manual. When items are updated, or supplements added, they
will be announced in preview and should be ordered as they become available.
TITLE FORM NUMBER
Service Manual Contents SB4081E00

Safety SB2003E00
Torque Specifications SB2004E00
DRIVE & CONTROL SYSTEM
MicroController Control System SB4082E00
POWER TRAIN
Power Train SB4083E00
VEHICLE SYSTEMS
Vehicle Systems SB4084E00

Vehicle Systems D & A SB4085E00
Hydraulic System Schematic SB4086E00
Electric System Schematic SB4087E00
OPERATION & MAINTENANCE
Operation & Maintenance Manual SB2329E00
Models ; B20S-3, B25S-3, B30S-3

SB2329E00
Operation &
Maintenance Manual
LIFT TRUCKS
B20S-3, B25S-3, B30S-3
Table of Contents
Table of Contents
Information Section Maintenance Section
Foreword ...............................................................2 Inspection, Maintenance and Repair of Lift Truck

Fork...................................................................... 53
Tire Inflation Information .................................... 57
Safety Section Torque Specifications......................................... 58
Battery Discharge Indicator ................................ 60
Important Safety Information.................................4
Battery ................................................................ 61
Safety ....................................................................5
Lubricant Specifications ..................................... 63
Warning Signs and Labels ................................5
Cold Storage Applications .................................. 65
General Hazard Information..............................9
Lubricant Viscosities and Refill Capacities......... 66
Operation Information .....................................11
Maintenance Information ................................13 Maintenance Intervals ........................................ 67
Crushing or Cutting Prevention.......................13 Quick Reference to Maintenance Schedule ....... 68
Burn Prevention ..............................................14 When Required .................................................. 69
Every 10 Service Hours or Daily ........................ 81
Fire or Explosion Prevention...........................15
First 50 - 100 Service Hours or a Week ............. 87
Operator Restraint System .............................16
First 250 Service Hours or a Month .................. 88
Avoiding Lift Truck Tipovers............................19
Every 250 Service Hours or Monthly.................. 89
How to Survive in a Tipover ............................24
Every 500 Service Hours or 3 Months ............... 93
Every 1000 Service Hours or 6 Months ............. 97
General Section Every 1500 Service Hours or 9 Months ........... 103
Every 2000 Service Hours or Yearly ............... 104
Serial Number .....................................................26
Every 2500 Service Hours or 15 Months ........ 109
Operator’s Warning and Identification Plate .......27
Environment Protection Section

Operation Section
Environment Protection .................................... 110
Operator’s Station and Monitoring Systems .......29
Lift Tuck Control ..................................................34
Before Operating the Lift Truck ...........................38 Index Section
Lift Truck Operation ............................................41
Index ................................................................ 111
Operating Techniques.........................................44
Parking the Lift Truck ..........................................47
Lift Fork Adjustment ............................................49 • WORLDWIDE NETWORK
Storage Information ............................................50
Transportation Hints............................................51
Towing Information .............................................52
-1-
Information Section
Foreword
Literature Information Photographs or illustrations guide the operator
through correct procedures of checking, operation
This manual should be stored in the operator’s and maintenance of the DAEWOO operator
compartment in the literature holder or seat back restraint system.
literature storage area.
SAFE and EFFICIENT OPERATION of a lift truck
This manual contains safety, operation, depends to a great extent on the skill and alertness
transportation, lubrication and maintenance on the part of the operator. To develop this skill the
information. operator should read and understand the Safe
Driving Practices contained in this manual.
Some photographs or illustrations in this publication
show details or attachments that can be different Forklift trucks seldom tipover, but in the rare event
from your lift truck. Guards and covers might have they do, the operator may be pinned to the ground
been removed for illustrative purposes. by the lift truck or the overhead guard. This could
result in serious injury or death.
Continuing improvement and advancement of
product design might have caused changes to your Operator training and safety awareness is an
lift truck which are not included in this publication. effective way to prevent accidents, but accidents
Read, study and keep this manual with the lift truck. can still happen. The DAEWOO operator restraint
system can minimize injuries. The DAEWOO
Whenever a question arises regarding your lift truck, operator restraint system keeps the operator
or this publication, please consult your DAEWOO substantially within the confines of the operator’s
dealer for the latest available information. compartment and the overhead guard.
This manual contains information necessary for

Safety Safe Operation. Before operating a lift truck make
sure that the necessary instructions are available
The Safety Section lists basic safety precautions. In and understood.
addition, this section identifies the text and locations
of warning signs and labels used on the lift truck.
Read and understand the basic precautions listed in Operation
the Safety Section before operating or performing
lubrication, maintenance and repair on this lift truck. The Operation Section is a reference for the new
operator and a refresher for the experienced one.
Operator Restraint System(If Equipped) This section includes a discussion of gauges,
switches, lift truck controls, attachment controls,
This manual contains safety, operation and transportation and towing information.
maintenance information for the DAEWOO operator Photographs and illustrations guide the operator
restraint system. Read, study and keep it handy. through correct procedures of checking, starting,
operating and stopping the lift truck.
WARNING Operating techniques outlined in this publication are

basic. Skill and techniques develop as the operator
Your DAEWOO truck comes equipped with an gains knowledge of the lift truck and its capabilities.
operator restraint system. Should it become
necessary to replace the seat for any reason, it
should only be replaced with another DAEWOO
operator restraint system.
-2-
Information Section
Maintenance Environment Management

The Maintenance Section is a guide to equipment Note that DAEWOO INDUSTRIAL VEHICLE
care. The illustrated, step-by-step instructions are DIVISION is ISO 14001 certified which is
grouped by servicing intervals. Items without harmonized with ISO 9001. Periodic
specific intervals are listed under “When Required” ENVIRONMENTAL AUDITS & ENVIRONMENTAL
topics. Items in the “Maintenance Intervals” chart PERFORMANCE EVALUATIONS have been made
are referenced to detailed instructions that follow. by internal and external inspection entities. LIFE-
CYCLE ANALYSIS has also been made through out
Maintenance Intervals the total product life. ENVIRONMENT
MANAGEMENT SYSTEM includes DESIGN FOR
Use the service hour meter to determine servicing ENVIRONMENT from the initial stage of the design.
intervals. Calendar intervals shown (daily, weekly, ENVIRONMENT MANAGEMENT SYSTEM
monthly, etc.) can be used instead of service hour considers environmental laws & regulations,
meter intervals if they provide more convenient reduction or elimination of resource consumption as
servicing schedules and approximate the indicated well as environmental emission or pollution from
service hour meter reading. Recommended service industrial activities, energy saving, environment-
should always be performed at the interval that friendly product design(lower noise, vibration,
occurs first. emission, smoke, heavy metal free, ozone depleting
substance free, etc.), recycling, material cost
Under extremely severe, dusty or wet operating reduction, and even environmentally oriented
conditions, more frequent lubrication than is education for the employee.
specified in the “Maintenance Intervals” chart might
be necessary.
Perform service on items at multiples of the original

requirement. For example, at “Every 500 Service
Hours or 3 Months”, also service those items listed
under “Every 250 Service Hours or Monthly” and
“Every 10 Service Hours or Daily”.
-3-
Safety Section
Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING”
as shown below.
WARNING
The meaning of this safety alert symbol is as follows :
Attention ! Become Alert ! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DAEWOO dealers have the most current
information available.
-4-
Safety Section
Safety
The safety rules and regulations in this section are Warning Signs and Labels
representative of some, but not all rules and
regulations noted under the Occupational Safety There are several specific safety signs on your lift
and Health Act(OSHA) and are paraphrased without truck. Their exact location and description of the
representation that the OSHA rules and regulations hazard are reviewed in this section. Please take the
have been reproduced verbatim. time to familiarize yourself with these safety signs.
Please refer to 1910. 178 in Federal Register Make sure that you can read all safety signs. Clean
Vol.37, No.202, the National Fire Protection or replace these if you cannot read the words or see
Association No.505(NFPA), American National the pictures. When cleaning the labels use a cloth,
Standard, ANSI B56. 1 Safety Standard for Low Lift water and soap. Do not use solvent, gasoline, etc.
and High Lift Trucks and subsequent revisions for a
complete list of OSHA rules and regulations as to You must replace a label if it is damaged, missing or
the safe operation of powered industrial lift trucks. cannot be read. If a label is on a part that is
Since regulations vary from country to country replaced, make sure a new label is installed on the
outside the U.S.A., operate this lift truck in replaced part. See your dealer for new labels.
accordance with local regulations.
Training Required To Operate or Service
DAEWOO lift trucks are manufactured according to
Warning
the regulations and standards laid down in EU
Machinery Directive 98/37/EC and EMC directive
89/336/EC. Please refer to the Directives 89/655/
EC and 89/391/EC and its amendments for the safe
use of DAEWOO lift trucks.
The most effective method of preventing serious

injury or death to the lift truck operator or others is
for the lift truck operator to be familiar with the
proper operation of the lift truck, to be alert and to
avoid actions or conditions which can result in an
accident.
Do not operate a lift truck if in need of repair, IC6O002P

defective or in any way unsafe. Report all defects
and unsafe conditions immediately. Do not attempt Located on the right side of the lift truck.
any adjustments or repairs unless trained and
authorized to do so.
WARNING
Improper operation or maintenance could result
in injury or death. Do not operate or work on this
truck unless you are properly trained. Read and
understand the Operation and Maintenance
Manual. Additional manuals are available from
DAEWOO Lift Truck dealers.
This also provides allowable lift truck capacity

information.
-5-
Safety Section
General Warnings to Operator 15. Forks should be completely under load and
spread apart as far as load permits.
16. Machine should be equipped with overhead
guard or equivalent protection. Where load
requires it, use load backrest extension. Use
extreme caution if operating without these
devices.
17. Parking-Lower lifting mechanism to floor. Put
directional control or shift lever in neutral. Set
parking/secondary brake. Turn “ON-OFF”
switch off. Chock wheels if machine is on
incline. Disconnect battery when storing
electric machines.
18. Observe safety rules when handling fuel for
ID5O0001 engine powered machine and when changing
batteries for electric machines.
Located on the right side of the operator’s seat, on
the battery cover.
Battery Restraint Warning
WARNING
Only trained and authorized personnel may
operate this machine. For safe operation,read
and follow the Operation and Maintenance
Manual furnished with this lift truck and observe
the following warnings :
1. Before starting machine. Check all controls and
warning devices for proper operation.
2. Refer to machine identification plate for allowable
machine capacity. Do not overload. Operate
machines equipped with attachments as partially
loaded machines when not handling a load.
3. Put directional control or shift lever in neutral Located on front of battery cover.
before “ON-OFF” switch is turned on.
4. Start, turn and brake smoothly. Slow down for turns,
slippery or uneven surfaces. Avoid running over WARNING
loose objects or holes in the roadway surfaces.
Use extreme caution when turning on inclines. Before operating truck, ensure that hood is
securely locked by hood latch, and turn stopper
5. Travel with load as low as possible and tilted back. to locking position. Otherwise, a battery may
If load interferes with visibility, travel with load trailing.
come out of a truck in case of tipover. It could
6. On grade operations travel with load up grade. cause the risk of serious injury or death.
7. Watch out for pedestrians and obstructions.
Check overhead clearances.
8. Do not permit riders on forks or machine at any time.
9. Do not allow anyone to stand or pass under the
elevated portion of any machine.
10. Be sure operating surface can safely support
machine.
11. Operate machine and attachments only from
operator’s position.
12. Do not handle unstable or loosely stacked loads.
13. Use minimum tilt when picking up or depositing a load.
14. Use extreme care when handling long, high, or
wide loads.
-6-
Safety Section
No Riders Warning No Standing on Forks Warning, No

Standing under Forks Warning
WARNING
WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.
Do not stand or ride on the forks. Do not stand

or ride on a load or pallet on the forks. Do not
stand or walk under the forks.
IA1O1004
Located on the right side of the operator station.
Hard Placement Warning

IA8O1005
WARNING
Located on the mast.
Load Backrest Must Be In Place

Warning
(No hands. Do not place hands in this area. Do WARNING

not touch, lean on, or reach through the mast or
permit others to do so.) Operation without this device in place may be
hazardous.
Located on the mast

Located on the load backrest.
-7-
Safety Section
Apply Parking Brake Warning Battery Disconnect Before Servicing

Warning
WARNING
WARNING
When leaving machine apply parking brake!
Parking brake is not automatically applied. Disconnect battery from truck and also
discharge high voltages between B+ and B-
with a 150 ohm, 24 watt Resistor before
attempting to service this truck.
Located on the top left side of the cowl.
Overhead Guard Must Be In Place

Warning
CAUTION
WARNING Do not steam to clean the controls. Use a low
pressure air hose to blow off controls when
Operation without this device in place may be
repuired.
hazardous. This guard conforms to
A.N.S.I.B56.1 and F.E.M. Section IV. This design
has been tested with an impact of 10,800 N•m
(8,000 lb•ft).
Located on the logic unit cover behind the control

panel cover for electrical controls.
IB9O004P
Located outside top frame member of overhead

guard.
-8-
Safety Section
General Hazard Information

WARNING
In many countries, recognized standards and/or
Install any seat to this seat frame. Switch must regulations apply to the use, operation and
shut off all power when operator is not seated. maintenance of lift trucks.
In the USA, please refer to current revisions of :
• 29 Code Federal Register, 1910.178 Powered

2Industrial Trucks.
WARNING • American National Standard, ANSI B56.1 Safety

INSTALL ANY SEAT TO THIS SEAT AStandard for Low Lift and High Lift Trucks.
FRAME. SWITCH MUST SHUT OFF
ALL POWER WHEN OPERATION IS • National Fire Protection(NFPA) 505, Powered
NOT SEATED.
Industrial Trucks, Type designation, Areas of Use,
Maintenance, and Operation.
IA1O1010 • Other OSHA Regulations which may be applicable

to the place of use.
Tagged to steering wheel, when not equipped with
seat cushions.
The most effective method of preventing serious
injury or death to the lift truck operator or others is
for the lift truck operator to be familiar with the
proper operation of the lift truck, to be alert and to
avoid actions or conditions which can result in an
accident.
Do not operate a lift truck if in need of repair,

defective or in any way unsafe. Report all defects
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and
authorized to do so.
G
IN
N
R
A
W
t
no ate
do per
o
IA1O1011
Do not start or service the lift truck when a “DO NOT

OPERATE” or similar warning tag is attached to the
start switch or controls.
Wear a hard hat, protective glasses and other

protective equipment as required by job conditions.
Do not wear loose clothing or jewelry that can catch

on controls or other parts of the lift truck.
-9-
Safety Section
Keep the lift truck, especially the deck and steps,

free of foreign material, such as debris, oil, tools and Keep hands, feet and head inside the operator
other items which are not part of the lift truck. station. Do not hold onto the overhead guard while
operating the lift truck. Do not climb on any part of
Secure all loose items such as lunch boxes, tools the mast or overhead guard or permit others to do
and other items which are not part of the lift truck. so.
Make sure all protective guards, shields and covers Do not allow unauthorized personnel to ride on the
are properly installed and secured in place on the lift forks or any other part of the lift truck, at any time.
truck.
Observe floor load limits and overhead clearances.
Always use the overhead guard. The overhead
guard is intended to protect the lift truck operator Never put maintenance fluids into glass containers.
from overhead obstructions and from falling objects.
Use all cleaning solutions with care.
The overhead guard is not intended to protect
against every possible impact. The overhead guard Do not use steam, solvent, or high air pressure to
may not protect against some objects penetrating clean electrical components.
into the operator’s station from the sides or ends of
the lift truck. Report all needed repairs.
If the lift truck must be operated without the

overhead guard in place due to low overhead
clearance, use extreme care. Make sure there is no
possiblility of falling objects from any adjacent
storage or work area. Make sure the load is stable
and fully supported by the carriage and the load
backrest extension(if equipped).
Do not raise loads any higher than necessary and

never raise a load higher than 1830 mm(72 in) with
the overhead guard removed.
IA8O1010
Always use load backrest extension when the Inspect the part of the chain that is normally
carriage or attachment does not full support the operated over the crosshead roller. When the chain
load. The load backrest extension is intended to bends over the roller, the movement of the parts
prevent the load or any part of the load from falling against each other causes wear.
backwards into the operator’s station.
When operating the lift truck, do not depend on Inspect to be sure that chain link pins do not extend
flashing lights or back-up alarm(if equipped) to warn outside of the bore hole.
pedestrians.
If any single link pin is extended beyond its
Always be aware of pedestrians and do not proceed connecting corresponding link, it should be
until the pedestrians are aware of your presence suspected of being broken inside of its bore hole.
and intended actions and have moved clear of the Inspect the chain anchor and the anchor links for
lift truck and/or load. wear.
Do not drive lift truck up to anyone standing in front

of an object.
Obey all traffic rules and warning signs.
Know the appropriate work-site hand signals and who

gives them. Accept signals from one person only.
- 10 -
Safety Section
Operation Information Starting the Lift Truck
Mounting and Dismounting Start the lift truck only from the operator’s station.
Make sure no one is standing and/or working on,

underneath or close to the lift truck before starting or
beginning to move the lift truck.
Refer to the topic “Start the Lift Truck” in the

“Operation Section" of this manual for specific
startng instructions.
Before Operating the Lift Truck
Operate the lift truck and controls only from the

operator’s station.
• Mount and dismount the lift truck carefully.
Make sure the lift truck horn, lights, backup alarm
(if equipped) and all other devices are working
• Clean your shoes and keep your hands and
properly.
steering wheel free of slippery material.
Check for proper operation of mast and
• Use both hands and face the lift truck when
attachments. Pay particular attention to unusual
mounting and dismounting.
noises or erratic movement which might indicate a
problem.
• Maintain a three point contact(two feet and one
hand or one foot and two hands contact) with the
Make sure service and parking brakes, steering,
steps and handholds.
and directional controls are operational.
• Never get on or off a moving lift truck.
Make sure all personnel are clear of lift truck and
travel path.
• Never jump off the lift truck.
• Do not try to climb on or off the lift truck when Operating the Lift Truck
carrying tools or supplies.
Always keep the lift truck under control.
• Do not use any controls as handholds when
entering or leaving the operator’s station. • Lower mast, with or without load, before turning or
traveling. Watch out for overhead obstructions.
Before Starting the Lift Truck
• Start, turn, and brake smoothly, slow down for
turns, grades, slippery or uneven surfaces.
Perform a walk-around inspection daily and at the
start of each shift. Refer to the topic “Walk-around
• Use special care when operating on grades. Do
Inspection” in “Every 10 Service Hours or Daily”
not angle across or turn on grades. Do not use lift
section of this manual.
truck on slippery grades. Travel with forks
downgrade when unloaded. Travel with load
Adjust the seat so that full pedal travel can be obtained
upgrade.
with the operator’s back against the seat back.
• When turning the lift truck, slow down to a safe
Make sure all hydraulic controls are in the HOLD
speed. Use extra caution when turning with the
position.
load not fully lowered.
Make sure the direction control lever is in the
• When turning on inclines, be extremely careful.
NEUTRAL position.
• Do not overload, or handle offset, unstable, or
Make sure the parking brake is engaged.
- 11 -
Safety Section
loosely stacked loads. Refer to load capacity plate floor.

on the lift truck. Use extreme caution when
handling suspended, long, high or wide load. Move the direction control lever to NEUTRAL.
• Do not stunt ride or indulge in horseplay. Engage the parking brake.
Always look and keep a clear view of the path of Turn the key switch off and remove the key.
travel.
Disconnect the battery.
• Travel in reverse if load or attachment obstructs
visibility. Use extreme caution if visibility is Block the drive wheels when parking on an incline.
obstructed.
• Stay in designated travel path, clear of dock edges,

ditches, other dropoffs and surfaces which cannot
safely support the lift truck.
• Slow down and use extra care through doorways,

intersections and other location where visibility is
reduced.
• Slow down and avoid pedestrians, other vehicles,

obstructions, pot holes and other hazards or
objects in the path of travel.
Refer to the topic “Operating Techniques” in the

“Operation Section” of this manual.
Loading or Unloading Trucks/Trailers
• Do not operate lift trucks on trucks or trailers which

are not designed or intended for that purpose.
• Be certain truck or trailer brakes are applied and

wheel chocks in place (or be certain unit is locked
to the loading dock) before entering onto trucks or
trailers.
• If trailer is not coupled to a tractor, make sure the

trailer landing gear is properly secured in place. On
some trailers, extra supports may be needed to
prevent upending or corner dipping.
• Be certain dockplates are in good condition and

properly placed and secured. Do not exceed the
rated capacity of dockboards or bridgeplaces.
Lift Truck Parking
When leaving the operator station, park the lift truck

in authorized areas only. Do not block traffic.
Park the lift truck level, with the forks lowered and
the mast tilted forward until the fork tips touch the
- 12 -
Safety Section
Maintenance Information Crushing or Cutting Prevention

Perform all maintenance unless otherwise specified Support equipment and attachments properly when
as follows : working on or beneath them. Do not depend on
hydraulic cylinders to hold it up. Any attachment or
• Lift truck on level ground. mast can fall if a control is moved, or if a hydraulic
line breaks.
• The mast fully lowered and the forks tilted forward
until the fork tips are touching the ground/floor. Never attempt adjustments while the lift truck is
moving or the motor is running unless otherwise
• All attachment controls are in HOLD position. specified.
• Direction control lever in the NEUTRAL position. Where there are implement linkages, the clearance
in the linkage area will increase or decrease with
• Parking brake engaged. movement of the implement.
• The key start switch off and the key removed. Stay clear of all rotating and moving parts.
• Disconnect the battery. Keep objects away from moving fan blades. They
will throw or cut any object or tool that falls or is
Pressure Air pushed into them.
Pressure air can cause personal injury. When using Do not use a kinked or frayed wire rope cable. Wear
pressure air for cleaning, wear a protective face gloves when handling the wire rope cable.
shield, protective clothing and protective shoes.
The maximum air pressure must be below 205 Retainer pins, when struck with force, can fly out
kPa(30 psi) for cleaning purposes. and injure nearby persons. Make sure the area is
clear of people when driving retainer pins.
Fluid Penetration
Wear protective glasses when striking a retainer pin
Always use a board or cardboard when checking for to avoid injury to your eyes.
a leak. Escaping fluid under pressure, even a pin-
hole size leak, can penetrate body tissue, causing Chips or other debris can fly off objects when struck.
serious injury, and possibly death. If fluid is injected
into your skin, it must be treated by a doctor familiar Make sure no one can be injured by flying debris
with this type of injury immediately. before striking any object.
- 13 -
Safety Section
Burn Prevention Service, exchange and handle batteries only in

authorized areas when proper safety and ventilation
Oils facilities are provided.
Do not smoke, or expose battery to sparks or flame

when checking, charging or servicing battery. Keep
chains and metallic tools away from top of battery.
Betteries give off flammable fumes which can

explode.
Highly explosive gases are especially hazardous

toward the end of the charging period as the battery
approaches a full charge condition.
Electrolyte is an acid and can cause personal injury

if it contacts skin or eyes.
Hot oil and components can cause personal injury.
Service batteries in accordance with battery
Do not allow hot oil or components to contact the manufacture instructions.
skin.
Refer to the topic “Batteries” in the “Maintenance
At operating temperature, the hydraulic tank is hot Section” of this manual.
and can be under pressure.
Remove the hydraulic tank filler cap only after the

motor has been stopped and the filler cap is cool
enough to remove with your bare hand.
Remove the hydraulic tank filler cap slowly to relieve

pressure.
Relieve all pressure in air, oil or cooling systems

before any lines, fittings or related items are
disconnected or removed.
Batteries
Only trained and designated personnel should

inspect, recharge or exchange batteries.
Always wear protective glasses when working with

batteries.
- 14 -
Safety Section
Fire or Explosion Prevention This work should be done only by trained personnel
using the proper tools and procedures.
General
AT LEAST 15m(150ft) AT LEAST 500m(1500ft)
Have a fire extinguisher-type BC and 1.5 Kg
minimum capacity-on rear overhead guard leg with
latch and know how to use it. Inspect and have it
serviced as recommended on its instruction plate.
Keep all fuels and lubricants stored in properly

marked containers and away from all unauthorized
persons.
All fuels, most lubricants and some coolant mixtures IA1O1016

are flammable.
Do not approach a tire closer than the outside of the
Clean and tighten all electrical connections. Check area represented by the shaded area in the above
daily for loose or frayed electrical wires. Have all drawing.
loose or frayed electrical wires tightened, repaired
or replaced before operating the lift truck. To inflate a tire, stand behind the tread and use a
self-attaching chuck. Make sure all personnel are
Store all oil rags or other flammable material in a away from the danger area where they will not be
protective container, in a safe place. struck by flying debris, should an explosion occur.
Do not weld or flame cut on pipes or tubes that Never inflate tires that have been run flat or are at
contain flammable fluids. Clean them thoroughly less than 80% of the recommended inflation
with nonflammable solvent before welding or flame pressure, or where damage to the tire or rim
cutting on them. components is present or suspected.
Remove all flammable materials such as oil and Whenever possible remove the wheel from the
other debris before they accumulate on the lift truck. truck and inflate the tire in a tire restraining cage or
rack.
Do not expose the lift truck to flames, extreme heat,
etc. Deflate the tire completely by removing the valve
core before starting to remove or to work on the
Do not operate in areas where explosive gases exist wheel.
or are suspected.
Inspect the rim parts and tire for defects, damage
Tire Information and foreign particles. Replace the rim, any side or
lock rings which are bent out of shape, heavily
A tire explosion is much more violent than a rusted or broken. Clean the wheel parts and tire as
blowout. The explosion can propel the tire, rim and necessary.
final drive components as far as 500m(1500ft) or
more from the lift truck. Both the force of the Never intermix rim parts made by different
explosion and the flying debris can cause personal manufacturers or of different brands, or rim parts
injury or death, and property damage. designed to fit a different size or type of rim.
Explosions of air inflated tires have resulted from Make sure the lock ring is correctly seated and
heat induced gas combustion inside the tires. The locked before inflating the tire. Do not attempt to
heat, generated by welding or heating rim seat partially seated side and/or lock rings while or
components, external fire, or excessive use of after inflating tire.
brakes can cause gaseous combustion.
Refer to the “Tire Inflation Information” section for
Explosions of air inflated tires have resulted from the the proper tire inflation pressures.
improper servicing and changing of tires and rims.
- 15 -
Safety Section
Lines, Tubes and Hoses Operator Restraint System(If Equipped)

Do not bend or strike high pressure lines. Do not Warning Signs and Labels
install bent or damaged lines, tubes or hoses.
Your DAEWOO lift truck has the following tipover
Repair loose or damaged oil lines, tubes and hoses. warning decals.
Leaks can cause fires. Contact your DAEWOO Lift
Truck dealer for repair or replacement. Make sure that you can read all safety signs. Clean
or replace these if you cannot read the words or see
Check lines, tubes and hoses carefully. Do not use the pictures. When cleaning the labels use a cloth,
your bare hand to check for leaks. Use a board or water and soap. Do not use solvent, gasoline, etc.
cardboard to check for leaks. See “Fluid You must replace a label if it is damaged, missing or
Penetration” in the safty section for more details. cannot be read. If a label is on a part that is
Tighten all connections to the recommended torque. replaced, make sure a new label is installed on the
Replace if any of the following conditions are found. replaced part. See you DAEWOO Lift Truck dealer
for new labels.
• End fittings damaged or leaking. The most effective method of preventing serious
injury or death to yourself or others is to familiarize
• Outer covering chafed or cut and wire reinforcing yourself with the proper operation of the lift truck, to
exposed. be alert, and to avoid actions or conditions which
can result in an accident.
• Outer covering ballooning locally.
• Evidence of kinking or crushing of the flexible part WARNING

of hose.
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
• Armouring embedded in the outer cover.
could result.
• End fittings displaced.
Make sure that all clamps, guards and heat shields

are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat during
operation. "Survive in tipover" decal
IB9O0002
"Survive in tipover" decal
IB9O0003
- 16 -
Safety Section
"Fasten seat belt" decal WARNING

Your DAEWOO truck comes equipped with a
DAEWOO operator restraint system. Should it
become necessary to replace the seat for any
"Survive in tipover" decal reason, it should only be replaced with another
DAEWOO operator restraint system.
If Optional Suspension Seat Equipped

IB9O0004
The “Survive in tipover” warning is located on the Forward and Backward

overhead guard. It shows the proper use of the Adjustment
operator restraint system.
Seat Adjustment
Front-to -backadjustment
Front-to-back adjustment
IC1O0085
Lever
IB9O0005
Move the lever, slide the seat to the desired

position, and release the lever.
IB9O0006
Adjust the seat before operating the lift truck. After

adjusting, joggle the seat to make sure it is properly
locked. DO NOT adjust the seat while the truck is in
motion.
- 17 -
Safety Section
Seat Belt 2. Replace the seat belt assembly every 3 years

even if it passes visual inspection.
For replacement, see the date of manufacture
labelled on the back side of the belt.
The Operator Restraint System prevents the

operator from jumping from the operator’s
compartment in the event of forward or side tipover. INSO019S
3. In the event of tipover, the seat and restraint

The system is designed to keep the operator on the system should be inspected for damage and
seat and in the operator’s compartment in the event replaced, if necessary.
of tipover.
Inspection WARNING
The seat belt may cause the operator to bend at
the waist. If you are pregnant or have suffered
from some abdominal disease, consult a doctor
before you use the seat belt.
Fasten the Seat Belt
Tung
INSO017S
1. If the seat belt is torn, if pulling motion is

interrupted during extension of the belt, or if the
belt cannot be inserted into the buckle properly,
replace the seat belt assembly.
Buckle
INSO020S
1. Grip the plate (connector) of the belt and pull the

belt from the retractor. Then insert the plate into
the slot of the buckle until a snap is heard.
Pull on the belt to confirm it is latched.
2. Make sure the belt is not twisted.
- 18 -
Safety Section
WARNING
Avoiding Lift Truck Tipovers
If you fasten the belt across your abdomen, the Lift Truck Stability
belt may injure your abdomen in an accident.
INSO023I
Counterbalanced lift truck design is based on the

INSO021S balance of two weights on opposite sides of a
fulcrum (the front axle). The load on the forks must
3. Be sure to fasten the belt across your hips, not be balanced by the weight of the lift truck.
across your abdomen. The location of the center of gravity of both the truck
and the load is also a factor. This basic principle is
NOTE : The belt is designed to automatically adjust used for picking up a load. The ability of the lift truck
to your size and movement. A quick pull on to handle a load is discussed in terms of center of
the belt will confirm that the automatic gravity and both forward and sideways stability.
adjuster will hold the belt position in the
event of an accident.
Center of Gravity (CG)
Release the Seat Belt
CG
INSO024I
INSO022S The point within an object, at which the whole weight

of the object may be regarded as being
Push the button of the buckle to release the belt.
concentrated, is called the center of gravity or CG. If
The belt will automatically retract when released.
the object is uniform, its geometric center will
Hold the plate of the belt and allow the belt to slowly
coincide with its CG. If it is not uniform, the CG could
retract.
be at a point outside of the object. When the lift truck
picks up a load, the truck and load have a new
combined CG.
- 19 -
Safety Section
Stability and Center of Gravity Lift Truck Stability Base
CG truck Combined CG CG load CG-Truck will tip over
INSO025I INSO027I
The stability of the lift truck is determined by the For the lift truck to be stable (not tip over forward or
location of its CG; or, if the truck is loaded, the to the side), the CG must stay within the area of the
combined CG of the truck and load. The lift truck has lift truck stability base – a triangular area between
moving parts and, therefore, has a CG that moves. the front wheels and the pivot of the steer wheels. If
The CG moves forward or backward as the mast is the CG moves forward of the front axle, the lift truck
tilted forward or backward. The CG moves up or will tip forward. If the CG moves outside of the line
down as the mast moves up or down. The CG and, on either side of the stability base, the lift truck will
therefore, the stability of the loaded lift truck, is tip to the side.
affected by a number of factors such as:
• the size, weight, shape and position of the load WARNING

Dynamic forces (braking, acceleration, turning)
• the height to which the load is lifted also affect stability and can produce tipover
even when the CG is within the stability triangle.
• the amount of forward or backward tilt
• tire pressure
Capacity Load (Weight and Load Center)
• dynamic forces created when the lift truck is
accelerated, braked or turned
• condition and grade of surfaces on which the lift

truck is operated
CG load
Combined CG INSO028I
The capacity load of the lift truck is shown on the

CG truck capacity/nameplate riveted to the truck. It is
determined by the weight and load center. The load
center is determined by the location of the CG of the
INSO026I
load.
These same factors are also important for unloaded
lift trucks. They tip over sideways easier than a The load center shown on the nameplate is the
loaded lift truck carrying its load in the lowered horizontal distance from the front face of the forks,
position. or the load face of an attachment, to the CG of the
- 20 -
Safety Section
load. The location of the CG in the vertical direction

is the same as the horizontal dimension.
Remember that, unless otherwise indicated, the

capacity load shown on the nameplate is for a
standard lift truck with standard backrest, forks and
mast, and having no special-purpose attachment. In
addition, the capacity load assumes that the load
center is no further from the top of the forks than it is
from the face of the backrest. If these conditions do
not exist, the operator may have to reduce the safe
operating load because the truck stability may be INSO031S
reduced. The lift truck should not be operated if its
DON’T go over rough terrain! If unavoidable, slow
capacity/nameplate does not indicate capacity load.
down.
NOTE : If the load is not uniform, the heaviest
portion should be placed closer to the
backrest and centered on the forks.
NOTICE
1. Capacity/Nameplates originally attached to
forklifts sold by DAEWOO shall not be removed,
altered or replaced without DAEWOO’s approval.
2. DAEWOO assumes no responsibility for lift trucks

INSO032S
placed in service without a valid DAEWOO
Nameplate. DON’T start, turn, or stop quickly.
Sudden movement can cause the lift truck to
3. If necessary to change your specification, contact tipover.
your DAEWOO lift truck dealer.
Safe Driving Practices
DON’T crowd. Maintain a safe distance from the

edge of docks, ramps and platforms. Always watch
“tail swing”
INSO030S
DON’T overload. Always handle loads within the

rated capacity shown on the capacity plate.
- 21 -
Safety Section
INSO034S INSO037S
DON’T drive on soft ground. DON’T elevate tilted loads !

This can also cause the lift truck to tipover forward.
INSO035S
INSO038S
DON’T turn on, or drive across an incline.
DON’T pick up an off center load ! Such a load
increases the possibility of a tipover to the side.
INSO036S
DON’T tilt elevated loads forwards ! INSO039S

This can cause the lift truck to tipover forward.
DON’T drive on slippery surfaces ! Sand, gravel, ice
or mud can cause a tipover. If unavoidable, slow
down.
- 22 -
Safety Section
INSO040S INSO043I
DON’T attempt to pick up or deposit a load unless DON’T travel with the mast raised.
the lift truck is level.
INSO041S
DON’T jump off if your truck starts to tipover !

Stay in your seat to survive.
INSO042I
DON’T compromise safety. Wear a hard hat if

required on your job site.
- 23 -
Safety Section
How to Survive in a Tipover

FASTEN SEAT BELT
TIPOVER CAN OCCUR

WARNING IF TRUCK IS IMPROPERLY
OPERATED.
INJURY OR DEATH
DON'T JUMP
HOLD ON TIGHT TO
STEERING WHEEL BRACE FEET
LEAN AWAY
FROM IMPACT
LEAN
FORWARD
WARNING COULD RESULT. IN CASE OF TIPOVER
HOLD ON TIGHT
INSO048I
Hold on tight.
FASTEN SEAT BELT
INSO045I FASTEN SEAT BELT
TIPOVER CAN OCCUR

IF TRUCK IS IMPROPERLY HOLD ON TIGHT TO LEAN AWAY
In the event of a tipover, the risk of serious injury or OPERATED.

INJURY OR DEATH
DON'T JUMP STEERING WHEEL BRACE FEET FROM IMPACT
LEAN
FORWARD

death will be reduced if the operator is using the
operator restraint system and follows the
instructions provided.
FASTEN SEAT BELT

BRACE FEET
TIPOVER CAN OCCUR
IF TRUCK IS IMPROPERLY HOLD ON TIGHT TO LEAN AWAY LEAN
INSO049I
OPERATED. DON'T JUMP STEERING WHEEL BRACE FEET FROM IMPACT FORWARD
INJURY OR DEATH
Brace your feet and keep them within the operator’s
compartment.
FASTEN SEAT BELT
FASTEN SEAT BELT TIPOVER CAN OCCUR

INJURY OR DEATH
INSO046I WARNING COULD RESULT. IN CASE OF TIPOVER
Always use operator restraint system.
FASTEN SEAT BELT
TIPOVER CAN OCCUR

IF TRUCK IS IMPROPERLY
OPERATED.
INJURY OR DEATH
DON'T JUMP
HOLD ON TIGHT TO
STEERING WHEEL BRACE FEET
LEAN AWAY
FROM IMPACT
LEAN
FORWARD LEAN AWAY
INSO050I
Lean away from the direction of fall.
DON'T JUMP
INSO047I
DON’T jump.
- 24 -
Safety Section
FASTEN SEAT BELT
TIPOVER CAN OCCUR

INJURY OR DEATH
LEAN FORWARD
INSO051I
Lean forward.
- 25 -
General Section
Serial Number
Serial Numbers Locations
For quick reference, record the serial numbers in the
space provided below the illustration photographs.
Lift Truck Serial Number

I
Hydraulic/Power Steering Motor Serial Number

I
Drive Motor Serial Number

I
- 26 -
General Section
Operator’s Warning and Identification Plate

Familiarize yourself with the information on the ldentification, Lift Capacity and Attachment Plates. Do not
exceed allowable lift truck working capacity load ratings.
Operator’s Warning Plate Identification, Lift Capacity and

Attachment Plate
Lift Truck Capacity Rating
DO NOT exceed allowable lift truck working

capacity load ratings.
The capacity of the lift truck is given by weight and

distance to the load center. For example: a capacity
of 1200kg(2540 lb) at 600mm(24in) means that the
lift truck can lift 1200kg(2640lb) if the load center is
600 mm (24in) from both the vertical and horizontal
ID5O0001
faces of the forks.
Located on the right side of the operator’s seat on
the battery cover. Before attempting to lift any load, ensure that the
weight and load center combination is within the
capacity of the lift truck as shown on the capacity
rating plate. To determine the load center measure
the distance from the face of the carriage to the
gravitational center of the load.
The rated capacity on the plate refers to the capacity

of the lift truck as it left the factory. Subsequent
changes of any form to the equipment or battery can
alter the lift truck’s rating.
The rated capacity of the lift truck applies to

operating conditions where the lift truck is on level
ground. The capacity of the lift truck is reduced on
inclines.
Mast Abbreviations
STD - Standard Mast(single inner member, low

free lift).
FF - Full Free Mast [single inner member, with

high free duplex or multiple cylinder(s)].
FFT - Triple Lift Mast (two inner members with

either low or full free lift).
QUAD - Quadruple(Quad) Mast(three inner

members).
SPEC - Special Mast, such as non-telescopic or

double mast, not within the other
classifications.
- 27 -
General Section
NOTE : When only a mast-type is listed on the LH - Log Handler.

identification plate, a standard carriage and
forks are used. PWH - Pulp Wood Handler.
Attachment Abbreviations (includes SS-ST - Sideshift-Side Tilt Carriage.

Special Forks)
SC - Special Carriage-increased width, height or

outreach.
SSS - Shaft-type Sideshift Carriage.
HSS - Hook-type Side Carriage(ITA).
CW - Special Counterweight.
SF - Special Forks.
NOTE : Numbers following this abbreviation

indicate number and/or length of forks.
SS - SWS-Sideshift-Swing Shift.
RAM - Ram or Boom
ROTC - Rotating Carriage.
DBCBH - Double Cube Block Handler
HFP - Hydraulic Fork Positioner, Non Sideshift.
CR - Crane Arm or Crane Boom.
TH - Tire Handler.
CTH - Container Top Handler.
CSH - Container Side Handler
LP - Load Push Device, Non Sideshift.
LPP - Load Push-Pull Device, Non Sideshift.
C - General Clamp (other than Bale, Carton

or Roll).
BC - Bale Clamp.
CC - Carton Clamp.
RC - Roll Clamp.
LS - Load Stabilizer.
- 28 -
Operation Section
Operator’s Station and Monitoring Systems

Read and understand the “Safety”, “Operation” and “Maintenance” sections before operating the lift truck.
Key Switch OPEN - When the operator’s seat is in the

up position the electrical circuits are
disconnected.
CLOSE - When the operator’s seat is in

the down position(operator seated) the
electrical circuits are connected.
The power steering pump motor is activated when

the key switch is turned to ON and the seat switch is
closed.
The key switch is located on the right side of the

steering column.
OFF - Turn the key switch to OFF to

disconnect the electrical circuits.
ON - Turn the key switch the ON to

connect the electrical circuits. If the key
switch is left in the ON position when the
operator leaves the lift truck, the LCD
display will show a flashing “EE”.
The power steering pump motor is activated when the

key switch is turned to ON and the seat switch is closed.
NOTE : The power steering pump motor will shut off if

the directional lever is left in NEUTRAL and no
control levers are actuated for approximately
six seconds. The motor will be turned on when
any control lever is used.
Seat Switch
The seat switch is located under the operator’s seat.

- 29 -
Operation Section
Monitoring Systems Indicator Battery Discharge Indicator with

Interrupt
Located on the middle of the console cover panel.

Indicates the battery state of charge, as
The symbols shown on the instrument panel identify shown by the LCD display on the
different features of the lift truck. The symbol for instrument panel. A fully charged battery
each feature is identified and an explanation of the will cause a “6” segments displayed on the
function and location is described on the following display. As the battery is discharged, the LCD
pages. display will count down 6,5,4,3 etc, until “EL” is
displayed.
Run Time Diagnostics When “1 segment” is flashed the battery has

reached 80% discharge level, the Controller will
cause the display to continuously index through the
entire range to signal, to the operator, that the
battery is discharged and lift interrupt is imminent. If
the warning is ignored lift interrupt will prevent the lift
and tilt from operating and a “EL” (zero) will be
flashed on the display.
Replacement of the discharged battery will reset the

lift interrupt and normal operation will resume again.
Power On Indicator
While operating the lift truck, diagnostic checks are
constantly being made. The LCD display is used to
indicate the following discrepancies from normal
operation.
When the key switch is on and the seat

switch is open an “EE” will flash on the
display. This is to remind the operator to
turn the key switch OFF when leaving the
lift truck.
- 30 -
Operation Section
Static Return to Off No LCD Display
If the directional control lever is placed in If the LCD display does not show any
forward or reverse and/or the accelerator indication when the key switch is on and
is depressed before both the key switch is the seat switch is closed, the line fuse and
turned to ON and the seat switch is key fuse should be checked.
closed, an “EE” will be shown on the display and the
lift truck will not operate. The directional control NOTE : the LCD display indicates the lift truck
lever must be returned to neutral and/or the discrepancies described, but will
accelerator released before the lift truck will automatically return to the battery
operate. discharge with interrupt function when the
problem is corrected.
Fault Detection Circuit

Over Temperature
During lift truck operation the drive and

hydraulic pump circuits are continuously If the controller or motors should overheat,
monitored for power circuit failure. The high temperature symbol will be
Additional drive and pump circuit shown on the LCD display. Lift truck
components are tested each time the key switch is performance will be reduced until
turned on. Should a fault be detected, the lift truck operating temperatures return to normal. When this
will shut off and the display will alternately flash “F” occurs, the lift truck should be parked and permitted
and a code. to cool.
NOTE : Refer to the “Test and Adjusting” section of

The “F” plus code indicates the controller failure with
the Service Manual or contact your
out “F0”.
DAEWOO Lift Truck dealer.
- 31 -
Operation Section
Self-Diagnostics Indicator Service Hour Meter
The LCD display is also used as an indicator for the Located on the RIGHT side of cowl.
self-diagnostics system built into the “Micro-
Controller.” A service mechanic can completely Indicates the total number of hours the lift
troubleshoot the electrical functions without truck has operated. Use it to determine
additional diagnostic equipment. service intervals.
See the topic “Self-Diagnostics” in the Maintenance

Section of this manual for further information on Front and Rear Floodlights Switch
your particular model for self-diagnostics.
Located on the right side of the steering column

Motor Brushes Wear Indicator - The above the key switch.
“E1” code is displayed when the motor
brushes are worn and need to be
replaced. Replace the brushes to reduce OFF - Push down on the left side of the
the risk of armature damage from overworn brush. switch to turn both front and rear flood
lights off.
Parking Brake Indicator - The LCD
Front Floodlights - Push down on the
P below parking brake symbol will be lit
right side of the switch, to the first position,
when the park brake is applied.
to turn the front floodlights on.
Front and Rear Floodlights - Push down

on the right side of the switch, to the second
position, to turn both front and rear floodlights
on. The rear floodlights are optional.
- 32 -
Operation Section
Horn Button Seat Adjustment

Adjust the seat at the beginning of each shift or
when changing operators.
Adjust the seat to allow full travel of all pedals with

the operator seated against the seat back.
The seat must be adjusted with the operator seated.
Located in the center of the steering wheel.

Push in on the horn button to sound the
horn.
Tilt Steering Column

IA8O3013
Move the lever to adjust the seat forward or

backward. Release the lever. Move the seat slightly
to lock it.
Located on the lower front of the steering column.
To adjust the steering column, raise the handle and

move the steering column to the desired position.
Release the handle and the steering column will
remain in the desired position.
- 33 -
Operation Section
Lift Truck Control

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

on the floor of the operator’s compartment.
Depress the service brake pedal to slow or

stop the lift truck.
Release the service brake pedal to allow

the lift truck to move.
Parking Brake - The parking brake lever

P is located on the left side of the cowl.
Parking Brake Engaged - Pull the

parking brake lever back, which will
engage the interlock switch that shuts off
power to the drive motor.
Parking Brake Disengaged - Push the

parking brake lever forward to release the
parking brake.
- 34 -
Operation Section
Accelerator Pedal Directional Control Lever
NOTICE
The service brake and accelerator pedals should
not be used at the same time, except for emergency
situations. Use of both the brake and accelerator
pedals at the same time may cause the drive motor
to overheat.
Forward - Push the lever forward.

The lift truck will move forward.
Neutral - Move the lever to center

position. The lift truck should not move
when lever is in neutral.
If the operator leaves the seat, or turns the key

switch off, the lever must be returned to NEUTRAL.
The lift truck will not move until accelerator pedal is
Accelerator Pedal - The accelerator pedal is released and lever is returned to NEUTRAL.
located on the floor of the operator’s compartment.
NOTE : Wait Mode of Operation-This condition will
Push down the pedal to increase travel speed. go into effect when the following occurs.
The seat switch is closed, key switch is on
If the accelerator pedal is depressed before the key and the directional control lever is left in
switch is turned to the ON position, the lift truck will NEUTRAL for more than five seconds, with
not move until the pedal is released and depressed no operator input to any control.
again.
The line contactor will open and the power steering
Release the pedal to decrease travel speed. motor will turn off to conserve energy. The lift truck
will remain in this mode until the operator moves the
Film For function of pedals (if equipped) directional control lever, pushes on the accelerator
pedal and/or moves any control valve lever.
Reverse - Pull the lever toward the

operator. The lift truck will move in
reverse.
NOTE : The directional control lever can be used

for electrical braking(plugging). To slow or
stop the lift truck when traveling in either
direction, move the directional control lever
to the opposite direction of travel while
keeping the accelerator depressed. The lift
truck will slow to a complete stop and then
This plate shows the function of the brake and accelerate in the opposite direction.
accelerator pedals.
When the operator raises off the seat (seat switch
opens) while the lift truck is in motion, the drive
- 35 -
Operation Section
motor will lose power. When this occurs, release the Tilt Control Lever
accelerator, close the seat switch(operator seated),
move the directional control lever to NEUTRAL and
then to desired direction of travel. Push down on the
accelerator.
Lift Control Lever
The forks’ tilt control is located at the operator’s right

side front. The tilt control lever is the lever at the
center.
Tilt Forward - Push the lever forward

smoothly to tilt the forks forward.
The forks’ lift control is located at the operator’s right

side front. The lift control lever is the lever at the left. Hold - Release the tilt lever. The lever will
return to the center(hold) position and the
Lower - Push the lever forward smoothly forks will remain in the position they are in.
to lower the lift forks.
Tilt Back- Pull the lever back smoothly to
tilt the forks back.
Hold - Release the lift lever. The lever will
return to the center(hold) position and the
forks will remain in the position they are in. NOTE : To prevent a sudden change of position of
the load, operate all lift, tilt and attachment
Raise - Pull the lever back smoothly to controls smoothly. Never tilt an elevated
raise the lift forks. load forward past vertical.
NOTE : To prevent a sudden change of position of

controls smoothly.
- 36 -
Operation Section
Sideshift Attachment Control (If

Equipped)
The sideshift attachment control is located at the

operator’s right side front. The sideshift attachment
control lever is the lever at the right.
Sideshift Left - Push the lever forward

smoothly to shift the carriage to the left.
Sideshift Hold - Release the sideshif

attachment lever. The lever will return to
the center(hold) position and sideshifting
action will stop.
Sideshift Right - Pull the lever back

smoothly to shift the carriage to the right.
NOTE : To prevent a sudden change of position of

controls smoothly.
- 37 -
Operation Section
Before Operating the Lift Truck

Walk-Around Inspection
For your own safety and maximum service life of the
lift truck, make a thorough walk-around inspection
before mounting the lift truck or starting to move it.
Look for such items as loose bolts, trash build-up, oil
leaks, condition of tires, mast, carriage, forks or
attachments.
6. Inspect the tires and wheels for proper inflation, cuts,

gouges, foreign objects and loose or missing nuts.
7. Inspect the overhead guard for damage, loose
or missing mounting bolts.
8. Inspect the hydraulic system for leaks, worn

hoses or damaged lines.
9. Inspect the drive axle housing and the ground

1. Inspect the operator’s compartment for loose
for oil leaks.
items and clean any mud or debris from the floor
plates for safe footing.
2. Inspect the instrument panel for damage to the

indicator display.
3. Test the horn and other safety devices for proper

operation.
10. Disconnect the battery. Tilt the steering column

to the full upright position. Release the battery
restraint lever in front of battery cover.
11. Raise the lever bracket assembly to the full

uplight position. Raise the seat and cover
assembly.
4. Inspect the mast and lift chains for wear, broken
links, pins and loose rollers.
5. Inspect the carriage, forks or attachments for

wear, damage and loose or missing bolts.
- 38 -
Operation Section
12. Inspect the battery compartment for loose

connections, frayed cables.
WARNING
13. Observe the battery electrolyte level for proper
Personal injury may occur from accidents
level. Lower the seat and cover assembly and
caused by improper seat adjustment. Always
connect the battery to the lift truck. Secure the
adjust the operator’s seat before operating the
battery restraint properly.
lift truck.
Seat adjustment must be done at the beginning

WARNING of each shift and when operators change.
Batteries give off flammable fumes that can
explode.
15. Adjust the steering wheel to comfortable
Do not smoke when observing the battery position. Grasp the steering wheel and raise the
electrolyte levels. handle to release the steering column. PULL the
steering column BACK or PUSH FORWARD to
Electrolyte is an acid and can cause personal obtain the most comfortable position. RELEASE
injury if it contacts skin or eyes. the knob and make sure the steering column is
locked in this position.
Always wear protective glasses when working
with batteries.
16. With the seat switch closed and the directional

IA8O3013
lever in NEUTRAL, turn the key switch ON.
Observe the battery discharge indicator.
14. Position the seat by operating the lever and
moving the seat forward or backward to a
comfortable position.
- 39 -
Operation Section
Better Battery Performance
NOTICE
The lift truck operator must not start his shift with a
battery that has been taken off a charger too soon.
A battery should never be disconnected from a

charge until the charge cycle has been completed.
The batteries that have been fully charged should

17. Make sure the battery is charged before have a tag attached for identification.
operating the lift truck. A fully charged battery
will cause “6 Segments” to be displayed on the In Operation, a battery should be discharged then
BDI display. recharged in 8 to 12 hours, depending on the
charger type. Then, they should be allowed to cool
and stabilize 4 to 8 hours. Repeated undercharging
must be prevented. It can damage the battery.
If there is an indication of low battery operation, the

lift truck operator should return the lift truck to the
battery charging area.
NOTE : Refer to the Maintenance Section of this

guide for additional battery exchanging and
charging information.
- 40 -
Operation Section
Lift Truck Operation
Be sure no one is working on or near the lift truck.
Keep the lift truck under control at all times.
Reduce speed when maneuvering in tight quarters

or when braking over a rise.
Do not allow the lift truck to overspeed downhill. Use

the service brake pedal to reduce speed when
traveling down hill.
1. Adjust the operator’s seat.

5. Turn the key switch to the ON position. Raise the
attachments to the travel position.
2. Fasten the seat belt (If Equipped).
3. Move the directional control lever into the 6. Move the directional control lever to the desired
NEUTRAL position, if it is not already in this direction of travel.
position.
7. Release the service brake pedal.

4. Push down on the service brake pedal and
release the parking brake.
- 41 -
Operation Section
8. Push down on the accelerator pedal to reach the 13. Push down on the service brake pedal to bring
travel speed. Release the pedal to decrease the lift truck to a complete stop and hold it.
travel speed.
14. To change direction, continue to push down on
9. To change the lift truck direction of travel, the accelerator pedal until the disired travel
electrical braking(plugging) can be used to slow speed in the opposite direction is obtained.
or stop the lift truck.
15. Do not use electrical braking (plugging) to stop
10. Electrical braking (plugging) can be used to slow the lift truck where the stopping distance is too
or stop the lift truck or to change the lift truck short.
direction of travel. Instead, release the accelerator pedal, push
down on service brake pedal, and bring the lift
truck to a smooth stop.
11. Move the directional control lever to the opposite

direction of lift truck travel.
12. Hold the accelerator pedal down until the lift

truck nearly comes to a complete stop. Release
the accelerator pedal.
- 42 -
Operation Section
Electrical Braking (Plugging)
Electrical braking uses the drive motor’s own power

to slow, stop or change direction when traveling in
either direction. It is a more gradual type of stop,
compared to using the service brakes. Electrical
braking can be used for normal operation where
there is adequate time and distance to stop safely.
Electrical braking should NOT be used for sudden or
emergency stops.
To start electrical braking, move the directional

control lever to the opposite direction while keeping
the accelerator pedal depressed.
The lift truck drive control senses that the motors are
turning opposite to the vehicle direction of travel and
immediately goes into the plugging mode.
Motor rotation is retarded at a predetermined rate by

eletrical braking (plugging).
If the accelerator pedal is kept depressed, the drive

control will slow the lift truck to a complete stop and
then accelerate in the opposite direction.
- 43 -
Operation Section
Operating Techniques
NOTE : The illustrations used here are typical examples and may not look exactly like your particular lift truck.
Inching into Loads Lifting the Load

1. Move the lift truck slowly forward into position and
engage the load. Lift truck should be square with
load, forks should be spaced evenly between
pallet stringers and as far apart as load will
permit.
IA1O3036
1. Lift the load carefully and tilt the mast back a short
distance.
2. Tilt the mast further back to cradle the load.

IA1O3034
2. Move the lift truck forward until the load touches

the carriage
IA1O3037
3. Operate the lift truck in reverse until the load is

clear of the other loads.
IA1O3035
4. Lower the load to the travel position before
turning or traveling.
- 44 -
Operation Section
Traveling Turning
Whether you are traveling with or without a load,
travel with the fork as low as possible, while still
maintaining good clearance above the floor.
IA103040
1. When turning sharp corners, keep close to the

inside corner. Begin the turn when the inside
IA1O3038
drive wheel meets the corner.
1. Carry the load as low as possible, but maintain

clearance.
IA103041
2. When turning in narrow aisles, keep as far from

IA1O3038
the stockpile as possible when making a turn into
the aisle. Allow for counterweight swing.
2. On grades, alway travel with the load on the
“uphill” side, as shown above.
IA1O3039
3. Travel in reverse with bulky loads. This gives you

better vision.
- 45 -
Operation Section
Unloading Lifting Drums or Round Objects
IA1O3042 IA1O3043
1. Move the lift truck into the unloading position. 1. Block the drums or round objects. Tilt the mast
forward and slide the fork tips along the floor to
2. Do not tilt the mast forward until it is directly over get under the load.
the unloading area.
WARNING
Do not tilt the mast forward with the load unless
directly over the unloading area, even if the
power is off.
IA1O3044
2. Tilt the mast back slightly until the load is cradled

on the forks before lifting.
3. Lift the load to the travel position.
IB9O2009
3. Deposit the load and back away carefully to free

the forks.
4. Lower the carriage and forks to either travel

position or park position.
- 46 -
Operation Section
Parking the Lift Truck
NOTICE
Parking or storage of electric lift trucks outdoor can
cause lift truck system damage or failure.
Park or store all electric lift trucks inside a building to

protect electrical system from moisture damage.
When leaving the operator’s station, park the lift

truck in authorized areas only. Do not block traffic.
Park the lift truck level, with the forks lowered and 3. Engage the parking brake.
floor. Block the drive wheels when parking on an
incline.
4. Tilt the mast forward and lower forks to the floor.
1. Apply the service brake to stop the lift truck.
5. Turn key switch to OFF and remove the key.
2. Move the directional control lever into NEUTRAL.
- 47 -
Operation Section
6. Disconnect the battery.
7. Block the wheels if parking on an incline.
- 48 -
Operation Section
Lift Fork Adjustment
WARNING
When adjusting the fork spread, be careful not
to pinch your hand between forks and the
carriage slot.
Hook-on type Fork
1. Move up the hook pin to the free position.
2. Raise the hook pin in each fork to side the fork on

the carriage bar.
3. Adjust the forks inth position most appropiate for

the load and as wide as possible for load stability.
4. When adjusting the forks, make sure that the

weight fo the load is centered on th truck.
5. After adjustment, set the fork locks to keep the

forks in place.
WARNING
Make sure the forks are locked before carrying a
load.
- 49 -
Operation Section
Storage Information
Before Storage
To place the machine in storage for an extended
period of time, the following measures must be
taken to ensure that it can be returned to operation
with minimal service.
1. After every part is washed and dried, the machine

should be housed in a dry building. Never leave it
outdoors. In case it has to be left outdoors, lay
wooden boards on the ground, park the machine
on the boards and cover it with canvas, etc.
2. Lubricate, grease and replace oil before storage.
3. Apply a thin coat of grease to metal

surface(hydraulic piston rods.)
4. Cover batteries after removing terminals, or

remove them from the machine and store
separately.
During Storage
Drive the truck for a short while once a month so that

new oil film will be coated over movable parts and
component surfaces. Charge the battery at the
same time.
After Storage
After storage(when it is kept without cover or rust-

preventive operation once a month is not made),
you should apply the following treatment before
operation.
1. Remove the drain plug on hydraulic tank and

drain mixed water.
2. Wipe off grease from hydraulic cylinder piston

rod.
3. Measure specific gravity and check that battery is

charged.
4. Drive at low speed to make sure inside of transfer

is well oiled.
- 50 -
Operation Section
Transportation Hints
Shipping 6. Disconnect the battery.
Check travel route for overpass clearances. Make 7. Block the tires and secure the lift truck with
sure there is adequate clearance if the lift truck tiedowns.
being transported is equipped with a high mast,
overhead guard or cab.
Machine Lifting and Tiedown
To prevent the lift truck from slipping while loading, Information
or shifting in transit, remove ice, snow or other
slippery material from the loading dock and the truck
bed before loading.
NOTICE
Improper lifting or tiedowns can allow load to shift
and cause injury and/or damage.
NOTICE
Obey all state and local laws governing the weight,
width and length of a load. 1. Weight and instructions given herein apply to lift
Observe all regulations governing wide loads. trucks as manufactured by DAEWOO.
2. Use properly rated cables and slings for lifting.

Position the crane for level lift truck lift.
NOTICE 3. Spreader bar widths should be sufficient to

Remove ice, snow or other slippery material from prevent contact with the lift truck.
the shipping vehicle and the loading dock.
4. Use the tiedown locations provided for lift truck
tiedown.
Check the state and local laws governing weight,

width and length of a load.
Contact your DAEWOO Lift Truck dealer for

shipping instructions for your lift truck.
IA1O3049
1. Always block the trailer or the rail car wheels

before loading the lift truck.
2. Position the lift truck on the trailer or the rail car.
3. Apply the parking brake and place the

transmission control in NEUTRAL.
4. Tilt the mast forward and lower forks to the floor.
5. Turn key switch OFF and remove the key.
- 51 -
Operation Section
Towing Information
sufficient control and braking when moving a
WARNING disabled lift truck downhill. This will prevent it from
rolling uncontrolled.
Personal injury or death could result when
towing a disabled lift truck incorrectly. The requirements of each towing situation will be
affected by many conditions. Minimum towing lift
Block the lift truck wheels to prevent movement truck capacity is required on smooth, level surfaces,
before releasing the brakes. The lift truck can while maximum capacity is needed on inclines or on
roll free if it is not blocked. poor surface conditions.
Follow the recommendations below to properly Consult your DAEWOO Lift Truck dealer for
perform the towing procedure. towing a disabled lift truck.
The towing instructions given here are for moving a

disabled lift truck only a short distance at low speed
[no faster than 1.2 mph (2 km/h)] to a convenient
location for repair. These instructions are for
emergencies only. If long-distance moving is
required, always haul the lift truck.
You must provide shielding on the towing lift truck to
protect the operator if the tow line or bar should
break.
IC1O0004
Do not allow an operator to sit on the lift truck being
towed unless the steering and braking can be 1. Release the parking brake.
controlled.
The operator on the towed lift truck must always

steer in the direction of the tow line pull. NOTICE
Release the parking brake to prevent excessive
Inspect the tow line or bar and make sure it is in
wear and damage to the parking brake system.
good condition and has enough strength for the
towing situation involved. For a disabled lift truck
stuck in mud or when towing on a grade, use a
2. Release the service brake pedal.
towing line or bar with a strength of at least 1.5 times
the gross weight of the towing lift truck. 3. Turn the key switch OFF.
Keep the tow line angle to a minimum. Do not 4. Disconnect the battery.
exceed a 30˚ angle from the straight-ahead position.
Connect the tow line as low as possible on the lift 5. Fasten the tow bar to the lift truck.
truck being towed.
6. Remove any wheel blocks. Tow the lift truck
Use gradual and smooth lift truck movement. slowly. Do not tow any faster than 2 km/h (1.2
Moving the lift truck quickly could overload the tow mph).
line or bar and cause it to break.
Normally, the towing lift truck should be at least as WARNING

large as the disabled lift truck. It should have
enough brake capacity, weight, and power to control Be sure all necessary repairs and adjustments
both lift trucks for the grade and distance involved. have been made before a lift truck that has been
towed to a service area is put back into
A larger towing lift truck or additional lift trucks operation. Personal injury or death could result.
connected to the rear could be required to provide
- 52 -
Maintenance Section
Inspection, Maintenance and Repair of Lift Truck Forks

The following section gives practical guidelines for Users may also refer to the International
inspection, maintenance and repair of lift truck forks. Organization For Standardization-ISO Technical
It also provides general information on the design Report 5057-Inspection and Repair of Fork Arms
and application of forks and the common cause of and ISO Standard 2330-Fork Arms-Technical
fork failures. Characteristics and Testing.
Lift truck forks can be dangerously weakened by While there are no specific standards or regulations
improper repair or modification. They can also be in the United States, users should be familiar with
damaged by the cumulative effects of age, the requirements for inspection and maintenance of
abrasion, corrosion, overloading and misuse. lift trucks as provided by the 29 Code Federal
Register 1910.178 Powerd Industrial Truck, and
A fork failure during use can cause damage to the ANSI/ASME Safety Standard(s) B56.1, B56.5 or
equipment and the load. A fork failure can also B56.6 as applicable to the type of machine(s) in use.
cause serious injury.
A good fork inspection and maintenance program

along with the proper application can be very
effective in preventing sudden on the job failures.
Repairs and modifications should be done only by

the fork manufacturer or a qualified technician who
knows the material used and the required welding
and heat treatment process.
Users should evaluate the economics of returning

the forks to the manufacturer for repairs or
purchasing new forks. This will vary depending on
many factors including the size and type of fork.
Forks should be properly sized to the weight and

length of the loads, and to the size of the machine
on which they are used. The general practice is to
use a fork size such that the combined rated
capacity of the number of forks used is equal to or
greater than the “Standard(or rated) Capacity” of the
lift truck.
The individual load rating, in most cases, will be

stamped on the fork in a readily visible area. This is
generally on the top or side of the fork shank.
• A fork rated at 1500 pounds at 24 inch load center

will be stamped 1500@24.
• A fork rated at 2000 kg at 600 mm load center will

be stamped 2000@600.
The manufacturer identification and year and date

of manufacture is also usually shown.
Some countries have standards or regulations

which apply specifically to the inspection and repair
of forks.
- 53 -
Maintenance Section
Causes of Fork Failure • Repetitive Overloading

Repetitive cycling of loads which exceeds the
Improper Modification or Repair fatigue strength of the material can lead to fatigue
failure. The overload could be caused by loads in
Fork failure can occur as a result of a field excess of the rated fork capacity and by use of the
modification involving welding, flame cutting or forks tips as pry bars. Also, by handling loads in a
other similar processes which affect the heat manner which causes the fork tips to spread and
treatment and reduces the strength of the fork. the forks to twist laterally about their mountings.
In most cases, specific processes and techniques • Wear
are also required to achieve proper welding of the
particular alloy steels involved. Critical areas most Forks are constantly subjected to abrasion as they
likely to be affected by improper processing are the slide on floors and loads. The thickness of the fork
heel section, the mounting components and the fork blade is gradually reduced to the point where it
tip. may not be capable of handling the load for which
it was designed.
Bent or Twisted Forks
• Stress Risers
Forks can be bent out of shape by extreme
Scratches, nicks and corrosion are points of high
overloading, glancing blows against walls or other
stress concentration where cracks can develop.
solid objects or using the fork tip as a pry bar.
These cracks can progress under repetitive loading
in a typical mode of fatigue failure.
Bent or twisted forks are much more likely to break
and cause damage or injury. They should be
removed from service immediately. Overloading
Extreme overloading can cause permanent bending
Fatigue or immediate failure of the forks. Using forks of less
capacity than the load or lift truck when lifting loads
Parts which are subjected to repeated or fluctuating and using forks in a manner for which they were not
loads can fail after a large number of loading cycles designed are some common causes of overloading.
even though the maximum stress was below the
static strength of the part.
The first sign of a fatigue failure is usually a crack

which starts in an area of high stress concentration
This is usually in the heel section or on the fork
mounting.
As the crack progresses under repetitive load

cycling, the load bearing cross section of the
remaining metal is decreased in size until it
becomes insufficient to support the load and
complete failure occurs.
Fatigue failure is the most common mode of fork

failure. It is also one which can be anticipated and
prevented by recognizing the conditions which lead
up to the failure and by removing the fork service
prior to failing.
- 54 -
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

IA8O3030
within acceptable tolerances. See “Forks, Step
Establish a daily and 12 month inspection routine by 4,” in the “2000 Service Hours or Yearly” in
keeping a record for the forks on each lift truck. “Maintenance Intervals”
Initial information should include the machine serial 3. Make sure positioning lock is in place and working
number on each the forks are used, the fork Lock forks in position before using truck. See
manufacturer, type, original section size, original “Forks, Step 7”, in the “2000 Service Hours or
length and capacity. Also list any special Yearly” in “Maintenance Intervals”.
characteristics specified in the fork design.
Record the date and results of each inspection, Daily Inspection

making sure the following information is included.
1. Visually inspect forks for cracks, especially in the
• Actual wear conditions, such as percent of original heel section, around the mounting brackets, and
blade thickness remaining. all weld areas. Inspect for broken or jagged fork
tips, bent or twisted blades and shanks.
• Any damage, failure or deformation which might
impair the use of the truck. 2. Make sure positioning lock is in place and
working. Lock the forks in position before using
• Note any repairs or maintenance. the truck. See “2000 Service Hours or Yearly” in
“Maintenance Intervals”.
An ongoing record of this information will help in
identifying proper inspection intervals for each 3. Remove all defective forks from service.
operation, in identifying and solving problem areas
and in anticipating time for replacement of the forks.
- 55 -
Maintenance Section
12 Months Inspection With the fork restrained in the same manner as its
mounting on the lift truck, apply the test load twice,
Forks should be inspected, at a minimum, every 12 gradually and without shock. Maintain the test for 30
months. If the truck is being used in a multi-shift or seconds each time.
heavy duty operation, they should be checked every
Check the fork arm before and after the second
six months. See “Forks” in the “2000 Service Hours
application of the test load. It shall not show any
or Yearly” in “Maintenance Intervals.”
permanent deformation.
Consult the fork manufacturer for further information
Maintenance and Repair as may be applicable to the specific fork involved.
Testing is not required for repairs to the positioning
1. Repair forks only in accordance with the lock or the markings.
manufacturer’s recommendations.
Most repairs or modifications should be done only
by the original manufacturer of the forks or an
expert knowledgeable of the materials, design,
welding and heat treatment process.
2. The following repairs or modifications SHOULD

NOT be attempted.
• Flame cutting holes or cutouts in fork blades.
• Welding on brackets or new mounting hangers.

• Repairing cracks or other damage by welding.
• Bending or resetting.
3. The following repairs MAY be performed.
• Forks may be sanded or lightly ground, to

remove rust, corrosion or minor defects from the
surfaces.
• Heel sections may be ground with a carbon
stone to remove minor surface cracks or
defects. Polish the inside radius of the heel
section to increase the fatigue life of the fork.
Always grind or polish in the direction of the
blade and shank length.
• Repair or replace the positioning locks on hook
type forks.
• Repair or replace most fork retention devices
used with other fork types.
4. A fork should be load tested before being

returned to service on completion of repairs
authorized and done in accordance with the
manufacturer’s recommendations.
Most manufacturers and standards require the
repaired fork to be tested with a load 2.5 times the
specified capacity and at the load center marked
on the fork arm.
- 56 -
Maintenance Section
Tire Inflation Information

Tire Inflation Tire Shipping Pressure
The inflation pressures shown in the following chart
are cold inflation shipping pressures for tires on
DAEWOO lift trucks.
Ply Rating Shipping

Size or Pressure
Strength Index kPa psi
B20/25/30S-3
18 x 7 - 8 Steer 16 1000 145
IA1O4001 23 x 10 - 12 Drive 16 930 135
The operating inflation pressure is based on the

weight of a ready-to-work lift truck without
WARNING attachments, at rated payload, and in average
operating conditions. Pressures for each application
Personal injury or death could result when tires
may vary and should always be obtained from your
are inflated incorrectly.
tire supplier.
Use a self-attaching inflation chuck and stand
behind the tread when inflating a tire.
Adjusted Inflation Pressures
Proper inflation equipment, and training in
using the equipment, are necessary to avoid A tire inflation in a warm shop area, 18˚C to 21˚C
overinflation. A tire blowout or rim failure can (65˚F to 70˚F), will be underinflated if the lift truck
result from improper or misused equipment. works in freezing temperatures. Low pressure
shortens the life of a tire.
NOTICE
Set the tire inflation equipment regulator at no more
than 140 kPa(20 psi) over the recommended tire
pressure.
- 57 -
Maintenance Section
Torque Specifications
Metric Hardware - This lift truck is almost totally Torque for Standard Bolts, Nuts
metric design. Specifications are given in metric and and Taperlock Studs
U.S. Customary measurement. Metric hardware
must be replaced with metric hardware. Check parts
books for proper replacement.
NOTICE
NOTE : Use only metric tools on most hardware for
The following charts give general torques for bolts,
proper fit. Other tools could slip and
nuts and taperlock studs of SAE Grade 5 or better
possibly cause injury.
quality.
Torque for Standard Hose Clamps

- Worm Drive Band Type Torques for Bolts and Nuts With
Standard Threads
Thread Size Standard Bolt & Nut Torque

NOTICE
Inch N.m 1 lb.in
The following chart gives the torques for initial
installation of hose clamps on new hoses and for 1/4 12 4 9 3
reassembly or retightening of hose clamps on 5/16 25 7 18 5
existing hose.
3/8 45 7 33 5
7/16 70 15 50 11
Initial Installation 1/2 100 15 75 11

Clamp Width Torque on New Hose 9/16 150 20 110 15
N.m 1 lb.in 5/8 200 25 150 18
16 mm (.625 inch) 7.5 0.5 65 5 3/4 360 50 270 37
13.5 mm (.531 inch) 4.5 0.5 40 5 7/8 570 80 420 60
8 mm (.312 inch) 0.9 0.2 8 2 1 875 100 640 75
Reassembly or Retightening 1 1/8 1100 150 820 110
Clamp Width Torque on existing hose
1 1/4 1350 175 1000 130
N.m 1 lb.in
1 3/8 1600 200 1180 150
16 mm (.625 inch) 4.5 0.5 40 5
1 1/2 2000 275 1480 200
13.5 mm (.531 inch) 3.0 0.5 25 5
1 1 Newton meter (N•m) is approximately the same
8 mm (.312 inch) 0.7 0.2 6 2 as 0.1 kg•m.
as 0.1 kg•m.
- 58 -
Maintenance Section
Torques for Taperlock Studs Torque for Metric Fasteners

Thread Size Standard Taperlock Stud Torque
N.m lb.in
1
Inch NOTICE
1/4 8 3 6 2 Be very careful never to mix metric with U.S.
5/16 17 5 13 4 customary (standard) fasteners. Mismatched or
incorrect fasteners will cause lift truck damage or
3/8 35 5 26 4
malfunction and may even result in personal injury.
7/16 45 10 33 7
1/2 65 10 48 7 Original fasteners removed from the lift truck should
be saved for reassembly whenever possible. If new
5/8 110 20 80 15 fasteners are needed, they must be of the same size
3/4 170 30 125 22 and grade as the ones that are being replaced.
7/8 260 40 190 30
The material strength identification is usually shown
1 400 60 300 45 on the bolt head by numbers.(8.8, 10.9, etc.) The
1 1/8 500 70 370 50 following chart gives standard torques for bolts and
nuts with Grade 8.8.
1 1/4 650 80 480 60
1 3/8 750 90 550 65
1 1/2 870 100 640 75 NOTE : Metric hardware must be replaced with
metric hardware. Check parts book for
proper replacement.
as0.1 kg•m.
2
METREC ISO THREAD
Thread Size Standard Torque
Metric N.m 1 lb.in
M6 12 4 9 3
M8 25 7 18 5
M10 55 10 41 7
M12 95 15 70 11
M14 150 20 110 15
M16 220 30 160 22
M20 450 70 330 50
M24 775 100 570 75
M30 1600 200 1180 150
M36 2700 400 2000 300
as 0.1 kg•m.
2 ISO-International Standard Organization.
- 59 -
Maintenance Section
Battery Discharge Indicator

The battery discharge indicator should be observed gravity. This specification varies with different
frequently before and during operation. battery manufacturers. See the manufacturer’s
specifications for specific gravity at 80% discharge.
If information is not available from the battery
supplier, use 1.140 specific gravity level.
A fully charged battery will cause a “6 segments” to

be displayed on the LCD display. As the battery is
discharged, the LCD display will count down, 6, 5, 4,
and etc., until “EL” is displayed. When the battery
reaches 80% discharge level, the Micro-Controller
will cause the LCD display to continuously index
through the entire range (1 through 6 segments ) to
signal that the battery is discharged and lift interrupt
is imminent.
If the warning is ignored, lift interrupt will

prevent the hydraulic pump motor from
operating and an “EL” will be displayed on
the LCD display.
To prevent over-discharge, the lift interrupt should

not be reset by disconnecting and reconnecting the
battery.
If the batteries are weak, have them charged or

replaced.
The batteries should not be discharged below 80%

of the full charge as indicated by their specific
- 60 -
Maintenance Section
Battery
to cool and stabilize, A battery should never be
WARNING disconnected from a charger until the charge cycle
has been completed.
When using pressure air for cleaning purposes,
wear a protective face shield and protective
Low battery operation must be prevented.
clothing. Maximum air pressure must be below
Operation with a low battery may cause damage to
207 kPa (30 psi).
the battery. Low battery operation will cause higher
than normal current in the electrical system. This
Do not smoke near batteries that are being
can damage contactor tips or shorten motor brush
stored or when checking the electrolyte level.
life.
Electrolyte is an acid solution and can cause
Batteries that have been fully charged should have
personal injury. Avoid contact with skin and
a tag attached for identification.
eyes.
A battery should be recharged in 8 to 12 hours after
being discharged, depending on the charger type,
Maximum life and performance of lift truck batteries then allowed to cool and stabilize 4 to 8 hours.
is dependent on the operator, battery charging, Repeated undercharging must be prevented
maintenance and service. because it can damage the battery.
Most dirt and dust picked up by the battery can A battery requires an equalizing charge at least
usually be blown off with low pressure compressed once every 20 normal charge/discharge cycles. This
air. helps correct and prevent unequal cell specific
gravity (SG) readings. An “equalizing charge” is a
However, if cells are overfilled and electrolyte cycle charge with modification, given usually at an
collects on the covers, the top of the battery will stay interval to bring all cells up to a state of equal
wet. charge. An equalizing charge usually adds three to
four more hours to the cycle charge, at a low finish
If necessary, clean the top of the battery with a rate. It is usually given when the specific gravity
solution of baking soda and hot water. (SG) of electrolyte has a variation of more than 20
points (.020) from cell to cell, after a regular cycle
charge.
NOTICE A “cycle charge” will completely recharge the

Vent caps must be tight to prevent soda solution battery. The typical cycle charge for a fully
from entering battery cells. discharged battery usually is an eight-hour charge.
The battery must be recharged before it has been
discharged over 80% of the rated capacity of the
battery. The work shift of the lift truck can be
To make the solution, add 0.5 kg (1 lb) of baking planned so the battery will not be discharged more
soda to 4 liters (1 gallon) of water. Use a brush than 80%.
having flexible bristles. Apply the soda solution to
the top of the battery until the cleaning action of the A battery should never be left in a discharged state
soda stops. because of sulfate formation. This reduces battery
life drastically. To extend life always recharge the
After cleaning action has stopped, rinse batteries battery without delay after it has been discharged.
thoroughly with water. Dry the batteries with low air
pressure. Repeated over discharging of the battery will
damage the cells, which will shorten battery life and
The lift truck operator must not start his shift with a increase operating cost. Battery life(number of
battery that has been taken off a charger too soon. cycles) decreases as the depth of discharge
Batteries are designed to be charged and allowed increases. The estimated life of the battery
- 61 -
Maintenance Section
discharged to 80% will be approximately twice as

long as if it were discharged 100%.
The battery’s maximum temperature is critical. The

electrolyte temperature should never exceed 43˚C
(110˚F) either while operating or charging. If higher
temperatures are maintained through use or abuse,
reduced battery service life can be expected.
Battery condition is important for a long life. The

elecrolyte level should be maintained at the
recommended levels and the battery should be kept
clean and dry. “Washing down” batteries at different
time periods will reduce the chance of “grounds”
caused by electrolyte spills and corrosion. If done
often enough, just washing with water alone will
eliminate the need for using baking soda. If not, a
solution of baking soda and water must be used to
wash battery at different time periods.
Add water at regular intervals. Enough water should

be added to bring the electrolyte approximately 13.0
mm (.50 inch) above the plates. This is a simple
matter with the use of an automatic cell filler, which
shows a light when the correct level has been
reached. Water should always be added before
charging to be sure thorough mixing with acid when
gassing occurs near the end of charging period. Use
distilled water or have the water supply analyzed.
Charge batteries correctly. It is important that all

batteries should be charged according to the
manufacturer’s instructions. Most of the charging
equipment is fully automatic and should be checked
periodically. Never operate the lift truck with a fully
discharged battery because this will damage the
battery.
When a battery charger operates correctly and

brings a good battery up to full charge, the current
readings will level to the “finish rate.” The charging
voltage will stabilize, the specific gravity will stop
rising and normal gassing can be seen.
NOTICE
• DISPOSAL OF OLD BATTERY
Careless disposal of a battery can harm the
environment and can be dangerous to persons.
Always dispose of a battery to an authorized
personnel only.
Do not attempt to open or dismantle a battery or a
cell.
- 62 -
Maintenance Section
Lubricant Specifications
Lubricant Information Hydraulic Oils (HYDO)
Certain abbreviations follow S.A.E. J754
nomenclature and some classifications follow
S.A.E. J183 abbreviations. The MIL specifications
are U.S.A. Military Specifications. The
recommended oil viscosities can be found in the
“Lubricant Viscosities” chart in this publication.
Chain and Linkage Oils (DEO or

EO)
The following commercial classifications can be

used in the hydraulic system.
• ISO 6743/4 HM
• AFNOR NFE 48-603 HM
• DIN 51524 TEIL 2 H-LP
• HAGGLUNDS DENISON HFO-HF2
• CINCINNATI P68, 69, 70
Viscosity : ISO VG32
Use following engine oils are recommended for use These oils should have antiwear, antifoam, antirust
on chains and linkages. and antioxidation additives for heavy duty use as
stated by the oil supplier. ISO viscosity grade of 32
• European oil specification CCMC D3. would normally be selected.
• API Specification CD, CD/SF, CE NOTICE

• Military specifications MIL-L-2104D or E Make-up oil added to the hydraulic tanks must mix
with the oil already in the systems. Use only
petroleum products unless the systems are
equipped for use with special products.
If the hydraulic oil becomes cloudy, water or air is

entering the system. Water or air in the system will
cause pump failure. Drain the fluid, retighten all
hydraulic suction line clamps, purge and refill the
system.Consult your DAEWOO Lift Truck dealer for
purging instructions.
- 63 -
Maintenance Section
Drive Axle Oil Hydraulic Brake Fluid

NOTE : Failure to follow the recommendation will • Shoe Brake
cause shortened life due to excessive gear
wear.
• Shoe Brake
Select oil that meets the following specifications.
• API GL-5
• MIL-L-2105 C, D
Gear Oil offers maximum protection against the

scoring and pitting of gear teeth and rolling element
bearings.
Gear Oil can also provide excellent stability under

Use heavy duty hydraulic brake fluid certified by the
high temperature conditions and has superior low
oil supplier to meet SAE J1703f latest revision, DOT
temperature performance. It will also give protection
3 or DOT 4 specifications.
against rust and corrosion.
•Oil Cooled Disc Brake (OCDB) •Oil Cooled Disc Brake (OCDB)
NOTE : Failure to follow the recommendation will
cause shortened life due to excessive gear Use heavy duty hydraulic brake fluid certified by the
wear. oil supplier to meet ISO 6743/4 HM, ISO VG 10
latest revision.
The API CD/TO-2 specification or MIL-L-2104D,E or
F oils could be used.
TOTAL Azolla ZS 10
AGIP Acer 10
Lubricating Grease (MPGM) BP Energol HP 10
HLP 10
Use multipurpose Molybdenum Grease(MPGM) for CALTEX Spindurn 10
all lubrication points. If MPGM grease can not be ELF Spinelf
used, a multipurpose type grease which contains Nuto H 10
ESSO Spinesso 10
3% to 5% molybdenum disulfide can be used.
FINA Hydran 10
NLGI No.2 grade is suitable for most temperatures. Velocite oil No.5
Use NLGI No.1 or No.0 grade for extremely low MOBIL
Velocite oil E
temperature. Tllvs oil C 10
SHELL Morlina 10
- 64 -
Maintenance Section
Cold Storage Applications

When an electric lift truck is operated in cold storage Hydraulic System
applications, at temperatures as low as -20˚C (-4˚F),
the battery capacity is decreased. Operation at cold
temperatures can also cause mechanical failures,
short circuits and too much wear due to the
formation of ice crystals.
The direct cause of these problems is the extreme

changes in temperature in combination with
humidity in the air which can result in condensation.
To protect the electric lift truck’s components and

decrease the effects of the cold temperature,
perform the following items before you put the lift
truck to work in cold storage applications.
Drain the hydraulic system and fill it with SAE 5.
MIL-H-5606A hydraulic oil
Battery
There is a reduction in battery capacity in cold
Lift Chains
storage applications. For this reason, it is important
1. Remove the chains Clean them in a
to :
nonflammable cleaning solvent.
a. Be sure the battery is completely charged at the
2. Put the chains in molybdenum disulfide (MPGM)
start of each work cycle.
grease for one hour. Then, before installation,
hang the chains, where they will not move, for
b. If possible, keep the lift truck in a warm storage
three hours.
area when it is not in use.
c. Do not store a discharged battery at below

freezing temperature.
3. Put MPGM grease on the chains at one-week

intervals.
4. Check chains very carefully for wear on the link

Observe the battery discharge indicator frequently.
plate edges, caused when they run over the
sheaves. Check the chains regularly for cracked
links, loss of shape in the holes, and corrosion.
- 65 -
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities Refill Capacities
LUBRICANT VISCOSITIES REFILL CAPACITIES-(APPROXIMATE)

FOR AMBIENT (OUTSIDE) TEMPERATURES
Compartment U.S. Imperial
C F Liters
Compartment Oil or System Gal Gal
or System Viscosities Min Max Min Max Hydraulic & Power
32 8.3 7.0
ISO VG 22 -30 +20 -22 +68 Steering System
Hydraulic and
Power Steering ISO VG 32 -20 +30 -4 +86
Drive Axle 9.2 2.64 2.15
System ISO VG 46 -10 +40 +14 +104
ISO 6743/4 HM Brake Reservoir 0.6 0.16 0.13
ISO VG 68 0 +50 +32 +122
Shoe Brake
SAE 80W90 -20 +50 -4 +122
Drive API GL-5
Axle
Disk Brake SAE 10W -20 +22 -4 +72
Housing
(OCDB)
API CD/TO-2 SAE 30 +10 +50 +50 +122
Shoe Brake
SAE J1703f -30 +50 -22 +122
Brake DOT 3,4
Reser
Disk Brake
-voir
(OCDB) ISO VG 10 -20 +30 -4 +72
ISO 6743/4 HM
- 66 -
Maintenance Section
Maintenance Intervals
Every 250 Service Hours or Monthly
NOTICE
All maintenance and repair, except every 10 service Brake Oil Level - Check ..................................... 89
hours or daily, on the lift truck must be performed by Parking Brake - Test, Adjust .............................. 89
qualified and authorized personnel only. Drive Axle Oil Level - Check .............................. 91
Mast Carriage, Chains and Attachments - Inspect,
Adjust, Lubricate ................................................ 91
Hydraulic Oil Level - Check ................................ 92
NOTICE
Every 500 Service Hours or 3 Months
Careless disposal of waste oil can harm the
environment and can be dangerous to persons. Mast Hinge Pins - Lubricate ............................... 93
Always dispose of waste oil to an authorized Drive Axle Oil(OCDB) - Change .............................
personnel only. Tilt Cylinders - Check, Adjust, Lubricate ............ 93
Crosshead Rollers - Check ................................ 94
Steering Mechanism - Lubricate ........................ 95
Quick Reference to Overhead Guard - Inspect.................................. 95
Control Panel - Clean, Inspect ........................... 95
Maintenance Schedule...............................68 Directional Control Lever - Check ...................... 96
When Required Every 1000 Service Hours or 6 Months

Quick Diagnostics - Test .....................................69
Drive Motor - Clean, Inspect .............................. 97
Head Capacitor - Discharge ...............................77
Hydraulic Return Filter - Change........................ 98
Brushes - Check, Replace ..................................78
Tires and Wheels - Inspect, Check .................... 99
Fuses - Replace ..................................................79
Hydraulic, Power Steering Pump Motor
Seat - Lubricate...................................................79
- Clean, Inspect ............................................... 100
Wheel Bolts - Check for Tightness......................80
Lift Chains - Test, Check, Adjust ...................... 101
Carriage Roller Extrusion - Adjust.......................80
Every 10 Service Hours or Daily
Drive Axle Oil(Shoe Brake) - Change .............. 103
Walk - Around Inspection - Inspect .....................81
Mast Channels - Lubricate ..................................83
Battery - Check, Exchange, Charge ...................83
Every 2000 Service Hours or Yearly
Indicator - Check .................................................85
Tires and Wheels - Inspect .................................85 Steer Wheel Bearings - Reassemble ............... 104
Back - up Alarm (If Equipped) - Test...................86 Drive Wheel Bearings - Reassemble ............... 106
Forks - Inspect ................................................. 106
Air Breather - Change ...................................... 108
First 50 - 100 Service Hours or a Week
Drive Axle Oil - Change.......................................87

Hydraulic Oil - Check, Change ......................... 109

First 250 Service Hours or a Month
Hydraulic Return Filter - Change.........................88
- 67 -
Maintenance Section
Quick Reference to Maintenance Schedule FIRST EVERY
2500 Service Hours or 15 Months

50-100 Service Hours or a Week

250 Service Hours or a Month
2000 Service Hours or a Year

250 Service Hours or a Week
10 Serive Hours or a Day
ITEMS SERVICES PAGE
When Required
Air Breather Change 109
Back-up Alarm(If Equipped) Test 86
Battery Check,Exchange,Charge 83
Brake Oil Level Check 89
Brushes Check, Replace 78
Carriage Roller Extrusion Adjust 80
Control Panel Clean, Inspect 95
Crosshead Rollers Check 94
Directional Control Lever Check 96
Drive Axle Oil Change 87
Drive Axle Oil Level Check 91
Drive Axle Oil(OCDB) Change 93
Drive Axle Oil(Shoe Brake) Change 104
Drive Motor Clean, Inspect 97
Drive Wheel Bearings Reassemble 107
Forks Inspect 107
Fuses Replace 79
Head Capacitor Discharge 77
Hydraulic Oil Check,Change 110
Hydraulic Oil Level Check 92
Hydraulic Power Steering Pump
Clean, Inspect 100
Motor
Hydraulic Return Filter Change 88
Hydraulic Return Filter Change 98
Indicator Check 85
Lift Chains Test, Check, Adjust 101
Mast Carriage, Chains & Attachments Inspect,Adjust,Lubricate 91
Mast Channels Lubricate 83
Mast Hinge Pins Lubricate 93
Overhead Guard Inspect 95
Parking Brake Test, Adjust 89
Quick Diagnostics Test 69
Seat Check, Lubricate 79
Steer Wheel Bearings Reassemble 105
Steering Mechanism Lubricate 95
Tilt Cylinders Check,Adjust,Lubricate 93
Tires & Wheels Inspect 85
Tires & Wheels Inspect,Check 99
Walk-Around Inspection Inspect 81
Wheel Bolts Inspect 80
- 68 -
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.
Quick Diagnostics - Test

Test Circuits and Components
This method will enable quick diagnostics of some

of the components without handheld console.
NOTE : Make sure the battery is fully charged

before any of the following tests are made.
5. While depressing the accelerator to above half

position other than OFF, turn the key switch to
ON.
6. Display will go to a solid “A3” and speed symbols

will increase from 0 to 10 on the LCD indicating
that you have entered diagnostics.
7. Move the directional control lever to NEUTRAL

and release the accelerator.
1. Park the lift truck level, with the forks lowered and
floor. Turn the key switch to OFF.
2. Block the drive wheels.
3. Release the parking brake.
An “A0” will be displayed, in the LCD, if

the logic module circuitry is correct.
4. Move the directional control lever to the forward

position.
- 69 -
Maintenance Section
Diagnostic Tests-Standard Models
See the “Service Manual” testing and adjusting

section of “Lift Trucks Micro-Controller Control
System” to see if the failed component should be
replaced or repaired.
The tests are performed as follows :
Direction Selector
Move the directional control lever from neutral to

forward.
Move the directional control lever from neutral to

reverse.
The directional control lever is forward,

the LCD display “A3”.
And the directional control lever is
neutral, the LCD display “A0”.
If still “A0” or “A3”, a failure has been detected.
The directional control lever is reverse, the LCD

display “A2”.
And the directional control lever is
neutral, the LCD display “A0”
If still “A0” or “A2”, a failure has been
detected.
- 70 -
Maintenance Section
Lift Switch
With the tilt control lever in maxmum

position, the LCD will display “A6” and
Pull the lift control lever slowly to maximum position “A0” when the lever is released.
and then release.
Auxiliary Switch 1
The LCD display the

, , ~ speed that the lift
lever is set to. As
lever is pulled back, Pull the auxiliary control lever to maximum position
1 through 10 will be shown.And the lift control lever and then release. If there is no auxiliary control
is released, the LCD display “A0”. lever, skip to next procedure.
If still “A0”, a failure has been detected.
Tilt Switch
With the 1st auxiliary control lever in

maximum position, the LCD will
display “A7” and “A0” when the lever is
released.
Pull the tilt control lever to maximum position and
then release. If still “A0” or “A7”, a failure has been detected.
- 71 -
Maintenance Section
Auxiliary Switch 2
With the parking brake lever in

Pull the auxiliary control lever to maximum positon display “A9” and “A0” when the lever is
and then release. If there is no auxiliary control released.
lever, skip to next procedure.
Accelerator Control Switch
With the 2nd auxiliary control lever in

display “A8” and “A0” when the lever is
released. Depress the accelerator pedal fully and then
release.
Parking Brake Switch
The accelerator pedal is depressed, the speed

symbols are increase from 0 to 10 on the LCD.
The accelerator pedal is released, the speed
Pull the parking brake lever to maximum position symbols are decrease to 0.
and then release.
If the speed symbols are not full on the LCD, a
failure has been detected.
- 72 -
Maintenance Section
Diagnostic Tests
Refer to the following table, and previous text and pictures to determine correct diagnostic procedure.
Display status
Step Procedure Circuit
Active Normal
Turn the key switch on with the directional A3 &

1 Speed
control lever forward and the accelerator depressed
Symbol
2 Depress the seat and then release Seat switch A0
Release the park brake level and move the

3 A2 A0
directional lever to reverse then to neutral
Directional switch
Move the directional lever to forward then to
4 A3 A0
neutral
Pull the lift lever to maximum position and 1, 2, 3

5 Lift switch A0
then release ~ 10
Pull the tilt lever to maximum position and

6 Tilt switch A6 A0
then release
Pull the 1st auxiliary lever to maximum position

7 Auxiliary switch 1 A7 A0
and then release
Pull the 2nd auxiliary lever to maximum position

8 Auxiliary switch 2 A8 A0
and then release
9 Pull the parking brake lever and then release Parking brake switch A9 A0
Depress the accelerator pedal to maximum Accelerator

10 Accelerator control
and then release Speed symbol
- 73 -
Maintenance Section
Programmable or Settable Feature

The controller contains a number of features which are either settable or programmable. The following is a list
of the features, however the “Service Manual” or your DAEWOO dealer should be consulted in determining
which options may be beneficial to the application.
DRIVE CONTROLLER
NO FEATURES
1 ACCELER. DELAY
2 INVERS BRAKING
3 RELEASE BRAKE
4 PEDAL BRAKE
5 BRAKING(PLUGGING)
6 BRAKING MODULE
7 CURVE BRAKING
8 CURVE TIME
9 CUT BACK SPEED
10 COMPENSATION
11 WEAK DROPOUT
12 I MAX
13 CREEP SPEED
14 MAX SPEED FORWARD
15 MAX SPEED BACKWARD
PUMP CONTROLLER
NO FEATURES
1 ACCELERATION DELAY
2 DECELERATION DELAY
3 EV. ACCELERATION
4 EV. DECELERATION
5 HYD. SPEED COARSE
6 HYD. SPEED FINE
7 HYD. SPEED COMP.
8 HYD. TIME
9 SPEED LIMIT
10 1 ST SPEED COARSE
11 1 ST SPEED FINE
12 1 ST SPEED COMP.
13 2 ND SPEED COARSE
14 2 ND SPEED FINE
15 2 ND SPEED COMP.
16 3 RD SPEED COARSE
17 3 RD SPEED FINE
18 3 RD SPEED COMP.
19 4 TH SPEED COARSE
20 4 TH SPEED FINE
21 4 TH SPEED COMP.
22 CREEP SPEED
23 MAX. CURRENT
24 MIN. VALVE VOLT
25 MAX. VALVE VOLT
26 AUX. FUNCTION 1
- 74 -
Maintenance Section
Possible Stored Error
The following are the possible error codes stored in memory. Most error codes are identical to the one
displayed during RUN. See “Service Manual” for futher explanation and troubleshooting of any of the following
error codes.
DISPLAY STATUS
F Internal circuit of logic problem

F0 Excessive drive motor current
F1 Accelerator problem
F2 Drive circuit problem(shorted)
F3 Pump circuit problem(shorted)
F4 Drive & pump circuit problem(All shorted)
F5 Drive circuit problem(opened)
F6 Pump circuit problem(opened)
F7 Drive & pump circuit problem(opened)
FA Brake contactor closed
Fb Battery Mismatch(Batt Voltᆙ40v Or Batt Voltᆚ60v)
Fc Contactor problem
FF Serial failure
FL Lift sensor problem
E1 Drive or pump motor brush problem
EC Drive controller thermal problem
Ec Pump controller thermal problem
Ed Drive motor thermal problem
EP Pump motor thermal problem
EL Battery Lock-Out(Below 45v)
A Head capacitor problem
Non Stored Error
The following are error codes not stored in memory. Most error codes are identical to the one displayed during
RUN. See “Service Manual” for further explanation and troubleshooting of any of the following error codes.
ERROR CODES DESCRIPTION
EE Static Return to OFF error (SRO)
"EE" (Flashing) Seat switch circuit problem
- 75 -
Maintenance Section
General Displaying Codes
The following are the general displaying codes and indicate any operation status
GENERAL CODES DESCRIPTION
OK System normal operation
PP Wait operation (After 6 seconds without any operation in NEUTRAL)
No display after all

Fuse blow out or Regen contactor is not operated.
display (2 times)
- 76 -
Maintenance Section
Head Capacitor - Discharge
WARNING
Personal injury could result if head capacitor
has not been discharged properly.
Battery voltage and high amperage are present.
The HEAD capacitor must be discharged before
any contact with the electrical control system is
made.
Before touching any electrical components,
remove rings, watches and other metallic
objects from the hands and arms, then The pump control panel is located on the right of the
discharge the HEAD capacitor. lift truck.
2. The head capacitor is located in the drive control
panel or pump control panel. Remove the bolts
and the control panel cover.
1. Disconnect the battery connector.

Drive control panel
The drive control panel is located at the rear of the Pump control panel
lift truck.
3. Before touching any electrical components, the
HEAD capacitor must be discharged. Put a 150
ohm, 24 watt resistor in position between B+ and
B- at controller as shown. Hold the resistor in this
position for approximately ten seconds. This will
discharge the capacitor.
4. Perform any necessary maintenance and repair
at this time.
5. Install the control panel cover.
6. Connect the battery connector.
- 77 -
Maintenance Section
Brushes - Check, Replace

Refer to “Drive Motor” and/or “Hydraulic/Power
Steering System Pump Motor” section in “Every
1000 Service Hours or 6 Months” section of
“Maintenance Intervals” if brush wear is suspected.
Brush Seating
1. All new drive and hydraulic motor brushes must

be seated. For drive motor brush seating, lift the
front of the lift truck until the drive wheels are off
the floor and free to turn. Put adequate stands Drive Motor
under the frame to support the lift truck.
NOTICE
Do NOT move the directional control lever from one
direction to the other when the drive wheels are off
the ground and rotating at full speed.
Damage can be caused to the control panel.
Hydraulic Motor
4. Check the contact surface of the brushes. At least
85% of the brush contact surface must show
contact with the commutator. If necessary repeat
the seating procedure.
NOTE : Do NOT use a brush seating stone that is

shorter than 63.5 mm (2.50 inch).
WARNING
2. Use a brush seating stone for drive and hydraulic Pressure air can cause personal injury.
motors.
When using pressure air for cleaning, wear a
3. Put the seating stone in position on the protective face shield, protective clothing and
commutator. Operate the motor slowly and move protective shoes.
the seating stone from side to side, at the back
edge of the brushes for a short time. This will take The maximum air pressure must be below 205
the shine off the commutator and seat the kPa (30 psi) for cleaning purposes.
brushes.
5. While operating the motor slowly, blow out all of

NOTICE the abrasive grit and dust with 205 kPa (30 psi)
air pressure.
Do NOT let the seating stone stay in contact with the
commutator for too long. It will cause more wear
than necessary to the brushes and the commutator.
- 78 -
Maintenance Section
Fuses - Replace
The fuses are located in the control panel on the
right side and at the rear of the lift truck.
They protect the electrical system from damage

caused by overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, have the circuit checked and repaired.
NOTICE
Pump control panel
Replace fuses with the same type and size only.
Key switch - 10 amps
Otherwise, electrical damage can result.
Drive Fuse - 675 amps
Pump Fuse - 400 amps
If it is necessary to replace fuses frequently, an
electrical problem may exist. Contact your
DAEWOO Lift Truck dealer. Seat - Lubricate
Horn - 10 amps
DC/DC converter - 10 amps
Lights(1) - 10 amps
Lights(2) - 10 amps
Check the operation of the seat adjusters. Make

sure that the seat slides freely on its track. Lightly oil
the seat slider tracks.
Drive control panel
- 79 -
Maintenance Section
Wheel Bolts - Check for Tightness Carriage Roller Extrusion - Adjust

Steer Wheels 1. Set the mast vertical.
2. Lower the carriage completely.
3. On full free lift and full free triple lift models, the
bottom of the inner mast must be flush with the
bottom of the stationary mast.
INNER MAST
Typical example
A
Carriage roller
1. Inspect tightness of wheel nuts in a sequence extrusion
opposite each other 100 N•m (75 lb•ft).
IB2O638I
Drive Wheels
4. Measure the distance from the bottom of the inner
upright to the bottom of carriage bearing.
5. The measurment(A) must be as follows in Chart

bew.
Height of carriage roller extrusion (A)

STD mast FF mast FFT mast
0 41 41
Typical example
2. Inspect tightness of wheel nuts in a sequence

opposite each other to 610 N•m (450 lb•ft).
- 80 -
Maintenance Section
Every 10 Service Hours or Daily

Walk - Around Inspection - Inspect
6. Inspect the tires, valve stems and wheels for cuts,

gouges, foreign objects and loose or missing
1. Inspect the operator’s compartment for loose item nuts. Refer to “Tires and Wheels” in “Every 10
and clean any mud or debris from the floor plates. Service Hours or Daily” section, if repairs or
replacement is necessary.
2. Inspect the instrument panel for damage to the
indicator display.
3. Test the horn and other warning devices for

proper operation.
7. Inspect the overhead guard for damage, loose or

missing mounting bolts.
4. Inspect the mast and lift chains for wear, broken

links, pins and loose rollers.
5. Inspect the carriage, forks or attachments for

wear, damage and loose or missing bolts.
8. Inspect the hydraulic system for leaks, worn

hoses or damaged lines.
- 81 -
Maintenance Section
12. Move the directional lever to NEUTRAL.

9. Inspect the drive axle housing and the ground for
oil leaks. Refer to “Drive Axle Oil Level-Check” in ‘
“Every 250 Service Hours or Monthly” section,
if an oil leak is found.
13. Turn the key switch to ON.
10. Adjust the operator’s seat.
14. Check the LCD display for battery discharge

status. A fully charged battery will be displayed
on the LCD display.
11. Adjust the steering wheel to a comfortable
15. Check the operation of parking brake, service
position.
brake, controls and other devices that may be
equipped on your lift truck.
- 82 -
Maintenance Section
Mast Channels - Lubricate
3. Release the battery restraint lever in front of the

battery cover.
The channels on the roller-type mast require a
break-in period. Apply a light film of lubricant on the
channels where the rollers ride. This will prevent
metal peel until the rollers set a pattern.
Battery - Check, Exchange, Change

Battery Access
Park the lift truck level, with the forks lowered and
floor.
4. Raise the control lever bracket assembly to the
full upright position.
Raise the seat and battery cover.
Check Electrolyte
2. Tilt the steering column to the full upright position.
1. Inspect the battery compartment for loose

connections, frayed cables.
2. Clean the top of the battery. If necessary, clean

the top of the battery with a solution of baking
soda and hot water.
- 83 -
Maintenance Section
Battery Exchanging
NOTICE
Vent caps must be tight to prevent soda solution NOTE : Batteries should be changed, water added
from entering battery cells. and charged only in areas where proper
protective and ventilation facilities are
A clean battery top is essential to avoid conductive provided.
paths on higher voltage batteries.
1. Refer to “Battery Access” topic for battery access.
2. Cover the battery with hinged battery cover or

To make the solution, add 0.5 kg (1 lb) of baking with plywood.
soda to 4 liters (1 gallon) of water. Use a brush
having flexible bristles. Apply the soda solution to 3. Install insulated battery tree and hoist, of
the top of the battery until the cleaning action of the sufficient capacity, to the battery.
soda stops. After cleaning action has stopped, rinse
batteries thoroughly with water. Dry the batteries 4. Remove the battery. Recharge the battery.
with low air pressure.
5. Install a fully charged battery.
6. Remove the battery tree. Remove hinged battery

cover or plywood from the top of the battery.
7. Connect the battery.
8. Lower the seat and battery cover to closed

position and secure battery restraint on the front
of the cover.
9. Adjust the seat position.
3. Check the specific gravity of the battery. If the Battery Charging

specific gravity reading is below 1.150, the
battery must be charged. With Battery Installed in Lift Truck
1. Refer to “Battery Access” topic for battery access.

NOTICE 2. Connect the battery to the charger and charge the
The battery should not be used if a difference in battery. Observe safety warnings for charging
specific gravity between two cells is greater than batteries.
.020. If this condition exists, the battery should be
put on an equalization charge. If this does not 3. When the battery is fully charged, disconnect the
correct the condition, consult your battery supplier. battery from the battery charger.
4. Connect the battery to the lift truck.

4. Check the electrolyte level of all cells. Maintain
5. Lower the seat and battery cover to closed
the electrolyte level about 13 mm (.50 inch)
position and secure battery restraint on the front
above the plates. Add water as needed. Use only
of the cover.
distilled water. Add water before charging the
battery.
6. Adjust the seat position.
5. Lower the seat and battery cover. Secure battery
restraint properly on the front of the cover.
- 84 -
Maintenance Section
Indicator - Check
5. Check the indicator LCD display for the discharge

state of the battery.
1. Turn the key switch to ON.
Tires and Wheels - Inspect
2. Engage the parking brake.

IA8O4036
Inspect tires and valve stems for wear, cuts, gouges

and foreign objects.
3. Move the directional control lever to the

NEUTRAL position.
IA8O4037
4. Close the seat switch. Check all components carefully and replace any
cracked, badly worn, damaged and severely rusted
or corroded parts with new parts of the same size
and type. If there is any doubt, replace with new
parts. Do not, under any circumstances, attempt to
rework, weld, heat or braze any rim components.
- 85 -
Maintenance Section
Check Inflation Pressure (If equipped with Back - up Alarm (If Equipped) -
pneumatic tires) Test
IA1O4001
Measure the tire air pressure on each tire. 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.
IA8O4038
Inflate the tires, if necessary. See “Tire Inflation

Information” section of this manual.
- 86 -
Maintenance Section
First 50 - 100 Service Hours or a Week

Drive Axle Oil - Change
WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.
5. Remove two drain plugs, one from the front

section and one from the rear section. Allow the
oil to drain.
6. Clean and install the two drain plugs.
Park the lift truck level, with the parking brake

engaged and directional control lever in NEUTRAL.
1. Lift the carriage high enough to access the drive

axle housing level/fill plugs.
2. Turn the key switch to OFF.
3. Raise the truck until the front tires just clear the
ground. 7. Remove the dipstick/filler plug, located on top of
the drive axle housing between the mast and the
4. Block the bottom of the mast and the frame with cowl.
a block of wood to hold the carriage and the truck
in the raised position. 8. Fill the drive axle housing with oil, see topic
“Refill Capacities”.
9. Maintain the oil level between the MAX and MIN

mark on the dipstick/filler plug.
10. Clean and install the dipstick/filler plug.
11. Remove the blocking. Lower the truck and the

carriage.
- 87 -
Maintenance Section
First 250 Service Hours or a Month
Hydraulic Return Filter - Change 5. Clean the housing base.
WARNING
contact skin.
Park the lift truck level with the forks lowered,

Filter Element
parking brake engaged, directional lever in
NEUTRAL and the key switch to OFF.
1. Remove the floor plate.
FILTER
2. Remove mounting bolts and filter housing. 6. Insert a new filter element into the filter housing.
7. Inspect the filter housing seal. Replace if

necessary.
8. Apply a small amount of clean oil to the filter

element seal and housing seal.
9. Install the filter housing with filter to the housing

base. Install bolts and tighten 20 to 30 N•m (15
to 20 lb•ft).
10. Turn the key switch ON with the seat switch

closed, and operate the hydraulic controls, and
the steering system, through a few cycles to fill
3. Remove and discard filter element from filter the lines. Look for oil leaks.
housing.
11. Retract all cylinders. Turn the key switch to OFF
4. Clean the filter housing with a clean, and check the oil level. Maintain the oil level to the
nonflammable solvent. FULL mark on the dip stick/filler cap assembly.
- 88 -
Maintenance Section
Every 250 Service Hours or Monthly
Brake Oil Level - Check Parking Brake - Test, Adjust

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

incline.
WARNING
To prevent personal injury, the operator must be
ready to use the service brake if the parking
brake is not adjusted correctly and the lift truck
starts to move.
The brake system reservoir is located at the left
side of the steering column.
1. Remove the filler cap.
2. Maintain the brake fluid level to the fluid level

mark on the brake system reservoir.
3. Clean and install the filler cap.
2. Halfway up the incline, stop the lift truck by

applying the service brakes.
3. Engage the parking brake.
4. Release the service brake.
- 89 -
Maintenance Section
If the parking brake has the correct adjustment, the

lift truck will be held in place.
NOTE : The lift truck may move slightly while the
parking brake is engaging.
5. If the parking brake does not hold, adjust the
parking brake lever screw.
Adjust-Parking Brake
1. Park the lift truck level, with the forks lowered and
the parking brake engaged.
IKOM059S
2. Move the directional control lever into NEUTRAL
and turn key switch to OFF and remove the key.
7. Measure the length of spring (6). Maintain 70L
3. Block the drive wheels and release the parking 5mm(2.76L.02 inch) with locknut (7) and adjusting
brake. nut (8) included. Loosen tne locknut (7) and turn
adjusting nut (8) counterclockwise to increase
4. Remove the battery and the floor plate under the length and clockwise to decrease the length.
battery. Tighten the locknut (7).
NOTE : Be sure the shoulder of the cable (9) is

seated against the strap assembly (2).
IKOM057S
5. Measure the clearance between brake drum(1)

and the lining of the strap assembly (2) at location
IKOM060S
(3). Maintain 0.25 to 0.50 mm (.010 to .020 inch)
clearance between the brake drum and the lining
of the strap assembly at location (3). 8. Engage the parking brake. Measure the clearance
between the bracket assembly(10) and the leg of
the strap assembly (2). Maintain 6 mm (.24 inch)
maximum clearance.
9. Release the parking brake. Check that the parking

brake foot pedal is in the full OFF position and the
leg of the strap assembly (2) and the stop bolts
(11) are in contact. Loosen the locknuts (12) and
adjust stop bolts (11), if necessary. Tighten the
locknuts(12).
IKOM058S
10. Install the floor plate and the battery.
6. Remove tne lockwire (4) from bolt (5). Turn the

adjusting nut (5) counterclockwise to increase the
clearance. Turn the adjusting nut (5) clockwise to
decrease the clearance. Recheck the clearance at
location (3). Readjust if necessary. Install lockwire
(4) on bolt (5).
- 90 -
Maintenance Section
Drive Axle Oil Level - Check Mast Carriage, Chains and

Attachments - Inspect, Adjust,
WARNING Lubricate
contact skin.
1. Operate the lift, tilt and attachment controls.

Listen for unusual noises. These may indicate a
need for repair.
1. Park the lift truck on a level surface with the

parking applied, directional control lever in
NEUTRAL.
2. Lift the carriage high enough to access the drive
axle housing level/fill plugs.
3. Turn the key switch OFF.
4. Raise the truck until the front tires just clear the
ground.
5. Block the bottom of the mast and the frame with 2. Inspect for loose bolts and nuts on the carriage
a block of wood to hold the carriage and the truck and load backrest. Remove any debris from the
in the raised position. carriage and mast.
3. Inspect the forks and attachments for free

operation and damage. Have repairs made if
needed.
6. Remove the housing level/fill plugs.

7. Maintain lubricant level. Install the housing level/
fill plugs.
8. Remove the blocking. Lower the truck and the 4. Brush in a film of oil on all links of the chain.
carriage.
- 91 -
Maintenance Section
5. Raise and lower the carriage a few times to work Hydraulic Oil Level - Check
lubricant into the chain links.
NOTICE
Lubricate chains more frequently than normal where
the atmosphere can cause corrosion to
components, or when lift truck must work in rapid lift
cycles.
1. Operate the lift truck for a few minutes to warm

the oil.
2. Park the lift truck level, with the forks lowered,
mast tilted back (all cylinders retracted), parking
brake engaged, directional control lever in
NEUTRAL, and the key switch to OFF.
IA8O4051
6. Inspect the chain anchors and individual links for

wear, loose pins or cracked leaves.
NOTE : Have all repairs and adjustments made as

required.
3. Remove the left floor plate.

4. Remove the dipstick
5. Maintain the oil level to the full mark on the dipstick.
6. Install the dipstick.
7. Install the floor plate.
- 92 -
Maintenance Section

Mast Hinge Pin - Lubricate Tilt Cylinders - Check, Adjust,

Lubricate
Chassis Pivot Eyebolts - Lubricate
IC1O0075
Typical Example
1. Lower the forks and the carriage.

Typical Example
1. Remove floor plates.
2. Lubricate the two fittings for the mast hinge pins,

one on each side of the mast.
2. Lubricate two fittings for the pivot eyebolts, one
on each tilt cylinder.
Drive Axle Oil(OCDB) - Change
3. Check the pivot eye pins for loose retainer bolts
See topic, “Drive Axle Oil - Change” in “First 50-100 and wear.
Service Hours or a Week”.
- 93 -
Maintenance Section
Mast Pivot Eyes - Lubricate 4. Turn the cylinder rod in or out of the clevis to
obtain the proper adjustment. Turning the rod into
the clevis shortens the stroke. Turning the rod out
of the clevis lengthens the stroke.
5. Tighten the pinch bolts to a torque of 95L15 N•m

(70L10 lb ft). Check the cylinder rods again for
even travel.
Crosshead Rollers - Check

Check Operation
Typical Example
1. Operate the mast through a lift cycle. Watch the
1. Lubricate two fittings for the mast pivot eyes, one chains move over the crosshead rollers. Make
on each side of the pin. sure the chain is tracking over the rollers
properly.
2. Check the pivot eye pins for loose retainer bolts
and wear.
Cylinder Rod Extension - Adjust
NOTE : The following description is for forward tilt.

For cylinder rod back tilt, the collar should
be stationary by the tilt eye. If it is not, the
O-ring inside the collar may need to be
replaced. To adjust back tilt, spacers must
be added or removed.
ILOM033P
Typical Example
2. Check for damaged crosshead rollers, guards

and retainer rings.
Typical Example
1. Check to make sure the tilt cylinders extend and

retract evenly.
2. If one cylinder continues to move after the other

cylinder has stopped in full forward or backward
tilt, an adjustment must be made to one cylinder.
3. To adjust the cylinder rod extension, move the

spacer to the rear and loosen the pinch bolt on
the clevis.
- 94 -
Maintenance Section
Steering Mechanism - Lubricate Control Panel - Clean, Inspect

Lubricate eight fittings Park the lift truck level, with the forks lowered,
parking brake engaged, directional control lever in
NEUTRAL, and the key switch to OFF.
1. Disconnect the battery connector.
WARNING
any contact with the control panel is made.
Personal injury could result if it has not been
discharged properly.
Lubricate 4 fitting on peach side.

Total of eight fittings.
Overhead Guard - Inspect
The drive control panel is located at the rear of the

lift truck.
Look for any loose or damaged bolts. Replace

damaged bolts or missing bolts with original
equipment part only. Retighten bolts to a torque of
100L15 N•m (75L11 lb•ft).
Check the overhead guard for bent or cracked

sections. Repair if needed.
- 95 -
Maintenance Section
WARNING
Pressure air can cause personal injury.
When using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.
The maximum air pressure must be below 205
kPa (30 psi) for cleaning purposes.
4. Clean the control panel with 205 kPa (30 psi)

maximum air pressure, until dust is removed from
The pump control panel is located on the right of the the control panel.
lift truck. 5. Check movement of contactors and inspect
contactor tips for burning or pitting. Replace if
2. The head capacitor is located in the drive control needed.
panel or pump control panel. Remove the bolts
and the control panel cover. 6. Inspect all wiring for loose connections, frayed
cables and loose mounting bolts.
7. Inspect the fuses for looseness, corrosion and
broken connections.
8. Install the control panel cover and connect the
battery.
Directional Control Lever - Check
Drive control panel
Check the tightness of the directional lever

mounting bracket. Adjust if needed.
Check for ease of movement of directional lever.
Adjust if needed.
Pump control panel Check for loose wiring. Secure wiring if needed.
3. Discharge the head capacitor. See “Head
Capacitor” in “When Required” section of this
manual.
- 96 -
Maintenance Section

before performing any aperation or maintenance procedures.
Drive Motor - Clean, Inspect
9. Unlatch and remove the commutator screen

cover.
10. Connect the battery. Turn the key switch to ON
2. Block the steer wheels. and apply pressure to the seat switch.
3. Remove the battery. See topic, “Battery” in “Every

10 Service Hours or Daily” section of this manual.
NOTICE
Do not move directional lever from one direction to
the other when the drive wheels are off the ground
and rotating.
Damage can be caused to the control panel.
WARNING

4. Fasten lift chains, of equal length, in lift openings
any contact with the control panel is made.
in the front of the lift truck.
Personal injury could result if it has not been
discharged properly.
5. Slowly lift the front of the lift truck, until the drive
wheels are just off the ground.
6. Put stands under the frame. Remove the tension 11. Operate the drive motor slowly. Blow off the
on the lift chains. drive motor brush area with 205 kPa (30 psi)
maximum air pressure, until dust is removed
7. Remove the battery. from the motor.
8. Remove the floor plate. 12. Release the pressure on the seat. Turn the key
switch to OFF. Disconnect the battery.
- 97 -
Maintenance Section
Typical example Typical example
13. Remove the brush retainer clip by pushing down 19. Install the commutator screen cover.
and in toward the brush to release it from the
brush holder. Then, pull out on the clip to 20. Install the floor plate.
remove it.
21. Slowly lift the front of the lift truck and remove
14. Remove the brush from the holder. Measure the the stands. Lower the lift truck to the floor.
length of the brush on the longest side. Remove the chains.
Ensure that all brushes move freely in their
holders. Use compressed air until all brushes 22. Lower the battery cover and adjust the seat.
are free to move. Install and connect the battery.
NOTE : To check the brush wear indicator wiring,

Change Brush Minimum
Type of connect one end of a jumper wire to the
if Length is Allowable Brush
Motor negative(-) side of the battery and touch the
Less Than Length Limit1
other end of the wire to the brush wear
Drive Motor 22 mm (.87 in) 20 mm (.79 in) indicator terminal on the side of the motor.
1
When the minimum brush length is less than the
dimension shown, replace all brushes. When the Hydraulic Return Filter - Change
brush is used beyond this dimension, motor
damage could result. See topic “Hydraulic Return Filter - Change” in “First
250 Service Hours or a Month”.
15. To replace the brushes, loosen the retaining
screws and disconnect the wires.
Remove the brushes from the holders.
16. Connect the wires on the new brushes. Install

the brushes in the holders.
17. Install the brush retainer clips. Make sure the

brushes move freely in the holder.
18. Seat the new brushes. See “Brushes” in “When

Required” section of this manual.
- 98 -
Maintenance Section
Tires and Wheels - Inspect, Check
WARNING
Servicing and changing tires and rims can
bedangerous and should be done only by
trained personnel using proper tools and
procedures. If correct procedures are not
followed while servicing tires and rims, the
assemblies could burst with explosive force and
cause serious physical injury or death. Follow IA8O4072
carefully the specific information provided by
your tire serving man or dealer. Do NOT inflate a tire that has been run while flat or
underinflated, without first checking to make sure
the locking ring on the wheel is not damaged and is
in position.
When tires are changed be sure to clean all rim

parts, and if necessary, repaint to stop detrimental
effects of corrosion.
Sand blasting is recommended for removal of rust.
Check all components carefully and replace any

cracked, badly worn, damaged and severely rusted
or corroded parts with new parts of the same size
and type. If there is any doubt, replace with new
parts. Do not, under any circumstances, attempt to
rework, weld, heat or braze any rim components.
Inspect tires for wear, cuts, gouges and foreign
objects. Look for bent rims and correct seating of
locking ring.
If equipped with pneumatic tires, check tires for

proper inflation. See topic, “Tire Infaltion Pressure.”
To inflate tires always use a clip-on chuck with

minimum 60 cm (24 inches) length of hose to an in-
line valve and gauge.
Always stand behind the tread of the tire, NOT in

front of the rim.
1. Install drive wheel. Install two nuts opposite each
Lift truck capacity is dependent on tire type. Your lift
other.
truck dealer should be consulted for possible down
ratings when pneumatic tires are used to replace
2. Install the remaining nuts. Tighten all nuts in a
solid (cushion) tires.
crisscross sequence opposite each other to
610N•m (450 lb•ft).
3. Reverse the lifting procedure for the front of the

lift truck and lower it to the ground.
- 99 -
Maintenance Section
Hydraulic, Power Steering Pump

Motor - Clean, Inspect
2. Remove the battery. See topic, “Battery” in the

“When Required” section of this manual.
Typical example
9. Remove the brush from the holder. Measure the

length of the brush on the longest side.
Ensure that all brushes move freely in their holders.

Use compressed air until brushes are free to move.
Change Brush Minimum

Type of
if Length is Allowable Brush
4. Unlatch and remove the commutator screen Motor
Less Than Length Limit1
cover.
Pump Motor 22 mm (.87 in) 20 mm (.79 in)
5. Connect the battery. Turn the key switch to ON 1
When the minimum brush length is less than the
and apply pressure to the seat switch.
dimension shown, replace all brushes. When the
brush is used beyond this dimension, motor
WARNING damage could result.
Pressure air can cause personal injury. 10. Replace the brushes by loosening the retaining
screws and disconnect the wires. Remove the
When using pressure air for cleaning, wear a brushes from the holders.
protective face shield, protective clothing and
protective shoes. 11. Connect the wires on the new brushes. Install
the brushes in the holders.
The maximum air pressure must be below 205
kPa (30 psi) for cleaning purposes. 12. Install the brush retainer clips. Make sure the
brushes move freely in the holder.
13. Seat the new brushes. See “Brushes” in “When

6. Operate the hydraulic pump motor slowly. Blow Required” section of this manual.
off the drive motor brush area with 205 kPa (30
psi) maximum air pressure, until dust is removed 14. Install the commutator screen cover.
from the motor.
15. Close the hood.
7. Release the pressure on the seat. Turn the key
switch to OFF. Disconnect the battery. 16. Install and connect the battery.
8. Remove the brush retainer clip by pushing down NOTE : To check the brush wear indicator wiring,
and in toward the brush to release it from the connect one end of a jumper wire to the
brush holder. Then, pull out on the clip to remove negative(-) side of the battery and touch the
it. other end of the wire to the brush wear
indicator terminal on the side of the motor.
- 100 -
Maintenance Section
Lift Chains - Test, Check, Adjust

Lift Chain Wear Test Check for Equal Tension
Inspect the part of the chain that is normally

operated over the cross head roller. When the chain
bends over the roller, the movement of the parts
against each other causes wear.
Inspect to be sure that chain link pins do not extend
outside of the link hole. If any single link pin is
extended beyond its connecting corresponding link,
it should be suspected of being broken inside of its
link hole. Lift chains are required to check for wear
about every 1,000 service hours or 6 months.
Chain wear test is a measurement of wear of the IB2O640P

chain links and pins. Take the following steps to Typical example
check chain wear.
1. Lift the mast and carriage enough for getting WARNING

tension on lift chains.
Personal injury can be caused by sudden
movement of the mast and carriage.
Keep hands and feet clear of any parts that can
move.
Lift Chain Adjustment
IB2O639P
Typical example
2. Measure precisely ten links of chain distance at

the center of pins in millimeter.
3. Calculate chain wear rate*.

IB2O639P
4. If the chain wear rate is 2% or more, replace the Typical example for carriage equal tension
lift chain.
If the tension is not the same on both chains, take
* Chain wear rate (%) the procedure as follows.
(Actual measurement - Pitch** X 10)
= X 100
Pitch** X 10 NOTE : If carriage height is not correct, make
adjustments by following procedures.
** Chain Pitch = 19.05 mm(0.75 in)
Carriage Chain Adjustment
Make sure that carriage height is correct. If correct,

adjust the chain for equal tension. If not, adjust the
chain for correct carriage height by adjusting anchor
nuts(1),(2).
- 101 -
Maintenance Section
NOTE : See the previous section, “Carriage Roller Mast Chain Adjustment - FF,FFT Mast
Extrusion” in “When Required”. for proper
height of carriage.
1. Fully lower the carriage and tilt mast forward or lift

the carriage and put blocks under the carriage to
release the tension from the lift chains. 3
2. Loosen nut(1) and adjust nut(2) to get proper

distance from bottom of inner upright to the
bottom of carriage bearing.
4
IB2O643P
Typical example for FF mast
3
IA8O4083
Typical example for carriage chain of STD mast
4
IB2O644P
2 Typical example for FFT mast
Make sure that mast height is correct. If correct,

adjust chain for equal tension. If not, adjust mast
chain for correct mast height by adjusting anchor
1 nuts(3),(4).
NOTE : See the previous section, “Carriage Roller

Extrusion” in “When Required”. for proper
IB2O642P
inner mast height.
Typical example for carriage chain of FF,FFT mast
1. Lift the inner mast and put blocks under the inner
3. Make adjustment anchor nut(1),(2) for equal mast to release the tension from the lift chains.
chain tension.
2. Loosen nut(3) and adjust nut(4) to make inner
4. Set the mast vertical and raise the carriage and mast rail flush with outer mast rail bottom.
check equal chain tension. If not equal, repeat the
same procedure as step 1 through step 3. 3. Make adjustment anchor nuts(3),(4) for equal
chain tension.
5. Put LOCTITE No. 242 Tread lock on the threads
of the anchor nuts(1),(2) after the adjustment is 4. Raise the inner mast and check equal chain
completed. tension. If not equal, repeat the same procedure
as step 1 through step 3.
5. Put LOCTITE No. 242 tread lock on the threads

of the anchor nuts(3),(4) after the adjustment is
completed.
- 102 -
Maintenance Section

Drive Axle Oil (Shoe Brake) -

Change
See topic, “Drive Axle Oil - Change” in “First 50-100
Service Hours or a week”.
- 103 -
Maintenance Section
Every 2000 Service Hours or Yearly

Steer Wheel Bearings - Reassemble
IKOM099S
4. Remove the outer wheel bearing. Inspect the

bearing for damage and wear. Replace if needed.
1. Block the drive wheels. Raise the steer wheels off

the ground. Block the lift truck up with blocking
under the frame and steer axle.
IKOM100S
5. Remove the wheel assembly.
IKOM097P 6. Examine the seal for damage and wear. Replace

the seal, if necessary.
2. Remove the hub cap.
7. Remove the inner bearing. Inspect the bearing for

3. Remove the locknut, lockwasher and flat washer. damage and wear. Replace if needed.
- 104 -
Maintenance Section
8. Clean and lubricate the steering knuckle.
9. Assemble the inner and outer bearing.
IKOM105P
13. Install the flat washer, lockwasher and locknut.
IKOM102S 14. Tighten the locknut to 135 N•m (100 lb•ft), while
10. Install the inner bearing. turning wheel hub to seat the bearing.
15. Loosen the locknut. Torque the locknut to 50L5

N•m (35L4 lb•ft).
Bend the lockwasher tang to secure locknut.
16. Bend the lockwasher tang to secure locknut.
17. Install the hub cap.
18. Raise the lift truck and remove the blocking.

Lower the lift truck to the ground.
IKOM103P
11. Install the wheel assembly on the steering

knuckle.
IKOM104P
12. Install the outer wheel bearing.
- 105 -
Maintenance Section
Drive Wheel Bearings - Reassemble Forks - Inspect

Consult your DAEWOO lift truck dealer for the
proper wheel bearing reassembling procedure.
Assembling bearings and adjustment procedure
must be made by a trained mechanic or dealer
personnel.
IA1O4092
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.
IKOM106P 1. Inspect the forks carefully for cracks. Special

Typical example attention should be given to the heel section (A),
all weld areas and mounting brackets (B). Inspect
Assemble power shaft ass’y (1) and spindle the top and bottom hooks on forks used on hook
bearings (2). Assemble ring gear (3) to the depth of type carriages and tubes on shaft mounted forks.
the teeth.
Forks with cracks should be removed from service.
“Wet Test” magnetic particle inspection is generally

preferred due to its sensitivity and the ease of
interpreting the results. Portable equipment is
usually recommended so it can be moved to the lift
truck.
Inspectors should be trained and qualified in

accordance with The American Society for Non-
Destructive Testing, Level II Qualifications.
IKOM107P Contact your local DAEWOO Lift Truck Dealer for

Typical example
further information.
Torque for single or dual wheel mounting nuts (1) is

644L34N.m(470L25 lb.ft).
Torque for brake drum or adapter assembly bolts(2)
is 285L13N.m(210L10 lb.ft).
Tighten wheel bearing nut (3) to 135N.m(100 lb.ft)
C
while the wheel is turned in both directions.
Loosen the nut completely and tighten nut again to
50L5N.m(37L4 lb.ft). Bend the lockwasher tab into
a groove of the nut.
IA1O4093
Torque for bolts (4) that hold cover to transaxle
housing is 55L10N.m(40L7 lb.ft). 2. Check the angle between the upper face of the
blade and the front face of the shank. The fork
Apply loctite No.242 to threads of spindle bolts(5). should be withdrawn from service if angle (C)
Torque for spindle bolts is 115L14N.m(85L10 lb.ft).
- 106 -
Maintenance Section
exceeds 93 degrees or deviates by more than 3

degrees from an original angle other than 90
degrees, as may be found in some special
application forks.
H
E
J
D
G
IA1O4096
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
IA1O4094 is reduced to 90 percent or less of the original
thickness.
3. Check the straightness of the upper face of blade
(D) and the front face of shank (E) with a straight Fork blade length may also be reduced by wear,
edge. especially on tapered forks and platens.
Remove the forks from service when the blade
The fork should be withdrawn from service if the length is no longer adequate for the intended loads.
deviation from straightness exceeds 0.5 percent of
the length of the blade and/or the height of the
shank respectively 5 mm/1000 mm (0.18”/36”). M
F
IA1O4097
6. Check the fork mountings (K) for wear, crushing

L and other local deformation, which can cause
IA1O4095
excessive side to side wobble of the forks.
4. Check the difference in height of one fork tip to Excessive clearance on hook type forks may
the other when mounted on the fork carrier. A allow them to fall from the carrier. Forks which
difference in fork tip height can result in uneven show visible signs of such damage should be
support of the load and cause problems with removed from service.
entering loads.
7. Check the positioning lock and other fork
The maximum recommended difference in fork tip retention devices to make sure they are in place
elevation (F) is 6.5 mm (0.25”) for pallet forks and 3 and working.
mm (0.125”) for fully tapered forks. The maximum
allowable difference in fork tip elevation between Hook type forks use a spring loaded pin (M), located
the two or more forks is 3 percent of blade length in the top hook, to engage notches in the top
(L). carriage bar to hold the fork in place.
Replace one or both forks when the difference in When adjusting the fork spacing, the forks are
fork tip height exceeds the maximum allowable prevented from sliding off the end of the carriage by
difference. stop blocks. These stop blocks are at both ends of
- 107 -
Maintenance Section
the carriage and in the path of the bottom fork hook. Air Breather - Change
The load backrest extension may be used in place
of the stop blocks in some cases.
Park the lift trucks level, with the forks lowered,
parking brake engaged, directional lever in
Shaft mounted forks may use set collars or spacers
NEUTRAL and the key switch to OFF.
on the shaft to either side of the fork. They may also
use U bolts, pins, or similar devices which engage
the fork through the top structure of the carriage.
IC1O0102
8. Check fork markings (N) for legibiligy. Renew 2. Remove and discard the air breather.
markings as required to retain legibility.
3. Install a new air breather.

9. a. Lift the mast and operate the tilt control lever,
until the top surface of the forks is parallel with 4. Install the floor plate.
the floor. Place two straight bars that are the
same width as the carriage, accross the forks
as shown.
9. b. Measure the distance from the bottom of each

end of the two bars to the floor. The forks must
be parallel within 3 mm (.12 in) for Full Tapered
and Polished (FTP) forks, all other forks 6.4
mm (.25 in), for their completer length.
9. c. Put one fork, one third from the tip, under a

fixture that will not move. Then operate the tilt
control with caution until the rear of the truck
lifts just off the floor. Follow the same
procedure with the second fork. Repeat Step a.
- 108 -
Maintenance Section

Hydraulic Oil - Check, Change
4. Remove the dipstick/filler cap assembly.
1. Operate the lift truck a few minutes to warm the 5. Fill the hydraulic tank. See topic, “Refill
oil. Park the lift truck level, with the forks lowered, Capacities”.
parking brake engaged, directional lever in Install the dipstick/filler cap assembly and the
NEUTRAL and the key switch to OFF. floor plate.
6. Turn the key switch to ON and close the seat

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

2. Remove the hydraulic tank drain plug. Allow the dipstick. Add oil if necessary.
oil to drain. Clean and install the plug.
- 109 -
Environment Protection Section
Environment Protection
When servicing this lift truck, use an authorized
servicing area and an approved container to collect
coolant, oil, fuel, grease, electrolyte and any other
potential environmental pollutant before any lines,
fittings or related items are disconnected or
removed. After servicing, dispose of those materials
in an authorized place and container. When
cleaning the lift truck, be sure to use an authorized
area.
- 110 -
Index Section
Index
A D
Accelerator Control Switch ................................ 72 Daily Inspection ................................................. 55

Accelerator Pedal .............................................. 35 Diagnostic Tests ................................................ 73
Adjusted Inflation Pressures ............................. 57 Diagnostic Tests-Standard Models .................. 70
After Storage ..................................................... 50 Directional Control Lever ................................... 35
Apply Parking Brake Warning ............................. 8 Directional Control Lever - Check ..................... 96
Auxiliary Switch 1 .............................................. 71 Direction Selector .............................................. 70
Auxiliary Switch 2 .............................................. 72 Drive Axle Oil ..................................................... 64
Avoiding Lift Truck Tipovers .............................. 19 Drive Axle Oil - Change ...................... 87, 93, 103
Drive Axle Oil Level - Check ............................ 91
Drive Motor - Clean, Inspect ............................. 97
B Drive Wheel Bearings - Reassemble .............. 111
Drive Wheels ..................................................... 80
Back - up Alarm (If Equipped) - Test ................. 86 During Storage ................................................. 50
Batteries .............................................................14
Battery ..........................................................61, 65
Battery Access .................................................. 83 E
Battery - Check, Exchange, Change ................. 83
Battery Charging ............................................... 84 Electrical Braking (Plugging) ............................ 43
With Battery Installed in Lift Truck .............. 84 Emergency Switch (If Equipped) ...................... 35
Battery Discharge Indicator ............................... 60 Environment Management ................................. 3
Battery Discharge Indicator with Interrupt ......... 30 Environment Protection ................................... 110
Battery Disconnet Before Servicing Warning ...... 8 Every 10 Service Hours or Daily ....................... 81
Battery Exchanging ........................................... 84 Every 1000 Service Hours or 6 Months ............ 97
Battery Restraint Warning ................................... 6 Every 1500 Service Hours or 9 Months ........... 103
Before Operating the Lift Truck ................... 11, 38 Every 2000 Service Hours or Yearly .............. 104
Before Starting the Lift Truck ............................ 11 Every 250 Service Hours or Monthly ................ 89
Before Storage ...................................................50 Every 500 Service Hours or 3 Months ............. 93
Bent or Twisted Forks ....................................... 54
Better Battery Performance .............................. 40
Brake Fluid (BF) ................................................ 70 F
Brake Oil Level - Check .................................... 89
Brushes - Check, Replace ................................ 78 Fatigue ............................................................. 54
Brush Seating ................................................... 78 Fault Detection Circuit ...................................... 31
Burn Prevention .................................................14 Film For function of pedals (if equipped) .......... 35
Fire or Explosion Prevention ............................ 15
First 250 Service Hours or a Month ................. 88
C First 50 - 100 Service Hours or a Week ........... 87
First Installation ................................................ 55
Carriage Roller Extrusion - Adjust ..................... 80 Fluid Penetration .............................................. 13
Causes of Fork Failure .......................................54 Foreword ............................................................ 2
Center of Gravity (CG) ...................................... 19 Fork Inspection ................................................. 55
Chain and Linkage Oils(DEO or EO) ..................63 Front and Rear Floodlights Switch ................... 32
Chassis Pivot Eyebolts - Lubricate ................... 93 Fuses - Replace ............................................... 79
Check Electrolyte .............................................. 83
Check Operation ............................................... 94
Cold Storage Applications ................................. 65
Control Panel - Clean, Inspect .......................... 95
Crosshead Rollers - Check ............................... 94
Crushing or Cutting Prevention ......................... 13
Cylinder Rod Extension - Adjust ....................... 94
- 111 -
Index Section
G Lift Truck Parking ............................................. 12

Lift Truck Stability ............................................. 19
General ............................................................. 15 Lift Truck Stability Base .................................... 20
General Displaying Codes ................................ 76 Capacity Load (Weight and Load Center).... 20
General Hazard Information ................................ 9 Lift Switch ......................................................... 71
General Warnings to Operator ............................ 6 Lines, Tubes and Hoses .................................. 16
Literature Information ......................................... 2
Load Backrest Must Be In Place Warning .......... 7
H Lubricate one fitting .......................................... 95
Lubricating Grease (MPGM) ............................ 64
Hard Placement Warning .................................... 7 Lubricant Information ....................................... 63
Head Capacitor - Discharge .............................. 77 Lubricant Specifications ................................... 63
Hook-on type Fork ............................................ 49 Lubricant Viscosities ........................................ 66
Horn Button ....................................................... 33 Lubricant Viscosities and Refill Capacities ....... 66
Hydraulic brake Fluid ..........................................64
Hydraulic Oil Level - Check ............................... 92
Hydraulic Oils (HYDO) ...................................... 63 M
Hydraulic, Power Steering Pump Motor - Clean,
Inspect .............................................................100 Machine Lifting and Tiedown Information ........ 51
Hydraulic Return Filter - Change ................. 88, 98 Maintenance ....................................................... 3
Hydraulic System .............................................. 65 Maintenance and Repair .................................. 56
Maintenance Information .................................. 13
Maintenance Intervals .................................. 3, 67
I Mast Carriage, Chains and Attachments - Inspect,
Adjust, Lubricate .............................................. 91
Identification, Lift Capacity and Mast Channels - Lubricate ............................... 83
Atteachment plate ...............................................27 Mast Hinge Pin - Lubricate ............................... 93
If Optional Suspension Seat Equipped ............. 17 Mast Pivot Eyes-Lubricate ............................... 94
Important Safety Information ............................... 4 Monitoring Systems Indicator ........................... 30
Improper Modification or Repair ........................ 54
Inching into Loads ............................................. 44
Indicator - Check ............................................... 85 N
Inspection, Maintenance and Repair of Lift Truck
Forks ................................................................. 53 No LCD Display ................................................ 31
Non Stored Error .............................................. 75
No Standing on Forks Warning, No Standing under
K Forks Warning .................................................... 7
No Riders Warning ............................................. 7
Key Switch ..........................................................29
O
L
Oils ................................................................... 14
Lift Chain Adjustment ...................................... 101 Operating Techniques ...................................... 44
Carriage Chain Adjustment ....................... 101 Operation ........................................................... 2
Mast Chain Adjustment - FF,FFT Mast ..... 102 Operation Information ...................................... 11
Lift Chains ......................................................... 65 Operator Restraint System ............................... 16
Lift Chains - Test, Check, Adjust...................... 101 Operator Restraint System(If Equipped) ............ 2
Lift Chain Wear Test ....................................... 101 Operator’s Station and Monitoring Systems ..... 29
Lift Control Lever ............................................... 36 Operator’s Warning and Identification Plate....... 27
Lift Fork Adjustment .......................................... 49 Operator’s Warning Plate ................................... 27
Lifting Drums or Round Objects ........................ 46 Overhead Guard - Inspect ................................ 95
Lifting the Load ................................................. 44 Overhead Guard Must Be In Place Warning ...... 8
Lift Truck Control ............................................... 34 Overloading ...................................................... 54
Lift Truck Operation .......................................... 41 Over Temperature ............................................ 31
- 112 -
Index Section
P T
Parking Brake ................................................... 34 Table of Contents ............................................... 1

Parking Brake Switch ........................................ 72 Test Circuits and Components ......................... 69
Parking Brake - Test ......................................... 89 Tilt Control Lever .............................................. 36
Parking the Lift Truck ........................................ 47 Tilt Cylinders - Check, Adjust, Lubricate .......... 93
Possible Stored Error ........................................ 75 Tilt Steering Column ......................................... 33
Power On Indicator ........................................... 30 Tilt Switch ......................................................... 71
Pressure Air ...................................................... 13 Tire Inflation ..................................................... 57
Programmable or Settable Feature ................... 74 Tire Inflation Information .................................. 57
Tire Information ................................................ 15
Tires and Wheels - Inspect .............................. 85
Q Tires and Wheels - Inspect, Check .................. 99
Tire Shipping Pressure ..................................... 57
Quick Diagnostics - Test ................................... 69 Torque for Metric Fasteners ............................. 59
Quick Reference to Maintenance Schedule........68 Torque for Standard Bolts, Nuts and Taperlock
Studs ................................................................ 58
Torque for Standard Hose Clamps - Worm Drive
R Band Type ........................................................ 58
Torques for Bolts and Nuts With Standard Threads
Refill Capacities ................................................ 66 .......................................................................... 58
Run Time Diagnostics ....................................... 30 Torques for Taperlock Studs ............................ 59
Torque Specifications ....................................... 58
Towing Information ........................................... 52
Traing Required To Operate or Service Warning
S
............................................................................ 5
Transportation Hints ......................................... 51
Safe Driving Practices ....................................... 21
Traveling .......................................................... 45
Safety .............................................................. 2, 5
Turning ............................................................. 45
Seat Adjustment .......................................... 17, 33
12 Months Inspection ....................................... 56
Seat Belt ........................................................... 18
Inspection .................................................... 18
Fasten the Seat Belt ................................... 18
Release the Seat Belt ................................. 19 U
Seat - Lubricate ................................................. 79
Seat Switch ....................................................... 29 Unloading ......................................................... 46
Self-Diagnostics Indicator ................................. 32
Service Brake Pedal ......................................... 34
Service Hour Meter ........................................... 32 W
Shipping ............................................................ 57
Sideshift Attachment Control (If Equipped) ....... 37 Walk-Around Inspection ................................... 38
Stability and Center of Gravity .......................... 20 Walk - Around Inspection - Inspect .................. 81
Starting the Lift Truck ........................................ 11 Warning Signs and Labels ........................... 5, 16
Static Return to Off ........................................... 31 Wheel Bolts - Check for Tightness ................... 80
Storage Information .......................................... 50 When Required ................................................ 69
Steering Mechanism - Lubricate ....................... 95
Steer Wheel Bearings - Reassamble .............. 104
Steer Wheels .................................................... 85
- 113 -
SB4087E00
Dec. 2002
Schematic
Lift Trucks Electric Systems
B20S-3, B25S-3, B30S-3
WIRING SCHEMATIC - ELECTRIC
MODEL : B20S-3, B25S-3, B30S-3
A174502
SB4086E00
Dec. 2002
Schematic
Lift Trucks Hydraulic Systems
B20S-3, B25S-3, B30S-3
MODEL : B20S-3, B25S-3, B30S-3
ITEM COMPONENTS
1 Hydraulic Tank
2 Hydraulic Pump
3 Steering Cylinder
4 Hydraulic Control Valve
5 Tilt Cylinder
6 Lift Cylinder - STD (Secondary - FFL and FFTL)
7 Lift Cylinder - Primary (FFL and FFTL)
8 Flow Regulator
9 Flow Protector
10 Steering Unit
11 Hydraulic Oil Filter

12 Priority Valve
SB4085E00
Dec. 2002
Disassembly &
Assembly
Lift Trucks Vehicle Systems
B20S-3, B25S-3, B30S-3
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
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.
1
Index
Accelerator Control Switch .....................................60
Backrest....................................................................7
Carriage....................................................................7
Counterweight ........................................................65
Drive Motor.............................................................62
Forks.........................................................................7
Hydranlic Control Valves ........................................41

Hydraulic Control Valve Switch Group .....................5
Hydraulic Pump Motor..............................................5
Mast........................................................................13
Master Cylinder ......................................................59
Parking Brake.........................................................60
Primary Lift Cylinder ...............................................32
Secondary Lift Cylinders .......................................29

Standard Lift Cylinders ...........................................26
Steer Axle ...............................................................58
Steering Column.....................................................55
Steering Cylinder....................................................39
Steering Unit...........................................................45
Steering Wheel.......................................................55
Tilt Cylinders...........................................................35
Transaxle................................................................64
Vehicle Systems 3 Index

Disassembly And Assembly Hydraulic Pump Motor
Remove And Install Hydraulic Pump

Hydraulic Control Valve Motor
Switch Group
Remove And Install Hydraulic 1

Control Valve Switch Group 3
5 6
2
2
1. Remove the battery, the plate under the battery and

the floor plates. Mark the wires and cables for
1
proper installation. Disconnect two wires (1) and
two cables (2) from the hydraulic pump motor.
1. Remove the cover over the hydraulic control valve. 2. Remove two bolts and hydraulic pump (3) from the
Disconnect connector (1). pump motor. Remove the pump coupling if
necessary. Pull the pump away from the motor, but
2. Remove four screws (2) and board assembly (3). keep the pump above the level of the hydraulic tank
to prevent oil leakage from the pump.
3. Remove two screws (4) for each micro switches (5).
4. Remove micro switches (5) and sensor (6).
5. Install the hydraulic control valve switch group in

the reverse order of removal.
Vehicle Systems 5 Disassembly & Assembly

4
IDCD307S
3. Remove four nuts(4) and washers.
4. Support pump motor(5) with hoist and remove

pump motor(5) from truck. Remove two bracket
from the motor if necessary.
5. Install the pump motor in the reverse order of

removal.

Forks Backrest
Remove & Install Forks

Remove & Install Backrest
Start By:
a. Remove forks.
1
2
IDCD001P
IDCD003P
1. Fasten a hoist to the backrest. Remove bolts(2)

that fasten the backrest to the carriage.
2. Remove backrest (1). Backrest(1) weighs 40kg

(90lb).
IDCD002P
3. Install backrest(1) in the reverse order of removal.
1. Lift fork pin(1). End By:
2. Use a suitable C-clamp, strap and hoist to support a. Install forks.

the fork as shown.
3. Slide the fork to slot(2) in the middle of the

carriage. Carriage
4. Remove the fork. The weight of the fork is 50 kg
(110 lb).
Remove & Install Carriage
5. Repeat steps 1 through 4 for the remaining fork.
6. Install the forks in the reverse order of removal. Tools Needed A
7. Put the forks in position. Lower both fork pins(1) to Retaining Ring Pliers 1
lock the forks in position.
Start By:
a. Remove forks.
b. Remove backrest.

NOTE: For purposes of reassembly, identify and
mark all hydraulic lines and connectors before
removing or disconnecting.
2
8
1
IDCD004P
IDCD006P
3. Remove four bolts(8) from the chain guard/hose

support assembly(6). Set the hoses aside, clear of
the primary cylinder and cross head.
4
IDCD005P 10
1. Raise carriage(1). Position a wooden block as

shown. Lower carriage(1) onto the wooden block.
2. Disconnect two hydraulic lines(4) from side shifter

cylinder (2). Plug and cap all openings to prevent
contamination and debris from entering system.
9
IDCD007P
WARNING
4. Remove two bolts (10) from the hose mounting
To prevent personal injury be sure pressure in the bracket. Set the hoses aside. Remove two nuts(9)
hydraulic system has been released before from the chain anchors. Set the chains aside,
disconnecting any hydraulic lines. Slowly loosen clear of the mast.
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.

12
15
IDCD008P
Typical Example
5. Use tool(A) to remove retainer ring(11) from the 14

cross head shaft.
IDCD010P
6. Remove cross head(12) from the shaft.
8. Raise the inner mast to pull out carriage as

shown.
9. Remove carriage from bottom of inner mast(15).

Carriage(14) weighs 116kg(255 lb).
13
NOTE: Use the following steps to install the carriage.
10. Raise the inner mast to put in the carriage onto

the mast, and lower the inner mast to cover
carriage(1) bearing fully.
IDCD009P
7. Remove carriage bolts(13).

13
IDCD009P
11. Install carriage bolts(13).

4
12
IDCD008P IDCD005P
12. Install cross head(12) and retaining ring(11). 15. Connect two hydraulic line(4) in their original
positions.
End By:
10
a. Install backrest.
b. Install forks.
Disassemble Carriage
9 Start By:
IDCD009P
a. Remove carriage.
13. Put the chains in position over cross head(12).

Install nuts(9) onto the chain anchors.
1
Install bolts(10) onto the hose mounting bracket. 2
IDCD011P
Typical Example
IDCD006P
1. Remove the roll pins and pins(2) to disconnect
chains(1).
14. Install chain guard/hose support assembly(6) and
four bolts(8).

A 3 4 B 5
3
VIEW A-A
A A
IDCD012P 6
B B C
2. Remove four lower roller bearings(3) and the
shims from the carriage.
VIEW B-B
7
C C
4 A
5
C VIEW C-C
8 A
IDCS125S
6
IDCD013P Carriage Adjustment
(3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Middle bearings. (8) Lower bearings. (A) Zero clearance.
(B) 6.0 to 9.0 mm. (.236 to .354 in) clearance.
3. Remove screw(5) and washer(4). Remove top (C) Minimum clearance.
roller bearings(6) and the shims.
1. Select lower bearings from the chart to obtain

minimum clearance (B) between bearings and
Assemble Carriage channel leg for full channel length. Use same
bearing in all six locations.
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 Mast And Carriage Bearings
in the following illustrations. Part No. Bearing Size Bearing O.D.*
To make the carriage clearance adjustments, D581814 Under Size 108.6 mm (4.276 in)
carriage must be removed from the mast. D581815 Standard 109.6 mm (4.135 in)
D581816 Over Size 110.7 mm (4.358 in)
Use the procedure that follows to adjust carriage
load bearings. * Permissible tolerance L 0.08 mm (.003in)

IDCD014P IDCD009P
2. Find narrowest point by ruler on the inner mast in 6. Shim stop bolt (11) as required to obtain a 6 to 9
the area where the bearings make contact. mm (.24 to .35 in) lap with top carriage stop on the
inner upright.
3. Install enough shims (4) that have been divided
into two equal groups behind bearings (3). At
installation, there is to be contact [zero clearance 8
(A)] between the bearings and the narrowest point
6
of inner mast.
7
4. Do step 2 through 3 for other sets of bearings (8),

9
(9).
IDCD011P
7. Position chains(6) on the carriage. Install pins(7)

and the rolt pins.
End By:
3
IDCD015P a. Install carriage, raise the inner mast and insert the
carriage from the bottom of inner mast.
5
IDCD016P
5. Tighten screw (5) that holds the top bearings to the

carriage to a torque of 34 L 7 NIm (25 L 5 lbIft)

Mast
4
Remove & Install Mast
Start By:
6
a. remove forks
5
b. drain the hydraulic oil to tank
7
IDCD019P
3. Disconnect two hydraulic lines(4).
WARNING
2 Tilt cylinders(7) can drop when pin(6) is removed.

To avoid component damage or personal injury,
support tilt cylinder(7) while removing pin(6).
IDCD017P
4. Remove bolt(5) from each side of mast assembly(2).

1. Support mast assembly(2) with a hoist and two
straps as shown. 5. Remove pin(6) from the tilt cylinders on each side
of the mast assembly(2).
8
IDCD018P
IDCD020P
6. Tilt forward mast assembly(2) about 8° with the

NOTICE hoist.
Place identification marks on all hydraulic connectors Remove bolts(8) from each side of the base of
and hoses to assure proper installation. Plug and cap mast assembly(2).
all hydraulic connectors and hoses to avoid debris and
contamination from entering the system.
2. Disconnect hose(3).

WARNING
Disassemble Mast
Start By:
Loose the tension of straps to be connected with
hoist when mast assembly(2) is tilted forward. a. Remove primary lift cylinder.
If straps are too tight, mast assembly(2) could be
got off when bolts(8) are removed. b. Remove side shift cylinder.
c. Remove mast.
7. Use the hoist to remove mast assembly(2) from NOTE: The following disassembly and assembly
the machine. procedure is for a full free triple lift mast.
8. Install the mast in the reverse order of removal.
End By:
a. Install forks.
b. Fill hydraulic oil to tank*.
* Refer to the Operation And Maintenance Manual

for further information.
1
IDCD021P
1. Remove hoses(1) along with the hose support

clamps.

3
6
IDCD023P IDCD025P
2. Remove hose sheave (3). 5. Remove top cylinder retainer bolt(6) from each
side of the mast.
3. Remove chain nut(4) from the top of the
mast(each side).
5
IDCD026P
IDCD024P
6. Remove cylinder retainer brackets(8) from each
cylinder.
4. Disconnect and remove chains(5) from the bottom
of the mast.

12
9
IDCD027P IDCD030P
7. Fasten a nylon strap and hoist to secondary 10. Check the condition of the seals and bearings(12)
cylinder(9) as shown. Remove secondary located in each of the mast mounting bores.
cylinders(9). Each cylinder weighs 50 kg(110 lb). Replace the seals and bearings(12) with new if
worn or damaged. Seal lips should be forward
outside
13
10
IDCD028P
IDCD031P
8. Check the condition of bearings(10) located in
each of the tilt cylinder pin bores. Replace
bearings(10) with new if worn or damaged. 11. Fasten nylon straps and hoist to inner
channel(13). Remove inner channel(13). The
weight of the inner channel is 150kg(330 lb).
IDCD029P
14
IDCD032P
9. Remove mast mounting pins(11) from the mast
mounting bores.
12. Remove rollers(14) and the shims from the inner
channel mast.

15
18
19
IDCD033P IDCD035P
13. Fasten nylon straps and a hoist to the intermediate 16. Remove rollers(18) and the shims from the
mast channel(15). Remove mast channel(15). stationary mast channel.
The intermediate mast channel weighs 168kg
(370 lb). 17. Remove nylon pads(19) and the shims.
16
17
IDCD034P
14. Remove rollers(16) and the shims from the

intermediate mast channel.
15. Remove nylon pads(17) and the shims.

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

IDCD036P
replacement.
A. Lower Bearing Adjustment of

Intermediate Mast 4. Find narrowest point by ruler on the staionary
mast in the area where the bearings make contact
at 475 mm (18.7 in) channel lap.
3 4 5 6 NOTE: When installing shims (2) behind bearings

(1), make sure the amount of shim is divided equally
when positioned behind each bearing (1).
5. Install the correct amount of shim (2) behind

rollers until contact (zero clearance) is made
between the rollers.
IDCS123S C
Mast Adjustment Lower Bearings
(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
3. Select lower bearings (3) and (4) from the chart to

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

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

NOTICE
When the correct amount of shim has been installed
behind rollers (1) there will be contact (zero clearance) 4 5 6
between the rollers and the inner mast at most narrow 3
point of mast (refer to step 4)
1 2
IDCD037P
C
IDCS123S

IDCD033P
6. Install 1 mm shim to each bearing of intermediate

lower and stationary upper basically. Lifting by
crane, insert intermediate mast into stationary
mast from the upper side. IDCD039P
NOTE: When installing shims (5) behind bearings

(4), make sure the amount of shim is divided equally 7. Make sure whether intermediate mast lower
when positioned behind each bearing (4). bearings are properly shimmed in the stationary
mast by rolling up and down and moving
intermediate mast to right and left. If clearance
between both masts can be detected, pull out the
intermediate mast from the stationary mast with
crane and add shim 0.5 mm or 1 mm to both
intermediate lower bearings.

D E
IDCD039P
F
8. In case of standard and full free mast, inner lower 9 7

bearings can be easily extruded by pulling down
the inner mast from the bottom of staionary mast.
If intermediate mast is stuck and do not move 8
rolling up and down, there might be excessive
shim. Pull out the intermediate mast from the
stationary mast and remove shim 0.5 mm to both E
intermediate lower bearings. Repeat same
10
procedure of aboves until properly shimmed. IDCS124S
There is to be contact zero clearance (C) between Mast Adjustment Upper Bearings
intermediate lower bearings and stationary (D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
channel at approximately 475 mm (18.7 in) (F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
channel lap.
B. Upper Bearing Adjustment of Stationary

Mast
IDCD038P
10. Make sure whether stationary mast upper

bearings are properly shimmed by rolling up and
IDCD033P
down and moving intermediate mast to right and
left. If clearance between both masts can be
detected, pull out the intermediate mast from the
9. Lifting by crane, and pull out intermediate mast stationary mast with crane and add shim 0.5 mm
from stationary mast. Install 1 mm shim to each or 1 mm to both stationary upper bearings.
bearing of stationary mast upper basically. Bearing
should be selected D581814 under size bearing.

C. Upper Pad Adjustment
D E
8
IDCD039P
F
11. In case of standard and full free mast, stationary
upper bearings can be easily extruded by pulling 7
9
down the inner mast from the bottom of staionary
mast. If intermediate mast is stuck and do not
move rolling up and down, there might be
8
excessive shim. Pull out the intermediate mast
from the stationary mast and remove shim 0.5
mm to both staionary upper bearings. Repeat
same procedure of aboves until properly 10 E
shimmed. There is to be contact zero clearance IDCS124S
(C) between staionary upper bearings and the
widest point of intermediate mast to be checked Mast Adjustment Upper Bearings
before. (D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
IDCD033P
12. Install shims (8) behind each pad (7) until there
is 0.80 mm (.031 in) maximum clearance (E)
between the pads and the inner and intermediate
masts with the masts at full extension. Lifting by
crane, and pull out intermediate mast from
stationary mast and insert the shims behind each
pad. In case of standard and full free mast, the
pads of stationary upper can be easily extruded
by pulling down the inner mast from the bottom
of stationary mast.

D. Lower Bearing Adjustment of Inner
Mast
3 4 5 6
IDCD040P
14. Find narrowest point by ruler on the intermediate

mast in the area where the inner lower bearings
make contact full length of intermediate mast
A
excluding minimum channel lap 475 mm (18.7 in).
C
IDCS123S

13. Select lower bearings (3) and (4) from the chart IDCD031P
to obtain minimum clearance (B) between
bearing and channel leg for full channel length.
Must use same bearing on left and right side. 15. Install 1 mm shim to each bearing of inner lower
and intermediate upper basically. Lifting by
Mast And Carriage Bearings crane, insert inner mast into intermediate mast
from the upper side.
D581814 Under size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.135 in)
D581816 Over size 110.7 mm (4.358 in)
* Permissible tolerance L 0.08mm (.003in)

E. Upper Bearing Adjustment of
intermediate Mast
4 5 6 Follow same procedure with above B.

3
F. Upper Pad Adjustment of Intermediate
Mast
Follow same procedure with above C.
C
IDCS123S IDCD041P

17. If the seals and bearings were removed from the
mast mounting blocks, install new ones.
16. Make sure whether inner mast lower bearings

are properly shimmed in the intermediate mast
by rolling up and down and moving inner mast to
right and left. If clearance between both masts
can be detected, pull down the inner mast from
the bottom of intermediate mast. Inner lower
bearings can be easily extruded. Add shim 0.5
mm or 1 mm to both inner lower bearings. If
inner mast is stuck and do not move rolling up
and down, there might be excessive shim. Pull
out the inner mast from the intermediate mast
and remove shim 0.5 mm to both inner lower IDCD042P
bearings. Repeat same procedure of aboves until
properly shimmed. There is to be contact zero
clearance (C) between inner lower bearings and
18. Put a small amount of clean grease on mounting
intermediate channel at narrowest point.
pins (11). Install mounting pins (11) into mast
mounting blocks.

14
IDCD043P IDCD025P
19. If the bearings were removed from the tilt 22. Install top retainer bolts (14) for the secondary
cylinder pin bores, install new ones. cylinders.
12
13° 15°
IDCD027P
20. Fasten a hoist and nylon strap to secondary

cylinder (12). Install secondary cylinders (12) into IDCD322S
the stationary mast.
23. Install hydraulic steel tube to each secondary

cylinder. When install the steel tube, assembling
angle should be kept as shown in above figure.
13 16
IDCD026P
21. Install secondary cylinder mounting brackets (13)

over the secondary cylinders. IDCD024P
24. Connect chains (16) at the bottom of the mast.

20
18
16
IDCD023P IDCD045P
25. Connect chains (16) at the chain bracket of 28. Install primary lift cylinder. Assemble primary lift
stationary mast upper. cylinder retainer bolt(20).
26. Install sheave (18) of lift hose.
19
IDCD044P
27. Install the lift hose support bracket(19) and

hoses.
IDCD010P
29. Install carriage assembly from the bottom of

inner mast.
21
IDCD008P
30. Install cross head(21) to primary lift cylinder.

Standard Lift Cylinders
Disassemble Standard Lift

Cylinders
Start By:
a. Remove standard lift cylinders.
IDCD007P
1
31. Install carriage chains to primary lift cylinder.
IDCD399P
23 1. Put standard lift cylinder (1) in position on vise (A).
22
2
IDCD005P
32. Install hydraulic hose (22) of side shifter to side

shifter cylinder (23).
B
IDCD406P
2. Loosen set screw (2) with wrench (B).
IDCD017P
33. Install mast to lift truck.

C
7
ICD407P IDCD410P
3. Remove bearing (3) with wrench (C). 6. Remove O-ring seal (6) and back-up ring (7) from
the bearing.
4
8
IDCD408P
IDCD411P
4. Remove rod (4) from the cylinder body.

7. Remove wiper seal (8) and seal (9) from the
bearing.
IDCD409P
5. Remove split rings (5) from the cylinder rod.

Assemble Standard Lift
Cylinders
5
9
IDCD409P
4. Install split rings (5) on the cylinder rod.
IDCD411P
4
1. Install seal (2) in the bearing.
2. Install wiper seal (1). Install the seal with the lip
toward the outside.
6 IDCD408P
5. Install cylinder rod (6) in the cylinder body.
7
IDCD410P
NOTE : Install back-up ring (4) with the curved side

contacting the O-ring seal.
3. Install O-ring seal (3) and back up ring (4) into the
5
bearing.
ICD407P
6. Install bearing (7) on the cylinder rod and tighten

using wrench (C).

2 Secondary Lift Cylinders
Disassemble Secondary Lift

Cylinders
Tools Needed A B
Hydraulic Cylinder Repair Stand 1
B
IDCD406P Wrench Assembly 1
7. Tighten setscrew (8) with wrench (B) to a torque of

6 L 1 NIm (53 L 9 lbIin). Start By:
End By: a. Remove standard lift cylinders.
a. Install standard lift cylinders.
A
1
IDCD201P
1. Put standard lift cylinder (1) in position on tool (A).
B
2
IDCD203P
2. Remove bearing (2) with tool (B).

13
3
12
IDCD204P IDCD208P
3. Remove rod (4) from the cylinder body. 7. Remove slyd ring (11), wear ring (12) and O-ring
(13) from the bearing.
4 5
16
14
7 6
IDCD206P
15
IDCD209P
4. Remove stop ring (4) from the cylinder rod.

8. Remove wiper seal (14) and retaining ring (15)
5. Remove wear ring (5), U-packing (6) and backup from the bearing.
ring (7).
9. Remove U-packing (16).
10 8 9
IDCD207P
6. Remove retaining ring (8), spacer (9) and check

valve (10).

Assemble Secondary Lift
Cylinders
10
13 12
IDCD206P
2
5. Install stop rings (10) on the cylinder rod.
3
IDCD209P
6. Install wear ring (11), U-packing (12) and backup
ring (13).
1. Install U-packing (1) in the bearing.
2. Install wiper seal (2) and retaining ring (3). Install

14
the seal with the lip toward the outside.
IDCD204P
5
6 7. Install cylinder rod (14) in the cylinder body.
IDCD208P
B
3. Install O-ring (4), wear ring (5) and slyd ring (6) in 15
the bearing.
IDCD203P
8. Install bearing (15) on the cylinder rod and tighten

7 8 using tool (B).
9
IDCD207P End By :
a. Install secondary lift cylinders *

4. Install check valve (7), retaining ring (8) and spac-
er (9). * Refer to the topic GGAssemble MastH in this module.

Primary Lift Cylinder
4
Remove & Install Primary Lift

Cylinder
3
Start By:
a. Remove carriage.
IDCD060S
WARNING 4. Pull the cylinder out far enough to disconnect

elbow (3). Remove primary lift cylinder (4). Weight
To prevent personal injury, move the control is 27 kg (60 lb).
levers backward and forward to release any pres-
sure in hydraulic system. Slowly loosen the cap of NOTE : The following steps are for the installation of
the hydraulic tank to release any pressure in the the primary lift cylinder.
tank. Be cautious of hot hydraulic oil when any
lines are disconnected in the hydraulic system. 5. Put primary lift cylinder (4) in position on the mast.
6. Connect elbow (3).
1 7. Install bolt (2), and bolts (1).
End By:
a. Install carriage.
IDCD059P
1. Fasten nylon straps and hoist to the primary lift

cylinder.
2. Remove bolts (1).
3. Remove bolt (2).

Disassemble Primary Lift
Cylinders
4
Tools Needed A B
Wrench Assembly 1
Start By:
IDCD211P
a. Remove primary lift cylinder.
4. Remove piston seal (4).
5
6
IDCD210P
IDCD212P
1. Remove flow protector valve (1) from the cylinder
body.
5. Remove retaining ring (5), and check valve (6).
3 A
7
IDCD215P
2. Remove bearing (2) with tool (A).

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

8
10
IDCD214P IDCD213P
7. Remove wiper seal (8) and retaining ring (9) and 3. Install O-ring seal (4).
U-packing (10) from the rod cover.
6
Assemble Primary Lift
Cylinders 5
Tools Needed A B
Wrench Assembly 1
IDCD212P
2
4. Install check valve (5), retaining ring (6).
3
1 8
7
IDCD214P
1. Install U-packing (1) in the rod cover.

IDCD211P
2. Install wiper seal (2) and retaining ring (3). Install
the seal with the lip toward the outside.
5. Install wear ring (7), piston seal (8) on the cylinder
rod.

10
9 A
3
IDCD215P 1
6. Install cylinder rod (9) in the cylinder body. WARNING

7. Install rod cover (10) on the cylinder body. Use To prevent personal injury, move the control
tool (A) to tighten bearing. levers backward and forward to release any pres-
sure in hydraulic system. Slowly loosen the cap of
the hydraulic tank to release any pressure in the
tank. Be cautious of hot hydraulic oil when any
lines are disconnected in the hydraulic system.
1. Disconnect elbow (2). Remove retainer bolt (3)

and pin (1).
IDCD210P
8. Install flow protector valve (14) on the cylinder

body.
End By:
a. Install primary lift cylinder. 6
4 5
Tilt Cylinders
2. Remove retainer bolt (6) from pin (5). Remove pin
(5).
Remove & Install Tilt Cylinders
3. Remove tilt cylinder (4).
NOTE : The procedure for removing and installing 4. Install the tilt cylinder in the reverse order of
the tilt cylinders is the same for both cylinders. removal.
WARNING
If both tilt cylinders are removed at the same time the

mast can fall. To avoid possible personal injury, make
sure the mast is securely held in place or supported
by a hoist before removing the tilt cylinders.

Disassemble & Assemble Tilt 4. Remove piston and seal assembly (4) from the
cylinder rod.
Cylinders
5. Remove head assembly (5).
Tools Needed A
Spanner Wrench 1 6
7
Start By:
a. Remove tilt cylinder.
8
1
IDCD423P
6. Remove spacer (6) from the cylinder rod.
7. Loosen the nut and bolt on the rod eye.

Remove cylinder rod (7) and shims (8).
2
IDCD421P
10
1. Use tool (A) to remove head (1) from the cylinder
body. 6
NOTICE
Use extra care not to damage the highly finished
surface of the cylinder rod and the bore of the cylin-
der body during disassembly and assembly of the tilt
IDCD424P
cylinder.
8. Remove seal assembly (10) and O-ring seal (9)

from the piston.
2. Remove rod assembly (2) from the cylinder body.
4 3
IDCD422P
3. Remove nut (3) from the cylinder rod.

14
15
16
IDCD253P IDCD426P
9. Remove seal (11) from the spacer. 12. Install seal (14) in the head. Position the lip of
the seal toward the inside of the head.
13. Install seal (15).

12
14. Install seal (16) in the cylinder head. Position the
lip of seal (16) toward the outside of the cylinder
head.
13
12
IDCD425P
10. Remove O-ring seal (12) and back-up ring (13)

from the head.
13
IDCD425P
14 NOTE: The curved side of back up ring (13) should

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

15 Make sure the curved side of back-up ring (13) is
in contact with O-ring seal (12).
16
IDCD426P
11. Remove seals (14), (15), and (16) from the head.
NOTE: Use the following steps to assemble the tilt

cylinder.

5 4
3
IDCD458P IDCD422P
16. Install seal (11) in the spacer. 20. Install head assembly (5) on the cylinder rod.
21. Install piston assembly (4) onto the cylinder rod.

2 8 6
22. Install nut (3). Tighten nut (3) to a torque of
270 L 30 N•m (200 L 22 lb•ft).
IDCD423P
17. Install spacer (6).
18. Install shims (8) and rod eye (2). Tighten the bolt
IDCD427P
on rod eye (2) to a torque of 95 L 15 N•m
(70 L 11 lb•ft).
23. Install the rod assembly in the cylinder body.
10
IDCD423P
19. Install seals (10) and O-ring seal (9) on the pis-
ton

Steering Cylinder
Disassemble Steering Cylinder

Start By :
a. Remove steering cylinder.
4. Remove piston seal (3) and wear ring (4).
1. Put location marks on end caps (1) as to their

position on the steering cylinder tube.
2. Remove end caps (1) from the steering cylinder.
3. Remove cylinder tube (2) from the rod assembly. 5. Disassemble each rod cover as follows.
a. Remove retaining ring (5) and dust wiper (6).

b. Remove U-packing (7).
c. Remove O-ring (8) and back up ring (9).
d. Remove DU-bush (10).
IDCD265S

Assemble Steering Cylinder
3. Install cylinder tube (2) on the rod assembly.
4. Install rod covers (1) on cylinder tube (2).
1. Assemble each rod cover as follows ;

a. Install DU-bush (10). End By :
b. Install back up ring (9) and O-ring (8)
c. Install u-packing (7).
d. Install dust wiper (6) and retaining ring (5). a.Install the steering cylinder.
2. Install piston seal (3) and wear ring (4).

Hydraulic Control Valves Disassemble Hydraulic
Control Valves
Remove & Install Hydraulic Start By :
Control Valves
a. Remove hydraulic control valve.
WARNING
Hydraulic oil under pressure can remain in the

hydraulic
IDCD273S system after the engine and pump have
been stopped. Personal injury can result if the
pressure is not released before any work is done
to the hydraulic system. To prevent possible per-
sonal injury, turn the engine off and move the con-
trol levers to make sure the hydraulic pressure is
released before any fitting, plug, hose or compo- 1
nent is loosened, tightened, removed or adjusted.
Always move the lift truck to a clean and level IDCD216P
location away from the travel of other machines.
NOTE : For purposes of assembly, put identification

1. Drain the hydraulic tank. marks on all valve sections.
1. Remove bolts (1) to separate the valve sections.
6
5
IKCS001P
4
IDCD218P
NOTE : For purposes of reassembly, put identifica-
tion marks on all lines, tubes and hoses before any
disconnections are made.
2. Remove dust cover 45), bolts (5) and retainer (6)
2. Disconnect seven hydraulic lines from control from the valve.
valve (3).
3. Support control valve (3). Remove two bolts and

control valve.
4. Install the control valve in the reverse order of

removal.
5. Fill the hydraulic tank to the correct level with fluid.

Refer to the Operation And Maintenance Manual
for further information.

12
12
7 13
8 9
IDCD219P IDCD222P
3. Remove side shift spool (7) from the valve body. 6. Remove lift and tilt valve spool assemblies (11)
from the valve body.
4. Remove seal (8) and spring (9) from the valve
spool. 7. Remove seals (12) from the valve spools.
8. Remove springs (13) from the valve spools.

10 10
10 10
15
16 14
10 10
IDCD221P
IDCD223P
5. Remove O-ring seals (10) from the valve body.
9. Remove plug (14) and spring (15).
10. Remove hydrostat (16).

Assemble Hydraulic Control
Valves
19
18
17
IDCD224P 1
2
3
11. Remove relief plugs (17), springs (18) and pop-
pets (19). IDCD224P
1. Make sure all valve parts are clean and free of

dirt.
2. Install poppets (1), springs (2), and relief plugs (3).
4 6
IDCD223P
3. Install hydrostat (4).
4. Install spring (5) and plug (6).

9
8
7
IDCD222P IDCD226P
5. Install springs (7) and seals (8) on the valve 10. Install retainer (14), dust cover (15) and bolt (16)
spools. to each section.
6. Install lift and tilt spool assemblies (9) to the valve

body.
10 10 10 10
17
IDCD216P
10 10
IDCD221P 11. Install bolts (17) to assemble the valve sections.
7. Install O-ring seals (10) to the valve body.
12 13
IDCD219P
8. Install seal (11) and spring (12) to the attachment

valve spool (13).
9. Install valve spool (13) to the valve body.

Steering Unit
Disassemble Steering Unit
Cleanliness is extremely important when repairing a

steering unit. Work in a clean area. Before discon-
necting lines, clean port area of unit thoroughly.
Use a wire brush to remove foreign material and
debris from around exterior joints of the unit.
Althouh not all drawings show the unit in a vise, we End Cap Cap Screw
recommend that you keep the unit in the vise during Seal
disassembly. Follow the clamping procedures
explained throughout the manual. IDCD279S
Gerotor (Meter) End 2. Remove 5/16 inch cap screws and washers if
applicable (7 each).
3. Remove end cap.
4. Remove seal from end cap.
Seal
IDCD278S
1. Clamp unit in vise, meter end up. Clamp lightly on

edges of mounting area. Use protective material
on vise jaws. Housing distortion could result if Spacer(s)
jaws are overtightened.
IDCD280S
5. Remove meter. Be careful not to drop star.
6. Remove seal from meter.
7. Remove drive spacer(s).

Control End
Drive
Seal Drive
IDCD281S IDCD282S
8. Remove drive. 11 Remove housing from vise. Place housing on a

clean soft cloth to protect surface finish. Use a
9. Remove spacer plate. thin bladed screwdriver to pry retaining ring from
housing.
10. Remove seal from housing.
Seal Gland
Bushing
IDCD283S
12. Rotate spool and sleeve until pin is horizontal.

Push spool and sleeve assembly forward with
your thumbs just far enough to free gland bush-
ing from housing. Remove bushing.

Quad
Ring
Seal
Dust Seal
Seal Gland
Bushing
Pin
IDCD284S IDCD286S
13. Remove quad ring seal from seal gland bushing. 16. Remove spool and sleeve assembly from 14 hole
end of housing.
14. Use a thin bladed screwdriver to pry dust seal
from seal gland bushing. Do not damage ATTENTION: Do not bind spool and sleeve in houst-
bushing. ing. Rotate spool and sleeve assembly slowly when
removing from housing.
17. Push pin from spool and sleeve assembly.
Needle Bearing
Thrust Race
Bearing
Bearing
Race
IDCD285S
15. Remove 2 bearing races and the needle thrust

bearing from spool and sleeve assembly.

Seal
9,3mm
[.36in.] ID
Check
Check
Ball
Set Screw Ball Check
Seat 7.7mm Ball
[.30 in.] ID
Retainer
IDCD287S IDCD288S
18. Push spool partially from control end of sleeve, 21. Remove set screw from housing.
then remove 4 centering springs from spool
carefully by hand. 22. Screw a #10-24 machine screw into end of check
ball seat. Then by pulling on screw, with a pliers,
19. Push spool back through and out of sleeve. lift seat out of housing.
Rotate spool slowly when removing from sleeve.
23. Remove 2 seals from check valve seat.
20. Remove seal from housing.
24. Tip housing to remove check ball and check ball
retainer.

Assemble Steering Unit
Control End
Check all mating surfaces. Replace any parts that

9,3 mm Set Screw
have scratches or burrs that could cause leakage.
Clean all metal parts in clean solvent. Blow dry with [.36 in.] ID
air. Do not wipe dry with cloth or paper towel
because lint or other matter can get into the Check Ball Seat
hydraulic system and cause damage. Do not use a
coarse grit or try to file or grind these parts. Check Ball
7,7 mm
[.30 in.]
NOTE: Lubricate all seals with clean petroleum jelly Check Ball
ID
such as Vaseline. Retainer
Do not use excessive libricant on seals for meter

section.
Refer to parts listings covering your steering unit
IDCD289S
when ordering replacement parts. A good service
policy is to replace all old seals with new seals.
1. Use a needle nose pliers to lower check ball

retainer into check valve hole of housing. Make
sure retainer is straight (not tilted on edge) in
housing.
2. Install check ball in housing
3. Lubricate 9.3 mm [.36 in.] ID seal and 7.7 mm [.30

in.] ID seal. Install seals on check ball seat as
shown.
4. Lubricate check ball seat and seals thoroughly

before installing seat in housing. When installing
seat do not twist or damage seals. Install check
ball seat in housing, insert open end of seat first.
Push check ball seat to shoulder of hole.
5. Install set screw. Use a 1/4 inch hex key to torque

set screw to 11 NIm [100 lbIin]. To prevent
interference make sure top of set screw in slightly
below housing mounting surface.

Spring Slot
Control Sleeve
Spring
Slot
Identification Control
Marks Spool
IDCD290S IDCD291S
6. Assemble spool and sleeve carefully so that the 7. Bring spring slots of both parts in line and stand
spring slots line up at the same end. Rotate spool parts on end of bench. Insert spring installation
while sliding parts together. Some spool and tool through spring slots of both parts. Tool is.
sleeve sets have identification marks, align these Position 2 pairs of centering springs on bench so
marks. Test for free rotation. Spool should rotate that extended edge is down and arched center
smoothly in sleeve with finger tip force applied at section is together. In this position, insert one end
splined end. of entire spring set into spring installation tool, with
spring notches facing sleeve.
8. Compress extended end of centering spring set

and push into spool sleeve assembly withdrawing
installation tool at the same time.
9. Center the spring set in the parts so that they

push down evenly and flush with the upper sur-
face of the spool and sleeve.
10. Install pin through spool and sleeve assembly

until pin becomecs flush at both sides of sleeve.

Needle
Thrust Bearing
Bearing Race (2)
Seal
Pin
IDCD292S
IDCD293S
11. Position the spool and sleeve assembly so that
the splined end of the spool enters the 14 hole
end of housing first.
12. Place housing on clean lint free cloth. Install 47,5
ATTENTION: Be extremely careful that the parts do mm [1.86 in.] ID seal in housing.
not tilt out of position while inserting. Push parts gen-
tly into place with slight rotating action, keep pin 13. Install 2 bearing reces and the needle thrust
nearly horizontal. Bring the spool assembly entirely bearing in the order shown.
within the housing bore until the parts are flush at the
meter end or 14 hole end of housing. 14. Install 25 mm [1 in.] ID dust seal in seal gland
Do not pull the spool assembly beyond this point to bushing, flat or smooth side must face down
prevent the cross pin from dropping into the dis- towards bushing.
charge groove of the housing. With the spool assem-
bly in this flush position, check for free rotation within 15. Install the quad ring seal in seal gland bushing.
the housing by turning with light finger tip force at the Smooth seal in place with your finger. Do not use
splined end. any seal that falls freely into pocket of bushing.

Retaining
Ring
Seal
Gland
Bushing
(with seals)
IDCD294S IDCD296S
16. Install seal gland bushing over the spool end with 18. Clamp housing in vise. Clamp lightly on edges of
a twisting motion. Tap the bushing in place with a mounting area. Do not over tighten jaws.
rubber hammer. Make sure the bushing is flush
against the bearing race. NOTE: Check to insure that the spool and sleeve are
flush or slightly below the 14 hole surface of the
housing.
ATTENTION: Clean the upper surface of the housing

by wiping with the palm of clean hand. Clean each of
Screwdriver
the flat surfaces of the meter section parts in a simi-
Dust Seal
lar way when ready for reassembly. Do not use cloth
Retaining
of paper to clean surfaces.
Ring
Seal Gland
Bushing
Quad Ring
Seal
Seal
IDCD295S
17. Install retaining ring in housing. After installing

IDCD297S
ring, tap on ring end or pry with screwdriver
around entire circumference of ring to properly
seat ring in groove.
19. Install 73.5 mm [2.89 in.] ID seal in housing.
20. Install spacer plate. Align bolt holes in spacer

plate with tapped holes in housing.

Seal Groove this Side of Gerotor (Meter)
Star Valley A
Port Face
Drive
Pin Parallel B
with Port
Face Drive
(Marked) C
D
Pin
IDCD298S
21. Rotate spool and sleeve assembly until pin is

parrallel with port face. Install drive, make sure Pin Port Face
you engage drive with pin, To assure proper
IDCD300S
alignment, mark drive as shown. Note relation-
ship between slotted end fo drive to splined end
of drive when marking.
23. With seal side of meter toward spacer plate, align
star valleys on drive. Note the parallel relation-
ship of reference lines A, B, C, and D. Align bolt
holes without disengaging meter from drive.
Seal
IDCD299S
22. Install 73,5 mm [2.89 in.] ID seal in spacer plate

or gerotor (meter).

24. Install drive spacer (s) when used, in meter.
25. Install 73.5 mm [2.89 in.] ID seal in gerotor (meter)

or end cap, see notes.
Seal
Drive Spacer(s) 26. Install end cap on gerotor, align holes.
IDCD301P
IDCD302P
Actual
Displacement Spacer
cm3/r(in3/r) Length mm[in.]
27. Install 7 dry cap screws in end cap. Pretighten
45[ 2.8] None
screws to 11 to 17 NIm [100 to 150 lbIin] then
60[ 3.6] None torque screws to specifications.
75[ 4.5] None
95[ 5.9] 3.56[ .140]
120[ 7.3] 6.10[ .240]
145[ 8.9] 10.29[ .405]
160[ 9.7] 12.19[ .480]
185[11.3] 15.62[ .615]
230[14.1] 21.97[ .865]
295[17.9] 28.45[1.120]
370[22.6] 41.15[1.620]
460[28.2] 53.67[2.113]
590[35.9] 66.37[2.613]
740[45.1] 91.77[3.613]

Steering Wheel Steering Column
Remove And Install Steering Wheel Remove Steering Column

Start By:
1 2 a. remove steering wheel.
4
3
1
2
3
IDCD309S
1. Remove cap (1) from the steering wheel.

1. Remove bolts (1) and front cover (2).
2. Remove nut (3) and cup (2) from the steering
2. Remove bolts (3), and top cover and instrument
wheel.
group assembly (4) from the support assembly.
3. Use a suitable puller to remove the steering
wheel. Later models will have threaded holes in
the steering wheel to install a puller.
7
NOTE: The following steps are for installation of the
steering wheel.
4. Put the steering wheel in position on the shaft.

Install cup (2) and nut (3). Tighten the nut to a
torque of 80 L 7 NIm (60 L 5 lbIft). 6
5. Install cap (1) on the steering wheel.
3. Put identification marks on all hoses and wires for

installation purposes. Disconnect four connectors
(6) from the light switch (if equipped). Disconnect
two wiring harness connectors (7). Remove the
cover and instrument group assembly from the
steering column.

10
13
17
8
4. Disconnect the four steering gear hoses.

Disconnect wires (8) from the ignition switch.
5. Disconnect all kinds of connector (9). 18
6. Remove bolts, clamp (10) and directional switch

(11) from the steering column. Disconnect hose
(13) from the steering gear. 8. Remove the nuts, washers and bolts (18).
Remove the bushings if a replacement is neces-
sary. Remove support assembly (17) from the
cowl. Remove ignition switches if necessary.
15
Install Steering Column
14
16
7. Remove four bolts (14), and separate steering 17

gear (16) from steering column (15). Remove
steering column (15) from the support assembly.
18
1. Install ignition switches into support assembly (17)

if they were removed. Install the bushings if they
were removed. Put the support assembly in posi-
tion on the cowl. Install bolts (18), washers, nuts.

7
15
14
6
16 6. Put the cover and instrument group assembly in

position over the steering column. Connect two
wiring harness connectors (7). Connect four con-
nectors (6) to the light switch (if equipped).
4
2. Put steering column (15) in position in the support
assembly. Connect steering gear (16) to column
1
(15), and install four bolts (14) that hold the steer-
ing gear and column together. Tighten the bolt to a
2
torque of 15 ~ 20 N•m. 3
10
7. Put front cover (2) in position on the support

assembly. Install bolts (1).
8. Put top cover and instrument group assembly (4)

13
in position on the top of the support assembly.
Install bolts (3).
End By:
3. Connect hose (13) to the steering gear. Put direc- a. Install steering wheel.
tional switch (11) in position on the steering col-
umn. Position clamp (10), and install bolts.
4. Connect all kinds of connector (9).
5. Connect wires (8) to the ignition switch. Connect

the four steering gear hoses to the steering gear.

Steer Axle
3 2
Remove Steer Axle
WARNING
Be sure the pressure in the hydraulic system is

released before any lines or hoses are disconnected.
6. Remove bolts (2) and mounting caps (3) from the

steer axle.
1. Put the lift truck in position on wood block or by

use hoist.
4
2. Put identification marks on hoses (1); then discon-

nect them.
7. Remove steer axle (4). Weight of the steer axle is
200 kg(440 lb).
2
Install Steer Axle
3. Put a floor jack in position under the steer axle.

4. Loosen axle mounting bolts (2) until approximately
two bolt threads are left in the mounting bosses.
5. Lower the steer axle onto the bolt heads with the
1. Put steer axle (4) in position with a floor jack.
floor jack. disconnect the hydraulic lines from the
steering cylinder.

Master Cylinder
2
Remove And Install Master Cylinder
5 3
NOTE: Install bolts (2) with approximately two bolt

threads into the mounting bosses.
4 1 2
2. Install bolts (2) and caps (3) in the mounting bosses.
3. Connect the hydraulic lines to the steering

cylinder. 1. Remove the floor plates from the lift truck. Drain the
brake fluid from the brake reservoir. Disconnect
4. Raise the steer axle with the floor jack, then hose (1) and line (4) from master cylinder (5).
tighten bolts (2).
2. Remove the cotter pin, washer and pin (3) from
the clevis and brake pedal.
3. Remove two bolts (2), the washers and master

cylinder (5) from the lift truck.

master cylinder.
1
4. Put the master cylinder in position, and install the
two washers and bolts (2).
5. Install pin (3) through the master cylinder clevis

and brake pedal. Install the washer and cotter pin.
5. Connect hoses (1) to the steering lines.
6. Connect brake line (4) and hose (1) to the master
cylinder. Fill the brake reservoir with brake fluid.
See the Operation And Maintenance Manual.
7. Bleed the brake system, and if necessary, adjust the

pedal free travel. See Brake System Air Removal
And Pedal Adjustment in Testing And Adjusting.

Accelerator Control Switch Parking Brake
Remove And Install Accelerator Remove And Install Parking Brake

Control Switch
2 3 5
1
2
3
6 7
8 4
1. Remove the floor plates. Disconnect connector
(1).
2. Remove four bolts(2). 9
3. Remove bracket from accelerator control switch

group if necessary. Remove accelerator control IDCD327S
switch group (3) from the lift truck.
NOTE: Install accelerator control switch group(3) in 1. Remove the battery and the plate under the
the reverse oder of removal. battery. Remove two nuts (1), two washers (2)
and spring (3).
2. Remove the bolt (4) and clip (7), and pull cable
assembly (5) away from the parking brake.
Remove plate (9).
3. Remove the three bolts and the parking brake

from the back of the drive motor.
4. Remove the cotter pin, locknut (8), the washer,

drum (6) and the key from the drive motor. If nec-
essary, use a puller to remove the drum.

parking brake.
5. Put the key and drum (6) in position on the drive

motor armature. Install the washer and locknut (8).
Tighten the locknut to a torque of 50 L 20 NIm
(37 L15 lbIft), and install the cotter pin.
6. Put the parking brake on the back of the drive

motor. Install the three bolts. Install plate (9).
7. Position cable assembly (5) through the parking

brake, and install washers (2), spring (3) and nuts
(1). Install clip (4).

9. With the parking brake lever assembly in the
10 11 “OFF” position and cable assembly shoulder (10)
1 seated against strap assembly (12), as shown in
X
BRAKE OFF, adjust nuts (1) until spring (3) over
travel (X) is 70.0 L 0.5mm (2.76 L .02 in).
3 10. With the parking brake applied, adjust off position

13 stop bolts (15) and (16) until there is a clearance
12 (Y) of 6.0 mm (.24 in) maximum between strap
assembly (12) and bracket assembly (11).
6 Tighten the nuts to hold the adjustment.
11. With the parking brake lever assembly in the

A “OFF” position, adjust retaining nut (13) so that
the lever assembly returns to the full off position
and strap assembly (12) contacts stop bolts (15)
14 and (16).
IDCD328S
Brake Off
Disassemble And Assemble Parking
15 Y 16 Brake
Start By:
a. remove parking brake
12 2 3
1
6
4
14
IDCD329S
Brake On 5
6
8. Adjust the parking brake as follows: adjust drum (6)

to the strap assembly lining clearance with bolt (14).
Adjust bolt (14) until the clearance at point (A) is IDCD330S
0.25 to 0.50 mm(.010 to .020 in). Install the wire to
hold the adjustment.
1. Remove the wire, bolt (7) and spring (6). Remove
retaining nut (5), spring (1) and ring (2).
2. Remove bracket assembly (3). Remove strap

assembly (4) from bracket assembly (8).

NOTE: The following steps are for assembly of the Drive Motor
parking brake.
3. Put the strap assembly in position on bracket Remove And Install Drive Motor
assembly (8). Install bracket assembly (3).
4. Install spring (6), bolt (7) and the wire. Install ring
Tools Needed A B
(2), spring (1) and retaining nut (5).
Link Bracket 1
End By: Socket 1
a. Install parking brake.
1. Remove the battery, the plate under the battery

and the floor plates. Drain the hydraulic tank.
Disconnect the hydraulic pump and steering pump
hoses from the hydraulic tank.
2. Put identification marks on all hoses and connec-

tors. Disconnect all kinds of hoses and connectors
from middle flace. Remove four bolts (4) and mid-
dle flace (5).
3. Remove nut (2) and the spacers from the end of

the parking brake cable assembly. Loosen the bolt
and clamp (1), and pull the cable assembly away
from the parking brake.
4. Disconnect thermal switch connector.

Disconnect brush wear indicator wire.
Disconnect four cables (3) (two at the back and
two at the front) from the drive motor.

The following steps are for installation of the drive
motor.
8. Put O-ring seal (10) on the drive motor, and put

clean SAE 10W oil on it. Install gear (9), the lock-
A washer, washer and nut (8). Tighten the nut with
tool (B) to a torque of 100 L 15 NIm (75 L 11
lbIft), and the lock the nut in position.
9. Raise the lift truck, and put the drive motor in posi-
tion under it. Attach a hoist to tool (A), and put the
drive motor in position in the transaxle. Install the
six bolts that hold the drive motor to the transaxle.
5. The weight of the drive motor is 101 kg(223 lb). 10. Connect four cables (3), brush wear indicator
Remove bolt and install tool (A) and a hoist. wire and thermal switch connector.
Remove the six bolts that hold the drive motor to
the transaxle. Remove the drive motor from the 11. Put the parking brake cable assembly in position
transaxle, and lower it to the floor. in the parking brake, and install the spacers and
nut (2). Tighten the bolt and clamp (1). Adjust the
6. Raise the lift truck, and remove the drive motor parking brake cable assembly. See Parking
from under it. Brake control Group Adjustment in Testing And
Adjusting.
12. Install middle plate (5) with four bolts (4).

Connect all kids of hoses and
6
13. Connect the hydraulic pump hoses to the
hydraulic tank. Fill the hydraulic tank with oil to
the correct level. See the Operation And
7 Maintenance Manual. Install the plate over the
motors, the battery and floor plates.
8
9 10
IDCD347S
7. Bend lockwasher (7) tab away from nut (8).

Remove nut (8) with tool (B), the lockwasher,
washer and gear (9). Remove O-ring seal (10) if
necessary.

Transaxle 5. Put wood black under the lift truck, and lower it
onto the tooling as shown.
Remove And Install Transaxle 6. The weight of the drive motor is 105 kg (232 lb)
Start By: Install tool (B) and a hoist, and remove the bolts and
the drive motor [see Drive Motor in this module for
a. Remove mast. placement of tool (B)].

transaxle.
1
7. Put the drive motor in position in the transaxle with
tool (B) and on hoist. Install the bolts that hold the
drive motor to the transaxle.
8. Put a lift truck with wood block on its forks, under

the transaxle as shown. Raise the lift truck off of
wood black, and roll the transaxle under it.
Remove wood black, and lower the truck onto the
transaxle. Install bolts (2), the washers and nuts,
and tighten them to 488 L 27 NIm (360 L 20 lbIft).
9. Connect brake lines (1). Connect the parking

brake switch wires and the parking brake cable
3 assembly.
2
10. Connect the cables and wires (if equipped) to the
drive motor. Install the plate over the motors, and
install the battery. Fill the brake reservoir to the
correct level. See the Operation And Maintenance
Manual. Bleed the brakes. See Brake System Air
Removal in Testing And Adjusting.
End By:
a. Install mast.
1. Remove the battery and the plate under the bat-

tery. Disconnect the four cables and wires (if
equipped) from the drive motor. Disconnect the
parking brake cable assembly and the two wires
from the parking brake switch (see Parking Brake
in this module). Drain the brake fluid reservoir.
2. Support two sideshifter hoses (3) (if equipped)

away from the transaxle so they do not interfere
during removal. Disconnect two brake lines (1).
3. Put wood block on the forks under the drive motor

for support. Attach a hoist to the lift truck as
shown.
4. Remove four bolts (2), the nuts and washers.

Raise the lift truck off of the transaxle, and roll the
transaxle from under the lift truck.

Counterweight
Remove And Install Counterweight
WARNING

Injury to personnel is possible. Disconnect battery
from truck and also discharge high voltages
between B+ and B- with 150ohm, 24watt resistor
before attempting to service this truck.
1. Remove the protector cover from the counter-

weight. Disconnect the battery and discharge high
voltages between B+ and B-.
2. Disconnect positive battery cable and negative

battery cable from the control panel.
3. Install tooling in the two holes at the top of the

counterweight. Attach a hoist. The approximate
weight of the counterweight is as follows:
B20S-3 .........................................................390 kg
B25S-3, B30S-3 ...........................................660 kg
4. Remove three bolts and the counterweight.

counterweight.
5. Put the counterweight in position on the lift truck

and install three bolts.
7. Install the protector cover on the counterweight.

SB4084E00
Dec. 2002
Specifications
Systems Operation
Testing & Adjusting
Lift Trucks Vehicle Systems
B20S-3, B25S-3, B30S-3
accident occurs. A person must be alert to potential hazards. This person should also have the necessary train-
ing, skills and tools to perform these functions properly.
WARNING
in injury or death.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publica-
tion.
and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubri-
cation, maintenance or repair procedures you choose.
and most current information before starting any job. DAEWOO dealers have the most current information avail-
able.
1
Index
Systems Operation
Brake System .........................................................17 Steering System .....................................................47
Master Cylinder...............................................17 Steering Axle Stop Adjustments .....................48
Oil Cooled Disc Brakes...................................18 Steering Knuckle Bearing Preload Adjustment ......48
Parking Brake .................................................19 Steering System Pressure Check...................49
Shoe Type Brakes ..........................................17 Steering Wheel Bearing Adjustment...............47
Electric Motors........................................................20 Troubleshooting......................................................22

Hydraulic Pump Motor ....................................20 Brake System .................................................27
Brake System (Oil Cooled Disc Type) ............28
Hydraulic system ......................................................5 Electric Motors ................................................29
Basic Schematic ...............................................5 Hydraulic System and Mast............................22
Hydraulic Control Valve ....................................7 Steering System .............................................26
Lift Cylinders and Mast ...................................10 Visual Checks .................................................22
Steering System .....................................................13

Schematic .......................................................13 Specifications
Steering Cylinder ............................................14
Steering Gear .................................................15 Brakes ....................................................................75
Carriage..................................................................67
Testing And Adjusting
Hydraulic Control Valve ..........................................62
Brake System ........................................................ 50 Hydraulic Pumps ....................................................63
Brake Adjustment............................................51 Hydraulic Pump Motor............................................77
Brake System Air Removal.............................50
Parking Brake Adjustment ..............................53 Lift and Tilt Mounting Group ...................................71
Parking Brake Control Group Adjustment.......54 Lift Cylinders...........................................................64
Parking Brake Test..........................................53 Standard ..........................................................64
Pedal Adjustment............................................52 Full Free Triple Lift and Full Free Lift Primary .......64
Full Free Triple Lift and Full Free Lift Secondary ...65
Hydraulic Pump Motor............................................55 Lift Relay Group - Standard Lift .............................68
Armature Tests................................................56 Lift Relay Group - Full Free Lift..............................69
Brush Holder Test ...........................................60 Lift Relay Group - Full Free Triple Lift....................70
Brush Life Estimate.........................................61
Commutator Inspection...................................58 Mast........................................................................67
Field Coil and Terminal Tests..........................59
Motor Brushes ................................................55 Parking Brake.........................................................76
Thermal Switch (Thermostat) Tests ................60 Priority Valve ..........................................................72
Hydraulic System ...................................................33 Steer Axle and Wheel.............................................74

Flow Control Valve Adjustment .......................34 Steering Gear .........................................................73
Relief Valve Pressure Check ..........................33 Steering Wheel.......................................................72
Standard Lift Cylinder Air Removal.................34 Steer Tire Installation..............................................74
Mast and Carriage..................................................36 Tilt Cylinders...........................................................66

Carriage Adjustment .......................................41
Carriage and Mast Height Adjustment............44
Chain Adjustments..........................................42
Chain Wear Test .............................................43
Drift Test..........................................................46
Forks Parallel Check.......................................44
Mast Adjustment .............................................36
Tilt Cylinder Alignment ....................................45
Vehicle Systems 3 Index

Systems Operation
Hydraulic System
Basic Schematic
2 3
1
1 4
8 6
10
13 11
15 9
14
16 12 17
IDCS101S
Basic Hydraulic Schematic(Lift Truck With Standard Lift and Full Free Lift Or Full Free Triple Lift)
(1) Lift cylinders (primary for STD, secondary for FFL and FFTL). (2) Excess flow protector (FFL and FFTL).
(3) Lift cylinder (primary for FFL and FFTL). (4) Excess flow protector. (5) Sideshift cylinder (if equipped). (6) Hydraulic control valve.
(7) Flow regulator valve. (8) Tilt cylinders. (9) Relief valve poppet(lift). (10) Hydraulic oil filter. (11) Relief valve poppet(sideshift and tilt).
(12) Hydraulic pump (13) Hydraulic oil tank. (14) Oil line. (15) Priority valve
(16) Oil line to steering gear. (17) Oil line.
Basic Oil Flow
The hydraulic system has hydraulic oil tank (13), The control valve levers move the valve spools in
which holds the oil for gear-type hydraulic pump (12). control valve (6). The spools direct control valve oil
Hydraulic pump (12) sends pressure oil to the to lift cylinders (1) and/or (3), tilt cylinders (8) and/or
hydraulic and steering systems. Pump oil flows from sideshifter cylinder (5).
pump (12) to priority valve (15), where the oil flow
divides. Part of the oil goes to the steering gear
through line (16). The remaining oil goes to hydraulic
control valve (6) through line (17).
Vehicle Systems 5 Systems Operation

The return hydraulic oil from the cylinders flows
through hydraulic control valve (6), line (14), into fil-
ter (10) and hydraulic tank (13). Relief valve poppet
(9) will release extra pressure to the hydraulic tank
when the pressure in the lift circuits goes higher than
relief valve pressure shown in the Control Valve sec-
tion of SPECIFICATIONS. Relief valve poppet (11)
does the same thing for the sideshift or tilt circuit
when pressure goes higher than the auxiliary relief
valve pressure shown in the Control Valve section of
SPECIFICATIONS.
The speed at which the lift cylinder(s) are lowered is

controlled by flow regulator (7).
Excess flow protector (2) and (4) will act as a flow

control valve if an line between them and flow regu-
lator valve (7) is broken when the mast is raised or
lowered. This prevents a sudden fall of the mast or
carriage if an oil line is broken.
The tilt forward, tilt back and sideshifter speed are

controlled by flow control valves in hydraulic control
valve (6). There is an anti-cavitation valve inside the
tilt spool to prevent cavitation (development of air
pockets) in tilt cylinders (8).
For a complete hydraulic schematic, see the foldout

in the back of this module.

Hydraulic Control Valve
CAUTION
Hex head must face out of
valve toward spring and
plug.
4
5 2
7
6
3
8
10
IDCS102S
(1) Relief Valve - Hydrostat. (2) Inlet/Outlet Body. (3) Center Spring. (4) Center Body. (5) Spool. (6) Tie Stud.
(7) Quick Disconnect Gauge Body. (8) Check Valve. (9) Seal Rings. (10) Main Relief Valve.
Assembly And Construction
Above figure is a cross-section view showing con- Passages between the bodies connect each section
struction and assembly of a three-section valve. to the common inlet and tank ports.
The Quick Disconnect Gauge Body section also con- Seal rings between the sections seal the connecting
tain a relief valve assembly. passages, Sections are held together by studs and
nuts.

Valve Operation Lift Spool
4
1
OUT -
6
CENTER -
IN -
INLET OUTLET
OUT Pressure to GGAH

2 GGBH blocked
By-pass blocked
3 5 7
CENTER GGAH and GGBH blocked
IDCS103S By-pass open
(1) Control Valve Sensing Orifice.
(2) Flow Control And Relief Valve-Hydrostat IN GGAH to tank
(3) Tank Passage. GGBH blocked
(4) By-pass Flow Control Orifice.
IDCS104S By-pass open
(5) Cylinder Ports.
(6) Pressure Passage.
(7) By-pass Passage.
Lift spool - used for control of single acting cylinder
applications. It directs flow to only one end of a cylin-
Figure IDCS103S is a schematic illustration of a der, as in the lift mechanism of a lift truck.
three section valve, showing the inlet and outlet ports Return flow is from the same end of the cylinder and
and the by-pass, pressure and tank passages. relies on gravity or mechanical means to retract.
The pressure passage is used to carry fluid to the
cylinder ports when the spools are shifted. The by-
pass passage permits flow directly to the outlet when
the spools are not being operated. The tank passage
also carries fluid to the outlet; either return flow from
the cylinder ports or fluid diverted past the flow con-
trol and relief valve.
The spools are shown in the centered or neutral

position. Under these conditions, fluid in the pressure
passage is blocked from the cylinder ports by the
spool lands. Flow through the valve is through the
by-pass and tank passages to the outlet.
IDCS105S

Tilt Spool Auxiliary Spool
IN Pressure to “B”
“A” to tank
IN Pressure to “B” By-pass blocked
“A” to tank
By-pass blocked CENTER “A” and “B” blocked
By-pass open
CENTER “A” and “B” blocked
By-pass open OUT Pressure to “A”
“B” to tank
OUT Pressure to “A” By-pass blocked
“B” to tank IDCS108S
IDCS106S
By-pass blocked
Auxiliary spool - directs flow to either end of a double

acting cylinder. Flow from the end that is not under
Tilt spool - a counterbalance spool normally used to
pressure is returned to tank via internal coring of the
control the tilt function of a lift truck.
valve section.
The counterbalance feature prevents the forks from
tilting forward faster than pump can supply oil, pre-
venting tilt.
IDCS109S
IDCS107S

Lift Cylinders and Mast
Standard Lift
(A)
1 2
IDCS001P IDCS002P
Standard Lift Mast Standard Lift Mast At Full Extension

(Typical Example) (Typical Example)
(A)Free lift period. (1) Lift cylinder. (2) Lift cylinder.
The inner mast and carriage will continue to move up

The rods of Standard Lift Cylinders (1) and (2) are
until they are in the extended position. If the control
moved up by oil under pressure and go back to their
valve lift lever is held in the lift position with the mast
original position by gravity.
fully extended, the pressure relief valve in the control
The combination of the single-acting hydraulic lift valve will release the extra pressure until the lift lever
cylinders with other mechanical lifting components is released. The oil flows through the relief valve and
will operate as follows: the control valve into the hydraulic tank. The carriage
and inner mast will be stationary at this full height
When the control valve lift lever is pulled back, the until the lift lever is moved to the lowered position.
hydraulic oil under pressure, pushes against the rods
When the lift lever is moved forward, the oil under
at the bottom of the lift cylinders. The inner mast
pressure is released in the lift cylinders. Gravity and
crossbar, which is connected to the top of the
the weight of a load will cause the carriage to move
cylinder rods, begins to move up. At this time, the down at a 2 to 1 ratio and the inner mast to move
carriage also starts to move up because it is down at 1 to 1 ratio with the rods of the lift cylinders
connected to the inner mast through the lift chains until the carriage and mast are completely lowered.
arrangement. From the start of the lift cycle until the
top of the inner mast becomes equal height to the The flow regulator located between the outer mast
top of the outer mast, the carriage and mast are in near the base of the lift cylinders, permits 54 to 66
their free lift period (A). liter/min (14 to 17 U.S. gpm) of oil flow back through
the control valve and into the hydraulic tank.
The inner mast moves at a 1 to 1 ratio and the
The lift cylinders also have excess flow protectors.
carriage moves at a 2 to 1 ratio with the rods of the
These flow protectors act as a lowering flow control
lift cylinders.
valve if an oil line is broken between them and the
flow regulator located near the base of the lift cylin-
ders.
The carriage and inner mast move up and down
smoothly on load bearings (rollers). Stability of the
mast and carriage is controlled by bearing size and
shims behind the bearings (rollers).

Full Free Triple Lift Mast
3 4
5
6
IDCS003P IDCS004P
Full Free Triple Lift Mast Full Free Triple Lift Mast At Free Lift
(Typical Example) (Typical Example)
(3) Primary lift cylinder. (4) Crosshead. (5) Intermediate mast. (3) Primary lift cylinder.
(6) Inner mast.
When the movement of the primary cylinder is com-

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

4
IDCS005P
Full Free Triple Lift Mast In The Extended Position

(Typical Example)
(3) Primary lift cylinder. (5) Intermediate mast. (6) Inner mast.
(7) Secondary cylinder.
The oil under pressure in the primary and secondary

cylinders is released when the lift control lever is
moved forward. Gravity and the weight of a load will
cause the cylinders to move back into their housings.
The secondary cylinders move completely back into
their housings before the primary cylinder starts to
move down. The flow regulator valve, located
between the outer mast near the base of the lift
cylinders, permits 54 to 66 liter/min (14 to 17 U.S
gpm) of oil to flow back through the control valve and
into the hydraulic tank.
The Full Free Lift and Full Free Triple Lift Masts also
have excess flow protectors connected to the prima-
ry lift cylinder and in the inlet of the secondary lift
cylinders. They will act as a lowering flow control
valve if an oil line is broken between any of them and
the flow regulator valve located near the base of the
lift cylinders.
The carriage and inner mast move up and down

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

Steering System
Schematic
5 4 3 6
1 2
7 8 9
12
11
IDCS111S
10
Steering System Schematic

(1) Steering gear. (2) Hose. (3) Hose (to hydraulic control valve). (4) Hose. (5) Hose. (6) Steering cylinder.
(7) Load sensing signal hose. (8) Check valve. (9) Hose. (10) Hydraulic pump. (11) Hydraulic tank.
(12) Priority valve.
The steering system uses hydraulic oil for its opera- During a left turn, pilot pressure is again increased in
tion. The system has priority valve (12) which sends load sensing signal hose (7) which moves the spool
oil to the steering gear as needed before the require- in priority valve (12) to the right. Oil flows through
ments of the mast are filled. hose (9) to steering gear (1). From the steering gear,
oil flows through hose (4) to steering cylinder (6) to
Hydraulic oil is pulled from hydraulic tank (11) to make a left turn. The displaced (return) oil flows
hydraulic pump (10). The pump sends the oil through through hose (5) back to the steering gear, hose (2)
hose to priority valve (12). When the steering gear is and into the hydraulic tank.
in NEUTRAL position, pilot pressure in load sensing
signal hose (7) is reduced so the spool in priority Check valve (8) is in hose (9) near the steering gear
valve (12) moves to the left. Oil flows through hose to prevent oil flow back to priority valve (12) right
(3) to the hydraulic control valve. after a turn is made.
During a right turn, pilot pressure is increased in load Relief valve in priority valve will open if the steering
sensing signal hose (7) and the spool in priority valve pressure goes above 7600 L 350 kpa(1100 L 50
(12) moves to the right. Oil flows through hose (9) to Psi) for B20/25/30S-3.
steering gear (1). From the steering gear oil flows
through hose (5) to steering cylinder (6) to make a
right turn. The displaced (return) oil flows through
hose (4) back through the steering gear, hose (2)
and into the hydraulic tank.

Steering Cylinder
Steering cylinder (1) gives power assistance through
the use of pressure oil at either end of the cylinder.
The steering cylinder is double ended and the body

of the cylinder is mounted stationary to the steer
axle. The rod assemblies at both ends of the cylinder
which allows the cylinder to move the link assem-
blies.
Steering Cylinder
(1) Steering cylinder.

Steering Gear
A B
2 3 4 5 6
8 9 10 11 12
IDCS113S
Steering Gear
(1) Spool. (2) Sleeve. (3) Outlet (to tank). (4) Inlet (for pump oil). (5) Internal pump gear. (6) External pump gear. (7) Centering springs.
(8) Pin. (9) Left turn port. (10) Right turn port. (11) Body. (12) Drive. (A) Control section. (B) Metering section.
Lift trucks use the load sensing, closed center (oil The steering gear has two main sections: control
flow to steering gear only when needed) steering section (A), and pump or metering section (B). These
gear. two sections work together to send oil to the steering
cylinder.
All lift truck hydraulic lines serve a dual purpose in
that they serve both the steering and cylinder Oil from the priority valve goes through inlet (4) into
hydraulics through the use of a priority valve. The the control section of the steering gear. When the
priority valve sends oil to the steering gear before the steering wheel is turned, the control section sends
needs of the cylinder hydraulics are met. the oil to and from the metering section and also to
and from the steering cylinder.
The metering section is a small hydraulic pump. It

controls (meters) the oil that goes to the steering
cylinder. As the steering wheel is turned faster, there
is an increase in the flow of oil to the steering cylin-
der. This increased flow causes the main valve spool
to move farther. As the spool moves farther, more oil
can flow from the priority valve or power steering
pump to the steering cylinder, and a faster turn is
made.

Oil Flow
The oil from the priority valve flows through inlet (4).
When the steering wheel is stationary (NEUTRAL),
5 6 8
the oil is stopped by spool (1). The oil can not flow
through the steering gear to the steering cylinder
until the steering wheel is turned.
The steering wheel is connected to spool (1) by a

shaft assembly and splines. When the steering wheel
is turned, spool (1) turns a small amount until springs
(7) are compressed. Then, sleeve (2) starts to turn.
As long as the steering wheel is turned, the spool
and sleeve both turn as a unit, but they turn a few
degrees apart.
When the spool and sleeve are a few degrees apart,

oil passages are opened between them. This lets the
pump oil from inlet (4) flow through passages in body
(11) to the metering section.
When the steering wheel is turned, pin (8) turns with 12

the sleeve and causes drive (12) to turn also. The
drive causes a rotation of gear (5) inside gear (6). IDCS114S
This rotation of the gear sends a controlled
Pump Gears In Metering Section
(metered) flow of pilot oil back through body (11). (5) Internal pump gear. (6) External pump gear. (8) Pin. (12) Drive.
This oil flows to port (9) or (10) and then to the steer-
ing cylinder. Port (9) or (10), that is not used for pres-
sure oil to the steering cylinder, is used for return oil If the steering wheel rotation is stopped, springs (7)
from the other end of the steering cylinder. will move sleeve (2) back in alignment with spool (1)
(NEUTRAL position). This will close passages
between the metering section and control section
and the steering gear will be in the NEUTRAL posi-
tion.
When the engine is off, the steering gear can be

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

Brake System
Master Cylinder Shoe Type Brakes
1 5
3
6
4
2 6
8
7 9
13
3
11
SECTION A-A
12 13 14 15 16 10
IDCS116S
Master Cylinder And Wheel Cylinder Wheel Brakes

(1) Master cylinder reservoir. (2) Master cylinder. (3) Wheel cylinder. (4) Primary shoe. (5) Secondary shoe.
(3) Wheel cylinder (6) Return springs. (7) Return spring. (8) Spring.
(9) Guide. (10) Star wheel. (11) Adjustment screw.
(12) Pin. (13) Plate. (14) Spring. (15) Spring. (16) Pin.
Brake fluid from remote reservoir (1) to replenish
master cylinder (2).
When the brake pedal is pushed down, the master
The master cylinder has a piston which pushes cylinder sends brake liquid to wheel cylinder (3).
brake liquid into the brake lines. The reservoir is The wheel cylinder pistons are pushed out and move
connected to inlet of master cylinder. The supply primary shoe (4) and secondary shoe (5). The brake
lines keep master cylinder (2) filled so no air enters shoes move until they make contact with the brake
the system. Reservoir (1) supplies brake liquid to the drum.
system. When the brake action first starts, primary shoe (5)
comes in contact with the brake drum as it is in rota-
When the brake pedal is first pushed, the piston tion. This contact of the primary shoe puts some
moves into the master cylinder and push brake liquid force on secondary shoe (6) to help put it in position
through outlet into the brake lines. When floating piston against the drum.
seats on seal, the liquid that is pushed by piston
goes around cup seal, out through loading piston When the brake pedal is released the brake shoe
and outlet. springs pull the brake shoes and push wheel cylinder
The liquid pushed through outlet goes through the pistons back into wheel cylinder (3). The liquid is
brake lines to wheel cylinders (3). pushed from the wheel cylinder back through master
Check valve in the master cylinder keeps a small cylinder outlet and into the master cylinder.
amount of pressure in the brake lines and wheel
cylinders (3) when the pedal is released. This small The brakes will automatically adjust themselves with
amount of pressure helps the wheel cylinder piston a forward or reverse brake application. In the above
cup seal seat, which keeps air out of the brake system. example. The drum rotation is counterclockwise in
forward which causes a counterclockwise rotation of
the brake shoes. As the shoes are pushed out
against the drum, guide (9) will move axially. This
causes a swing movement of plate (14). The dis-

tance that the plate swings is controlled by the slots Oil Cooled Disc Brakes
in the plate and pins (12) and (16). If there is enough
wear, plate (13) will engage the next tooth of star 3
2 4
wheel (10).
1
When the brakes are released, return springs (6)
and (7) will bring the brake shoes back to their rest
position. Springs (8), (14) and (15) will bring the
adjustor back to its original position. The star wheel
is turned one tooth and adjustment screw (10), which
is engaged with the primary shoe web, is turned out.
The brake shoe has a new position after the
adjustment.
5
IDCS117S 6 7
Disc Brake Assembly
(1) Inlet (from master cylinder). (2) Passage. (3) Plates (five).
(4) Discs (four). (5) Piston. (6) Seal. (7) Seal.
When the brake lever is pulled, the master cylinder

pushes brake liquid through the master cylinder out-
let, the brake lines, to inlet (1) of each disc brake
assembly. Liquid flows through inlet (1), passage (2)
and pushes on piston (5). Piston (5) pushes against
plates (3) and friction discs (4) to stop any movement
of the lift truck. The five separator plates (3) are
splined to the wheel cover and the four friction discs
(4) are splined to the hub. During brake activation
the piston seals (6) and (7) are deflected by the
brake piston movement.
When the brake pedal is released, the brake liquid

pressure is released and seals (6) and (7) return to
their original position. This seal retraction gives the
running clearance needed between plates (3) and
discs (4). This action will release the brakes on the
lift truck. As the seals retract brake liquid is returned
to the master cylinder. The piston automatically
slides outward from the cylinder bore as the friction
discs wear. This new location then becomes the
beginning or at rest position of the seals. This will
maintain the proper clearances of the discs and
plates.

Parking Brake
4 5 6
1
IDCS119S
IDCS118S
Parking Brake
(1) Lever. (2) Cable assembly. (4) Spring. (5) Strap assembly. (6) Drum.
The band-type parking brake is installed on the front When the lever is pulled, cable assembly (2)
of the electric drive motor. The parking brake control compresses strap assembly (5) around drum (6).
is actuated with the lever (1), and is released with With the drum prevented from turning, all lift truck
lever (1). The lever is mounted on the cowl and is movement is stopped.
connected by a cable assembly to the parking brake.
When parking brake lever (1) is depressed, the cable
is released and spring (4) forces the strap assembly
away from the brake drum.

Electric Motors
Hydraulic Pump Motor
9
10
11 13 7
14
12 1
2 4,5 3 6
Electric Motor
(1) Armature As. (2) Field As. (3) Spring. (4) Brush-BWI. (5) Brush. (6) Endbell-Anti DE. (7) Holde As. (8) Bearing (9) Cover
(10)Thermal Switch. (11) Seal. (12) Endbell DE. (13) Bearing. (14) Fan.
The hydraulic system is operated by a direct current commutator. Field coils (2) are fastened to the inside
(DC) motor. Electric storage batteries are the source of the motor frame. The motor brushes (5) are held
of power for the (DC) motor. in the four brush holders (7).
The hydraulic pump motor is a series motor and The motor have eight brushes (5) and four springs.
uses high temperature insulation. Armature (1) is The spring holds the brushes against commutator
mounted with single row ball bearings at each end. and makes compensation for brush wear.
The ball bearings are permanently lubricated with The parts of armature (1) include the shaft, core,
high temperature lubricant. windings and commutator.
The electrical connections to the motor are made at The motors are protected from over temperature by
corrosion resistant terminals on motor frame. On the thermal switch (2). When the normally closed thermal
outside of the motor frame is cover (9) that can be switch is open, the amount of current through the
removed for easy access to brushes (5) and motor is limited to allow the motor to cool. All motors

are fan (8) cooled.
The hydraulic pump motor is activated when the key

and seat switches are closed and a lift, tilt or auxil-
iary lever is moved. In lift operation, the speed of the
motor is variable. The larger the distance the lever is
moved, the faster the motor will rotate.
The speed of tilt or auxiliary operation could be
pre-settable.
The motors are protected from over temperature by

thermal switch (2). When the normally closed thermal
switch is open, the amount of current through the
motor is limited to allow the motor to cool. All motors
are fan (8) cooled.
The hydraulic pump motor is activated when the key

and seat switches are closed and a lift, tilt or auxil-
iary lever is moved. In lift operation, the speed of the
motor is variable. The larger the distance the lever is
moved, the faster the motor will rotate.
The speed of tilt or auxiliary operation could be

pre-settable.

3. Check all oil lines and connections for damage or
Testing and Adjusting leaks.
4. Check all the lift chains and the mast and carriage
Troubleshooting welds for wear or damage.
Troubleshooting can be difficult. A list of possible

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

Visual Checks in the system. They can also be used to find a bad
valve or pump. The speed of rod movement when
A visual inspection of the hydraulic system and its the cylinders move can be used to check the
components is the first step when a diagnosis of a condition of the cylinders and the pump.
problem is made. Lower the carriage to the floor and
Lift, lower, tilt forward and tilt back the forks several
follow these inspections;
times.
1. Measure the oil level. Look for air bubbles in the 1. Watch the cylinders as they are extended and
oil tank. retracted. Movement must be smooth and regular.
2. Remove the filter element and look for particles 2. Listen for noise from the pump.
removed from the oil by the filter element. A magnet
3. Listen for the sound of the relief valve. It must not
will separate ferrous particles from nonferrous
open except when the cylinders are fully extended
particles (piston rings, O-ring seals, etc.).
or retracted, when the forks are empty.
Vehicle Systems 22 Testing And Adjusting

Hydraulic Oil Temperature 3. The carriage or mast rollers (bearings) are worn
(Too Hot) and do not move (seized).
When the temperature of the hydraulic oil gets over

98.8C (210d), polyurethane seals in the system Problem: Lift cylinder extends too slowly.
start to fail. High oil temperature causes seal failure
to become more rapid. There are many reasons why Probable Hydraulic Cause:
the temperature of the oil will get this hot.
1. Not enough oil supply to lift cylinder.
1. Hydraulic pump is badly worn.
2. Defective lift cylinder seals.
2. Heavy hydraulic loads that cause the relief valve
to open.
Probable Mechanical Cause:
3. The setting on the relief valve is too low.
1. The mast is not in alignment with the other lifting
4. Too many restrictions in the system. components and does not move freely.
5. Hydraulic oil level in the tank is too low. 2. Not enough lubricant on the parts of the mast that
move.
6. High Pressure oil leak in one or more circuits.
3. The carriage or mast rollers (bearings) are worn
7. Very dirty oil. and do not move (seized).
8. Air in the hydraulic oil.
NOTE: If the problem is because of air in the oil, it Problem: Mast does not move smoothly.
must be corrected before the system will operate at
Probable Hydraulic Cause:
normal temperatures. There are two things that
cause air in the oil (aeration). These are: 1. Air in the hydraulic system.
a. Return oil to the tank goes in above the level of 2. Relief valve sticks or defective.
the oil in the tank.
b. Air leaks in the oil suction line between the pump

and the tank.
1. Not enough lubricant on the parts of the mast that
move.
Mast and Carriage
2. Load rollers (bearings) defective or not adjusted
Problem: The hydraulic system will not lift the correctly.
load.

Problem: Mast will not lower completely or will
1. There is an air leak, which lets air into the not lower at all.
hydraulic system on the inlet side of the hydraulic
pump.
1. Lift cylinder damaged or bent.
2. The relief valve opens at low oil pressure.
2. Load rollers (bearings) defective or not adjusted
3. The hydraulic pump has too much wear.
correctly.
4. The load is not correct (too heavy).
move.

components and does not move freely.

move.

Problem: The mast does not tilt correctly or 2. Control valve leakage caused by worn valve
moves too slowly. spools.
3. The check valve or flow control valves in the con-
1. There is an air leak, which lets air into the trol valve are bad.
hydraulic system on the inlet side of the hydraulic
pump. 4. Leakage of the cylinder lines or piston seals.
2. The relief valve opens at low oil pressure. 5. There is foreign material in the control valve.
3. The hydraulic pump has too much wear.

Hydraulic Pump
4. The internal valve of the tilt spool is stuck.
Problem: Noise in the pump.
5. Control valve tilt spool has a restriction.
Probable Cause:
Probable Mechanical Cause: 1. The oil level is low.

1. Damage or failure of the piston rods on the tilt
2. The oil is thick (viscosity too high).
cylinders.
3. The pump inlet line has a restriction in it.
Problem: The carriage will not lower correctly. 4. Worn parts in the pump.
5. Oil is dirty.
1. There are restrictions in the lift line.
6. Air leaks into the inlet line.
2. The lift spool in the control valve has a restriction
caused by foreign material and does not operate
freely. Problem: The oil temperature is too high.
3. The lift cylinder flow control valve has a restriction. Probable Cause:
4. Lift cylinders excess flow protectors have a restric- 1. The oil level is low.
tion.
2. There is a restriction in an oil passage.
5. Air in the hydraulic system.
3. The relief valve setting is too low.
4. The oil is too thin.

5. There is air leakage in the system.
components and does not move freely. 6. The pump has too much wear.
2. Carriage chains need an adjustment. 7. The system operates at too high a pressure.
a. Relief valve setting too high.
3. Not enough lubricant on the part of the mast that
b. Attachment components cause a restriction dur-
moves.
ing movement.
4. The carriage or mast rollers (bearings) are worn c. Restrictions in flow control valve, check valve
and do not move (seized). and in oil lines.
Problem: The lift or tilt cylinders do not hold their Problem: Leakage at the pump shaft seal.
position with the valve control levers in neutral
position. Probable Cause:
1. The shaft seal is worn.

Probable Cause:
2. The inner parts of the pump body are worn.
1. The valve spools do not hold their positions
because the springs for the valve spools are weak 3. Operation with too low oil level in tank causes
or broken. suction on the seal.

4. Seal cut on shoulder of pump or keyway during Problem: Control valve spools have leakage
installation. around the seals.
5. Seal lips are dry and hardened from heat. Probable Cause:
1. There is foreign material under the seal.

Problem: There is failure of the pump to deliver
2. The valve spools are worn.
fluid.
3. The seal plates are loose.
Probable Cause:
4. The seals have damage or are badly worn.
1. Low level of the oil in the tank.
2. There is a restriction in the pump inlet line.

Problem: The load lowers when the lift spool is
3. There is air leakage in the pump inlet line. moved from the NEUTRAL position to the RAISE
a. Loose bolts. position.
b. Defects in suction line.
Probable Cause:
4. The viscosity of the oil is wrong.
1. There is foreign material in the check valve area.
5. The pump has too much wear.
2. The check valve poppet and seat show wear.
6. Failure of the pump shaft.
3. Sudden loss of pump oil pressure.
7. The bolts of the pump do not have the correct
torque. 4. Damage to the relief valve which causes low oil
pressure.
Hydraulic Control Valve

Problem: Spools do not return to neutral.
Problem: The control spools do not move freely.
Probable Cause:
Probable Cause:
1. The springs are broken.
1. The temperature of the oil is too high.
2. The spool is bent.
2. There is foreign material in the fluid.
3. The system or valve has foreign particles in it.
3. The fitting connections in the valve body are too
tight. 4. The control linkage is not in alignment.
4. The fastening bolts of the valve assembly do not 5. The fastening bolts of the valve have too much
have the correct torque and have twisted the body. torque.
5. Linkage of the lift and tilt levers does not operate

smoothly.
Problem: No motion or slow, then a too sudden
6. Bent lift or tilt spools. action of the hydraulic system.
7. Damage to the return springs of the spools. Probable Cause:
8. The hydraulic oil is not at normal temperature for 1. The relief valve is not correctly set, or will not
operation. move in base and/or is worn.
2. There is air in the system.
3. Dirt or foreign particles between relief valve control

poppet and its seat.
4. Valve body has a crack inside.
5. Spool not moved to a full stroke.

Lift and Tilt Cylinders Problem: Steering wheel does not return to cen-
ter position correctly.
Problem: Leakage around the cylinder rod.
Probable Cause:
Probable Cause:
1. Steering gear covers are too tight.
1. Cylinder head (bearing) seals are worn.
2. Steering column is not in correct alignment.
2. Cylinder rod is worn, scratched or bent.
3. Valve spool in the steering gear has a restriction.
Problem: There is leakage of oil inside the cylin- 4. Priority valve check valve permits lift and tilt
der or loss of lift or tilt power. hydraulic oil to affect steering hydraulic circuit.
Probable Cause:
Problem: Oil leakage at the pump.
1. The piston seals are worn and let oil go through.
Probable Cause:
2. Cylinder has damage.
1. Loose hose connections.
Problem: The tilt cylinder rods show wear. 2. Bad shaft seal.
Probable Cause:
Problem: Low oil pressure.
1. The cylinders are not in correct alignment.
Probable Cause:
2. Oil is dirty.
1. Low oil level.
Problem: Foreign material behind the wiper rings 2. Priority valve (if equipped) relief valve spring
causing scratches on the cylinder rod. weak.
Probable Cause: 3. Relief valve (priority valve) will not move from the
open position.
1. The wiper rings shoe wear and do not remove dirt
and foreign material. 4. Oil leakage inside or outside of the system.
5. Bad pump.
Steering System
Problem: Pump makes noise and the steering
Problem: Too much force needed to turn steering
cylinder rod does not move smoothly.
wheel.
Probable Cause:
Probable Cause:
1. Air in the steering hydraulic circuit.
1. Priority valve (if equipped) releases pressure oil at
a low setting. 2. The pump has too much wear.
2. Pump oil pressure is low, worn pump. 3. Loose connection of the oil line on the inlet side of
the pump.
3. Steering gear covers are too tight.
4. Steering column not aligned with steering gear.
5. The oil level in the hydraulic tank is low.
5. Priority valve spool is held in one position.
6. Steering gear without lubrication.
7. Low fluid level in the hydraulic supply tank.

Problem: Lift truck does not turn when steering 3. Mechanical resistance at the pedal or shoe.
wheel is slowly turned.
4. Restriction in the brake line.
Probable Cause:
5. Bad wheel cylinder.
1. The oil level of the tank is low.
2. There is air in the steering system. Problem: Pedal resistance is not solid (spongy).
Probable Cause:
3. The pump operation is not correct.
1. Leakage or low fluid level.
4. Dirt in the steering system.
2. Air in the brake hydraulic system.
5. Steering gear operation is not correct.
3. Master cylinder is loose.
6. Steering cylinder has worn parts.
7. Restriction in the steer axle linkage.

Problem: Extra (excessive) pedal pressure need-
ed for braking action.
Problem: The temperature of the oil is too hot.
Probable Cause:
Probable Cause:
1. Mechanical resistance on the pedal or shoe.
2. Brake shoe adjustment not correct.
2. Air is mixed with the oil.
3. The relief valve is set too high (priority valve).
4. Bad master cylinder.
4. There is a restriction in the return line circuit.
5. Lining surface looks like glass (glazed) or is worn.
Brake System Problem: Pedal gradually goes to the floor.

Probable Cause:
Drum Type Brakes
Problem: Brakes make noise or pull (grab).
2. Bad master cylinder.
Probable Cause:

Problem: Extra (excessive) pedal travel.
2. Lining surface looks like glass (glazed) or is worn. Probable Cause:
3. Oil or brake fluid is on the lining. 1. Pedal adjustment is not correct.
4. Dirt on the brake drum lining surface. 2. Leakage or low fluid level.
5. Brake drum is worn or has grooves (scored). 3. Air in the brake hydraulic system.
6. Restriction in the brake line. 4. Bad master cylinder.
7. Brake drum is out of round. 5. Lining surface is worn.
6. Operation of automatic adjustment is not correct.

Problem: Both brake shoes will not release all
the way (drag).
Probable Cause:
2. Brake pedal adjustment not correct.

Problem: Brake will not make application. Problem: Pedal gradually goes to the floor (under
normal pedal pressure).
Probable Cause :
Probable Cause:
1. Leakage or low brake fluid or oil level.
2. Defective master cylinder.
3. Master cylinder is loose.
4. Lining surface looks like glass(glazed) or worn.

Problem: Extra (excessive) pedal travel (under
5. Oil or brake fluid is on the lining. normal pedal pressure).
6. Bad master cylinder. Probable Cause:
1. Pedal adjustment is not correct.

Problem: Not braking evenly or rough feeling 2. Leakage or low brake fluid or oil level.
during braking (chatter).
Probable Cause :
1. Lining surface looks like glass(glazed) or worn.
2. Oil or brake fluid is on the lining

Problem: Brake will not make application.
3. Bad contact between the lining and drum.
Probable Cause:
4. Loose lining.
5. Brake drum out of round.
6. Loose wheel Bearing.
3. Linkage is not in correct adjustment or is bent.
7. Bad wheel cylinder.
5. Bent plates or discs.

Brake System (Oil Cooled Disc Type)
NOTE: If excessive force is applied to the brake Problem: Hard pedal.
pedal, the pedal can be forced to the end of the Probable Cause:
stroke. This is normal and should not be interpreted
as a problem. 1. Mechanical resistance at pedal or disc assembly.

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

Problem: Both brake disc assemblies will not
2. Air in the brake hydraulic system. release all the way (drag).
3. Master cylinder is loose. Probable Cause:
1. Brake disc assemblies defective (pistons stuck).
2. Brake disc uneven (out of flat).

Problem: Brakes will not make application after Electric Motors
being bled.
Before an analysis is made of any electric motor
Probable Cause: problems, always make reference to the troubleshooting
section of MicroController Control System Module.
1. Leak in hydraulic line or connection.
2. Damaged cup seal or boot in the master cylinder.

WARNING
Problem: Brake oil low in master cylinder reser- If an electrical failure or an overload of the motor
voir, fluid must be added frequently. is present, personnel must not breathe the toxic
fumes which are a product of the burnt insulation.
Probable Cause: All power must be disconnected from the motor
before any inspection is made to find the failure.
1. Leak in hydraulic line or connection.
The area around the motor must be well ventilated
2. Damaged ring seal in the master cylinder. (air flow) and the motor is to be cooled before any
repair work is done. Water must not be used on
3. Leak in the disc assemblies. any electrical equipment because of the danger of
electrical shock. If a fire is present, disconnect the
electrical power and use a carbon dioxide extin-
Parking Brakes guisher to put the flame out.
Problem: Brake will not make application.
Probable Cause : Do not operate the drive motor without a load as too
much speed may cause damage to the motor and
1. Parking brake assembly out.
injury to personnel.
2. Parking brake control cable out of adjustment.
3. Worn brake band. NOTICE

Never use air pressure that is more than 30 psi (205
kPa) and make sure the air line is equipped with a
water filter.
Problem: Hydraulic pump motor will not operate.
Probable Cause :
1. Bad connections or fuses.

Check battery connections. Check battery con-
nector
Check the key 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 currect draw.
c) Possible short circuit in motor.
2. Key switch, seat switch or line contactor not

closed.
Close the seat and key switch. Use a multime-
ter(VOM) to check power flow thru the seat
switch, key switch, line contactor coil and line
contactor. The key switch, seat switch and line
contactor must be closed for the power steering
pump to operate.

The key switch, seat switch, control valve switch, Problem 2: Neither traction or hydraulic will last
and the line contactor must be closed for the through a complete normal work period.
hydraulic pump motor to operate.
Probable cause:
3. Not enough voltage. High resistance in battery
1. Too small a battery installed in the lift truck.
cells or cables.
Study and question the use of the lift truck in its
Charge the battery or make a replacement of the
complete working conditions, select and purchase
battery.
appropriate capacity of battery regarding work
Check all the cells for one or more that has
hours.
defects.
Check the specific gravity of each cell. The 2. Battery not being fully charged or equalized during
maximum density difference from the highest to the battery charging operation.
lowest cell must not be more than .020 SG Check the battery cells for an equalization
(specific gravity). charge (a charge to make the specific gravity the
Check cable terminals for tight fit at battery ter- same in all cells).
minal and control panel connectors. Check for Check the battery charger for defects.
broken inner wires in cables.
3. Battery Discharge Indicator (BDI) lift interrupter
4. Brushes are worn. circuit which protects the battery, shuts off the
Disconnect the battery and discharge the capacitors hydraulic motor circuit too soon.
(HEAD CAP). Inspect the pump motor commutator See Battery Discharge Indicator Operation
for burnt marks or scoring (scratches). Adjustment and Troubleshooting in the
Make corrections or make a repair of the arma- MicroController Control System module.
ture commutator, replace the brushes as neces-
sary. 4. Battery charge interval is too long or charged
See Armature Commutator Inspection and Brush battery cooling time is too short. This causes
Inspection in Testing And Adjusting. excessive (too much) cell temperatures which
Make reference to Problem: Pump Motor decreases the capacity of the battery to supply the
Overheat (Too Much Heat). rated ampere hours.
Check for opens in the field coil. Decrease the battery work duration before a
Test coils according to procedures in Testing And change.
Adjusting. If there are opens, make a replacement Increase the battery cooling time after a charge
of the coils. before it is put to use.
5. Check for short or open circuit in the armature or 5. Battery has one or more defective cells which can
between armature and field. result in much less than the rated capacity and
Loose field winding pole pieces. ability of the battery.
Check poles for damaged insulation, repair or Test and locate the defective cells. Replace the
replace damaged insulators. defective cell(s).
Failed armature bar insulation or armature bar Battery cells are connected in series, one bad
connector open. Repair or rebuild the insulation, cell causes a high resistance in series with the
make a replacement of the armature. other cells. This slows down the speed of the
motor as the cell resistance increases. This can
NOTE: If armature opens caused commutator bar occur with the other cell almost fully charged.
pitting or burnt areas, armature will need replace-
ment. Heat from the arcing causes the hardened 6. Hydraulic system draws too much battery power
copper commutator bars to be annealed (soft). Just because of lifting and tilting arrangements or
machining (turned to a lesser diameter) of the hydraulic controls are not correct for the duty
commutator will not correct the problem from cycle.
occurring again. The armature must be replaced. Decrease hydraulic relief valve setting to the
capacity that only will be used.
Opens in the armature bar connections must be Change to a smaller hydraulic pump (if available).
found and soldered (repaired). Check the mast for restriction during operation.
Remove quick disconnects and install fittings
7. Lift and drive system operation not correct.
with lesser resistances to oil flow.
See troubleshooting section of the MicroController
Check for defective hydraulic control valve, the
Control System module.
pilot operated relief valve.

Remove any restrictions in the hydraulic circuit. a. At installation, pull upon brush leads to make sure
Make an inspection of the movable hydraulic they return to contact with commutator correctly.
attachments for restrictions. Check for See Brush Installation in Testing And Adjusting.
components that slide, bearing wear, hinges
binding and the correct amount of lubrication on b. If brushes are too tight remove the brush material
necessary components. with sandpaper until brush movement in brush box
is acceptable.
7. Loose movement of the brushes.

Problem 3: Sparks at the commutator and/or
Check the brush springs for cracks and overheat
rapid brush wear.
signs (bluing).
Probable Cause: Compare spring force with a new brush spring.
Check the brush holder for oversize (too much
1. Worn brushes. larger than brush size).
Make a replacement of the brushes and make Replace the brush spring if necessary.
sure the brushes are seated. See New Brush
installation and Brush Inspection in Testing And 8. Loose brush leads or motor bus bar connections.
Adjusting. Check the brushes for tight connections. Replace
if leads are loose in brush material
2. Loose cable connections at the motors terminals Check all cables and wire connections for tight-
cause a high resistance in the circuit. The ness.
resistance increases amperage draw
(consumption), as a result brushes deteriorate 9. Wrong grade of brushes installed that are not
(destroy), there is arcing on the commutator, adaptable to the motor.
insulation on wires burns and causes a short Make sure all the brushes are of DAEWOO
circuit to lift truck frame. standards. Do not use other brands brushes.
Tighten the nuts or bolts that hold the cable
10. Replacement brushes are not seated, the current
connections on the motor terminals.
goes through a small contact area with the
3. Overheating (too much heat) of the pump motor. commutator. As a result the brush temperature
Check for an overload motor or a motor with increases. Possibly if the contact area is poor the
defects. See Armature Commutator Inspection in brushes will be destroyed in a few service meter
Testing And Adjusting. hours.
The duty cycle is too heavy, use the hydraulics Always seat new brushes when installed, see
only to the limited capacity of the lift truck. New Brush Installation in Testing And Adjusting.
If the motor has EE covers and the duty cycle is
11. Pump motor armature or field windings have a
heavy and within the lift truck capacity, remove
defect that results in high current draw at low
the covers if permitted.
torque output.
4. Commutator bars burnt in two or more positions at See Armature Tests and Field Coil and Terminal
180°apart because: Tests in Testing And Adjusting.
Armature bars open, replace armature.
12. Possible heavy working conditions that cause too
Short circuit in the armature, see Armature Test.
much motor heat and rapid brush wear.
Armature not in balance which causes brush
Commutator skin is very black which gives an
bounce, see Specifications.
indication of high temperatures.
Motor was stalled against a heavy load and
Make a replacement of the brushes and make
caused the two bars in contact with the brushes
sure the brushes are seated. See New Brush
to burn, see Armature Commutator Inspection.
Installation and Brush Inspection in Testing And
5. Dirty motor that has metallic or carbon dust. This Adjusting.
dust is a conductor which causes electrical shorts, Install extra heavy duty brushes when available.
increase amp draw and decrease pump motor Check the brush spring for the correct installation
output. and for the correct spring usage. Too strong a
Remove any dirt with air pressure. spring rate will increase amperage draw and
brush wear rate.
6. Brushes too tight in brush box. Brush springs not Prevent operation in an overload condition
strong enough to force one or more brushes in caused by excessive duty cycle which increases
contact with commutator. motor temperature and gives rapid brush wear.

13. Restriction caused by system components. 3. Grade of brushes mixed.
Operate the hydraulic and steering systems with Make sure all of the brushes are of Caterpillar
an ammeter and a pressure gauge installed. If standards. Do not use other brands of brushes.
amperage draw and oil pressure are too high,
see Testing And Adjusting and Specifications for 4. Overload on brushes.
the acceptable amperage draws and oil pressure, Check the brush springs for the correct installation
the system must be inspected for both mechanical and make sure the lift truck is operating at a
and hydraulic restrictions. rated capacity.
Problem 4: Low resistance to ground [ battery Problem: Lift truck has slow hydraulic speeds.
potential either positive (+) or negative (-) or a
Probable Cause:
medium voltage is in direct contact with truck
frame (body) or drive motor body.] 1. Hydraulic pump motor overheated and pump
motor thermal switch opens (if equipped).
Probable Cause:
Allow the motor to cool so the thermal switch will
1. Dirty battery, electrolyte on top of cells and is in close. See Specifications for thermal switch will
contact with the frame. Current flows through opening and closing temperatures.
battery box which places a voltage on the truck
2. Pump motor control circuit overheated and thermal
frame.
switch opens.
Clean off the battery with baking soda and water
Allow the control panel to cool so the Controller
solution.
thermal switch will close. The thermal switch
2. Battery or control panel wire connections in contact to opens at 85 L 4 °C (185 L 7 °F) and close at
truck frame. 73 L 4 °C (163 L 7 °F).
Make a continuity test to move the wire from
contact. Remove wires in sequence until the fault
is cleared. The fault will be in the wire last
disconnected.
3. Dirty motor.
Remove the metallic or carbon dust with air
pressure.
4. Wet pump motor.

Dry the motor with heat to 90°C (190°F).
Problem 5: Commutator surface has groove or

extra wear.
Probable Cause:
1. Brushes are worn too low, brush wires caused

arcing on commutator.
Inspect the commutator for damage. If the arcing
caused light pitting on commutator, install new
brushes and seat the brushes with the Brush
Seater Stone which will also clean the commutator
surface.
Make another inspection, if there is still pitting,
commutator surface must be machined only to
the minimum diameter as shown 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
90°C (190°F).

Hydraulic System With the key switch off, remove cap (1) from nipple
assembly (2) and connect the 28000 kpa (4000 psi)
Relief Valve Pressure Check gauge to the nipple assembly.
Use the Pressure Gauge Kit to check the relief valve

pressure. Lift Relief Valve Check and Adjustment
1. Turn the key switch on and activate the hydraulics

until the hydraulic oil is at the normal operating
WARNING temperature.
2. With the motor at fast rpm under unload condition,

Hydraulic oil, under pressure can remain in the
hydraulic system after the engine and pump have hold the lift control lever in the lift up position and
been stopped. Personal injury can be caused if watch the gauge. The gauge indication is the pres-
this pressure is not released before any work is sure that opens the relief valve at the end of lift
done on the hydraulic system. To prevent possible cylinder stroke.
injury, lower the carriage to the ground, turn the
3. The correct pressure setting is shown in the chart.
key switch off and move the control levers to
make sure all hydraulic pressure is released 4. If an adjustment to the relief valve setting is nec-
before any fitting, plug, hose or component is essary, loosen locknut (3).
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 the
engine is running and tests or adjustments are
made.
3 4
1
IKCS001P
Relief Valve Adjustment

(3) Locknut. (4) Stud
IKCS001P 5. Turn stud (4) clockwise to increase or counterclock-

wise to decrease the pressure setting of the relief
Pressure Tap Location
valve.
(1) Cap (2) Nipple assembly.
6. Tighten the locknut and check the pressure setting
Relief Valve Pressure again for correct adjustment.
Main Relief Tilt, Auxiliary Relief
kPa psi kPa psi
Model Mast +500,-0 +75,-0 L350 L50
STD
B20S-3 FFL 16600 2400 15500 2250
FFTL
STD
B25S-3 FFL 19300 2800 15500 2250
FFTL
STD
B30S-3 FFL 20700 3000 15500 2250
FFTL

Tilt and Sideshifter Relief Valve Check and
Adjustment
Lift Section
1. Turn the key switch on and activate the hydraulics
until the hydraulic oil is at the normal operating
temperature. Put the carriage in the full sideshift
position. Remove nut
tie stud here
2. With the motor at fast rpm, hold the sideshift posi-
tion and watch the gauge. The gauge indication is
the pressure that opens the relief valve.
1
3. The correct pressure setting is shown in the chart. IDCS121S
4. If an adjustment to the relief valve setting is nec-

essary, loosen locknut (5). 1. Remove the nut from the slotted tie-stud of main
hydraulic valve.
2. Remove the slotted tie-stud from the valve.
3. Use Hex Wrench (6mm or 1/4 inch), turn the flow

5
control adjuster clockwise to increase the flow or
counterclockwise to decrease the flow.
4. Assemble the tie stud in the valve. Torque the stud

to 40.5 L 2.5 NIm (360 L 24 lbIin)
5. Reinstall the nut.
IKCS001P
6 WARNING
Relief Valve Adjustment Hydraulic oil, under pressure, can remain in the
(5) Locknut. (6) Stud hydraulic system after the motor and pump have been
stopped. Personal injury can be caused if this pressure
is not released before any work is done on the
5. Turn stud (6) clockwise to increase or counter- hydraulic system. To prevent possible injury, lower the
clockwise to decrease the pressure setting of the carriage to the ground, turn the key switch off and
relief valve. move the control levers to make sure all hydraulic pres-
sure is released before any fitting, plug, hose or com-
6. Tighten the locknut and check the pressure stting ponent is loosened, tightened, removed or adjusted.
again for correct adjustment. 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 the
Flow Control Valve Adjustment engine is running and tests or adjustments are made.
The tilt and first attachment speeds can be adjusted

at the control valves. They can be adjusted by turn-
ing the plug in the hydraulic control valve body. The Standard Lift Cylinder Air Removal
lift speed can not be adjusted.
Do the procedure that follows to change the flow After the standard lift cylinder has been disassem-
control assembly. bled and then assembled again, it may be necessary
to remove the air (bleed) from the cylinder.
1. With no load, lift and lower the mast and carriage

through one complete cycle.
2. With the forks on the floor, check the oil level in

the hydraulic tank. Add oil (if necessary) to bring
the oil level to the full mark.
3. With no load, lift and lower the mast and carriage

again through four complete cycles.

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

stages of the lift cylinders.
IDCS122S
Setscrew Locations
(Standard Cylinders)
NOTE: The Standard Lift mast has two secondary

cylinders and no primary cylinders. The Full Free and
Full Free Triple Lift mast has one primary and two
secondary cylinders.
5. Locate the setscrew on each lift cylinder. Slowly

open secondary cylinder(s) setscrews no more
than one turn. The weight of the carriage will force
air and hydraulic oil out of the cylinders through
the setscrews. Close the setscrews before all the
pressure is out of the cylinders. This will prevent
air from entering through the setscrews.
6. Repeat Steps 4 and 5 until there are no air bub-

bles at the setscrews.
7. After all the air is removed, tighten the setscrews

to a torque of 5 to 7 NIm (45 to 60 lbIin).
8. Fill the hydraulic tank to the full mark.
9. Lift and lower the mast and carriage again through

one complete cycle. If the mast does not operate
smoothly, repeat Steps 3 through 9.

Mast and Carriage Mast And Carriage Bearings
Mast Adjustment D581814 Under Size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.135 in)
NOTE: The Standard, Full Free Lift and Full Free D581816 Over Size 110.7 mm (4.358 in)
Triple Lift mast load bearings are all adjusted the
same way. The mast shown in the following illustra- * Permissible tolerance L 0.08mm (.003in)
tions is the Full Free Triple Lift mast.
To make the mast clearance adjustments, mast must

be removed from the lift truck.
Carriage, chain and lift cylinder must be removed

from the mast for easy adjustments.
Use the procedure that follows to adjust the load

bearings.
A. Lower Bearing Adjustment of

Intermediate Mast
IDCD036P
2. Find narrowest point by ruler on the stationary

3 4 5 6 mast in the area where the bearings make contact
at 475 mm (18.7 in) channel lap.
C
IDCS123S


and channel leg for full channel length. Use same
bearing on left and right side.

3 4 5 6
IDCD037P
C
IDCS123S

IDCD033P (A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
3. Install 1 mm shim to each bearing of intermediate

lower and stationary upper basically. Lifting by
crane, insert intermediate mast into stationary
mast from the upper side.
NOTE: When installing shims (5) behind bearing (4),

make sure the amount of shim is divided equally
when positioned behind each bearing (4).
IDCD039P
4. Make sure whether intermediate mast lower bear-

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

B. Upper Bearing Adjustment of Stationary
Mast
IDCD039P
5. In case of standard and full free mast, inner lower

IDCD033P
bearings can be easily extruded by pulling down
the inner mast from the bottom of stationary mast.
If intermediate mast is stuck and do not move
rolling up and down, there might be excessive 1. Lifting by crane, and pull out intermediate mast
shim. Pull out the intermediate mast from the sta- from stationary mast. Install 1 mm shim to each
tionary mast and remove shim 0.5 mm to both bearing of stationary mast upper basically. Bearing
intermediate lower bearings. Repeat same proce- should be selected D581814 under size bearing.
dure of aboves until properly shimmed. There is to
be contact zero clearance (C) between intermedi-
ate lower bearings and stationary channel at
approximately 475 mm (18.7 in) channel lap.
D E
9 7
10 E
IDCS124S
Mast Adjustment Upper Bearings

(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.

C. Upper Pad Adjustment
D E
8
IDCD038P
F
2. Make sure whether stationary mast upper bear-
ings are properly shimmed by rolling up and down 9 7
and moving intermediate mast to right and left. If
clearance between both masts can be detected,
pull out the intermediate mast from the stationary 8
mast with crane and add shim 0.5 mm or 1 mm to
both stationary upper bearings.
10 E
IDCS124S
Mast Adjustment Upper Bearings

(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
IDCD014P
3. In case of standard and full free mast, stationary

upper bearings can be easily extruded by pulling
down the inner mast from the bottom of stationary
mast. If intermediate mast is stuck and do not
move rolling up and down, there might be exces- IDCD033P
sive shim. Pull out the intermediate mast from the
stationary mast and remove shim 0.5 mm to both
stationary upper bearings. Repeat same proce- 1. Install shims (8) behind each pad (7) until there is
dure of aboves until properly shimmed. There is to 0.80 mm (.031 in) maximum clearance (E)
be contact zero clearance (C) between stationary between the pads and the inner and intermediate
upper bearings and the widest point of intermedi- masts with the masts at full extension. Lifting by
ate mast to be checked before. crane, and pull out intermediate mast from station-
ary 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.

D. Lower Bearing Adjustment of Inner
Mast Mast And Carriage Bearings
D581814 Under Size 108.6 mm (4.276 in)
5 6 D581815 Standard 109.6 mm (4.135 in)

3 4
D581816 Over Size 110.7 mm (4.358 in)
IDCD040P
C
IDCS123S
2. Find narrowest point by ruler on the intermediate
Mast Adjustment Lower Bearings mast in the area where the inner lower bearings
(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance. make contact full length of intermediate mast
excluding minimum channel lap 475 mm (18.7 in).

and channel leg for full channel length. Use same
bearing on left and right side.
IDCD031P
3. Install 1 mm shim to each bearing of inner lower

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

Carriage Adjustment
3 4 5 6 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, car-

riage must be removed from the mast.
Use the procedure that follows to adjust carriage

load bearings.
A 3 4 B 5
B
C
C
IDCS123S VIEW A-A
A A
6
B B C
4. Make sure whether inner mast lower bearings are
properly shimmed in the intermediate mast by
rolling up and down and moving inner mast to
VIEW B-B
right and left. If clearance between both masts can 7
be detected, pull down the inner mast from the C C
bottom of intermediate mast. Inner lower bearings A
can be easily extruded. Add shim 0.5 mm or 1 mm
to both inner lower bearings. If inner mast is stuck
and do not move rolling up and down, there might
be excessive shim. Pull out the inner mast from
the intermediate mast and remove shim 0.5 mm to
both inner lower bearings. Repeat same proce-
C VIEW C-C
8 A
dure of aboves until properly shimmed. There is to IDCS125S
be contact zero clearance (C) between inner lower
Carriage Adjustment
bearings and intermediate channel at narrowest
(3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw.
point. (7) Middle bearings. (8) Lower bearings. (A) Zero clearance.
(B) 6.0 to 9.0 mm. ( .236 to .354 in) clearance.
E. Upper Bearing Adjustment of (C) Minimum clearance.
intermediate Mast
Follow same procedure with above B. 1. Select lower bearings from the chart to obtain
minimum clearance (B) between bearings and
channel leg for full channel length. Use same
F. Upper Pad Adjustment of Intermediate bearing in all six locations.
Mast
Follow same procedure with above C.

Mast And Carriage Bearings
Part No. Bearing Size Bearing O.D.
D581814 Under Size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.135 in)
D581816 Over Size 110.7 mm (4.358 in)
IDCD016P 5
5. Tighten screw (5) that holds the top bearings to the

carriage to a torque of 34 L 7 NIm (25 L 5 lbI ft)
IDCD014P
2. Find narrowest point by ruler on the inner mast in

the area where the bearings make contact.
3. Install enough shims (4) that have been divided 11

into two equal groups behind bearings (3). At IDCD009P
installation, there is to be contact [zero clearance
(A)] between the bearings and the narrowest point 6. Shim stop bolt (11) as required to obtain a 6 to 9
of inner mast. mm (.24 to .35 in) lap with top carriage stop on the
inner upright.
4. Do step 2 through 3 for other sets of bearings.
Chain Adjustments
Chain Adjustment Check
IDCD015P
IDCD006P
Chain Adjustment Check
Lift the carriage and mast high enough to put their

full weight on the carriage and mast chains. Check
the chains, and make sure the tension is the same.

Chain Adjustment
If the tension is not the same on both chains, do the

procedure that follows:
WARNING
Personal injury can be caused by sudden move-

ment of the mast and carriage. Blocks must be
used to prevent the mast and carriage from any
movement while the adjustments are made. Keep
IDCD023P 2
hands and feet clear of any parts that can move.
Outer Lift Chains
(2) Chain anchor bolts.
Chain Wear Test

Chain wear test is a measurement of wear of the
chain links and pins. Do the steps that follow to
check chain wear.
1. Lift the mast and carriage enough to put tension

1 on the lift chains.
IDCD007P 2. Measure precisely ten links of chain distance at

the center of pins in millimeter.
Inner Lift Chains
(1) Chain anchor nuts.
3. Calculate chain wear rate.
New one pitch = 19.05 mm

1. Lift the mast and carriage and put blocks under
the mast and carriage to release the tension from
Chain wear rate (%)
the lift chains.
2. Make adjustments to chain anchor nuts (1) for Actual measurement - 190.5
= x 100
equal tension of the mast and carriage chains. 190.5
3. Put LOCTITE NO.242 Thread Lock on the threads

of the locknuts after the adjustment is completed. 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.
4. If the chain wear indication is 2% or more, replace

the lift chain.

Carriage and Mast Height Adjustment Forks Parallel Check
1. Move the mast either forward or backward so it is 1. Lift the mast and operate the tilt control lever, until
in the vertical position. the top surface of the forks is parallel with the
floor. Place two straight bars, that are the same
2. Lower the carriage completely. width as the carriage, across the forks as shown.
Measure the distance from the bottom of each end
of the two bars to the floor. The forks must be par-
allel within 3 mm (.12 in) for Full Tapered and
Polished (FTP) forks, all other forks 6.4 mm (.25
in), for their complete length.
2. If not parallel put one fork, one third back from the
tip, under a fixture that will not move. Then oper-
ate the tilt control with caution until the rear of the
truck just lifts off of the floor. Follow the same pro-
cedure with the second fork, and then check the
forks again as in Step 1.
A
IDCS191S
3. On Full Free Lift and Full Free Triple Lift models,

the bottom of the inner mast must be even with
the bottom of the stationary mast.
4. Measure the distance from the bottom of the inner

IDCS130S
upright to the bottom of carriage bearing.
Forks Parallel Check
5. The measurement (A) must be as follows: (Typical Example)
STD.................................................................Zero
FFL & FFTL ............41 L 1.5 mm (1.61 L .06 in)
NOTE: On Standard Lift models the bearing must be

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

Tilt Cylinder Alignment Tilt Cylinder Length Check
If the tilt cylinders are out of alignment, extra stress-

es in the mast assembly and the mast hinge area will
result. To prevent damage, the tilt cylinders must
stop evenly at the end of the tilt back and tilt forward
strokes.
Tilt Angle Check
IDCD036P
Tilt Cylinder Length Check
1. Tilt the mast to full forward position. Measure the

extended length of the cylinder rods from the cylin-
der housing to the mast. The difference of length
between the two cylinder rods must be within 3.18
mm (.125 in) of each other.
IDCD008P
Tilt Angle Check (Typical Example)

Tilt Cylinders With Tilt Back Limiting Group
The tilt angle of the mast must be checked in the full

tilt back and full tilt forward positions. A tilt indicator
or a protractor can be used to measure the angle.
Both sides of the mast must be checked to make 1 2 3 4 5 6
sure that the mast is not twisted.
The tilt angle is determined by the tilt cylinders used.

See tilt cylinders in specifications to determine the tilt
angle from the cylinder being used.
IDCS129S
Tilt Cylinder Adjustment

(1) Pivot eye. (2) Bolt. (3) Rod. (4) Shims. (5) Spacer.
(6) Head.
1. With the mast at full forward tilt, loosen bolt (2).
2. Slide spacer (5) back so rod (3) can be turned into

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

Drift Test
WARNING
Drift is movement of the mast or carriage that is the
Tilt cylinder pivot eyes can loosen if the torque on result of hydraulic leakage in the cylinders or control
the pivot eye clamping bolt is not tight enough. This valve. Before testing the drift:
will let the tilt cylinder rod turn in the tilt cylinder eye.
The cylinder rod may then twist our of the pivot eye WARNING
and the tilt cylinder will be out of alignment or may
let the mast fall and cause personal injury or Personal injury can be caused by sudden move-
damage. When the rod lengths are made even, the ment of the mast or carriage. Use wood blocks
tilt angle differences or the mast alignment will no and clamps to hold the mast in this position. Keep
longer be a problem. hands and feet clear of any parts that can move.
3. Tighten bolt (2) and the nut to a torque of 95 L 15 1. Check the chain adjustment and tilt cylinder align-
NIm (70 L 10 lbIft). ment and make necessary adjustments.
4. With mast at full back tilt, install shims (4) as 2. Lift the mast approximately 762 mm (30 in). Use
required to permit no gap between spacer (5) and wood blocks and clamps to hold the mast in this
head (6). Shim so mast does not twist at full tilt position.
back.
3. Check the mast hinge bolts to make sure they are
tight.
4. Remove the blocks and clamps and lower the

mast.
Drift Test For Lift System
1. Put a rated capacity load on the forks of the lift

truck. Operate the lift truck through a complete lift
and tilt cycle until the oil is at normal temperature
of operation, 45 to 55˚C.
2. Put the mast in a vertical position.

Raise a rated capacity load to a sufficient height to
test the lift cylinders.
3. Measure any drift of the carriage for a ten minute

period. Drift for all models shall not exceed 100.0
mm (4.00 in).

Drift Test For The Tilt System Steering System
1. Put a rated capacity load on the forks on the lift
truck. Operate the lift truck through a complete lift
and tilt cycle until the oil is at normal temperature Steer Wheel Bearing Adjustment
for operation, 45 to 55°C.
2. Put the mast in a vertical position. Raise a rated

capacity load to a height of 2.5 meters (8.2 ft). In
the case of trucks with less than 2.5 meters (8.2 ft) 1
2
height extension, raise the load to the truck’s max-
imum height.
IDCS192S
Bearing Adjustment
(1) Nut. (2) Lock
1. Tighten nut (1) slowly to 135 NIm (100 lbIft) while

the wheels is rotated in both directions put the
IDCS009P
bearings into position.
Tilt Drift Check.
2. Loosen nut (1) completely. Tighten nut (1) again to
50 L 5 NIm (37 L 4 lbIft) .
3. The tilt drift is measured as the charge in the tilt 3. Bend lock (2) over nut (1) to hold the nut in posi-
cylinder stroke. Measure any drift of the mast for tion.
ten minute period.
Drift for shall not exceed 35.5 mm (1.40 in).

Steering Axle Stop Adjustment Steering Knuckle Bearing Preload
Adjustment
1
6
2
A
3 4 5
7 8 9
IDCS132S IDCS133S
Steer Angle Steering Knuckle Bearing Preload Adjustment

(1) Bolt. (2) Nut. (3) Bolt. (4) Nut. (5) Bolts. (A) 80° angle (6) Steering link. (7) Shims. (8) Cover. (9) Bolts.
Use the procedure that follows to make an adjust- 1. During assembly of the steering knuckle, install
ment to the steer axle turning angle. the upper bearing cup, cone and seal.
1. Adjust the cylinder rod extension so it is equal on 2. Install lower bearing group cover (8) without
both sides of the axle. shims. Tighten two opposed cover bolts (9) to a
torque of 5.6 NIm (50 lbIin) .
2. Loosen nuts (2) and (4) on both sides of the steer
axle. 3. Measure the clearance between cover (8) and the
axle beam at each bolt with a feeler gauge.
3. Turn the steer wheel one direction until the steer
cylinder rod extension measures 94mm(3.7 in) for 4. Take an average of the measurements found in
B Models and 80mm(3.2in) for BC Models more Step 3. Select shims (7) equal in thickness to the
than the straight ahead measurement. average clearance.
4. Adjust stop bolt (1) on one side and stop bolt (3) 5. Remove the bearing group and install shims (7),
on the other. cover (8) and bolts (9). Tighten bolts (9) to a
torque of 55 L 6 NIm (40 L 5 lbIft) .
5. Tighten nut (2) on one side and nut (4) on the
other side. Turn the steer wheel the opposite 6. With steering links (6) disconnected from the
direction and do the same procedure for the steering cylinder, check knuckle for 4.5 to 6.8
opposite stop bolts. This will give a maximum NIm(40 to 60 lbIin) of rolling torque. Add or
cramp angle of 80°. remove shims from cover (8) to obtain the proper
rolling torque.
7. Connect links (6) to the steering cylinder. Tighten

cylinder mounting bolts (5) to a torque of
460 L 60 NIm (340 L 40 lbIft) .

Steering System Pressure Check 3. Move the seat to the normal position for operation,
turn the key switch to the ON position and activate
If the steering system does not work correctly, check the hydraulic controls until the oil is at a tempera-
the hydraulic tank for the correct oil level and the ture for normal operation.
hoses and connections for leakage. If all these items
4. Turn the steer wheels to the left or right against
are correct, use the Pressure Gauge Kit to check the
the stops and make a note of the indication on the
steering hydraulic system and its relief pressure
pressure gauge.
setting.
5. The indication on the pressure gauge must be the
priority valve relief setting of 8000 L 350 kPa
(1160 L 50 psi). If the indication is correct and a
problem exists, then there is possibly a mechani-
cal failure in the steering system.
6. If the indication is not correct, then there is steer-

ing hydraulic failure in the components.
Hydraulic Steering Gear (6)

(2) Pressure line (from priority valve).
WARNING
Hydraulic pressure can cause personal injury.

Before any steering system hydraulic lines or
components are disconnected, make sure all (5)
hydraulic pressure is released in the steering sys-
tem. Move the steer wheels to the left and right
and then to the straight forward direction.
Check steering system relief pressure as follows: (4)
1. Turn the motor off. IDCS134S
2. Remove plug from elbow(1) (4) Pressure-checking adapter (5) Pressure-tube

Install pressure-checking adapter(4) and connect (6) Pressure gauge
pressure-tube (5) and pressure gage (6). Pressure
gage(6) has a range of 2800 kpa (4000psi).

Brake System
NOTICE
Do not let Valve be closed for more than 3 or 4 seconds
or damage can be caused to the steering system Brake System Air Removal
components.
When the brake pedal resistance is spongy (not
solid) it is usually an indication that there is air in the
brake hydraulic system. The cause may be low fluid
a. With the motor running, turn the steer wheels in or oil level, leakage in the system, a broken brake
any directions and read the indication on pressure line or a brake line that is not connected.
gauge (6).
To remove air from the brake system, do the proce-
b. If the indication is approximately the pressure dure that follows.
shown in Step 5, then the steering gear has a
hydraulic failure.
c. If the indication is too low or too high, then the pri-

1
ority valve or its components must be replaced.
7. If the steering gear and the priority valve are work-

ing properly, the steering cylinder is defective and
must be repaired.
8. Correct the problem and check steering relief

valve pressure again.
Reservoir Location
(1) Reservoir.
1. Fill reservoir (1) with the correct fluid to 12.7mm

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

Brake Adjustment
Drum Type Brakes
2
The brakes make an adjustment automatically when
an application is made in forward and reverse. With
each application, there will be an adjustment made
until the lining-to-drum clearance is made small
enough to stop the movement of automatic adjuster
(7).
Manual brake adjustment is necessary only when

new brake shoes are installed and the automatic
Bleed Screw Location adjustment has been moved.
(Standard Lift Truck)
(2) Bleed screw
NOTE: During manual brake adjustment, do not
loosen bolt (4). Likewise, do not change the position
of adjuster (7). If the position of adjuster (7) is
2. Put pressure on the brake pedal and open bleed changed, then it will have to be centered on the
screw (2) to let air out of the system. Close bleed housing.
screw (2), while pressure is still on the brake
pedal, then let the pedal return to the original posi- To make a manual adjustment to the brakes, do the
tion. procedure that follows:
3. Do step 2 again as many times as necessary until

the brake fluid is free of air.
WARNING
4. (If equipped): Use the procedure in Steps 2 and 3
again, except this time use the other bleed Wood blocks or jack stands of the correct capaci-
screw(not shown). ty must be used under the machine to prevent the
machine from a fall that is not expected. Failure to
5. Fill the reservoir again, with the correct fluid, to the do so can result in injury or death.
level explained in Step 1.
1. Put blocks or jack stands of the correct capacity

under the machine.
Brake Adjustment
(1) Hole. (2) Wheel.
2. Turn wheel (2) or brake drum until the hole (1) is

in alignment with star wheel (3) of the brakes.
3. Put brake adjustment tool through the hole and

into a tooth of star wheel (3).

3 6 8
3
9 10
4 Y
X
Z
5 5
IDCS139S
6 7 8
Brake Adjuster
(3) star wheel. (6) Plate (8) Star wheel. (9) Screw. (10) Screw.
IDCS138S (X) Distance 1.05 mm (.041 in).
(Y) Distance 1.05 mm (.041 in). (Z) Distance 85 mm (3.35 in)
Wheel Brakes
(3) Star wheel. (4) Bolt. (5) Tongue. (6) Plate. (7) Adjuster.
(8) Star wheel.
1. Check distance (X) and (Y) from the inside edge
of star wheels (3) and (8) to the rounded edge of
plate (6). Distance (X) or (Y) is 1.05 mm (.041 in)
4. Turn star wheel (3) until a heavy resistance (drag)
maximum. Distance (X) + (Y) must be 1.0 to 1.6
is felt when the wheel is turned.
mm (.039 to .063 in)
5. Put a thin blade screwdriver into the hole and hold
NOTE: Distances (X) and (Y) are adjustable with
tongue (5) of plate (6) away from star wheel (3).
shims behind the star wheels and should have to be
NOTE: Tongue (5) must be held away from star adjusted only if the adjuster is disassembled.
wheel (3) as the adjustment wheel is turned back-
2. Next, check distance (Z) between the slots of
ward. screws (9) and (10). Distance (Z) must be 85 mm
6. Put the brake tool through the hole, into a tooth on (3.35 in). Adjust screws (9) and (10) evenly to get
the correct distance and make sure the distance
star wheel (3) and turn wheel (3) backward until
between each screw and its star wheel is the
there is no resistance (drag) on the wheel.
same.
7. Turn wheel (2) until the hole is in alignment with
3. Put the adjuster in position on the housing. Do not
star wheel (8) of the brakes.
tighten bolt (4) yet.
8. Do Steps 3 through 7 to adjust the other brake lin- 4. Install the wheel on drum. After installed, tighten
ing-to-drum clearance. bolt (4) to a torque of 72 L 5 NIm (55 L 4 lbIft)
and do the manual brake adjustment.
9. Test the brakes to be sure both wheels stop even-
ly when a brake application is made.
Pedal Adjustment
Brake Adjuster Installation The brake pedal must have enough free play to let
If the adjuster was removed to replace the housing the master cylinder piston return to the release posi-
tion and open the relief outlet.
or adjuster, do the procedure that follows to center
the adjuster correctly. Hydraulic pressure in the brake lines goes back
through the relief opening and releases the brakes. If
there is no pedal free play, the pressure can not go
back through the relief opening, and the brakes will
tighten and not release.

If there is too much free play, the brake pedal will be Parking Brake Test
low even with the correct brake adjustment.
1. Drive the lift truck with a rated load up a 15%
The master cylinder push rod must be adjusted so incline.
the brake pedal has 3.0 to 8.0 mm (.118 to .315 in)
of free play from the pedal stop to the push rod con-
tact point with the master cylinder piston.
WARNING
If the pedal free play adjustment is not correct, do To prevent personal injury, the operator must be
the procedure that follows: ready to use the service brake if the parking brake
is not adjusted correctly and the lift truck starts to
move.
1
2
2. Half way up the incline, stop the lift truck with the
service brakes. Make an application of the parking
brake.
3. If the parking brake has the correct adjustment,

the lift truck will be held in this position.
4. If the parking brake does not hold, do the steps in

Parking Brake Adjustment.
Location of Master Cylinder
(1) Pin. (2) Boot.
Parking Brake Adjustment
NOTE: On some trucks the rubber boot may have to

be moved to expose the adjustment nuts. 1
4
3
A
IDCS142S
2 3
Brake Pedal Adjustment
(3) Jamnut. (4) Nut. parking Brake
(1) Strap assembly. (2) Brake drum. (3) Adjuster.
1. Loosen jamnut (3).

1. Put the parking brake in the OFF position.
2. Adjust nut (4) until there is the correct amount of
free play. 2. Measure clearance between brake drum (2) and
strap assembly (1) at “A”. Set clearance “A” to
3. Hold nut (4) and tighten jamnut (3).
0.25 to 0.50 mm (.010 to .020 in) using adjuster
(3).
3. Use wire to lock adjuster in position.

Parking Brake Control Group Adjustment.

Parking Brake Control Group
Adjustment 4 2
Y
3
5 X
IDCS144S
2 Parking Brake Off

(2) Cable assembly. (3) Jamb nut. (4) Brake strap assembly.
(5) Spring. (Y) 70 L 0.5 mm (2.76 L 0.2 in).
1. Put the brake lever (1) in the fully raised OFF

position. Seat the shoulder of cable assembly (2)
against brake strap assembly (4) at “X”. Adjust
overtravel spring (5) length (Y) to 70.0 L 0.5 mm
(2.76 L 0.2 in). Tighten jamb nut (3).
Parking Brake Control Group

(1) Brake lever. (2) Cable assembly.
6 7 7 6
Z
IDCS143S Z
8 9
IDCS145S
Parking Brake On
(6) Bolt. (7) Nut. (8) Retaining nut. (9) Jamb nut.
(Z) 6 mm(.24 in) maximum.
2. Apply parking brake. Adjust stop bolts (6) to

dimension (Z) of 6 mm (.24 in) maximum. Tighten
jamb nut (7).
3. Release parking brake. Adjust cable assembly

retaining nut (8) so that parking brake pedal (1)
returns to full off position and brake strap assem-
bly contacts stop bolt. Tighten jamb nut (9).

Motor Brushes
Brush Inspection
NOTICE
1. Measure the brush material on the longest side. Installation of the wrong brushes can cause early
motor failure. Always make sure the correct DAEWOO
brushes are installed.
4. Install new brushes (1). Make sure the brushes

move freely in the brush holders. Use a piece of
plain bond paper to remove brush material if there
is a restriction of brush movement.
Brush Measurement
2. Brush measurement:
If the brush material is less than 19 mm (.75 in) on
the longest side, replace the brushes.
2
New Brush Installation
NOTE: Installation of new brushes is a two person Install

(2) Spring.
operation.
1. Disconnect the batteries and remove them from

the lift truck. Put the batteries close enough to the 5. Install brush springs (2) and make sure they fas-
truck that the battery connector can be plugged in. ten into the brush holder box.
2. Discharge the head capacitor 6. Lift the spring into position on the top of the brush.
3. Remove the commutator cover. Remove the old 7. Pull up on the two wires of each brush until the
brushes. contact end of the brush moves away from the
commutator. Release the wires to see if the brush
moves smoothly back into contact with the com-
mutator. If it is too difficult to pull out, or it does not
move smoothly in the brush holder box, remove
the spring and brush. Make an inspection to find
and correct the cause of the problem.
8. Connect the batteries to the battery connector.
Install Brushes
(1) Brushes.

WARNING NOTICE
Never use air pressure that is more than 205 kPa (30
Wear eye protection when seating, polishing or psi). Make sure the line is equipped with a water filter.
cleaning the motor with air pressure. During the
seating and polishing procedure, keep fingers
away from components in rotation. For prevention
of injury to finger, do not use a commutator clean-
12. After the brushes have correct seat contact sur-
er or seater stone that is shorter than 63.5 mm
face, operate the motor at slow speed. Use com-
(2.50 in).
pressed (pressure) air to remove all dust and
abrasive grit.
Armature Tests
Tools Needed
Digital Multimeter Or Equivalent 1
Growler Tester 1
Short Circuit Test

3
Brush Seating 1
(3) Brush seater stone. 4 5
9. Put ZLX0036 Brush seater Stone (3) on the com-

mutator and operate the motor at a slow speed.
NOTICE
Do not let stone (3) stay in contact with the commuta- 3
tor bar too long a time. This causes more wear than is
necessary to the brushes and the commutator. 2
Short Circuit Test

(1) Growler. (2) Armature. (3) Hacksaw blade. (4) Green light.
(5) Red light.
10. Move stone (3) across the commutator at the
back edge of the brushes for a short time. This
will take the shiny finish off the commutator and 1. Turn the growler(1) on.
seat the new brushes.
11. Turn the key switch to the OFF position and dis- 2. Slowly turn the growler on the armature (2) while a
connect the batteries. Check the contact surface hacksaw blade (3) is held over the windings.
of each brush. At least 85% of the brush contact 3. If the windings are shorted, the green light (4) will
surface of each brush most show wear. If neces- be on. The red light (5) will be on if the windings
sary, do Steps 9 through 12 again until the cor- do not have a short.
rect wear can be seen on the brush contact sur-
face. The odor of burned insulation from the pump motor
while it is in operation is an indication of a short in
the armature.

Ground Test Open Circuit Test
1. Digital multimeter can also be used to test for 1. Put the digital muitimeter Function/Range Switch
grounds. Put the Function/Range Switch on the on the 200 ohm resistance ( ) scale.
2M resistance (A) scale. When the test leads are
put on the commutator and the shaft, the meter 2. Put one test lead on one commutator bar. Put the
must give an indication of overload (OL). This other test lead on an adjacent (next to) bar and
means that the resistance is more than 2 there must be less than one ohm resistance.
megohms.
This test can also be done with an instrument, such
as a Kelvin Double Bridge, that can make a mea-
surement of very low resistance. Do the test the
NOTICE same as above and make a comparison of the resis-
Never use air pressure that is more than 205 kPa (30 tance measurements.
psi). Make sure the air line has a water filter.
Two burned areas on opposite sides of the commu-
tator are indications of an open armature winding.
These burned areas can cause very rapid brush
wear.
If there is an indication of a ground in the above test,
remove any dirt or debris from the armature with
compressed (pressure) air.
Do the ground test again. If there is still an indication

of a ground, replace the armature.

Commutator Inspection
Surfaces of Commutators that need Replacement
IDCS156S
Grooves on the Commutator Surface
IDCS154S
Marks on the Commutator Surface Grooves on the commutators surface are caused by
a cutting material in the brush or atmosphere.
Marks on the commutator surface are an indication

that metal has moved from the commutator surface
to the carbon brushes. Marks will cause fast brush
wear.
IDCS157S
Copper Drag on the Commutator Surface
IDCS155S Copper drag is an extra amount of commutator

material at the back edge of the commutator bars.
Threads on the commutator Surface
Threads (grooves that look like threads) on the com-

mutator surface, will also cause fast brush wear.

1
Brush Test
(1) Field terminal. (2) Brush leads.
IDCS158S 4. Put one test lead to one of outer field terminals

Pitch Bar-Marks on the Commutator Surface
(1). Put the other test lead to each of brush leads
(2) that connect to the brush holders. There must
be continuity to two of the leads with a resistance
Pitch bar-marks cause low or burnt marks on the of less than 1 ohm.
commutator surface. 5. Put one test lead the other outer field terminal.
There must be continuity from this field terminal to
the other two brush holder leads.
Field Coil and Terminal Tests
Tools Needed Ground Test

1
2
Open Circuit Test
Ground Test
(1) Field terminal. (2) Motor housing.
1. Put the digital multimeter Function/range Switch

on the 20M resistance (A) scale.
Open Circuit Test 2. Put one test lead to either outer field terminal (1)
and the other test lead to motor housing (2). There
1. Put the digital multimeter Function/Range Switch must be more than one megohm resistance.
on the 200 ohm resistance (A) scale. 3. If there is a measurement of less than one
2. Put one test lead to each outer field terminal megohm, it can be caused by wet insulation on
(P1,P2). the field windings or excessive brush dust in hous-
ing. Heat the motor at 88C(190D) until the resis-
3. The resistance must be less than one ohm. If the tance goes above one megohm. If the resistance
resistance is too high, it is an indication of corro- does not go above one megohm, the shell and
sion on the terminals or an open field coil. field assembly must be replaced.

Brush Holder Test Thermal Switch (Thermostat) Tests
Tools Needed Tools Needed

Digital Multimeter Or Equivalent 1 Digital Multimeter Or Equivalent 1
2
Open Circuit Test
Brush Holder Test

(1) Brush holder. (2) End bell.
Open Circuit Test(Typical Example)

1. The brush holders are mounted on an insulator at
the commutator end of the motor. Make a visual
inspection of the brush holders and insulator. 1. Put the digital multimeter Function/Range Switch
on the 200 ohm resistance (A) scale.
2. Put digital multimeter. Function/Range Switch on
the 200 ohm resistance ( ) scale. Put one test 2. Put one test lead to each side of the thermal
lead to brush holder (1) and the other test lead to switch harness.
the end bell (2). The meter must show overload
(OL). 3. The resistance must be less than one ohm.
3. Check each brush holder. If meter reading is low,

the brush holder is grounded. Replace the Ground Test
insulator.
Ground Test (Typical Example)
1. Put the digital multimeter Function/Range Switch

on the 20M resistance ( ) scale.
2. Put one test lead to either of the plug prongs. The

other test lead must be grounded to the motor
housing. There must be more than one megohm
resistance.

Brush Life Estimate
1. Before installation of new brushes, inspect the
armature commutator. See Armature Commutator
Inspection in Testing and Adjusting.
2. Do the steps and procedures for New Brush
Installation in Testing and Adjusting.
3. Make the initial (first) inspection of brush wear
between 250 smh and 500 smh. The reason for
this initial inspection is to see if the brush wear
rate is normal and not too fast. The measurement
will help make an estimate of the length of brush
life to be expected.
NOTE: If there is an indication that brush wear is too
fast, see Troubleshooting, Problem: Sparks
at the commutator and/or rapid brush wear.
4. Inspect all brushes in the motors. Measure and
record each brush length. See Hydraulic Pump or
Steering Pump Motor in Specifications for new
and minimum brush length.
5. Estimate expected brush life (hours). Use the
shortest measurement from Step 4 and the
following Sample Procedure:
Length of new brush ....................45.8 mm (1.803 in)
Minimum length of brush.....................19 mm (.75 in)
New brush length [45.8 mm(1.803 in)] - Minimum
brush length [19 mm (.75 in)] = Total amount of usable
brush wear [26.8 mm (1.055 in)].
Length of shortest brush at 500 smh is 43.3 mm ( 1.703
in)
New brush length [45.8 mm (1.803 in)] - Length of
shortest brush at 500 smh [ 43.3 mm (1.703 in)] =
Amount of brush wear at 500 smh [2.5 mm (.10 in)].
Amount of brush wear at 500 smh [2.5 mm (.10
in)] Total amount of usable brush wear [ 26.8 mm
(1.055 in)] = Portion of brush used at 500 smh ( .1).
Service Meter Hours (smh) at brush wear
measurement (500 smh) Portion of brush used ( .1)
= Approximate total brush life of a new brush (5000 smh).
Approximate total brush life of a new brush (5000
smh) - Amount of smh at brush life estimate (500
smh) = Remainder of usable brush life (4500 smh).
6. The smh estimate of brush life can be used if the
machine is to work at the same rate (duty cycle),
the battery is not discharged too much or the
battery cells have not become damaged. If the
machine is made to work harder, the battery is
discharged too much, or the battery cells become
damaged, the motor temperature will get hot very
fast. This will cause rapid wear of the brushes.
7. It is important to check brush length and brush
condition at a specific time, such as during the
preventive maintenance check. If an inspection
shows that brush life will not extend to the next
preventive maintenance check, install new brushes.

(1) Torque for bolts that hold control valve sections
Specifications together ...........40.5 L 2.5 NIm (360 L 24 lbIin).
(2) Adjust main system relief valve pressure for lift as

Hydraulic Control Valve shown above. See Relief Valve Pressure Check
in Testing And Adjusting
(3) Adjust secondary relief valve pressure for tilt and

sideshift as shown above. See Relief Valve
Pressure Check in Testing And Adjusting.
1 (4) Torque for plug ..29.5 L 1.5 NIm ( 264 L 12 lbIin) .
(5) Torque for plug ..101 L 5 NIm ( 894 L 42 lbIin) .
(6) Adjust tilt and sideshift flow rate by using 1/4 inch
hex-wrench if required. See Flow Control Valve
Adjustment in Testing And Adjusting.
7
(7) Torque for plug ..55.5 L 2.5 NIm ( 492 L 24 lbIin) .
(8) Torque for plug ....79 L 4 NIm ( 696 L 36 lbIin) .

3 (9) Torque for screws
...........................5.4 L 2.7 NIm (48 L 24 lbIin) .
2 8 Control Valve Pressure to Open Relief Valve and Current

Draw (Amps) of Pump Motor
9 Relief Current Draw
Pressure 48Volt
IDCS167S +500, -0 kPa
Model Mast (+75, -0psi) Min. Max.
STD 16600 kPa
B20S-3 FFL (2400 psi) 400 450
FFTL
STD 19300kPa
B25S-3 FFL (2800 psi) 430 480
FFTL
STD 20700 kPa
B30S-3 FFL (3000 psi) 450 500
3 FFTL
4 8 *Main relief is for the lift valves (first levers).
5 1
2
Relief Valve Pressure
Main Relief Tilt, Auxiliary Relief
kPa psi kPa psi
Model Mast +500,-0 +75,-0 L350 L50
STD
B20S-3 FFL 16600 2400 15500 2250
FFTL
6 9 STD
B25S-3 FFL 19300 2800 15500 2250
FFTL
STD
B30S-3 FFL 20700 3000 15500 2250
IDCS168S
FFTL
Vehicle Systems 62 Specifications

Hydraulic Pumps
Rotation is clockwise when seen from drive end.
Type of pump: Gear
Displacement : 33 cc/rev

Lift Cylinders Full Free Triple Lift and Full Free
Lift Primary
Standard
1
1 1
IDCS170S
IDCS169S
(1) Put Thread Lock on the last three threads of bear-

ing.
(1) Put pipe sealant on the lost three threads of bear-
ing. NOTE: All seals to be lubricated with hydraulic oil.
(2) Torque for setscrews....6 L 1 NIm ( 53 L 9 lbIin)
NOTE: All seals to be lubricated with hydraulic oil.

Full Free Triple Lift And Full Free
Lift Secondary
1 1
IDCS171S
(1) Put Thread Lock on the last three threads of bear-

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

Tilt Cylinders
2 3
1
4
IDCS189S
TILT CYLINDER CHART

Tilt Gp Forward Tilt Backward Cyl.Stroke(X) Cyl. Closed (z)
Model
Part No. Angle* Tilt Angle* mm(in) mm(in)
A215207 3 3 43.5(1.71) 525.0 (20.67)
A215230 6 3 65.0 (2.56) 525.0 (20.67)
A215206 3 5 58.0 (2.28) 510.3 (20.08)
B20S-3 A215202 6 5 79.5 (3.13) 510.3 (20.08)
B25S-3 A215205 3 8 81.0 (3.19) 487.8 (19.21)
B30S-3 A215201 6 8 102.0 (4.02) 487.8 (19.21)
A215204 3 10 96.0 (3.78) 473.0 (18.62)
A215200 6 10 117.0 (4.61) 473.0 (18.62)
* Permissible tolerance of 1/2°

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

Mast Carriage
A A 1 A B 1 2 B
A
2 3
a
C
2
VIEW A-A
A A
B
VIEW A-A 4
1
3 A B
A C
3
A VIEW B-B
B B 1
VIEW B-B C C
A
IDCS172S
(1) With mast at 475 mm (18.7 in) channel lap,

equally shim both sides until contact (A) is made C VIEW C-C
1 A
(zero clearance) between bearings and mast
IDCS173S
uprights.
(2) With mast at full extension, shim behind pads

until there is clearance (B) between the mast (1) Select bearings from the chart to obtain minimum
uprights and the pads of ...........0.80 mm (.031 in) clearance (C) between bearings and channel leg
for full channel length. Must use same bearing at
(3) Select lower bearings from the chart to obtain
all six locations.
minimum clearance (c) between bearing and
channel leg for full channel length. Must use (2) Equally shim both sides until contact (A) is made
same bearing on left and right side. (zero clearance) between bearings and inner
mast at narrowest point.
(See Mast Adjustment in Testing And Adjusting).
(3) Shim bolt as needed to obtain a 6.0 to 9.0 mm
MAST BEARING CHART (.236 to .354 in) overlap (B) between bolt (3) and
D581814 Undersize 108.60mm the carriage stop on the inner upright.
(4.276in) (See Carriage Adjustment in Testing and
Adjusting.)
D581815 Standerd 109.60mm
(4.315in)
(4) Torque for screw .....34 L 7 NIm (360 L 24 lbIin)
D581816 Oversize 110.70mm
(4.358in)
CARRIAGE BEARING CHART
* Permissible tolerance of L0.08 mm (.003 in).
Part No. Bearing Size Bearing OD*
D581814 Undersize 108.60 mm (4.276 in)
D581815 Standard 109.60 mm (4.315 in)
D581816 Oversize 110.70 mm (4.358 in)
*Permissible tolerance of L0.08 mm (.003 in).

Lift Relay Group - Standard Lift WARNING

1 2 could cause damage or injury to persons.
(1) Put LOCTITE NO. 242 Thread Lock on the threads

of the relay group locknuts after adjustment of the
lift chains is completed.
(2) Maximum chain wea........................Less than 2%

(See Chain Wear Test in TESTING AND
ADJUSTING).
(3) Distance from bottom of inner mast to bottom of

lower bearing on carriage must be even (flush)
with the inner mast.
IDCS174S

Lift Relay Group - Full Free Lift WARNING

2 could cause damage or injury to persons.
1
(1) Tighten bolts until contact is made with guard.
(2) Put LOCTITE NO. 242 Thread Lock on the

threads of the relay group locknuts after adjust-
ment of the lift chains is completed.
(3) Maximum chain wear Less than 2%(See Chain

Wear Test in TESTING AND ADJUSTING).
(4) Distance from bottom of inner mast to bottom of

lower bearing on carriage must be 41 L1.5 mm
(1.61 L 0.6 in).
Bottom of inner mast must be even (flush) with
2 bottom of stationary mast. Adjust inner first.
4
IDCS175S

Lift Relay Group - Full Free WARNING
Triple Lift
indication is 2% or more. A Reading of 2% or more
could cause damage or injury to persons.
1 (1) Maximum chain wear Less than 2%(See Chain

Wear in TESTING AND ADJUSTING).
(2) Put LOCTITE NO. 242 Thread Lock on the

threads of the relay group locknuts after adjust-
ment of the lift chains is completed.
(3) Tighten bolts until contact is made with guide

2 assembly.
3 (4) Distance from bottom of inner mast to bottom of

lower bearing on carriage must be 41 L1.5 mm
(1.61 L 0.6 in).
Bottom of inner mast be even (flush) with bottom
1 of stationary mast. Adjust inner mast first.
IDCS193S

Lift and Tilt Mounting Group (1) (Standard Mast or Full Free Triple Lift mast Only):
With chains adjusted for equal tension, run mast
to full lift. If mast does not kick (move) to one
side, no shims are needed. If mast does kick
(move) to one side, disconnect cylinder from the
bar on that side. Add shim, connect cylinder,
1
adjust chains and run mast to full lift to check for
A kick. Repeat process if necessary. The total shim
pack must not be more than three shims maxi-
A mum.
(2) Install bearing outer race to a depth of (F) 4.5 L

VIEW A-A F 0.8 mm (.177 L .031 in).
2 (3) Tilt cylinder installation shown for M40D thru

MC60d models.
B B
(4) Bearing split to be located at angle (d) 45 L15°
VIEW B-B 3 (5) Install bearing outer race to a depth of (G)
............................4.5 L 0.8 mm (.177 L .031 in).
C
C (6) (Full Free Lift Mast Only):
Tighten nuts until U-bolts is firm against cylinder,
do not apply standard torque.
4 (7) (Full Free Lift Mast Only):
With chains adjusted for equal tension run mast
5 to full lift. If mast does not kick (move) to one
side, no shims are needed. If mast does kick
(move) to one side, hold lift cylinder tube on that
D
side and loosen bearing 1/4 turn and check mast
Bearing again. Loosen bearing until kicking (movement)
Split stops or gap (H) reaches 3.0 mm (.12 in) (approx-
VIEW C-C
imately 1.5 turns)), whichever is less. Insert shims
G (8) under bearing (it may be necessary to loosen
bearing an additional amount of turns to install
IDCS176S shims). Tighten bearing again.
NOTE: Tighten the cylinder clamp bolts to a maxi-

mum torque of 35 NIm ( 26 lb ft) to prevent cylinder
7 rotation.
6
8 DETAIL E H
IDCS177S

Steering Wheel Priority Valve
:B20/25/30S-3
1
IDCS179S
Flow .......................................................Load sensing

IDCS178S
Relief valve (no adjustment) opens at:
.............................7600 L 350 kPa ( 1100 L 50 psi)
(1) Torque for steering wheel nut...........75 to 88 NIm

( 55 to 65 lbIft)

Steering Gear
1 2
VIEW B-B VIEW C-C
TIGHTENING SEQUENCE
FOR BOLTS 4
A
C
C
SECTION A-A
A
5
IDCS180S
(1) Pin (1) in the body must be aligned with internal

pump gear (gerotor) (2) and drive (3) as shown.
(4) Tighten bolts in sequence shown.

Tighten to a first torque of 14.1 L 2.8 NIm (125
L 25 lbIin)
Tighten to a final torque of 28.2 L 2.8 NIm(250
L 25 lbIin)
(5) Torque for plug 11.3 NIm(100 lbIin)

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

Steer Axle and Wheel (9) tapered Roller Bearing Axles Only:
Torque for bolts that hold cover
.....................................55 L 6 NIm(40 L 5 lbIin)
3
(10) Add or remove shims under cover until torque
required to turn knuckle assembly is ...4.5 to 6.8
NIm (40 to 60 lb in) See Steering Knuckle
Bearing Preload Adjustment in Testing And
A 4 Adjusting section.
5
Steer Tire Installation
1 B20/25/30S Models
2
IDCS181S 6 7 8
1
NOTE: Steer axles with tapered roller bearings
shown.
(1) Do the steps that follow for steer wheel bearing

adjustment.
a. tighten nut (1) slowly to 135 NIm(100 lb ft) while
turning the wheel.
b. Loosen nut 91) completely. Tighten it again to
.......................................50 L 5 NIm(37 L 4 lbIft)
c. Bend lock (2) over nut (1).
(3) torque for bolt that holds pin

..................................11 L 1 NIm (100 L 9 lbIft)
(4), (6) Loosen nuts (5) and (7) on both sides. Adjust
bolts to get steering knuckle turning angle (A) of
78 to 80° See Steering Axle Stop Adjustment in
Testing And Adjusting section. IDCS183S
(8) Tapered Roller Bearing Axles Only:

Torque for bolts that hold steer cylinder to axle
beam.....................300 L 40 NIm(220 L 30 lbIft) WARNING
The cushion steer tire must be installed as shown.

Failure to do so will decrease machine stability.
Install the cushion tire so that the edge of the tire is

even with the outside edge of the wheel.
Tighten the cushion tire wheel mounting bolts (1) to a
torque of.........................95 L 15 NIm(70 L 10 lbIft)
IDCS182S
9 10

Brakes
Shoe Type Brakes Oil Cooled Disc Brakes
1 2 1 2
VIEW A-A
Z Y 4
3
IDCS185S IDCS186S
(1) Torque for for brake line nuts (1), (2) Put #17430 Liquid Gasket on contact surface
.....................................14 L 2 NIm(10 L 1 lbIft) area of the ax.e flange cover assembly and cover
before installation.
(2) Torque for wheel cylinder mounting bolts
......................................15 L 2 NIm(11 L 1 lb ft) (3) Thickness of one new D700251 Plate
......................2.50 L .064 mm (.100 L .0025 in)
(3) Torque for adjuster mounting bolt (after it is cen- Thickness of one new friction disc:
tered) ............................72 L 5 NIm(55 L 4 lbIft) D141112 .............4.59 L .13 mm(.181 L .005 in)
(4) Adjuster dimensions: Minimum depth of grooves before replacement is

(X) or (Y) ........................1.05 mm (.041 in) maximum necessary:
(X) + (Y) .....................1.3 L 0.3 mm(.051 L 0.12 in) D141112 ....................................0.32 mm (.013 in)
(Z) .......................................................85 mm(3.35 in) Soak new discs in transmission drive train oil for
(See Brake Adjuster Installation in Testing And one hour before installing.
Adjusting).
Brake drum diameter (not shown) ........245 to 245.29
mm(9.646 to 9.657 in)
Maximum total diameter brake drum can be

machined from the original diameter
........................................................1.52 mm (.060 in)

Parking Brake
IDCS187S
(1) Torque for brake drum retaining nut 50 L 20

NIm(37 L 15 ftIlb)
(2) Clearance for brake drum and brake strap

assembly at location marked (A) 0.25 - 0.50 mm
(.010 - .020 in)
See Parking Brake and Parking Brake Control Gp
in Testing and Adjusting for brake and cable
adjustment procedure.

1 9
11
7
12
13 3 4,5 6
14 1 12
HYDRAULIC PUMP MOTORS

New Brush Size Minimum Minimum
Voltage
Thickness X Width X Length Brush Length * Commutator Diameter**
12.5 mm X 24.9 mm X 45.8 mm
48 19.0 mm (0.75 in) 78 mm (3.07 in)
(0.5 in X 0.98 in X 1.8 in)
*Measured on longest side.
** All rough edges (burrs) must be removed after the commutator is machined.

Machine chamfer on the commutator bars
........................................................0.40 mm (.016 in)
Torque for the terminal bolts (not shown) that hold
cable connection...............................14 NIm (10 lbIft)
Depth of the insulation below commutator bars
............................................................1.0 mm (.04 in)
Width of the insulation below commutator bars
........................................................0.76 mm (.030 in)
Maximum difference between commutator high and
low point (out of round) 0.03 mm (.001 in)
Maximum difference between bar to bar
.............................................0.005 mm (.0002 in) TIR
Thermal switch (not shown)
Opening temperature 150 L 6°C...........(302 L 11°F)
Closing temperature 130 L 7°C ............(266 L 13°F)

SB4083E00
Dec. 2002
Specifications
Systems Operation
Testing & Adjusting
Disassembly & Assembly
Lift Trucks Power Train
B20S-3, B25S-3, B30S-3
accident occurs. A person must be alert to potential hazards. This person should also have the necessary train-
ing, skills and tools to perform these functions properly.
WARNING
in injury or death.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publica-
tion.
and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubri-
cation, maintenance or repair procedures you choose.
and most current information before starting any job. DAEWOO dealers have the most current information avail-
able.
1
Index
Systems Operation Disassembly & Assembly

Brakes, Brake Adjuster And Wheel Cylinder...........35
Axle Lubrication Schematic
(Oil Cooled Disc Type Brake)....................................9
Final Drives And Hubs.............................................44
Drive Motor............................................................... 6
Final Drive ................................................................ 8
Oil Cooled Disc Type Brake ....................................47
General Information.................................................. 5
Power Transfer Group.............................................. 7
Power Transfer Group .............................................38

Drive Motor..............................................................15
Armature Terminal Test ......................................20
Armature Tests ...................................................16
Brush Holder Test ..............................................20
Brush Life Estimate............................................21
Commutator Inspection......................................18
Field Coil And Terminal Tests.............................19
Motor Brushes....................................................15
Thermal Switch Tests.........................................21
Final Drive ...............................................................28

Wheel Bearing Adjustment.................................28
Power Transfer Group Adjustments ........................22

Pinion Bearing Adjustment.................................25
Pinion Depth Check ...........................................25
Pinion Installation...............................................23
Power Transfer Group........................................22
Power Transfer Group Bearing And Gear
Clearance (Backlash) Adjustments...............26
Troubleshooting...................................................... 10
Checks During Operation ................................. 10
Drive Motor .................................................. 10
Power Transfer Group And Final Drive ........14
Visual Checks ....................................................10
Specifications
Drive Axle Mounting Group .....................................34
Drive Motor..............................................................31
Drive Tire Installation...............................................34
Final Drive ...............................................................33
General Tightening Torque ......................................29
Power Transfer Group .............................................32
Power Train 3 Index

Systems Operation
General Information
Power Flow
(1) Final drive (2) Power transfer group (3) Drive motor
The power train consists of three main components:

drive motor (3), power transfer group (2) and final
drive (1).
Electric storage batteries are used as a power source

for drive motor (3). The drive motor turns power
transfer group (2). The power is sent through the
power transfer group to the axles. The axle turns final
drive (1), which is part of the drive wheels.
Power Train 5 Systems Operation

Drive Motor
3 2
5 6 7 8
Drive Motor
(1) Shaft. (2) Cover. (3) Thermal switch (thermostat). (4) Commutator. (5) Armature assembly. (6) Field coils. (7) Frame.
(8) Brush holder.
The drive system is operated by a direct current (DC) The four motor brushes are held in four brush hold-
motor. Electric storage batteries are the source of ers (8). A spring holds each of the brushes against
power for the DC motor. commutator (4) as the brushes wear.
The drive motor is a series wound motor and uses a The Optional Superior (S) function equipped lift
high temperature insulation. A series wound motor is truck’s drive motor is protected from overheating by a
a commutator motor. The field and armature circuits thermal switch (thermostat) (3). The thermal switch
are a series, which provides a single path for the cur- opens at 150 L 6°C (302 L 11°F). It closes at 130 L 7°C
rent. Armature (5) is mounted with single row ball (266 L 13°F). When the normally closed thermal
bearings at each end. The ball bearings are perma- switch is open, the amount of current through the
nently lubricated with a high temperature lubricant. motor is limited to allow the motor to cool. The motor
has a fan for cooling.
The electrical connections to the motor are made at
corrosion resistant terminals on motor frame (7). On The drive motor is activated when the parking brake
the outside of the motor frame is cover (2) that can is released, the key and seat switch are closed, a
be removed for easy access to the brushes and the direction is selected and the accelerator pedal is
commutator. Field coils (6) are fastened to the inside depressed.
of the motor frame.
The drive motor powers the power transfer group
through shaft (1).

Power Transfer Group
2 3
1
4
6

(1) Bevel gear (2) Differential case (3) Helical gear (4) Spiral hypoid pinion (5) Input Gear (6) Drive Motor Shaft
The power transfer group is mounted under the transfer group lets the inside wheel stop or turn slow-
frame in the front of the lift truck. It’s a double reduc- er in relation to the outside wheel.
tion unit with the final reduction through spiral hypoid
pinion (4) and bevel gear (1). When the truck is moving straight in a forward direc-
tion with the same traction under each wheel, there is
Power for the transfer group comes from the electric equal torque on each axle. This holds (stops) differ-
drive motor through the input gear connected with ential pinion gears which give the same effect as if
the Drive Motor Shaft (6) through the spline . The both wheels were on the same axle. During a turn,
input gear (5) turns helical gear (3) that is mounted the force (traction) that is on the drive wheels is dif-
on the shaft of the hypoid pinion (4). ferent. These different forces are also felt on opposite
The hypoid pinion is engaged with bevel gear (1) sides of the power transfer group and cause differen-
which is mounted to differential case (2). tial pinion gears to turn. The rotation of differential
pinion gears stops or slows the inside wheel and lets
Differential case (2) has two pinion gears that are the outside wheel go faster. This moves the machine
engaged with two side gears. The side gears turn the through a turn under full power.
axle shafts.
The power transfer group gets lubrication from oil
The power transfer group is used to send the power thrown about inside the housing, by the rotating
from the electric drive motor to the wheels. When gears.
one wheel turns slower than the other, the power

Final Drive
Final Drive
(1) Axle shaft (2) Hub (3) Drive wheel (4) Spindle
The power transfer group turns axle shaft (1). The

gear teeth on the end of axle shaft (1) engage the
gear teeth of hub (2). The gear teeth of hub (2) are
on the inside diameter of the hub, which causes the
rotation of the hub to be the same as the axle shafts.
The reduction in size between the axle shaft and the
hub causes the hub to turn at a slower speed.
Spindle (4) is fastened to the truck frame and is used
as a support for hub (2).
Drive wheel (3) is fastened to hub (2) and turns with
the hub.
The final drive is a grease lubricated unit.

Axle Lubrication Schematic
(Oil Cooled Disc Type Brake)
The axle is lubricated by means of the electric motor

mounted lubricant pump (2) which gets oil from the
axle suction port (1) and supplies it to the hub section
pressure parts (3) to lubricate and cool hub drive and
multi-disc brakes.
Oil returns to the sump through the drive shaft
bearings and axle housing.
Power Train 9 Testing And Adjusting

Troubleshooting WARNING
If an electrical failure or an overload of the motor

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

motor problem, always make reference to the
Troubleshooting section of the MicroController
System Operation module. Problem 1: Drive Motor Will Not Operate.
Probable Cause:
WARNING 1. Switch not closed (battery connector, key switch,

seat switch, direction switch or parking brake
The lift truck can move suddenly. Battery voltage switch):
and high amperage are present. Injury to Close the switch. If it still does not operate, test
personnel or damage to the lift truck is possible. for power to the control panel and power flow
Safely lift both drive wheels off the floor. Put wood through each switch with a voltmeter.
blocks or jack stands of the correct capacity under
the frame so the drive wheels are free to turn. 2. Bad connection. Fuse bad:
During any test or operation check, keep away Check battery connections. Check connections
from the drive wheels. The head capacitor (HEAD at battery connector. Check fuses, drive and
CAP) will have to be discharged before any logics.
contact with the control panel is made. Disconnect Replace fuse if bad.
the battery and discharge the HEAD CAP. Rings, Check the Drive motor and control panel for
watches and other metallic objects should be possible reasons for a bad fuse. Some causes
removed from hands and arms when are:
troubleshooting the MicroController control a. Operate during too heavy transistor load, too
system. high current limit (C/L).
b. Operate in stall conditions.
To prevent personal injury, never use air pressure c. Possible short circuit in drive motor, see
that is more than 205 kPa (30 psi), and wear Probable Causes 5, 6 and 7.
protective clothing and a face shield.
3. Low battery voltage:
Check battery terminal voltage. If too low,
charge the battery.
Check all the cells for one or more that have
NOTICE defects.
To prevent damage to electrical components, make Check the specific gravity of each cell. The
sure the air line is equipped with a water filter when maximum density difference from the highest to
they are cleaned with air. the lowest cell must not be more than. 020 SG
(specific gravity).

4. Control panel operation not correct: These can cause transistors to become defective,
See the MicroController System Operation control panel failure or drive fuse to go bad.
module.
Problem 3: Neither traction or hydraulic will last
5. Brushes are worn: through a complete normal work period.
Inspect the drive motor commutator for burnt
marks or scoring (scratches). Make corrections Probable Cause:
or make a repair of the armature commutator
and replace the brushes as necessary. 1. Too small a battery equipped in the lift truck:
See Armature Commutator Inspection and Use a larger battery for the complete work cycle
Brush Inspection in Testing And Adjusting. and normal work period.
Make reference to Problem: Sparks At The
Commutator And/Or Rapid Brush Wear. 2. Battery not being fully charged or equalized during
the battery charging operation:
6. Check for opens in the field coils: Check the battery cells for an equalization
Test coils according to procedures in Testing charge (a charge to make the specific gravity
And Adjusting. If there are opens, make a the same in all cells). Check the battery charger
replacement of the field assembly. for defects.
7. Check for a short circuit in the armature windings: 3. Battery change interval is too long or changed
Loose field winding pole pieces, make the battery cooling time is too short. This decreases
necessary corrections. the capacity and the ability of the battery:
Field armature bar insulation. Decrease the battery work duration before a
Repair or rebuild the insulation or make a change. Increase the battery cooling time after
replacement of the armature. a charge before it is put to use.
8. Static return to off circuit actuated: 4. Battery has one or more defective cells which
If the static return to off is actuated, the control results in less than the rated capacity and ability of
will not start again until the accelerator is the battery:
released and the directional control lever is Replace the battery.
returned to neutral.
5. Traction system draws (make a consumption of)
Problem 2: Traction will not operate through a too much battery power because of traction
normal work period, but hydraulic operation is system faults. Operation of the duty cycle
normal. (complete working cycle) condition is not correct:
Check the brake adjustment according to the
Probable Cause: procedures in Testing And Adjusting in the
Vehicle Systems module, Check the mechanical
1. Brakes have a defect, cause a resistance (lack of components such as wheel bearings, axles,
free movement). Heat increases, which causes the etc., for corrections to eliminate the faults.
motor to stall: Change to a tire with less friction.
Check the brake adjustment according to the
procedures in Testing And Adjusting in the 6. Hydraulic system draws too much battery power
Vehicle Systems module. because of lifting and tilting arrangements, or
hydraulic conditions are not correct for the duty
2. Too much heat in MicroController control panel cycle:
because: Decrease hydraulic relief valve setting to the
a. Extra heavy traction loads. capacity that only will be used.
Decrease the duty cycle load. Change to a smaller hydraulic pump.
b. Faulty thermal switch. Check the mast for restriction during operation.
See the MicroController System Operation
module. 7. Lift truck working more than the capacity of its
c. Too high current limit (C/L) setting. design with no available power after one work
Lower the setting on the C/L adjustments. shift:
Have available an extra (exchange) battery.
Decrease the speed and work load required to
complete the work shift.

Problem 4: Sparks at the commutator and/or c. Brush movement causes arcing and brush wear:
rapid brush wear. Check the brush springs for cracks, and
overheat signs (blue).
Probable Cause: Compare spring force with a new brush spring.
Check the brush holder for oversize (larger size
1. Worn brushes: than for brush).
Make a replacement of the brushes. See New Replace the brush spring if necessary.
Brush Installation And Brush Inspection in d. Loose brush leads or motor bus bar connections.
Testing And Adjusting. Loose cable connections at motor terminals.
Results are:
2. Overheating (too much heat) of the traction motor:
Check for an overload motor or a motor with (1) High resistance and heating.
defects. See Armature Commutator Inspection (2) Faster brush wear.
in Testing And Adjusting. Check brushes for tight-connections.
Decrease the current limit (C/L) adjustments if Replace the brushes if leads are loose in
set too high. See the MicroController System brush material. Check all cable and wire
Operation module. connections for tightness.
Test the plugging rate, if set too short it will
cause arcing and wear at the brushes. e. Wrong grade of brushes installed that are not
The duty cycle is too heavy, change the duty adaptable to the motor:
cycle. Make sure all the brushes are of DAEWOO
standards. Do not use other brands of brushes.
3. Defective drive motor:
See Armature Commutator Inspection in Testing f. Possibly heavy working condition that causes too
And Adjusting. much motor heat and rapid brush wear:
Make a replacement of the brushes and make
a. Commutator bars burnt in two or more positions at sure the brushes are seated. See New Brush
180° apart because: Installation and Brush Inspection in Testing And
Adjusting.
(1) Armature bars open. Check the brush springs for the correct
Make a replacement of the armature. installation and for the correct spring usage. Too
strong a spring rate will increase amperage
(2) Motor was stalled against a heavy load while draw and brush wear rate.
power discharged and caused the two bars, in Prevent operation in stall condition. Excessive
contact with the brushes, to burn. (too much) duty cycle which increases motor
temperatures and rapid brush wear.
4. Overload of the drive motor such as: towing loads,

NOTICE
constant ramp operation, chiseling (hydraulic
Too heavy a load can stall the motor, and result in a
actions that are not practical) loads and dragging
failure to the drive motor.
(pull or push loads on the ground) loads:
Operator training for better working practices.
Add an auxiliary cooling to the drive motors.
(3) Short circuit in the armature.
See Armature Tests in Testing And Adjusting. 5. Current limit (C/L) set too high that causes too
much current consumption through motors in the
(4) Armature not in balance, out of round, off center transistor range:
or with high commutator bars. This causes the Decrease the current limit (C/L) adjustment to
brushes to bounce (move up and down). the correct setting, see the MicroController
Make sure the diameter is the same all the way System Operation module.
around and is in center line with the shaft. See
Specifications. 6. Drive motor, armature or field windings have a
defect that results in high current draw at low
b. Dirty motor that has a metallic or carbon dust. this torque output:
dust is a conductor which causes electrical shorts, See Armature Tests and Field Coil and Terminal
increase amp draw and decrease drive motor Tests in Testing And Adjusting.
output:
Remove any dirt with air pressure.

7. Restriction caused by components: Problem 7: Lift truck moves faster in one
Correct and make adjustments to wheel brakes direction than the other direction with the same
and parking brakes that drag. amount of accelerator pedal movement in Bypass
Make changes to tires with less restriction. mode (speed).
Check and correct wheel bearing torques.
Probable Cause:
Problem 5: Low resistance to ground [battery
polarity either positive (+) or negative (-) or a 1. Motor brushes not located in the correct electrical
medium voltage is in direct contact with truck position (brush neutral settings):
frame (body) or drive motor body]. If the holes in the brush holder are not
extended, make them longer so that brush
Probable Cause: holder can have a little rotation. When the
holder is in the correct position, lift truck speed
1. Dirty battery, electrolyte on top of cells and is in will be the same in both directions.
contact with the frame. Current flows through
battery box, which places a voltage on the truck 2. One directional contactor worn more than the
frame: other or loose connection on one contactor:
Clean the battery with baking soda and water Check contactor for wear and tighten any loose
solution. connections.
2. Battery or control panel wire connections in Problem 8: Lift truck will not get to top speed.
contact with truck frame:
Make a continuity test and move the wire from Probable Cause:
contact.
Remove wires in sequence until the fault is 1. Battery not fully charged or battery has bad cells:
cleared. Charge the battery. Check for bad cells.
The fault will be in the wire last disconnected. Replace battery if necessary.
3. Dirty motor: 2. A fault either in the drive motor, control panel or

Remove metallic or carbon dust with air drive train:
pressure. Check lift truck speed in both directions. If the
MicroController panel needs tuned up, make
4. Wet motor: adjustments as shown in the respective
To dry the motor, heat it to 90°C (194°F). MicroController System Operation module. If
the drive motor is at fault, make the tests of the
Problem: 6. Commutator surface has groove or motor components in Testing And Adjusting.
extra wear.
Problem 9: Lift truck does not have enough
Probable Cause: power to position itself under a load. Lift truck
does not have enough power on ramps or towing
1. Brushes are worn too low, brush wires caused trailers.
arcing on the commutator:
Replace the brushes. See Brush Inspection in Probable Cause:
Testing And Adjusting and the method to make
the Brush Lift Estimate in Testing And Adjusting. 1. Current limit (C/L) set too low:
Set current limit (C/L) to specification in the
2. Dirty motor; and possibly salt water got inside: MicroController System Operation module.
Disassemble motor, remove the debris with air
pressure. If necessary, dry the motor with heat
to 90°C (194°F)
3. Grades of brushes mixed:

Make sure all the brushes are of DAEWOO
standards. Do not use other brands of brushes.

2. Current limit (C/L) circuit has a defect:
Make test to the MicroController control panel as 8. Loose or worn side bearings.
stated in the respective service module. Repair or
replace components as necessary. 9. Noise in the drive wheel reduction components.
3. Unpolished or improperly positioned forks: Problem 2: Noise at different intervals.

Install tapered and polished forks. Position forks
correctly for load being lifted. Probable Cause:
4. Lift truck equipped with tires that have poor 1. Bevel gear does not run evenly.
traction: a. Nut on drive gear not tightened correctly.
Install tires that have good traction per b. Drive gears have a defect (warped).
recommendation from DAEWOO Inc.
2. Loose or broken bearings.
5. Lift truck work load is too heavy or the duty cycle
too long: 3. Failure of or not enough lubricant on the drive
Decrease the work load and/or duty cycle. wheel reduction components.
Problem 10: Lift truck has slow acceleration: Problem 3: One drive wheel does not turn (motor
operates).
Probable Cause:
Probable Cause:
1. Drive control overheated and the thermal switch
opens: 1. Broken axle shaft.
a. Loose wheel bearings.
NOTE: The lift truck will still go into the bypass b. Loose flange studs or nuts.
mode, but current limit will be cut back in the c. Bent housing.
transistor mode if the thermal switch opens.
Allow the MicroController control panel to become 2. Pinion gear teeth have damage.
cool so the thermal switch will close.
3. Bevel gear, pinion or gears broken.
NOTE: The thermal switch will open circuit if the
temperature is 150 L 6°C (302 L 11°F) and reclose Problem 4: Leakage of lubricant.
(short circuit) at 130 L 7°C (266 L 13°F).
Probable Cause:
Power Transfer Group and Final Drive 1. Loss through axle shafts.
a. Lubricant above specified level.
Problem 1: Constant noise in drive axle housing. b. Wrong kind of lubricant.
c. Restriction of axle housing breather.
Probable Cause: d. Axle shaft oil seal installed wrong or has
damage.
1. Lubricant not to the specified level.
2. Loss at pinion.
2. Wrong type of lubricant. a. Lubricant above specified level.
b. Wrong kind of lubricant.
3. Wheel bearings out of adjustment or have a defect. c. Restriction of axle housing breather.
d. Drive motor seal worn or not installed correctly.
4. Bevel gear and pinion not in adjustment for correct
tooth contact.
5. Teeth of bevel gear and pinion have damage or

wear.
6. Too much or too little pinion to bevel gear

clearance (backlash).
7. Loose or worn drive motor bearings.

Drive Motor
Motor Brushes
Brush Inspection
1. Measure the brush material on the longest side. 1
Install Brushes
(1) Brushes.
NOTICE
Installation of the wrong brushes can cause early
motor failure. Always make sure the correct DAEWOO
brushes are installed.
Brush Measurement
5. Install new brushes(1). Make sure the brushes

2. If the brush length is less than 19 mm (.75 in) on move freely in the brush holders. Use a piece of
the longest side, replace the brushes. plain bond paper to remove brush material if there
is a restriction of brush movement.
New Brush Installation
NOTE : Installation of new brushes is a two person

operation.
1. Disconnect the batteries and remove them from

the lift truck. Put the batteries close enough to the
truck that the battery connector can be plugged in.
2
2. Lift the truck and put blocks under it so that the
drive wheels are off the ground. Put blocks in front
and in back of the steering wheels.
Install Springs
3. Discharge the head capacitor.
(2) Spring.
4. Remove the commutator screen cover remove old

brushes. 6. Place carefully the brush spring(2) on the top of
brush and make sure they fasten into the brush
holder box.
7. Pull up on the two wires of each brush until the

contact end of the brush moves away from the
commutator. Release the wires to see if the brush
moves smoothly back into contact with the
commutator. If it is too difficult to pull out, or it does
not move smoothly in the brush holder box,
remove the spring and brush. Make an inspection
to find and correct the cause of the problem.
8. Connect the batteries to the battery connector.

WARNING
NOTICE
Wear eye protection when seating, polishing or
psi). Make sure the line is equipped with a water filter.
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 12. After the brushes have the correct seat contact
cleaner or brush seater stone that is shorter than surface, operate the motor at slow speed. Use
63.5 mm (2.50 in.). compressed (pressure) air to remove all dust and
abrasive grit.
Armature Tests
Tools Needed
3 Digital Multimeter Or Equivalent 1

Growler Tester 1
Test For Short Circuit
Brush Seating
(3) ZLX –0036 Brush seater stone.
1 5
4
9. Put ZLX–0036 Brush Seater Stone (3) on the

commutator and operate the motor at a slow
speed.
NOTICE
Do not let stone (3) stay in contact with the commutator
bar too long. This causes more wear than is necessary
to the brushes and the commutator. 2 3
Short Circuit Test

10. Move stone (3) across the commutator at the (1) Growler. (2) Armature. (3) Hacksaw blade.
(4) Green light. (5) Red light.
backe edge of the brushes for a short time. This
will take the shiny finish off the commutator and
seat the new brushes. 1. Put armature windings (2) in the jaws of growler.
(3).
11. Turn the key switch to the OFF position and
disconnect the batteries. Check the contact 2. Turn the growler (1) on. Slowly turn the growler on
surface of each brush. At least 85% of the brush the armature (2) while a hacksaw blade (3) is held
contact surface of each brush must show wear. If over the windings.
necessary, do Steps 8 through 11 again until the
correct wear can be seen on the brush contact 3. If the windings are shorted, the green light (4) will
surface. be on. The red light (5) will be on if the windings
do not have a short.
The odor of burned insulation from the drive motor

while it is in operation is an indication of a short in
the armature.

Ground Test. Open Circuit Test
A digital multimeter can also be used to test for 1. Put the digital multimeter Function / Range Switch
grounds. Put the Function/Range Switch on the 2M on the 200 ohm resistance ( ) scale.
resistance ( ) scale. When the test probes are put
on the commutator and the shaft, the meter must 2. Put one test lead on one commutator bar. Put the
give an indication of over load (OL). This means that other test lead on an adjacent (next to) bar and
the resistance is more than 2 megohms. there must be less than one ohm resistance.
This test can also be done with an instrument,

NOTICE
such as a Kelvin Double Bridge, that can make a
measurement of very low resistance. Do the test
psi). Make sure the air line has a water filter.
the same as above and make a comparison of the
resistance measurements.
If there is an indication of a ground in the above test, Two burned areas on opposite sides of the
remove any dirt or debris form the armature with commutator are indications of an open armature
compressed (pressure) air. winding. These burned areas can cause very rapid
brush wear.
Do the test for grounds again. If there is still an
indication of a ground, make a replacement of the
armature.

Commutator Inspection
Surfaces of Commutators that need Replacement
EHPS009B EHPS011B
Marks on the Commutator Surface Grooves on the Commutator Surface
Marks on the commutator surface are an indication Grooves on the commutators surface are caused by
that metal has moved from the commutator surface a cutting material in the brush or atmosphere.
to the carbon brushes. Marks will cause fast brush
wear.
EHPS012B
Copper Drag on the Commutator Surface

EHPS010B
Threads on the Commutator Surface
Copper drag is an extra amount of commutator
material at the back edge of the commutator bars.
Threads (grooves that look like threads) on the
commutator surface, will also cause fast brush wear.

Ground Test
EHPS013B
Ground Test
Pitch Bar–Marks on the Commutator Surface
(1) Field Terminal. (2) Motor housing.
Pitch bar–marks cause low or burnt marks on the

commutator surface.
2. Put one test lead to either outer field terminal (1)

and the other test lead to the motor housing (2).
Field Coil and Terminal Tests There must be more than one megohm resistance.
Tools Needed 3. If there is a measurement of less than one

Digital Multimeter Or Equivalent 1 megohm, it can be caused by wet insulation on the
field windings or excessive brush dust in housing.
Heat the motor at 88°C (190°F) until the resistance
Open Circuit Test goes above one megohm. If the resistance does
not go above one megohm, the shell and field
assembly must be replaced.
Open Circuit Test

on the 200 ohm resistance ( ) scale.
2. Put one test probe to each outer field terminal

(S1,S2).
3. The resistance must be less than one ohm. If the

resistance is too high, it is an indication of
corrosion on the terminals or an open field coil.

Armature Terminal Test
Tools Needed
2. Put one test lead to an outer brush terminal (1)
and the other test lead to the motor housing (2).
Test for Continuity There must be more than one megohm resistance.
3. Do the test again with one test lead on the other

outer brush terminal.
Brush Holder Test
Tools Needed
1
Brush Test

on the 200 ohm resistance ( ) scale.
2. Put one test lead to an outer armature terminal

and the other test lead to each brush lead that
connects to that terminal. There must be less than
one ohm resistance. 2
3. Do Step 2 again with the other outer armature Brush Holder Test
terminal and brush leads. (1) Brush Holder. (2) End Bell.
4. Too much resistance is an indication of corrosion

1. The brush holders are mounted on the rocker at
at the connection to the terminal.
the commutator end of the motor. Make a visual
inspection of the brush holders and the rocker.
Ground Test
2. Put digital multimeter Function/Range Switch on
the 200 ohm resistance ( ) scale. Put one test
lead to a brush holder (1) and the other test lead
to the end bell (2). The meter must show overload
1 (OL).
3. Check each brush holder. If meter reading is low,

2 the brush holder is grounded. Replace the rocker.
Ground Test
(1) Armature Terminal. (2) Motor Housing.

Thermal Switch Tests Brush Life Estimate
Tools Needed
1. Before installation of new brushes, make an
Digital Multimeter Or Equivalent 1 inspection of the armature commutator, see
Armature Commutator Inspection in Testing and
Open Circuits Test Adjusting.
2. Do the steps and procedures for New Brush

Installation in Testing and Adjusting.
3. Make the initial (first) inspection of brush wear

between 250 smh and 500 smh. The reason for
this initial inspection is to see if the brush wear
rate is normal and not too fast. The measurement
will help make an estimate of the length of brush
life to be expected.
NOTE : If there is an indication that brush wear is too

fast, see Troubleshooting, Problem: Sparks
at the commutator and/or rapid brush wear;
Open Circuit Test for probable causes of this problem.
1. Put the digital multimeter Function/Range Switch 4. Inspect all brushes in the motors. Measure and
on the 200 ohm resistance ( ) scale. record each brush length (see Specification for
each new brush length and minimum brush length).
2. Put one test lead to each side of the thermal
switch harness. 5. Estimate expected brush life (hours). Use the
shortest measurement from Step 4 and the
3. The resistance must be less than one ohm. following Sample Procedure:
Length of new brush ................45.8 mm (1.803 in.)

Ground Test Minimum length of brush...............19 mm (0.75 in.)
New brush length [45.8 mm (1.803 in.)] - Minimum
brush length [19 mm(0.75 in.)] = Total amount of
usable brush wear [26.8 mm(1.055 in.)].
Length of shortest brush at 500 smh is 43.3 mm

(1.703 in.).
New brush length [45.8 mm (1.803 in.)] - Length of

shortest brush at 500 smh [43.3 mm (1.703 in.)] =
Amount of brush wear at 500 smh [2.5 mm (.10 in.)].
Amount of brush wear at 500 smh [2.5 mm (.10

in.)] ÷ Total amount of usable brush wear [26.8
mm (1.055 in.)] = Portion of brush used at 500
Ground Test
smh (.1).
Service Meter Hours (smh) at brush wear

measurement (500 smh) ÷ Portion of brush
used (.1) = Approximate total brush life of a new
brush (5000 smh).
2. Put one test lead to either of the plug prongs. The
other test lead must be grounded to the motor
Approximate total brush life of a new brush
housing.
(5000smh)–Amount of smh at brush life estimate
There must be more than one megohm resistance.
(500 smh) = Remainder of usable brush life
(4500 smh).

6. The smh estimate of brush life can be used if the Bevel gears and pinions are available in sets that are
machine is to work at the same rate (duty cycle), machined for each other and must never be installed
the battery is not discharged too much or the separately. The same identification mark of letters
battery cells have not become damaged. If the and numbers is put on both the pinion and bevel
machine is made to work harder, the battery is gear. Make sure they have the same identification
discharged too much, or the battery cells become mark before going to the procedures that follow.
damaged, the motor temperature will get hot very The distance from the centerline of bevel gear (1) to
fast. This will cause rapid wear of the brush. the flat end of pinion (2) is 78.0 mm (3.071 in.). The
end of each pinion has a mark of either a plus (+)
7. It is important to check brush length and brush number, a minus (-) number, or zero (0). These
condition at a specific time, such as during the numbers indicate the position where each gear set
preventive maintenance check. If an inspection runs best. The dimension is controlled by shim pack
shows that brush life will not extend to the next (3) behind inner bearing cup (4).
preventive maintenance check, install new
brushes. If a pinion has a mark of (+.10), it needs 0.10 mm
(0.004 in.) less shims than a pinion with a mark of (0).
This increases the distance from the centerline of the
bevel gear to the end of the pinion to 78.1 mm (3.075
Power Transfer Group in.). This increase of 0.10 mm (0.004 in.) is the
Adjustments meaning of a (+.10) mark on the pinion. If the pinion
has a mark of (-.10), it needs 0.10 mm (0.004 in.)
more shims than a pinion with a (0) mark. This
Power Transfer Group reduces the dimension from the centerline of the
bevel gear to the end of the pinion to 77.9 mm (3.067
in.).
ID MARKS
2 4 3

(1) Bevel gear. (2) Pinion gear. (3) Shim pack. (4) Bearing
cup.

Pinion Installation
Pinion Configuration
(2) Shim pack. (3) Bearing cup. (4) Bearing cup.
(5) Bearing cone. (6) Pinion gear. (7) Bearing cone.
(8) Locknut. (9) Ring. (10) Gear. (11) Ring.
NOTE: The adjustment procedures that follow only

cover the shim set configuration. Look for additional
service publications to provide more detailed
information on the change.

PINION SHIM CHART
Old New Pinion Marking
Pinion
Marking +.10 +.08 +.06 +.04 +.02 0 -.02 -.04 -.06 -.08 -.10
+.10 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm +0.14mm +0.16mm +0.18mm +0.20mm
(0.001 in.) (0.002 in.) (0.002 in.) (0.003 in.) (0.004 in.) (0.005 in.) (0.006 in.) (0.006 in.) (0.007 in.) (0.008 in.)
+.08 -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm +0.14mm +0.16mm +0.18mm
+.06 -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm +0.14mm +0.16mm
+.04 -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm +0.14mm
+.02 -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm +0.12mm
0 -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm +0.10mm
-.02 -.0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm +0.08mm
-.04 -0.14mm -0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm +0.06mm
-.06 -0.16mm -0.14mm -0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm +0.04mm
-.08 -0.18mm -0.16mm -0.14mm -0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0 +0.02mm
-.10 -0.20mm -0.18mm -0.16mm -0.14mm -0.12mm -0.10mm -0.08mm -0.06mm -0.04mm -0.02mm 0
1. If the original bevel gear and pinion set is to be 6. Recheck pinion depth. The measured pinion depth
used again, measure old shim pack (2) and make must be within 0.03 mm (0.001 in.) of the required
a new shim pack the same thickness. If a new pinion depth.
bevel gear and pinion set is used, refer to the
Pinion Shim Chart for the amount that the original 7. After the pinion depth is correct, remove
shim pack should be changed. Pinion Depth Gauge and the pinion shaft. Put ring
If three or more shims are used, the smaller shims (9) on the pinion shaft and put gear (10) in position
are to be put in the center of the shim pack. in the housing. [NOTE: Side of gear (10) with
recessed hub must be installed next to ring (9)].
EXAMPLE: If the old pinion has a mark of (+.06) and Put the pinion shaft in the housing and through
the new pinion has a mark of (-.08), add 0.14 mm gear (10). Install ring (11) on pinion shaft (6).
(0.006 in.) shims to the original shim thickness.
8. Set pinion bearing preload. See Pinion Bearing
2. Install bearing cups (3) and (4) with new shim Adjustment.
pack (2) behind bearing cup (3). Install bearing
cone (5) on pinion shaft (6). 9. Recheck pinion depth.
3. Put the pinion shaft assembly into the housing and 10. After pinion bearing preload and pinion depth are
install bearing cone (7) and nut (8). Tighten nut (8) correct, bend a tab on the lockwasher into a slot
to a torque of 15 to 34 N•m (11 to 25 lb•ft) while of nut (8) to lock it in position.
rotating the pinion.
4. Measure the distance from the centerline of the

differential bearing bores to the end of the pinion
and determine the amount of shims needed
behind bearing cup (3). See Pinion Depth Check.
5. Remove bearing cup (3) and add or remove the

required shims. Reinstall bearing cup (3).

Pinion Depth Check Pinion Bearing Adjustment
Tools Needed: Tools Needed:
Pinion Bearing Preload Gauge (A)
Pinion Depth Gauge (A). Dial Indicator Group (B).
Pinion Depth check

(1) Bearing cap (A) Pinion Depth Gauge
1. Put the bar and discs of tool (A) in the bearing

bores of the housing assembly as shown. Install
bearing caps (1) and tighten the bolts.
Pinion Bearing Preload Adjustment
2. Measure the distance from the end of the pinion (1) Shim pack (2) Bearing cone (3) Locknut (4) Pinion gear
shaft to the bottom of the bar with an inside
micrometer. Record this measurement. Preload Shim Chart
Part No. Thickness
3. Measure the outside diameter of the bar with an
outside micrometer. Divide this measurement by 2 Part No. Thickness
and add it to the recorded measurement from Step 924760 0.04 mm (.002 in.)
2. Record this total measurement. This is the
actual mounting distance. 924761 0.08 mm (.003 in.)
924762 0.12 mm (.005 in.)
4. Calculate the required shim thickness to add or
924763 0.25 mm (.010 in.)
remove as follows: the nominal mounting
distance+deviation from nominal (as marked on the 924764 0.8 mm (.03 in.)
end of the pinion, either + or - number, in 924765 1.6 mm (.06 in.)
millimeters) = required mounting distance. The
actual mounting distance (from Step 3) - the
required mounting distance = required shim 1. Install tool (A) [or 4.0 mm (.16 in.) of shims] in
thickness to add or remove (added if difference is +, place of shim pack (1). Install bearing cone (2), the
removed if difference is -). washer, lockwasher, and nut (3). Tighten nut (3) to
a torque of 15 to 34 N•m (11 to 25 lb•ft.). (NOTE:
Example: See Preload Shim Chart for shim numbers.)
78.00 mm (3.071 in.) - nominal mounting distance
- 0.08 mm (0.003 in.) - deviation from nominal 2. Use tooling (B) to measure the end play of pinion
(marked on end of pinion) shaft (4). Record this measurement. Remove nut
(3), the lockwasher, washer, and bearing cone (2).
77.92 mm (3.068 in.) - required mounting distance
78.10 mm (3.075 in.) - actual mounting distance 3. Remove tool (A) (or shims). Measure the thickness
from Step 3 of tool (A) with an outside micrometer (if shims
-77.92 mm (3.068 in.) - required mounting distance were used, measure each shim individually and
add the measurements together). subtract from
0.18 mm (0.007 in.) - thickness of shims to be this thickness the recorded end play from Step 2.
added or removed This is the thickness of shims (1) that are needed
with no bearing preload.

4. In order to get bearing preload, subtract 0.05 mm Power Transfer Group Bearing and
(.002 in.) from the shim pack thickness found in
Step 3. This is the shim pack thickness that needs
Gear Clearance (Backlash)
to be installed. Adjustments
5. Install the correct thickness of shims (1), bearing Tools Needed:

cone (2), the washer, lockwasher, and nut (3). Dial Indicator Group (A)
Tighten nut (3) to a torque of 180 L 25 N•m
(135 L 18 lb•ft).
4 1
3
2
Rolling Torque Check

5 7 8 9
6. Check the rolling torque of the pinion as shown. It
must be 0.85 to 1.70 N•m (7.5 to 15.0 lb•in). If the
torque is not correct, add or remove shims (1) until
it is correct. Removal of shims (1) increases the
rolling torque. Adding shims (1) decreases the
Backlash Adjustment
rolling torque. Record the actual rolling torque after (1) Bearing Cone. (2) Bevel Gear. (3) Bolt. (4) Bearing Cup.
the shims have been added or removed. (5) Bearing Cap. (7) Lockwasher. (8) Locknut.
(9) Pinion Gear.
1. Install bearing cones (1) on the differential case.
2. Put bevel gear (2) on the differential case and

tighten ten bolts (3) to a torque of 70 L 15 N•m
(50 L 11 lb•ft). Put bearing cups (4) on bearing
cones (1).

Correct Tooth Contact Setting
7. Check the tooth contact pattern as follows. Check

the tooth contact setting between the bevel gear
and pinion after the gear clearance (backlash) and
bearing preload adjustments have been made as
follows.
a. Put a small amount of Prussian blue, red lead or
Install Carrier Assembly
(5) Bearing cap (6) Bolts paint on the bevel gear teeth. Turn the pinion in
both directions and check the marks made on the
bevel gear teeth.
3. Put the carrier assembly in position in the housing
assembly. Install bearing caps (5) and four bolts
(6).
Tighten bolts (6) to a torque of 220 L 25 N•m
(160 L 18 lb•ft).
4. Install lockwashers (7) and locknuts (8). Use

tooling (A) to check gear clearance (backlash)
between bevel gear (2) and pinion (9). Adjust
locknuts (8) until the clearance is 0.15 to 0.20 mm
(0.006 to 0.008 in.).
Adjust the clearance by turning one locknut (8) in
and the other locknut out an equal amount.
Short Toe Contact Setting
5. Check the rolling torque again as shown in Pinion
Bearing Adjustment, Step 6. Tighten locknuts (8)
equally to preload the differential case bearings. b. With no load, correct tooth contact setting will be
Proper bearing preload will increase the rolling as shown. The area of contact starts near the toe
torque at the pinion (recorded in Pinion Bearing of the gear and goes 30 to 50% up the length of
Adjustment, Step 6) by 0.63 to 0.88 N•m (5.6 to the tooth.
7.8 lb•in). With this setting, when a load is put on the gear,
the load will be over the correct area of the teeth.
6. Measure backlash again. After backlash and
preload are correct, bend a tab on each
lockwasher (7) into a slot in locknuts (8) to hold
them in position.

Final Drive
Wheel Bearing Adjustment
Short Heel Contact Setting
c. If bevel pinion shaft is too far away from bevel

gear, short toe contact will be the result as shown.
The teeth of pinion will be in contact with toe ends
of convex faces (part that makes a curve toward
the outside), and top edge of heel end of concave
faces (part that makes a curve toward the inside).
To correct this, add shims under pinion bearing
cup. After this is done, check gear clearance
(backlash) and tooth contact again.
d. If bevel pinion shaft is too near to center of bevel

gear, short heel contact will be the result as
shown. The teeth of pinion will be in contact with
the toe ends of concave faces (part that makes a Wheel Bearing Adjustment
curve toward the inside) and the heel ends of (1) Hub. (2) Washer. (3) Nut.
convex faces (part that makes a curve toward the
outside). To correct this, remove shims from under
1. Tighten nut (3) slowly to 135 N•m (100 lb•ft) while
pinion bearing cup. After this is done, check gear
hub (1) is turned to put the bearings in position.
clearance (backlash)and tooth contact again.
NOTE: Several adjustments of both pinion and bevel

gear can be needed before correct tooth contact and
gear clearance (backlash) is made. Always
remember that a change to gear clearance
(backlash) will also change the tooth contact.
Therefore, be sure gear clearance (backlash) is in
correct adjustment before tooth contact is checked.
3
e. After gear clearance (backlash) and tooth contact
are correct, remove extra Prussian blue, red lead 2
or paint from bevel gear and pinion.
Wheel Bearings
(2) Washer. (3) Nut.
2. Loosen nut (3) completely and tighten it again to

50 L 5 N•m (37 L 4 lb•ft).
3. Bend washer (2) to hold the nut in position.

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 Standard torque
inches lb•ft N•m*
Use these torques for bolts and nuts with 1/4 9L3 12 L 4
standard threads (conversions are 5/16 18 L 5 25 L 7
approximate). 3/8 32 L 5 45 L 7
7/16 50 L 10 70 L 15
1/2 75 L 10 100 L 15
9/16 110 L 15 150 L 20
5/8 150 L 20 200 L 25
3/4 265 L 35 360 L 50
7/8 420 L 60 570 L 80
standard thread 1 640 L 80 875 L 100
1-1/8 800 L 100 1100 L 150
1-1/4 1000 L 120 1350 L 175
1-3/8 1200 L 150 1600 L 200
Standard thread 1-1/2 1500 L 200 2000 L 275
5/16 13 L 2 20 L 3
Use these torque for bolts and nuts
3/8 24 L 2 35 L 3
on hydraulic valve bodies.
7/16 39 L 2 50 L 3
1/2 60 L 3 80 L 4
5/8 118 L 4 160 L 6
Use these torques for studs with 1/4 5L2 7L3

taperlock threads. 5/16 10 L 3 15 L 5
3/8 20 L 3 30 L 5
7/16 30 L 5 40 L 10
1/2 40 L 5 55 L 10
9/16 60 L 10 80 L 15
5/8 75 L 10 100 L 15
3/4 110 L 15 150 L 20
7/8 170 L 20 230 L 30
taperlock Stud
1 260 L 30 350 L 40
1-1/8 320 L 30 400 L 40
1-1/4 400 L 40 550 L 50
1-3/8 480 L 40 650 L 50
1-1/2 550 L 50 750 L 70
*1 newton meter (N•m) is approximately the same as 0.1 kg•m.
Power Train 29 Specifications

Metric fasteners
Metric ISO thread
torque
thread size (mm)
(N•m)* (lb•ft)
M6 12 L 4 9L3
M8 25 L 7 18 L 5
[Usually, material strength identification on bolt

M10 55 L 10 40 L 7
head is with numbers (i.e., 8.8, 10.9, etc.)] M12 95 L 15 70 L 10
The chart on the right gives the torque for M14 150 L 20 110 L 15
bolts and nuts with Grade 8.8. M16 220 L 30 160 L 20
NOTICE: Caution must be taken to avoid

M18 325 L 50 240 L 35
mixing metric and standard (customary) M20 450 L 70 330 L 50
fasteners. Mismatched or incorrect fasteners M22 600 L 90 440 L 65
can result in vehicle damage or malfunction, or M24 775 L 100 570 L 75
possible personal injury.
Original fasteners removed from the vehicle
M27 1150 L 150 840 L 110
should be saved for assembly when possible. M30 1610 L 200 1175 L 150
If new ones are required, caution must be M33 2000 L 275 1450 L 200
taken to replace with one that is of same part M36 2700 L 400 200 L 300
no. and grade or better.
ISO – International Standard Organization
Hose clamps - worm drive band type

initial assembly reassembly or
clamp width torque on new hose retightening torque
N•m* lb•in N•m* lb•in

15.9 mm (.625 inch) 7.5 L 0.5 65 L 5 4.5 L 0.5 40 L 5
13.5 mm (.531 inch) 4.5 L 0.5 40 L 5 3.0 L 0.5 25 L 5
7.9 mm (.312 inch) 0.9 L 0.2 8L2 0.7 L 0.2 6L2
Ground engaging and cutting edge bolts and nuts

-Round dome shaped head- Torque requirements for plow bolts
Proof load - 120,00 psi min. thread diam. standard torque
Tensile strength - 150,000 psi min.
Hardness - Rockwell C 33 to 39 inches lb. ft. N•m*
Size - 5/8
5/8 195 L 20 265 L 25
-Seven radial dashes- 3/4 350 L 50 475 L 70
Round dome shaped head
Proof load - 135,000 psi min. 7/8 565 L 85 765 L 115
Tensile strength - 160,000 psi min. 1 900 L 110 1220 L 150
Hardness - Rockwell C 36 to 42
Sizes 3/4 thru 1-1/4 1-1/4 1500 L 185 2000 L 250
*1 newton meter (N•m) is approximately the same as 0.1 kg•m.

Drive Motor
Drive Motors
(1) (2)
New Brush Size Minimum New Commutator Minimum
Model Voltage Thickness B width B length Brush Length* Diameter Commutator Diameter**
B20S-2, B25S-2 12.5 mm B 25.0 mm B 45.8 mm 19.0 mm 117.4 mm

36/48 111.0 mm (4.37 in.)
B30S-2 (.49 in. B 0.98 in. B 1.8 in.) (.75 in.) (4.62 in.)
BC20S-2,
BC25S-2, 36/48 16.0 mm B 28.0 mm B 45.8 mm 19.0 mm 119.0 mm
BC30S-2 (.63 in. B 1.10 in. B 1.80 in.) (.75 in.) (4.69 in.) 111.0 mm (4.37 in.)
B20S, B25S
12.5 mm B 40.0 mm B 45.8 mm 19.0 mm 117.4 mm
B30S, BC20S 72/80 111.0 mm (4.37 in.)
(.49 in. B 1.57 in. B 1.8 in.) (.75 in.) (4.62 in.)
BC25S, BC30S
*As measured manually on standard trucks. As measured by the Brush Wear Indicator (BWI) on Superior (S) option trucks.
**All rough edges (burrs) must be removed after the commutator is machined.
Machine chamfer on the commutator bars ...0.40 mm Maximum difference between bar to
(.016 in.) bar .......................................0.005 mm (.0002 in.) TIR
Torque for the terminal bolts (not shown) that hold Thermal switch (not shown) [Superior (S) Option.
only]:
cable connections ...............................12 N•m (9 lb•ft)
Opening temperature ...........150 L 6°C (302 L 11°F)
Depth of the insulation below commutator
bars ....................................................1.0 mm (.04 in.) Closing temperature ...........130 L 7°C (266 L 13°F)
Width of the insulation below commutator Thermal switch (Not Shown)[Standard only]
bars ................................................0.76 mm (.030 in.) Opening Temperature ............135 L 4° (275 L 10°F)
Maximum difference between commutator high and Closing Temperature ..............118 L 6° (244 L 11°F)
low point (out of round) ...........0.03 mm (.001 in.) TIR

2
3
1
4
2
7 6
(8) Apply Loctite No. 242 to six bolts (10).
(9) Apply 6V1541 Primer and Loctite No. 17430 to

cover (9) and housing assembly (8) prior to
assembly.
(1) Torque for bolts (1) that hold ring gear to
differential case assembly ................70 L 15 N•m
(50 L 11 lb•ft)
(2) Adjust differential bearings with locknut (2) to a

rolling torque of ...........................2.12 to 2.97 N•m
(19 to 27 lb•in)
(3) Amount of free play (backlash) between bevel

gear and pinion (3) ......................0.15 to 0.20 mm
(.006 to .008 in.)
(4) Tighten nut (4) to 180 L 25 N•m (135 L 18 lb.ft.).

Install shims (6) as needed to obtain rolling torque
of 0.85 to 1.70 N•m (7.5 to 15.0 lb•in) at the
pinion without the differential case assembly.
(5) Apply LOCTITE NO.609 Sealant to outside

diameter of cap (5) prior to assembly.
(6) Install shims (7) as needed. See Power Transfer

Group Adjustments in Testing and Adjusting.
(10) Torque for differential bearing cap bolts (11).
............................220 L 25 N•m (160 L 18 lb•ft)
NOTE: The marks on the bearing caps and gear

carrier must be in correct alignment.

Final Drive
(1) Apply Loctite No.242 Thread Lock to thread of

bolt (1) and tighten to a torque of
........................................................115 L 14 N•m
(2) Torque for wheel mounting bolts (2)

..............................270 L 25 N•m (200 L 18 lb•ft)
(3) Torque for bolts (3) holding service brake

....................................55 L 10 N•m (41 L 7 lb•ft)
(4) Heat retainer (4) to a temperature of 371 to

427°C (700 to 801°F) for no more than four hours
and install on axle shaft.

Drive Axle Mounting Group
(1) Install four bolts (1) that fasten drive axle housing Tighten the pneumatic tire wheel nuts (2) to a torque
to the chassis frame. Tighten bolts (1) to a torque of ................................644 L 34 N•m (475 L 25 lb•ft)
of ...........................488 L 27 N•m (360 L 20 lb•ft)
Use “crisscross” procedure to tighten the nuts.
Drive Tire Installation
Pneumatic Tire Mounting

Disassembly & Assembly 4
Brakes, Brake Adjuster And

Wheel Cylinder
Remove Brakes, Brake Adjuster

And Wheel Cylinder
Tools Needed A
Jack Stand 1 3. Remove brake retainer springs (4). Remove the
brake shoes.
1 5
2
1. Put the lift truck in position on tooling (A), and

remove the drive wheels and remove the brake 4. Remove bolts (6) to remove wheel cylinder cover
drum also. (5).
2. Remove brake return springs (1), (2) and (3) with

a suitable brake shoe spring tool. 7
8 10
5. Disconnect brake lines (7). Remove plungers (8)

from the wheel cylinder.
6. Remove bolts (9) to remove wheel cylinder (10).
Power Train 35 Disassembly & Assembly

11 Install Brakes, Brake Adjuster And
Wheel Cylinder
19 18
12
7. Remove bolt (11) to remove brake adjuster (12).

17 20
1. Install spring (17) in the wheel cylinder.

13 14
NOTE: Put clean brake reservoir oil on the seals and
inside of the wheel cylinder before assembly.
2. Install pistons (18) with seals (19) in the wheel

cylinder.
3. Install dust caps (20).

15 16
8. Disassemble the brake adjuster. Remove springs

(15) from the adjuster. Remove bolt (14), wheel 13 14
(16) and shims (13). Do the same for the other
side of the brake adjuster.
19 18
15 16
4. Install shims (13) on wheel (16). Install wheel (16)

in the brake adjuster with bolt (14). Do the same
for the other side of the brake adjuster. Install
springs (15) on the arms of the brake adjuster.
17 20
9. Disassemble the wheel cylinder. Remove dust

caps (20) from each end of the wheel cylinder.
10. Remove pistons (18) with seals (19) and spring

(17) from the wheel cylinder.

11
4
12
5. Install brake adjuster (12) and bolt (11) that holds 9. Install the brake shoes and brake retainer springs
it. Tighten the bolt to a torque of 72 L 5 NIm (55 L (4).
4 lbIft). See Brake Adjuster Installation in Testing
And Adjusting of Vehicle Systems for further
adjustments.
1
2
7
3
8 10
10. Install brake return springs (1), (2) and (3) with a
suitable brake spring tool.
6. Install wheel cylinder (10) and bolts (9). Tighten 11. Install the brake drums and install the drive
the bolts to a torque of 15 L 2 NIm (11 L 1 lbIft). wheels.
7. Install plungers (8). Connect brake lines (7), and

tighten the nuts to a torque of 14 L 2 NIm
(10 L 1 lbIft).
8. Install wheel cylinder cover (5) and bolts (6).

Power Transfer Group Disassemble Power Transfer Group
Tools Needed A B C
Remove And Install Power Transfer
Spanner Wrench 1
Group
Handle 1
Tools Needed A Bearing Puller 1
Link Bracket 1 Spanner Wrench 1
Start By:
Start By:
a. Remove transaxle
a. Remove power transfer group.
b. Remove final drives and hubs
1
1. Mark the bearing caps and locknuts for proper

installation. Bend the tab on the lockwasher back.
1. The weight of power transfer group (1) is 50 kg
Remove locknuts (2) with tooling (A) and the
(110 lb). Install tool (A) on the power transfer
lockwashers. Remove bearing caps (1). The
group, and attach a hoist.
weight of the carrier assembly with the bevel gear
is 50 kg (110 lb). Attach a hoist, and remove the
2. Remove four bolts (2) and the power transfer
carrier assembly.
group. Remove the O-ring seal if it is necessary.
NOTE: The following steps are for installation of the 3

power transfer group.
3. Put the O-ring seal on the power transfer group if

it was removed. Put clean drive axle oil on the 4
seal.
4. Put the power transfer group in position on the

drive axle housing. Install the four bolts.
End By:
a. Install final drives and hubs.

2. Remove two bearing cups (3). Remove the 10
b. Install transaxle. bolts and bevel gear (4).

6
5
21 15 22 17
12 13
11
7
9
8
3. Use a hammer and punch to remove roll pin (6) 18 19 23 20

from the carrier. Remove pin (8), pinion gears (7)
and the thrust washers. IDCD356S
4. Remove side gears (9) and the thrust washers. If

bearing cones (5) need to be replaced, use tool 6. Remove outer bearing cone (17), shims (23) and
(B) and a press to remove them from the carrier. ring (22) from the pinion shaft. Pull pinion shaft
(12) out of gear (15) and the housing assembly.
Remove ring (21) from the pinion shaft. Remove
the gear from the side of the housing assembly
that cover (10) was removed from.
7. If necessary, remove inner bearing cone (13) from

the pinion shaft with a press.
8. If necessary, remove bearing cups (18) and (20)

10
and shim (19) from the housing assembly.
11
5. Remove cover (10) from the housing assembly.

Remove the cap from over pinion nut (11). Bend
the lockwasher away from nut (11). Remove nut
25 26
(11) with tool (C). Remove the lockwasher and
24
washer.
9. Remove the snap ring (24) from the gear shaft

(26).
10. If necessary, remove the bearings (25) from the

gear shaft (26) with a bearing puller.

Assemble Power Transfer Group
TOOLS NEEDED A C D E F 21 15 22 17
12 13
Spanner Wrench 1
Handle 1 11
Spanner Wrench 1
Pinion Depth Gauge 1
Shim Pack, 4.0 mm (.16”) 1
Dial Indicator Set 1
18 19 23 20
1 2 3 5 IDCD356S
13 21 15 10
1. Install bearing cups (18) and (20) without shims
4 17 11 (19) behind cup (18) in the housing assembly.
Press bearing cone (13) on the pinion shaft.
2. Position pinion shaft (12) into the housing

assembly. Install outer bearing (17) and nut (11)
on the pinion shaft. Tighten the nut to a torque of
15 to 34 NIm (11 to 25 lbIft) while rotating the
pinion.
12 18 19 24
25 23
26 20
IDCD359S
3. Put the bar and discs of tool (D) in the bearing

bores of the housing assembly as shown. Install
bearing caps (1), and tighten the bolts.
4. Measure the distance from the end of the pinion

shaft to the bottom of the bar with an inside
micrometer. Record this measurement.
5. Measure the outside diameter of the bar with an

outside micrometer. Divide this measurement by 2,
and add it to the recorded measurement of Step 4.
Record this total measurement.

6. Calculate the required shim thickness as follows: 9. After the pinion depth is correct, remove tool (D) and
the nominal mounting distance L deviation from pinion shaft (12) again.
nominal (as marked on the end of the pinion in
millimeters, either + or - number) = required
mounting distance. The measured distance (from
Step 5) - the required mounting distance =
required shim thickness. The measured distance
must be within 0.03 mm (.001 in) of the required
mounting distance. If it is, the correct thickness of
shims have been installed. If the required 25 26
mounting distance is greater than the measured 24
distance, remove some shims (19). If the required
mounting distance is less than the measured
distance, add some shims (19).
EXAMPLE 1:
78.00 mm (3.071 in) - nominal mounting distance
- 0.09 mm (.004 in) - deviation from nominal
(marked on end of pinion)
77.91 mm (3.067 in) - required mounting distance
78.10 mm (3.074 in) - actual mounting distance

from Step 5
- 77.91 mm (3.067 in) - required mounting distance

10. Press bearings (25) on the gear shaft (26).
0.19 mm (.007 in) - thickness of shims
to be installed under cup (18)
11. Install the gear shaft (26) in the housing. Install
EXAMPLE 2: the snap ring (24) on the gear shaft (26).
78.00 mm (3.071 in) - nominal mounting distance
- 0.09 mm (.004 in) - deviation from nominal
(marked on end of pinion) 15 22 17
12 21
77.91 mm (3.067 in) - required mounting distance 13
11
77.91 mm (3.067 in) - actual mounting distance
- 77.91 mm (3.067 in) - required mounting distance
0 mm (0 in) - thickness of shims that need

to be added or removed
from under cup (18)
7. If the original bearings and ring gear and pinion

set are used, install bearing cups (18) and (20) 18 19 23 20
with original amount of shims (19) behind bearing
cup (18) in the housing assembly. Press bearing IDCD356S
cone (13) on the pinion shaft.
8. Do Steps 2-5. To calculate if the installed shims

are the correct thickness, proceed as follows : the 12 13 21 15
nominal mounting distance L deviation from
nominal (as marked on the end of the pinion,
either + or - number) = required mounting
distance. The measured distance must be within
0.03 mm (.001 in.) of the required mounting
distance. If it is, the correct thickness of shims
have been installed. If the required mounting
distance is greater than the measured distance,
remove some shims (19). If the required mounting
distance is less than the measured distance, add
some shims (19).

NOTE: Be sure to measure each shim in shim pack (E)
separately. The shims for setting rolling torque are not
shown in the parts book. The part numbers are:
PART NO. THICKNESS

924760 0.04 mm (.002 in)
924761 0.08 mm (.003 in)
924762 0.12 mm (.005 in)
22
924763 0.25 mm (.010 in)
17 E 924764 0.8 mm (.03 in)
924765 1.6 mm (.06 in)
12. Put ring (21) in position on the pinion shaft. Put gear
(15) in position in the housing assembly with the side 15. Remove tooling (E). Measure the thickness of
that has a recessed hub next to ring (21). Put the tooling (E). Subtract from this thickness the
pinion shaft in the housing assembly and through recorded end play from step (14). This is the
gear (15). thickness of shims (23) that are needed with no
bearing preload (actual gauge thickness
13. Install ring (22). Install tooling (E). Install bearing measured end play = clearance).
(17), the washer, lockwasher and nut (11).
Tighten the nut to a torque of 15 to 34 NIm (11 to 16. In order to get bearing preload, subtract from the
25 lbIft) while rotating the pinion. shim pack found in Step 15, 0.05 mm (.002 in).
This is thickness of shims that need to be
installed.
17. Install the correct thickness of shims (23),

bearing cone (17), the washer, lockwasher and
nut (11). Tighten the nut to a torque of 180 L 25
NIm (135 L 18 lbIft) with tool (C) and lock within
this range.
14. Install tooling (F) as shown, and measure the

end play of pinion shaft (12). Record the
measurement. Remove nut (11), the lockwasher,
washer and bearing cone (17).
IDCD361S

3
18. Check the rolling torque of the pinion as shown. 21. Put bevel gear (4) on the carrier and the ten
It must be 0.85 to 1.70 NIm (7.5 to 15.0 lbIin). If bolts. Tighten the bolts to a torque of 70 L 15
the rolling torque is not correct, add or remove NIm (50 L 11 lbIft). Put bearing cups (3) on the
shims (23) until it is correct. Removal of shims bearing cones.
(23) increases rolling torque. Adding shims (23)
decreases the rolling torque. Record the actual
rolling torque after the shims have been added or
removed. Do not put the cap over the pinion nut 1
yet.
2
5
6
9 22. Put the carrier assembly in position in the

8 housing assembly. Install bearing caps (1) and
the four bolts. Tighten the bolts to a torque of 220
L 25 NIm (160 L 18 lbIft).
19. If bearing cones (5) were removed, heat them to 23. Install the lockwasher and locknuts (2). Install
135°C (275°F), and install them on the carrier. tooling (F) as shown, and adjust locknuts (2) with
Put the thrust washers and axle gears (9) in tooling (A) until there is a backlash of 0.13 to
position in the carrier. 0.20 mm (.005 to .008 in). To adjust backlash,
turn one locknut in and the other one out the
20. Install the thrust washers, side gears (7) and pin same amount of turns.
(8). Install roll pin (6) through the carrier and pin
(8). 24. Check the rolling torque again as shown in step
18. Tighten locknuts (2) with tooling (A) equally to
preload the bearings. Proper bearing preload will
increase the recorded preload in Step 18 by 0.63
to 0.88 NIm (5.6 L 7.8 lbIin).
25. Measure backlash again. Bend a tab from each

lockwasher into a slot of locknuts (2) to hold
them in position.

Final Drives And Hubs
Remove Final Drives And Hubs
Tools Needed A
10 Spanner Wrench 1
Start By:
11
a. Remove brakes.
26. After all the adjustments have been completed,

put Bearing Mount Compound on the outside 2
3
diameter of cap (11) and install it.
27. Put Gasket Maker on cover (10) and the housing 1

assembly. Also, use Quick Cure Primer if the
temperature is below 10 °C (50 °F).
End By: 4
a. Install power transfer group.
1. Bend back one of the tabs in locking washer (1).
2. Remove nut (3) with tool (A). Remove locking

washer (1) and bearing (2).
3. Remove cover and hub assembly (4).
4. Remove bearing cone (5) from the spindle.

Install Final Drives And Hubs
8 6
Tools Needed A B
Spanner Wrench 1
Driver set 1
7
10
5. Remove bolts (6), and remove spindle (7).
6. Remove shaft assembly (8).
1. Install bearing (10) with a press. Heat the retainer

to 317 to 427°C (700 to 801°F) and install it
against bearing (10) with a press.
9
7. Remove lip seal (9) from the housing.

9
10
2. Install lip seal (9) in the housing with tool group

(B) and a suitable press. Install the seal with the
lip toward the inside.
8. Remove the retainer and bearing (10) from the

shaft.

2
3
8 6
3. Install shaft assembly (8) in the housing. 7. Put hub and cover assembly (4) in position on the
housing, and install the bolts that hold it. Tighten
4. Put Loctite No.242 Thread Sealant on th threads the bolts to a torque of 55 L 10 NIm (41 L 7 lbIft).
of the bolts that hold the spindle.
8. Install bearing (2) locking washer (1) and nut (3)
5. Put spindle (7) in position, and install bolts (6) that on the spindle.
hold it. Tighten the bolts to a torque of 115 L 14
NIm (85 L 10 lbIft). 9. With tool (A), tighten nut (3) slowly to 135 NIm
(100 lbIft) while the hub is turned to put the
bearings in position.
10. Loosen nut (3) completely, and tighten it again to

a torque of 50 L 5 NIm (37 L 4 lbIft).
11. Bend one of the tabs in washer (1) to hold the nut
in position.
End By:
5
a. Install brakes.
6. Install bearing (5) on the spindle.

Oil Cooled Disc Type Brake 5
6
Remove & Install Brakes

(Oil Cooled Disc Type)
Tools Needed A
Jack Stand 4
NOTE : The procedure to remove and install oil

cooled disc type brakes is the same for both sides of
the machine.
4. Remove bolts (5) and cover (6).
IDCD382S
5. remove the plates and discs (7) from cover-brake

1. Put the lift truck in position on tooling (A).
(8).
2. Remove the bolts (1) and wheel (2).
3 10
6. Remove piston (9) from cover-brake (8).

3. Remove bolts (3) and adapter (4).
7. Remove bolts (10) and cover-brake (8).
NOTE : Check the condition of all O-ring seals and

components. If any seals or components are worn or
damaged use new parts for replacement.

NOTE : Use the following steps to install the oil cooled
6 5
disc type brakes. If new discs (7) are installed, soak
the discs in transmission drive train oil for one hour 8
prior to installation. Refer to the Operation and
Maintenance Manual for further information.
6
3
11. Put Loctite No.17430 on the mating surfaces of

cover-brake (8) and cover-end (6). Install bolts (5)
and cover-end (6).
12. Install adapter (4) and bolts (3).
13. Install bolts (1) and wheel (2).
14. Bleed the brake system. Refer to the Testing and

Adjusting Manual for further information.
9 7
8
15. Remove tooling (A).
8. Put Loctite No. 17430 on the mating surfaces of

cover-brake (8) and the transaxle housing. Install
cover-brake (8) and bolts (10).
9. Install piston (9).
10. Install the plates and discs (7) into cover-brake

(8).

SB4082E00
Dec. 2002
Specifications
Systems Operation
Testing & Adjusting
MicroController Control System
Models : B20S-3, B25S-3, B30S-3
for Electric Lift Trucks

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, skill 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 operater or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING” as shown
below.
WARNING
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
pulication and on the product are therefore not all inclusive. If a tool, procedure, workmethod or operating technique
not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others.
ou 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.
MicroController Control System 1 Specifications

Index
Specifications
Component Measurements........................................ 5 Operational Circuit Elements....................................17

Console...................................................................... 7 Battery Discharge Indicator (BDI) ........................21
Contactor ................................................................... 8 Central Vehicle Monitoring System.......................17
Control Panel (Layout) ............................................... 9 Chat (Wait) Mode .................................................20
Current Measurements .............................................. 5 Contactor..............................................................20
Direction Switch ......................................................... 7 CVMS International Pictorial Symbols..................19
Display Layout............................................................ 7 “On Board” “Run Time”
Fuses ......................................................................... 8 Diagnostics(Fault Detection) ................................17
H2/HP Technical Specifications ................................. 5 Shunts ..................................................................20
Instrument Panel ........................................................ 7
MOSFET Connections ............................................... 6 Symbol Library .........................................................14
MOSFET Measurements ........................................... 6
Thermal Senders-Control Panel ................................ 8 Thermal Protection Circuits......................................40
Control Panel .......................................................40
Drive Motor...........................................................40
System Operation Hydraulic Pump Motor..........................................40
Accessory Circuits ................................................... 22

DC-DC Converter Circuit ..................................... 22 Testing And Adjusting
Horn Circuit.......................................................... 22
Hour Meter Circuit................................................ 22 Alarm Displayed on
the Console & Instrument Panel...............................46
Actuation Circuit....................................................... 25
Analysis of ALARMS Displayed on the Console ......47
Description of Connectors........................................ 23
Component Tests ...................................................100
Drive Circuit ............................................................. 31 Conductor and Switch Continuity .......................100
Bypass Circuit...................................................... 36 Contactor ...........................................................101
Control Circuit ...................................................... 31
Current Limit ........................................................ 35 Control and Power System Operation Checks .........45
Electrical Braking (Regenerative and Plugging) .. 37
Flyback Cicrcuit.................................................... 34 Digital Console .......................................................105
Power Circuit........................................................ 32 ADJUSTMENTS : Adjust Battery .......................112
ADJUSTMENTS : SET BATTERY TYPE ...........111
General Information ................................................. 16 Description of ALARMS Functions.....................116
Description of PARAMETER CHANGE Menu.....119
Glossary................................................................... 10 Description of PROGRAM VACC Function ........113
Description of RESTORE PARAM. Function......118
Hydraulic Pump Circuit ............................................ 26 Description of SAVE PARAM. Function..............117
Flyback Cicrcuit.................................................... 29 Description of SET OPTIONS Functions ...........109
Lift Circuit............................................................. 27 Description of Standard Console Menu .............107
Lift Control Circuit ................................................ 30 Description of TESTER Functions .....................114
Power Circuit........................................................ 28 How to use the PARAMETER CHANGE Menu...... 122
Power Steering Circuit ......................................... 26 How to use the TESTER Functions....................115
PARAMETER Settings .......................................121
Location of Control Panel Components ................... 15 Using Digital Console.........................................106
MicroController Control System 3 Index

Electrical System Adjustments............................... 102
Accelerator Control Linkage .............................. 102
Lift Sensor.......................................................... 103
Parking Brake Switch......................................... 102
Tilt and Auxiliary Switches Adjustment .............. 104
Valve Control Card Adjustment.......................... 103
LED Diagnosis for Drive controller ........................... 47
Preparation Tests and Checks ................................. 41
System Tests and Adjustments ................................ 96

Discharge Head Capacitors ................................. 96
Logics Removal.................................................... 97
“Run Time” Tests .................................................. 99
Test Equipment .................................................... 96
Quick Diagnostic Mode ............................................ 44
Troubleshooting........................................................ 41
Troubleshooting Problem List.............................52~95
MicroController Control System 4 Index

Specifications
Component Measurements
Meter Meter Positive Meter Negative

Component Scale (+) Test Lead (-) Test Lead Desired Indication
CONTACTOR COILS (resistance Indication)
Line, Bypass 200 X Y 90 to 110 ohms
Directional, Regen 200 X Y 60 to 80 ohms
H2 / HP Technical Specifications
Motor Types : ...................................................................................................DC Series Traction + DC Series Pump

Power ratings : Traction .....................................................................................................................................13.5kW
Pump ........................................................................................................................................11.0kW
Supply Voltage : .................................................................................................................................................... 48V
Traction Motor Switching frequency : .................................................................................................................18kHz
Pump Motor Switching frequency : ....................................................................................................................18kHz
Temperature range : ............................................................................................................................-30˚C to + 40˚C
Maximum Controller temperature : .......................................................................................................................85˚C
Current Measurements
48V SYSTEM CURRENT VALUES (AMPS)

Maximum Traction Motor Current Maximum Pump Motor Current
650 ± 5 % 600 ± 5 %

MOSFET Connections
2
2
1
1 2 3
1. Gate 2. Drain 3. Source
MOSFET Measurements
SPECIFICATIONS
Multimeter Setting (+) Test Lead (-) Test Lead Results
Resistance Gate Source Over 20 Mohms
Resistance Gate Drain Over 20 Mohms
Resistance Drain Source Over 20 Mohms
Resistance Drain Gate Over 20 Mohms
Resistance Source Gate Over 20 Mohms
Resistance Source Drain Over 20 Mohms
Diode Drain Source 0.4 ~ 0.7V

Display Layout Console
Instrument Panel (1) Tighten bolts that fasten the cover to a torque of
............................... 1.5 to 2.5 N•m (13 to 22 lb•in)
Direction Switch
1 2
(1) Tighten screws that fasten the instrument panel to

a torque of
................................... 0.5 to 0.7 N•m (4 to 6 lb•in) (1) Torque bolts that hold bracket to steering
column to................ 2.8 to 3.4 N•m (25 to 31 lb•in)
(2) Torque bolts that hold bracket to switch to

............................... 3.4 to 3.9 N•m (31 to 35 lb•in)

Thermal Senders - Control Panel
Thermal protection at..............................80°C (176°F)
Contactor
Torque for nuts that hold contactor bridge

assembly.........................................2.2 N•m (20 lb•in)
Fuses
Traction ................................................................675A
Pump....................................................................400A
Key .........................................................................10A
Horn .......................................................................10A
DC / DC Converter.................................................10A
Light .......................................................................10A
Option light.............................................................10A

Control Panel (Layout)
(1) Use a backup wrench to hold bolts and tighten (4) Tighten screw that fasten the contactors to
nuts the fasten bus bars and cables to a torque of backplate to a torque of
..................................... 4 to 6 N•m (36 to 54 lb•in) ..................................... 2 to 4 N•m (18 to 36 lb•in)
(2) Tighten screw that fasten the controllers to heatskin (5) Apply sealant (Loctite cataloge No. & name No. 242,
to a torque of Adhesive/Sealane) on the bolts used to tighten the
..................................... 2 to 4 N•m (18 to 36 lb•in) heatskin to the control panel to a torque of
................................10 to 14 N•m (90 to 125 lb•in)
(3) Use a backup wrench to hold bolts and tighten
the nuts that fasten the cables or bus bars to a (6) Control panel plate. Apply a small amount of
contactors to a torque of D557047 Thermal Joint Compound on control
..................................... 4 to 6 N•m (36 to 54 lb•in) panel plate and mating surface prior to assembly.

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.
Activate Word used with a component or circuit. To change from the normal condition
to the “activated” condition because of an application of force or electricity.
Ammeter An electric meter used to measure current flow in amperes.
Ampere (or Amp) The unit of measurement of current flow. The amount of current that one
volt can push through a resistance of one ohm.
Analog to Digital Converter A device that converts an analog voltage into a pattern of digital HIGH and
LOW voltage signals.
Anode The positive (+) side of a diode.
Armature The rotating portion of an electric motor or generator.
Battery Two or more cells connected together for a supply of electric current.
BDI Battery Discharge Indicator - An electrically controlled display showing the
operator the state of battery charge.
Brush A conductor, normally a block of carbon, that makes sliding contact
between the stationary and moving part of the motor or generator.
Bus Bar A heavy electrical conductor to which other smaller wires are connected.
Capacitor Device used to store electrical energy for short periods of time.
Cathode The negative (-) side of a diode.
CVMS Central Vehicle Monitoring System.
Circuit A way for current to go from the positive (+) side of an electrical power
source to the negative (-) side of an electrical power source. This can be
through wires and electrical components.
Coil A component made from many circles or turns of wire used to concentrate
a magnetic field.
Commutator An armature component used to transfer current from the brushes to the
armature windings.
Conduct To allow the flow of current.
Conductor A material that provides a path for current flow.
Connector Part of a wire assembly or harness that connects with another wire
assembly or harness. Used for ease of assembly and disassembly.
Contactor Assembly An electrical component consisting of an electromagnetic coil and a set of
heavy contact tips. Control current passes through the coil, building a
magnetic field which closes or opens the contact tips.
Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly.
Contact Tips or Contacts The portion of a switch, relay or contactor where the circuit can be opened
or closed.
MicroController Control System 10 System Operation

NAME DESCRIPTION
Continuity Having the ability to allow current flow.

Control Circuits The wires and components carrying low current used to signal the logic
unit, turn on main components, or support auxiliary circuits (indicated by
narrow lines on a schmatic).
Counter Electromotive An opposing voltage set up by a collapsing or increasing magnetic field Force
(CEMF) within a coil.
Current The movement or flow of electricity through a conductor. A circuit must be
complete for current to flow.
Current Limit The maximum allowable armature current of a stalled drive motor during
pulsing.
Deactivate To change from the activated condition back to the normal (deactivated)
condition. It can be caused by the application of force, the removal of
force,or the removal of electricity.
Digital Signal A signal in which the elements may be either of two distinct values.
For example high voltage, low voltage.
Diode A semiconductor device that allows current to flow in one direction, from
the anode to the cathode.
Display An electrical device that converts voltage inputs to a visual output.
Drain The terminal of a MOSFET through which flow the main current.
Electrical Braking Electrically trying to rotate the drive motor opposite to the direction of
truck movement.
Electromagnet A coil of wire, most often wound on an iron core, which produces a strong
magnetic field when current is sent through the coil.
Electromotive Force (EMF) The force that causes an electric current to flow in a circuit. This force is
measured in volts.
Field Windings The stationary coils that produce a magnetic field in motors and generators.
Filter An electrical device or component for restriction or suppression of
undesired voltage spikes.
Fuse A component in an electrical circuit that will open the circuit if too much
current goes through it.
Gate The terminal of a MOSFET through which control the main current.
Harness An assembly made of two or more wires that are held together.
Heat Sink A mounting frame used for semiconductor cooling.
Hour Meter An electrically activated device used to record the amount of usage a
truck receives.
Indicator LCD that gives an indication of some vehicle condition when it turns on or
flashes.
Input A voltage change at the incoming connection of a component.
Insulator A material that has a very large resistance so that it will not let current flow
through it.
LCD Liquid Crystal Display.

NAME DESCRIPTION
Logics or Logic Unit The main printed circuit board containing a microprocessor and circuits to
condition the voltage signals that go into or come out of the logics.
It electronically monitors and controls the truck's functions.
Magnetic Field The area around a magnet where magnetic forces can be detected.
Microprocessor A small computer chip preprogrammed to control the various electrical
functions on a lift truck.
Normal Condition Words used with a switch or relay. Their normal condition is their
condition when they are not controlled by the application of force,
temperature, pressure, or electricity.
Normally Close (N.C.) A switch or relay whose contacts are closed in the normal condition.
Normally Open (N.O.) A switch or relay whose contacts are opened in the normal condition.
MOSFET A semiconductor component used in electric lift trucks as an electronic

switch. A MOSFET most often has three terminals, a GATE(G), a
DRAIN(D), a SOURCE(S). A MOSFET is a voltage-controlled device and
required only a small input current. The switching speed is very high.
OFF-Time The amount of time current does not flow through a transistor.
Ohm The unit of measurement of resistance. The amount of resistance that will
let one volt push only one ampere of current through it.
ON-Time The amount of time current flows through a transistor.
Open Circuit Wiring or components of a circuit that have no continuity.
Output The current flow from a component which initiated from a voltage change
at the component's input.
Overload The presence of voltage or current which is greater than an electrical
circuit or component is designed to handle.
Pin The male contact of a connector that fits into a female contact (socket) of
another connector.
Plugging A portion of electrical braking where the generated current is directed
back through the armature.
Plugging Current Limit The maximum allowable current at the drive motor armature during the
plugging portion of electrical braking.
Power Circuits The main current carrying components and conductors (indicated by the
heavy lines on a schematic).
Pulsing Current flow in a circuit being turned on and off.
Relay An electrical component consisting of an electromagnetic coil and a set of
small contact tips. Control current passes through the coil, building a
magnetic field which closes or opens the contact tips. When the contact
tips are closed, low current can flow in a separate isolated circuit.
Resistor A component made of a material that has a specific resistance to the flow
of current.
Schematic A line drawing of an electrical or electronic assembly which uses symbols
to show individual components. It shows how the components, wires and
connectors function electrically.

NAME DESCRIPTION
Semiconductor Components such as, transistors, diodes, thyristors, etc. Having electrical
characteristics between a conductor and an insulator.
Series Wound Motor A motor in which the armature is connected in series with the field windings.
Short Circuit An electrical connection between two or more components that is not
desired.
Socket The female contact of a connector that slips over a male contact (pin) of
another connector.
Solid State Reference to semiconductor components or circuits that use semiconductor
components that have no moving parts, such as diodes and transistors.
Source The terminal of a MOSFET through which flow the main current.
Switch A component used to control an electric circuit . It can close or open a circuit.
Systems The electrical components, circuits, and connections that deliver power to
perform specific tasks.
Terminal An electrical connection point on an electrical component.
Thermal Switch A switch that activates at a set temperature.
Turn ON When an electrical component conducts current.
Varistor A component terminated across the horn connections to eliminate
voltage spikes when the horn is activated.
Volt The unit of measurement of electromotive force. One volt is the force
needed to make one ampere of current flow through one ohm of
resistance in a circuit.
Watt The unit of measurement of power. The amount of power used when one
volt pushes one ampere of current through a resistance of one ohm. The
result of amperes (current) multiplied by volts (voltage) is watts (power).
Wire A conductor used to provide a path for current to flow to and from
electrical components.
Wiring Diagram A drawing using visual representation of components the way they
actually look. It is used to show the locations of components and the
connections between them.
Zener Diode A special diode used to regulate voltage or as an overvoltage (too high a
voltage) protector.

Symbol Library
2 3 5
4
8
6 7
10
19
ARM.
13
11 12
16
P10-10 14
15
18
17
Schematic Symbols
(1) MOSFET (2) Shunt (3) Thermal Sender (4) Thermal Switch (5) Battery
(6) Resistor (7) Diode (8) Normally Closed Contacts (9) Normally Open Contacts (10) Armature
(11) Male Terminal of Connector(Pin) (12) Female Terminal of Connector(Socket) (13) Wire Connection
(14) No Wire Connection (15) Contactor Coil (16) Field Windings (17) Capacitor (18) Fuse (19)Switch

Location of Control Panel Components
< DRIVE >
2 1
8 6 5 4 3
MicroController Control Panel

(1) Controller-drive (2) Logic card(Logics) (3) Line Contactor (4) Directional Contactor (5) Regen. Contactor
(6) Bypass Contactor (7) Drive Fuse (8) Key Fuse
< PUMP >
2 1
MicroController Control Panel

(1) Controller-pump (2) Logic card(Logics) (3) Pump Fuse

General Information The speed of the hydraulic pump motor is controlled
by voltage and switch inputs to and outputs from the
logics. Outputs pulses the hydraulic pump MOSFET
The MicroControl Panel is the control center and the
The MOSFET pulse to control the speed of the
Logic Unit (logics) is the decision making part of the
hydraulic pump motor. To provide full speed the
MicroController System. The logics provide a self
logics turns the MOSFET ON 100%. The hydraulic
contained Battery Discharge Indicator (BDI) with lift
pump system includes a failure protection circuit to
interrupt and built-in diagnostic capabilities. The
protect against malfunctions of the power circuit.
battery charge state and Quick diagnostic are
monitored by the logics and displayed by the
Thermal protection circuits are used on the
Central Vehicle Monitoring System (CVMS) located
hydraulic pump motor, the drive motor and the
on the steer console.
control panel to prevent permanent damage caused
by over heating.
NOTICE
Damage to all motors and control panels will
result. The motors and control panels are 48 volt
unit and must be operated at their designed
voltage. The voltage can not be changed
without changing motors and control panel.
The steering system is activated when the truck is

powered up and the line contactor closes. The truck
uses a combined power steering/hydraulic system
where the hydraulic fluid for steering is provided by a
DC series hydraulic motor, pump, and priority valve.
The traction motor and the hydraulic pump motor are

controlled by pulsing MOSFETS ON and OFF and
controlling contactor operation.
The speed and direction of the drive motor are

controlled by voltage inputs to and outputs from the
logics. Inputs to the logics are generated by the
accelerator control and direction switch. Outputs
from the logics control contactor coil and drive
MOSFET pulsing.
The drive circuit pulses MOSFET to provide travel

speed control up to 95% of full speed, after which the
bypass contactor close to provide full speed.
The drive circuit includes a failure protection circuit
which detects malfunctions of the drive power circuit,
a plugging circuit to provide electrical braking and a
current limit circuit to prevent excessively high
currents during MOSFET pulsing.

Operational Circuit Elements On Board “Run Time” Diagnostics
(Fault Detection)
Central Vehicle Monitoring System
“Run Time” diagnostics use letters and numbers on
The Central Vehicle Monitoring System (CVMS) is the seven segment LCD portion of the CVMS,
located on the steering console. International Pictorial Symbols and LCD to signal
It is a self contained, solidstate instrument panel both improper operating sequences and truck
with two seven segment liquid crystal displays, circuit defects.
warning and system condition segments.
The LCD consists of seven segments which are Display = “blank”
turned on or off to form numbers and letters.
If just the seven segment LCD and Symbols go blank,
then the main line fuse has blow out or regen
contactor is not operated. See Troubleshooting
section for additional problems.
Display = “EE” Static Return to Off (SRO)
The logics has a Static Return to Off (SRO) circuit

which assures that the direction switch has been
returned to neutral and the accelerator returned to
the full up position after the key and seat switch are
closed. This safeguards against an accidental
actuation of direction and speed when an operator
resumes operation of an idle truck.
Seven Segment Display Layout If SRO occurs, the direction lever can be moved to
neutral and the accelerator pedal released.
The Central Vehicle Monitoring System interacts The direction can now be reselected and the
with the logics and failure detection circuits. accelerator pedal depressed to start normal lift truck
It functions as a battery discharge indicator (BDI) drive operation.
and provides on-board diagnostic data on the
operational condition of the truck. Display = “EE” (Flashing) Seat Circuit Problem
During normal operation it provides “Run Time”
diagnostics, and during troubleshooting it provides Anytime the battery is connected, the key is turned
“Quick” diagnostics. to ON and no one is in the seat longer than 4 seconds
the letter “EE” will flash on and off. The truck will not
operate until the seat switch is closed.
Display = “E1” Drive & Pump Motor Brush Problem
The logics monitor the length of the brush in the

drive pump motor. As the brush wear, a brush spring
moves down and makes contact with the brush
holder. A wire from a brush holder is connected to
the logics. If brush wear down to a preset limit, an
“E1” will appear on the LCD.
Display = “EC” Drive Controller Over Temperature
The drive logic monitors the temperature of the drive

controller. If the controller overheat(85°C), the logic
will reduce drive speed, the truck acceleration will
decrease, and “EC” will appear on the LCD with
symbol.

Display = “Ec” Pump Controller Over Temperature Display = “F0” Overcurrent in Drive System
The pump logic monitors the temperature of the pump The logics monitors the drive motor current via the
controller. If the controller overheat(85°C), the logic shunt and compares the amount of current measured
will slow lifting speeds and “Ec” will appear on the LCD to the current levels set on logic. If current exceeds
with symbol. these levels for longer than a preset time. the logics
will shutdown, and an “F0” will appear on the display.
Display = “Ed” Drive Motor Over Temperature
Display = “F1” Accelerator Problem
The drive logic monitors the temperature of the drive
motor. If the drive motor overheat(150°C), the logic The logics monitors the output voltage from the
will reduce drive speed & acceleration and “Ed” will accelerator. If these signals do not appear the “F1”
appear on the LCD with symbol. will appear on the display and the truck will shutdown.
Display = “Ep” Pump Motor Over Temperature Display = “F2” Drive Armature Circuit Failure
The pump logic monitors the temperature of the pump The logic monitors the voltage at S2 terminal(VMS) of
motor. If the pump motor overheat(150°C), the logic Drive system and Drive Armature current through
will reduce lifting speed and “Ep” will appear on the Shunt in controller. If the voltage is abnormal or the
LCD with symbol. current is too high, the logic will deactivate the Regen
contactor and an “F2” will appear on display.
Display = “A” Head Capacitor Display = “F3” Pump System Failure
The head capacitor ensures that a steady voltage is The logic monitors the voltage at P2 terminal of
maintained to the positive heatsink and that large Pump system and Pump current through Shunt in
voltage spikes are filtered out. The logics monitors controller. If the voltage is abnormal or the current is
this. If the logics detects that the head capacitor has too high, the logic will deactivate the Regen contactor
failed, an “A” will be displayed and truck and an “F3” will appear on display.
performance will be reduced.
Display = “F4” Drive & Pump System Failure
Display = “EL” Battery Lock-out
If the failures occur on both “F2” and “F3”, the
When the battery is discharged, the CVMS displays logic will deactivate the Regen contactor and an “F4”
“EL” and pump motor will not operate. If key switch will appear on display.
turn off and then on, pump will operate for only 5
seconds. Drive motor speed will not exceed 70% of Display = “F5” Drive Armature Circuit Failure
the max. regardless of an accelerator’s output voltage.
The logic monitors the Drive Armature current
Display = “F” Logic Board Failure through Shunt in controller. If the current is zero, the
logic will deactivate the Regen contactor and an “F5”
The logics can detect some internal crcuit failures. will appear on display.
When a failure is detected an “F” will appear on the
display. Display = “F6” Pump System Failure
Display = “F0-F7”, “FA”, “Fb”, “Fc”, “FF”, “FL” The logic monitors the Pump current through Shunt in
Failure Protection Circuits controller. If the current is zero, the logic will deactivate
the Regen contactor and an “F6” will appear on display.
The Failure Protection Circuit guards against a
condition which could cause the operator to lose Display = “F7” Drive & Pump System Failure
control of the lift truck. If one of the failure protection
circuits is activated, the display will appear the letter “F” If the failures occur on both “F5” and “F6”, the
and a number. The logics will prevent normal logic will deactivate the Regen contactor and an “F7”
operation of the lift truck. will appear on display.

Display = “FA” Regen Contactor Failure(Closed) Central Vehicle Monitoring System
(CVMS) International Pictorial
If the Regen contactor is not opened in running, “FA” Symbols
will appear on the LCD, and all contactors will not be
operated. Park Brake Symbol
Display = “Fb” Battery Mismatch
If the battery voltage is lower than 40 volts or higer

than 60 volts, the logic will deactivate the Regen
contactor and an “Fb” will appear on display.
Display = “Fc” Line Contactor Failure
If the coil of Directional contactor or the coil driver in

Park Brake Symbol
logic is failed, the logic will deactivate the Regen
contactor and an “Fc” will appear on display. If the park brake is applied, the park brake symbol
will turn on to warn the operator that the brake is
applied, and drive operation will be prevented.
Overtemperature Symbol
Normally closed thermal switches are in drive and

pump motors constantly monitored by the logics and
the CVMS. All these thermal switches are normally
closed, so must open for the LCD to turn on.
Truck performance will automatically be cut back by
the logics, and the CVMS will light the LCD until the
component cools.
Control Panel Overtemperature Symbol
Control Panel Overtemperature Symbol
Two thermal senders (Drive and Pump Module) are

connected to the logics. If any of the control panels
overheat(85°C), the logics will slow lifting speeds and
reduce drive speed. Truck acceleration will decrease.
The overtemperature symbol and “EC” or “Ec” will
appear on until the controller cools.

Drive Motor Overtemperature Symbol Chat(Wait) Mode
If the seat switch is closed, key turned to ON and

the direction lever is left in neutral with no other
operator requests, the line contactor will deactivate
after approximately six seconds. The LCD will
display “PP”.
The lift truck will remain in this condition until the
operator activates the direction switch, accelerator
pedal or a control valve lever. The line contactor
then reactivates and the truck is ready for normal
operatation.
Drive Motor Overtemperature Symbol
Contactor
The drive motor thermal switch, held against the
drive motor field, will open if the motor gets too Contactors should be fitted with a coil corresponding
hot(150˚C). to the battery voltage. The current absorbed by the
The logics will reduce drive pulsing. The truck speed coil must not be greater than 3Amps..
and acceleration will be reduced.
The overtemperature symbol and “Ed” will appear Shunts
on until the motor cools.
The logic monitors the currents which are flowed
through the each Shunts in controller.
Three Shunts are on Drive Armature & Field and
Pump Motor Overtemperature Symbol
Pump circuits in controller.
Pump Motor Overtemperature Symbol
The pump motor thermal switch, similar to the drive

motor thermal switch, will open if the motor gets too
hot(150˚C). The logics will reduce pump motor speeds.
The overtemperature symbol and “EP” will appear on
until the pump motor cools.

Battery Discharge Indicator(BDI)
The logics monitors the battery voltage during truck BAR SYMBOLS BATTERY TERMINAL
operation and shows the level of battery charge on DISPLAY VOLTAGE
the LCD. If the battery voltage is below 40.0V or 6 ABOVE 49.1V
above 60.0V, this is a battery mismatch or 5 48.4V ~ 49.1V
misconnection. If these voltages are monitored, the
4 47.7V ~ 48.3V
display will show “Fb” on the LCD and no lift truck
operate. 3 47.1V ~ 47.6V
2 46.4V ~ 47.0V
Full 6 bars on the LCD indicates a fully charged 1 45.9V ~ 46.3V
battery. As the battery discharges, the bars “1” 45.0V ~ 45.8V
decreases to 5, 4 etc, down to 1st bottom bar. EL BELOW 45.0V
“ ” : FLASHING
When the battery nears the 80% discharge level, the
1st bar continuously flashes. This is a warning that
lift interrupt is near. The operator should complete
the current lift operation and travel to the battery
replacement or charge area. If the truck is kept in
operation, the display go to a “EL”. The lift, tilt and
auxiliary functions will be vastly reduced in speed,
operating only with steering flows and the vehicle
travel speed will be cut in harf. At this point the
battery is greater than 80% discharged. The logics
will now remember that the battery has been
discharged to lift interrupt and require a fully
charged battery to reset the remembered interrupt.
See Parameter Setting NO. 26.
Descriptions of BDI symbol on the LCD
Bar Symbols
MicroController Control System 21 Systems Operation

Accessory Circuits
Horn Circuit
The horn will operate when the battery is connected The 12 volt output of the converter is protected
and the horn button is pushed. Current flows from against short circuits and overloading by an
battery positive through horn fuse, horn switch and internal 15 amp current limit circuit. A fuse on the
horn, back to battery negative. converter protects it from reverse connection of the
battery voltage.
Hour Meter Circuit Refer to Problem 28 in Troubleshooting section.
Battery voltage is always supplied from Drive

controller DD-2 to the positive terminal of hourmeter NOTICE
through seat switch. The negative terminal of Do not connect the 12 volt negative output of the
hourmeter go to battery negative. DC-DC converter to battery negative. Damage to
system components could occur.
DC-DC Converter Circuit
DC-DC Converter Circuit System
The DC-DC converter changes the lift truck battery

voltage to 12 volts. This 12 volts is used to power
accessories such as floodlights, brakes/side lights
and backup alarms.
The positive of the 12 volt output is common to the

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

Description of Connectors
DRIVE CONTROLLER
PIN FUNCTION DESCRIPTION NORMAL VOLT
DA-1 -LED ALARM LED NEGATIVE 0
DA-2 +LED ALARM LED POSITIVE 12V
DB-1 PCLRXD SERIAL RECEPTION POSITIVE HIGH/LOW
DB-2 NCLRXD SERIAL RECEPTION NEGATIVE HIGH/LOW
DB-3 PCLTXD SERIAL TRANSMISSION POSITIVE HIGH/LOW
DB-4 NCLTXD SERIAL TRANSMISSION NEGATIVE HIGH/LOW
DB-5 GND CONSOLE SUPPLY NEGATIVE 0
DB-6 +12V CONSOLE SUPPLY POSITIVE 12V
DB-7 SPEED REDUCTION INPUT FOR SPEED REDUCTION (ACTIVE HIGH) 0
DB-8 - - -
DC-1 CPOT CENTER OF ACCELERATOR POTENTIOMETER 0
DC-2 NPOT NEGATIVE SUPPLY TO ACCELERATOR 0
DC-3 PPOT POSITIVE SUPPLY TO ACCELERATOR 12V
DD-1 KEY INPUT FROM KEY SWITCH B (+)
DD-2 CM(+) COMMON RUNNING MICROSWITCHES B (+)
DE-1 HAND BRAKE INPUT FOR HAND BRAKE MICROSWITCH B (+)
DE-2 D/TEMPERATURE DRIVE MOTOR TEMPERATURE INPUT(NORMAL CLOSED) B (+)
DE-3 FWD FORWARD MICROSWITCH INPUT 0
DE-4 SEAT SEAT SWITCH INPUT B (+)
DE-5 PEDAL BRAKE PEDAL BRAKE MICROSWITCH INPUT 0
DE-6 REV REVERSE MICROSWITCH INPUT 0
DE-7 ENABLE INPUT FOR ACCELERATOR PEDAL MICROSWITCH 0
DE-8 - - -
DE-9 - - -
DG-1 COMMON POSITIVE FOR CONTACTOR COIL 0
DG-2 BACKWARD NEGATIVE FOR BACKWARD CONTACTOR COIL 0
DG-3 BYPASS NEGATIVE FOR BYPASS CONTACTOR COIL 0
DG-4 REGEN. BRAKE POSITIVE FOR REGEN. BRAKE CONTACTOR COIL 0
DG-5 FORWARD NEGATIVE FOR FORWARD CONTACTOR COIL 0
DG-6 REGEN. BRAKE NEGATIVE FOR REGEN. BRAKE CONTACTOR COIL 0
NOTE : “NORMAL VOLT” ; Battery connected, key switch and seat switch and parking brake switch are closed.

PUMP CONTROLLER
PIN FUNCTION DESCRIPTION NORMAL VOLT

PA-1 LOAD OF DISPLAY OUTPUT FOR INSTRUMENT(LOAD) HIGH/LOW
PA-2 - - -
PB-1 PCLRXD SERIAL RECEPTION POSITIVE HIGH/LOW
PB-2 NCLRXD SERIAL RECEPTION NEGATIVE HIGH/LOW
PB-3 PCLTXD SERIAL TRANSMISSION POSITIVE HIGH/LOW
PB-4 NCLTXD SERIAL TRANSMISSION NEGATIVE HIGH/LOW
PB-5 GND CONSOLE SUPPLY OR INSTRUMENT NEGATIVE 0
PB-6 +12V CONSOLE SUPPLY OR INSTRUMENT POSITIVE 12V
PB-7 - - -
PB-8 - - -
PC-1 CPOT-LIFT CENTER OF LIFT POTENTIOMETER 0
PC-2 NPOT NEGATIVE OF POTENTIOMETER 0
PC-3 PPOT POSITIVE OF POTENTIOMETER 12V
PD-1 KEY INPUT FROM KEY SWITCH B (+)
PD-2 CM(+) COMMON RUNNING MICROSWITCHES B (+)
PE-1 P/TEMPERATURE PUMP MOTOR TEMPERATURE INPUT(NORMAL CLOSED) B (+)
PE-2 3RD-AUX2 AUX2 SPEED INPUT(ACTIVE IF CLOSED ON +BATT.) 0
PE-3 2ND-AUX1 AUX1 SPEED INPUT(ACTIVE IF CLOSED ON +BATT.) 0
PE-4 FWD/BWD DIRECTION SIGNAL FOR IDLING 0
PE-5 1ST - TILT TILT SPEED INPUT(ACTIVE IF CLOSED ON +BATT.) 0
PE-6 BWI DRIVE AND PUMP MOTOR BWI 0
PE-7 - - -
PE-8 - - -
PE-9 - - -
PG-1 - - -
PG-2 - - -
PG-3 DATA OF DISPLAY OUTPUT FOR INSTRUMENT(DATA) HIGH/LOW
PG-4 - - -
PG-5 CLOCK OF DISPLAY OUTPUT FOR INSTRUMENT(CLOCK) HIGH/LOW
PG-6 - - -
NOTE : “NORMAL VOLT” ; Battery connected, key switch and seat switch and parking brake switch are closed.

Actuation Circuit
Actuation Circuit
NOTE : The circuit diagrams have shaded lines for closed, current flows from battery positive through
illustration of current flow in each circuit. the key fuse, key switch, wire #5 to the logic connector
Other circuits can be activated at the same DD-1, and through the line contactor coil to battery
time, but each one is shown separately to negative, then the line contactor will be closed.
illustrate current flow in each individual The logic is connected to battery negative. The logic
circuit. circuits are powered up to accept voltage inputs and
create voltage outputs whenever the battery is
This circuit supplies power to the MicroController connected and the key is turned to ON.
Control System and the Central Vehicle Monitoring
System(CVMS). It must be activated before power The Central Vehicle Monitoring System(CVMS) is
steering, hydraulics or drive will operate. also powered at this time. The CVMS first does
When the battery is connected and the key switch is a “LCD test” which will light all the warning lights

through 5 shield wires(RD, WH, GN, YL, BK). Hydraulic Pump Circuit
The logics will start to perform a set of “Run Time”
Only one hydraulic pump motor (series winding) is
diagnostic checks. The letter “EE” will flash on the
used for all power steering, lift, tilt and auxiliary
CVMS display indicating the key is ON with no
hydraulic functions. To activate the pump circuit, the
operator in the seat.
seat switch, key switch and line contactor must be
closed first as explained in the topic, Actuation
When the seat switch is closed, current will flow Circuit.
from the logic DD-2 through the seat switch to logic
DE-5.
And the seat switch is also connected to hourmeter

Power Steering Circuit
positive to run the hourmeter.
The power steering (PS) circuit has speeds
When the key switch is closed, the battery is used to
(PS idle and PS boost-up) independent of the lifting
power the fan to prevent from overheating controllers.
speeds.
With the power supplied the logics continues its

Followings are standard TP pulsing rates of the
checks for any “Run Time” faults. If no faults are
signal at the logics.
detected the display will indicate the battery charge
level, the power steering(IDLE) system operates, the
pump and drive power circuits receive battery Motor TP Pulsing Connection
Speed Rate NO.
voltage and the logics receives battery voltage from
BATT + terminal. IDLE &
POWER STEERING
4.8% + compensation -
TILT 16% + compensation PE - 5

LIFT PC - 1
AUX1 60% + compensation PE - 3
AUX2 60% + compensation PE - 2
The above pulsing rate can be adjustable in

“Parameter Setting Menu.”
NOTE: The circuit diagrams have shaded lines for

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

Control Circuit
Lift Circuit
If the steering wheel is turned, hydraulic pressure When the lift lever is pulled, the logics will pulse the
increases and then current increase too. pump MOSFET TP.
When this change is present the logics knows that
more hydraulic flow is required and will supply more If the lift lever is pulled, the logic increase the pulse
higher pulse ratio to TP. The pump motor speed will with a higher percentage “on-time” according to the
increase. analog voltage from valve control card.

Power Circuit
TP Gate Input Signal
After the line contactor is closed the logic generates a

positive pulsing signal to the gate of TP MOSFET.
This is a rapidly changing signal that can only be
viewed on an oscilloscope. Because TP is N type
MOSFET, the positive signal into the gate causes
current flow through the drain/source junction. When
current flows through the gate/source junction the
MOSFET turns ON and main current will flow through
the drain/source junction. When the gate signal is
OFF, TP will be OFF.

Flyback Circuit
Flyback Circuit
DP is a flyback diode for the power steering and

hydraulic motor circuit. This circuit uses the current
created by the collapsing magnetic field of the field
wingdings in the pump motor to keep current flowing
when MOSFET TP is OFF. When TP is OFF all
current from the field goes through armature(ARM),
M-, DP, SHUNT and M+ back to the field.
When TP is pulsing the flyback circuit causes the

average pump motor current to be greater than the
average battery current through TP.

Lift Control Circuit
Location of Components
(1) Valve control card.
This control panel accept a analog lift control signals When the operator pulls the lift lever, magnet (3)
and tilt/aux lever signals. The analog voltage is moves closer to the lift sensor (2). The sensor
controlled by valve control card (1) mounted at the top detects the increasing magnetic field and sends an
of the control valve. increasing voltage to the valve control card. The
valve control card produces voltage changes which
The valve control card uses a hall-effect transducer input to the logics at PC-1. The logics uses these
(LIFT SENSOR) and a magnet to sense lift lever changing voltages to determine what speed to
movement. The closer the magnet is to the operate the pump motor. The logics then controls the
transducer the greater the hydraulic pump motor pump transistor TP.
speed.
LIFT SPOOL
Location of Components
(2) Lift Sensor. (3) Magnet.

Drive Circuit
Control Circuit
Drive Control Circuit
NOTE: The circuit diagrams have shaded lines for Selecting a direction will change the voltage from
illustration of current flow in each circuit. 0V to 48V on DE-3 for forward or DE-6 for reverse.
Depressing the accelerator pedal will cause the
With the actuation circuit complete the logics accelerator analog voltage on DC-1.
supplies a HIGH voltage (48 volts) to the direction With the forward direction seleted, current flows from
(F/R) switch at DD-2(wire #4). 12V is also the logics DG-1 through forward direction contactor coil
supplied to the power of accelerator at DC-3. to logic DG-5 back to battery negative. The forward
Releasing the park brake closes the park brake contactor tip closes.
switch and provides voltage to DE-1.

Power Circuit
Drive MOSFET Gate Input Signals
NOTE: The circuit diagrams have shaded lines for switch and line contactor must be closed first.
illustration of current flow in each circuit. The logic generates a positive pulsing voltage to the
Other circuits can be activated at the same gates of TD MOSFET.
time, but each one is shown separately to
illustrate current flow in each individual circuit. If you select the direction switch to forward and push
down the accelerator pedal, regen contactor and for-
The high amperage current, which provides the power ward contactor will be activated. And logic will start to
and torque necessary to drive the lift truck, flows in generate a positive plusing voltage to the gate of TD.
this circuit. The speed of the drive motor is With the MOSFET ON, high amperage motor current
controlled separately from the pump motor circuit by can flow through regen contactor, forward contactor,
the MicroController Control System. armature, reverse contactor, SHUNT, field and TD
To activate the drive circuit, the seat switch, key back to battery negative.

The percent “on-time” of the voltage at gate of TA is
also the percent "on-time" of the MOSFET TA.
As the “on-time” increases, the average voltage
applied to the drive motor increases which
increases the speed of the lift truck. The percent
“on-time” out of the logics is determined by how far
the accelerator is depressed.

Flyback Circuit
Flyback Circuit
When the drive MOSFET TD is ON, battery current Because of this, the average drive motor armature
flows through the armature windings of the drive motor current will be greater than the average battery
and a magnetic field is created around the windings. current. Refer to following Average Current Flow
When the TD is turned OFF battery current through the chart.
windings stops and the magnetic field collapses. This
collapsing magnetic field induces current which is
used to power the drive motor while the TD is OFF
(during pulsing). Induced current flows from the
Armature windings through the direction contactor tip,
the Shunt, Field, DF, the regen contactor tip and the
direction contactor tip back to the Armature windings.

Average Current Flow
Current Limit
The logics monitors the current that flows through through the shunt and will increase or decrease as
each 3 circuits and limit this current flow to a preset current changes. The logics uses this voltage to
value. As this current flows through TD the drive monitor the current in the circult.
motor and the shunt, a voltage is created by the When the current has increased too high, the logics
shunt. decreases the pulse rate to the MOSFETs to prevent
This voltage is proportional to the current flowing current higher than the preset value.

Bypass Circuit
Bypass Circuit Activated
The bypass circuit bypasses TD and connects the drive

motor in series with the battery, applying full battery
voltage to the drive motor. If the accelerator pedal is fully
depressed, and the logics has pulsed TD through 95%
“on-time”, the logic will activated the BYPASS contactor
after 1.5 sec.

Electrical Braking (Regenerative and Plugging)
Electrical Braking Regenerative Circuit
Electrical braking permits the lift truck operator to through the battery. This system has much better
slow, stop and change the direction of travel characteristics than previous “plugging only”
electrically without using the service brake. This systems. The braking energy is used to charge the
action allows for smooth shuttle operation while battery momentarily, reduce heat build-up in the
saving wear on the service brakes. drive motor and extend motor brush life.
Whether the truck is in plugging or regenerative Plugging applies when armature generated current
mode depends on where the current generated by takes a more direct path back to armature without
the drive motor armature is routed. passing through the battery.
Regenerative braking applies when armature Electrical braking begins when the operator selects
generated current is forced to flow backwards a direction opposite the lift truck’s motion, while

keeping the accelerator depressed. The logic will the armature generates it’s own current. The generated
deactivate the regen and bypass contactor (if activated), current flows from the armature through the direction
and change the direction contactor to the new direction contactor tips, shunt, motor field, TD, regen contactor,
selected. The momentum of the truck causes the drive direction contactor tips and back into the armature.
motor to generate current and the logics will pulse the
MOSFET at a slow rate. When the MOSFET TA is turned to OFF, combined
flyback current and generated current will now flow
This battery current energizes the field and tries to from the drive motor armarture, through direction
turn the armature opposite the rotation caused by contactor tips, shunt, DA (or field, DF), drive fuse, line
the trucks motion. contactor tips, battery, regen contactor, direction
contactor tips and back to the drive motor armature.
The current acts to electrically brake the truck. With
the field energized and momentum of the truck This is the charging cycle for the battery. When the
turning the armature opposite the pulsed direction,

combined flyback and generated current decreases,
the logics will turn ON the MOSFET TD and the cycle
starts again.
When the speed of the truck slows, the drive motor

is no longer turning fast enough to generate enough
current to charge the battery. The logics monitors
this condition through the shunt.
When the truck has come to a stop, the armature no

longer is turning opposite the pulsed direction.
The armature stops generating current. The logics will
switch into drive mode, activate the regen contactor
and normal acceleration in the opposite direction
starts.

Thermal Protection Circuits
Control Panel Hydraulic Pump Motor
If the MOSFETs overheat, a thermal senders If the hydraulic pump motor overheats a thermal
mounted in the MOSFET heatsink will give a voltage switch mounted in the pump motor housing will
signal to logic. If the temperature is over than preset open at a predetermined temperature(150°C).
value(85°C), the Central Vehicle Monitoring System When it opens, voltage at logic connection PE-1 will
will display a “Run Time” diagnostic symbol and EC go LOW. The Central Vehicle Monitoring System will
(or Ec). The logics will decrease the pulsing of the drive display a “Run Time” diagnostic symbol and EP. To
system(EC) or restrict the hydraulic circuit decrease the amount of current allowed to flow
pulsing to 50%(Ec). The amount of current allowed to through the pump motor, the logics will reduce the
flow through the MOSFETs is decreased to permit hydraulic pump motor to 50% pulsing. When the
them to cool. When the heatsink cools off the truck hydraulic pump motor cools off and the thermal
will return to normal operation. But due to the reduced switch closes, the truck will return to normal
pulsing, acceleration performance will be decreased. operation. This alarm is stored in memory.
This alarms are stored in memory.
Drive Motor
If the drive motor overheats a thermal switch

mounted in the drive motor will open at a
predetermined temperature(150°C). When it opens,
voltage at logic connection DE-2 will go LOW.
The Central Vehicle Monitoring System will display a
“Run Time” diagnostic symbol and Ed. To decrease
the amount of current allowed to flow through the
drive motor, the logics will reduce the pulsing. When
the drive motor cools off and the thermal switch
closes, the truck will return to normal operation.
Drive system acceleration performance is affected by
an overheated drive motor.
This alarm is stored in memory.

Troubleshooting
NOTICE
Damage can be caused to the control panel. Do not
The following Troubleshooting Check List is an aid in switch the direction lever from one direction to the
troubleshooting MicroController lift trucks. The other (plug the lift truck) when the drive wheels are
troubleshooting check list, “Run Time” diagnostic off the ground and in rotation at full speed.
indications, “Self” diagnostic tests, problem list and
problem flow charts will assist in:
1. Defining the problem and verifying a problem

Troubleshooting Check List
exists.
2. Performing the checks in a logical order.

1. Perform Preparation Tests and Checks.
3. Making the necessary repairs.

2. Correct any display problems and “Run Time”
diagnostic faults.
4. Verifying the problem has been resolved.
3. Correct the “Self” diagnostic faults.
WARNING 4. Perform Operational Checks.
5. Correct “Failure Code Problems” in the

The lift truck can move suddenly. Battery Troubleshooting Problem List.
voltage and high amperage are present. Injury
to personnel or damage to the lift truck is 6. Perform Operational Checks to verify repairs.
possible. Safely lift both drive wheels off the
floor. Put blocks of wood under the frame so the
drive wheels are free to turn. During any test or Preparation Tests and Check
operation check, keep away from drive wheels.
Before any contact with the control panel is
made, disconnect the battery and discharge Battery Tests
HEAD CAP. Ring's, watches and other metallic
objects should be removed from hands and A weak battery can cause or contribute to problems
arms when troubleshooting, the MicroController in the MicroController and power circuits.
Control System. Verify the battery is good before investigating other
possibilities.
1. Verify proper polarity at the battery connector and

NOTICE the MicroController panel. Positive cable should
Damage can be caused to the test equipment. be at the line fuse and negative at the negative
Make resistance and continuity checks only on control panel..
after the battery is disconnected.
2. If the lift truck is operational, perform a battery
load test.
NOTICE 3. If the truck is not operational and the battery is

Damage can be caused to the control panel. Do suspected, perform a cell voltage or specific
not use steam or solvent to clean the controls. gravity test.
Use pressure from an air hose with a maximum
pressure of 205 kPa (30 psi) to clean the control
panel when necessary. Make sure the air pressure
supply is equipped with a water filter.
MicroController Control System 41 Testing And Adjusting

Battery Load Test Cell Voltage Test
1. Turn the range switch on the multimeter to read With the truck powered up and the pump(Idle) motor
battery voltage. running, measure the voltage at each cell. Normal
voltage should be between 1.95V and 2.12V per
2. Connect the battery. cell. If the voltage on each cell is below 1.95V the
battery must be charged or repaired before
continuing to troubleshoot.
NOTE : The indication between cells should not differ

more than 0.05 volts. If it does, the battery
must have an equalizing charge or be
repaired.
Hydrometer Test
Test each cell of the battery with a hydrometer. If the

2 1 specific gravity indication is below 1.140, the
battery must be charged. The battery is fully
charged if the indication is 1.265 to 1.285.
Battery Voltage Test.
(1) Positive cable connection.
(2) B- cable connection. NOTE : The indication between cells should not differ
more than .020. If it does, the battery needs
an equalizing charge or needs to be repaired.
3. Connect the multimeter leads between positive (+)
cable connection (1), and negative (-) cable
connection (2). Battery Maintenance
4. In a safe area, operate the hydraulic system, (hold NOTE : It is important that all batteries be charged
tilt lever to maximum position momentarily) while and maintained according to the battery
reading the voltage indicated on the multimeter. manufacturers instructions.
5. If the indication is less than 45.0 volts, the battery The care and maintenance of batteries is most
needs to be charged or repaired before continuing important to maximize battery life and efficient truck
to troubleshoot. operation. Periodic inspection and service will
increase the life of batteries. Special attention should
be given to the rules that follow:
1. Keep batteries clean at all times. Cleaning will

prevent corrosion, current leakage and shorts to
chassis. Tighten all vent plugs, wash the battery
with water and a brush, then dry with an air hose.
It may be necessary to use a baking soda solution
if water alone will not clean the top of the battery.
2. Add enough water to cover the plates before

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

3. Charge the battery correctly. A battery should be 3. Visually check the parking brake switch, the
discharged to 80% of its capacity then fully hydraulic switches and accelerator linkage for
recharged. It should cool four to eight hours to adjustment or interference problems.
allow the voltage to stabilize before being put
back in use. The battery should have an equalizing
charge (an extra three or four hour charge at a low Resistance to Chassis Checks
finish rate) once a month to make sure all cells are
in a fully charged condition. Properly charged Resistance between any point in the truck wiring
batteries should be identified to prevent low and the chassis should be a minimum of 10,000
batteries from being installed in trucks. ohms or more.
4. Operation with a low battery must be prevented. Many malfunctions are caused by shorts to chassis.
Low battery operation may damage the battery Usually, two shorts must exist before a malfunction
and will cause higher than normal current in the will occur. But, since batteries can have chassis
electrical system. High current draw due to a low leakage, only one short to chassis in the truck wiring
battery will damage contactor tips and shorten can cause problems. To prevent problems because of
motor brush life. shorts, do the following:
5. The battery's maximum temperature is critical. 1. Disconnect the battery and discharge the HEAD
The electrolyte temperature should never exceed CAP.
43°C (110˚F) either while operating or charging.
Overcharging a battery will cause over heating 2. Randomly measure any component connection or
and warp the battery plates. Maximum battery life wiring connection in respect to the lift truck chassis
will result from maintaining 25˚C (77˚F) electrolyte for a minimum resistance of 10,000 ohms. Any test
temperature. Most of the charging equipment is point with low resistance must have the short to
fully automatic but should be checked periodically chassis removed.
to assure proper working order.
3. Always keep batteries clean to minimize current
6. Keep accurate battery records. Regular battery leakage to the chassis.
readings should be taken with a battery tester or
voltmeter and a written record kept. Specific 4. Routinely clean the brush dust from the motors.
gravity and voltage of each cell should be
checked and recorded at least once each month. 5. Be sure that all attachments, such as horns and
This inspection should be made after an equalizing lights are designed for no chassis connection (a
charge. Readings should never be taken directly two wire system).
after water has been added. Records of all battery
maintenance should be made and filed so it will be
known which batteries are being abused or Removal of Shorts to Chassis
wearing out.
When a short is found, it must be cleared even if the
Repairs should be made immediately otherwise machine has normal operation. It is necessary to
the battery may become damaged. Batteries narrow the field of possible problem areas before
stored in a discharged condition may be difficult to inspection of individual wires and components.
recharge due to sulfate formation.
When a low resistance circuit is located, it should be
opened at various points. This will permit the
Visual Checks shorted wire or component to be pin-pointed for
repair or replacement.
1. Verify all components and wires are in their proper
place. Check fuses, components, contactor tips,
wires and connections. Verify that they are not
burned, broken or loose.
2. Verify there is no mechanical binding or

interference in the contactor.

Quick Diagnostics Mode
This will enable Quick Diagnostics of some of the

components without console and access to
controller room.
Procedure
1. Initial set
- Seat switch : Open
- Directional switch : Forward
- Handbrake : Released
- Accelerator : Depressed to above half position.
2. Key switch to on
display ‘A3’ and accelerator symbols
3. Directional lever to neutral and release the
accelerator
display ‘A0’ only
4. Some switch to on display as following codes.
and switches to off display ‘A0’
SWITCH DISPLAY
ALL OFF A0
REVERSE A2
FORWARD A3
LIFT 1 TO 10
TILT A6
AUX 1 A7
AUX 2 A8
HAND BRAKE A9
ACCELERATOR SYMBOLS

Control and Power System
Operational Checks
All operational checks are to begin with the Check 5: Reverse Drive Performance
battery connected, directional switch in neutral,
drive wheels off the ground and the accelerator 1. Select reverse direction and depress the
and parking brake released. accelerator slightly. The drive wheels should turn
in reverse slowly.
NOTE: Perform all operational checks before
returning to the Troubleshooting Check List. 2. Slowly increase the amount of accelerator
depression. The drive wheels should turn in
Check 1: Key Switch, Seat Switch and Power reverse and slowly increase in speed.
Steering
3. Depress the accelerator fully. The drive wheels
1. Activate the key and seat switch. The line will turn in reverse at full speed.
contactor activate and the hydraulic pump motor
should turn on at slow speed (idle). Check 6: Electrical Braking (Plugging)
Performance
2. Turning the steering wheel will increase the
hydraulic pump motor speed (boost-up).
NOTICE
3. After five to ten seconds the line contactor Do not perform this check with the lift truck at
deactivates and the motor turns off(PP). full speed. Damage to the Drive Train can result.
Check 2: Lift Performance

1. Select forward direction and depress the
1. Pull the lift lever half way. The hydraulic pump accelerator to the 80% of max. acceleration.
motor activates slowly to a preset speed. While continuing to depress the accelerator,
change the direction switch to reverse.
2. Pull the lift lever to maximum. The hydraulic pump There should be a smooth deceleration of
motor activates full speed. forward tire rotation. After the forward tire rotation
stops, there is a smooth acceleration of reverse
Check 3: Tilt and Auxiliary Performance tire rotation.
1. Slowly pull and push the tilt and auxiliary levers. 2. Continue to depress the accelerator while in
The hydraulic pump motor activates to one of the reverse direction. Change the direction switch to
preset speeds with each lever movement. forward. There should be a smooth deceleration
of reverse tire rotation. After the reverse tire
Check 4: Forward Drive Performance rotation stops, there is a smooth acceleration
forward tire rotation.
1. Engage the parking brake. Select forward direction
and depress the accelerator slightly. The drive
wheels should NOT turn.
2. Release the parking brake, select forward direction

and depress the accelerator slightly. The drive
wheels should turn forward slowly.
3. Slowly increase the amount of accelerator

depression. The drive wheels should turn forward
and slowly increase in speed.
4. Depress the accelerator fully.

The drive wheels will turn forward at full speed.

Alarm Displayed on The Console & Instrument Panel
DISPLAY STATUS CONSOLE ALARM MESSAGE

OK System normal operation -
No Display - Fuse blow-out
After all display BRAKE CONT OPEN
(two times) - Regen. contactor is not operated
Wait(chat) mode
PP (after hyd. Time without any operation in neutral) -
E1 Drive motor brush is worn. -
Drive controller thermal protection when the
EC(With Symbol) THERMAL PROTECTION
temperature rises above 85°
Pump controller thermal protection when the
Ec(With Symbol) TH. PROTECTION
temperature rises above 85°
Ed(With Symbol) Drive motor thermal protection
EP(With Symbol) Pump motor thermal protection
EL Battery Lock-out(Below 45V) BATTERY LOW
The key switch is turned to on or seat switch
are closed after seat switch delay time when
EE the position of direction lever is not neutral or INCORRECT START
accelerator is pressed.
- The key switch is turned to on and no one is
EE(Flashing) in the seat. -
- The seat switch is opened longer than seat
delay time.
A Head capacitor problem CAPACITOR CHARGE
- EEPROM PAR KO
- EEPROM CONF KO
F Internal circuit of logic problem - EEPROM DATA KO
- EEPROM OFF LINE
- CHOP NO CONF
- WATCHDOG
- Drive over current during 5 sec. In chopper mode. HIGH CURRENT
F0
- Drive over current during 1.5 sec. In bypass mode.
F1 Accelerator problem VACC NOT OK
- VMN LOW
F2 Drive mosfet failure(shorted) - I HIGH AT STAND
- STAND BY VMN LOW(HP)
F3 Pump mosfet failure(shorted) - I HIGH AT STAND(HP)
F4 Drive & pump mosfet failure(shorted) -
- VMN HIGH
F5 Drive mosfet failure(opened) - I = 0 EVER
- NO FULL COND.
F6 Pump mosfet failure(opened) - I = 0 EVER(HP)

- NO FULL COND.(HP)
F7 Drive & pump mosfet failure(opened) -
FA Regen. contactor closed - BRAKE CON CLOSED
Battery Mismatch
Fb -
(Batt Volt ≤ 40V Or Batt Volt ≥ 60V)
- DIR CONT OPEN
Fc Contactor problem - DIR CON CLOSED
FL Lift sensor problem VACC NOT OK(HP)
FF Serial communication failure -

LED Diagnosis for Drive controller Analysis of Alarms Displaged on the Console
Description of the alarms signalled by the diagnostic Drive controller

LED. The alarm code is shown in parentheses.
A detailed description is given in the next section 1) BRAKE CON CLOSED
Test carried out in the passage from running to
1 BLINK = Logic anomaly (EEPROM DATA KO,
initial regenerative braking. If, on running contactor
EEPROM PAR. KO, EEPROM CONF. KO,
closure, the VMN is >2/3 VBATT, an alarm is issued.
EEPROM OFF-LINE, CHOPPER NO
Possible causes:
CONF, WATCH-DOG).
a) The normally open contact of the braking contactor
is stuck. Unlock the contact and clean it: if it is too
2 BLINKS = Running request on startup or error in
much damaged replace the contator.
handle/speeds sequence
b) The braking contactor remains excited for a
(INCORRECT START).
defect in the logic board or because the coil wire
is in short towards the negative.
3 BLINKS = Error on VMN test
For understanding if the defect is produced by
(NO FULL CONDUCTION, VMN LOW).
one of these causes, select the running and
press the pedal without giving the seat or tiller
4 BLINKS = Accelerator high in standby - this error
request, if the activation only of the braking
inhibits operation (VACC NOT OK).
contactor is in synchrony with the pedal
(or selector) command verify what follows:
5 BLINKS = Error in reading current- this error
disconnect the wire from the connector and do
inhibits operation
again the test above, if the contactor remains
(I HIGH AT STAND, I=0 EVER).
disactivated replace the logic, otherwise if the
contactor moves check that there is not a wire in
6 BLINKS = Malfunctioning of the contactor driver
short with a metallic part.
circuit
(DRIVER SHORTED, COIL SHORTED).
2) DIR. CONT. OPEN
7 BLINKS = Excessive temperature, greater than Test carried out at running request :
80˚C (TH. PROTECTION). running contator closure is verified by checking
that the VMN signal is consistent. Possible causes:
8 BLINKS = Contactors do not open or VMN high in A1) There is not a good contact either on NO
standby (BRAKE CONT. OPEN, (=nomally open) of FWD CTR or NC (=nomally
DIR CONT. OPEN, VMN HIGH). closed) of REV CTR, due to dust, dirt or any
particles which prevent a valid contact.
9 BLINKS = Contact stuck (BRAKE CON CLOSED) Clean contacts by means of compressed air :
only for regenerative;(DIR. CON CLOSED) if necessary remove dirt applying a soft
only standard traction. abrasive movement.
It could be necessary changing both contactors.
CONTINUOUS BLINKING (32BLINKS) A2) There is not a good contact either on NO of
= Low battery charge, battery with <10% of residual REV CTR or on NC of FWD CTR due to dust,
charge (BATTERY). dirt or any particles which prevent a valid contact.
Clean contacts by means of compressed air;
LED REMAINS ON if necessary remove dirt applying a soft
= Double running request (FORW BACK). abrasive movement.
It could be necessary changing both contactors.
A3) The most probably reason is that the normally
closed contact of the braking contactor dosen’t
make a good contact towards the battery
negative for dust, dirt or because the contact
doesn’t lean completely for a mechanical
defect of the contactor.
It could be necessary to replace the contactor.

It may be due to 1 of following causes of motor A4) There is not a good contact on the NO of
connecting interruption: REGEN CTR, clean the contact, if it is too
a) brushes lift up from collector (fig.1). much damaged replace the contactor.
b) brushes’ cable burn up (fig. 2). B4) Replace the contactor coil or the complete
c) Interruption either on motor winding or on motor contactor.
itself cabling. B5) Contactor mechanically locked, unlock it and
replace it.
B6) Contactor with working nominal voltage bigger
than the feeding one.
C4) Supply doesn’t come up to the contactor coil,
please check the cabling and the connections
of the coil connector.
4) DIR.CON.CLOSED
Test carried out during the passage to standby or
braking.
Checks that the running contactor opens by
comparing the consistent status of the VMN
potential. Possible causes:
B1) FWD CTR is supplied with a correct voltage
a) Running contactor stuck or slow to open.
but it doesn't close.
b) Logic failure.
Possible cause:
1) Contactor coil is interrupted, verify its
5) VMN LOW
resistance using an ohmmeter.
2) Contact can't move due to mechanic block. The test is carried out at standby and in running up
3) Nominal working coil voltage is greater than to 80% of PWN. If the VMN voltage is lower than
battey one. 1/3 of the battery voltage, an alarm is shown.
B2) REV CTR is supplied with a correct voltage but
it doesn't close; everything said at point B1 for B7) If the running contactor remains stuck, you can
FWD CTR is valid here. verify:
B3) Backward and forward contactor are supplied 1) if the wire for direction contactor coil is
with a correct voltage but they don't close; see casually in short with a metallic part
point B1. connected to the battery negative;
C1) Supply don't come up to FWD CTR, please 2) disconnecting the contactor wire always
check cabling and connections of FWD CTR excited from board connector if the contactor
coil connectors. is no longer excited, replace the logic board.
C2) Supply don't come up to REV CTR, please B8) A running contactor is stuck on working
check cabling and connections of REV CTR position, unlock the contact, it could be possible
coil connectors. to replace the contactor.
C3) Supply don't come up to FWD CTR and REV D1) Wrong connections of the motor cables.
CTR, please check cabling and connections of The stator and the armature are crossed.
the all coil connectors.
- For points C1, C2, C3 replacing controller may be
necessary
For H2B standard configuration the solutions at
point A1-A2-A3-B1-B2-B3-C1-C2-C3 are valid; for
the last two points please respect the different
connections rather than the regenerative configuration.
3) BRAKE CONT. OPEN

Test carried out during the passage to running.
D2) There is a current dispersion in the motor
After closure of the running contact, the braking
between the stator winding and the armature
contactor loses, verifying that the VMN goes
one otherwise there some electric parts of these
from < 1/3 to > 2/3. If this does not occur, an alarm
windings that makes a contact inside the motor.
is shown.

C5) The most probably reason is that the failure is 10) INCORRECT START
inside the controller, replace it.
An incorrect starting sequence.
E1) If there's the bypass contactor check that it is
The machine only starts if sequence is followed :
not stuck or it is too much slow in opening.
key-handle(or seat)-running.
For verifying this possibility, disconnect the
Possible causes :
bypass and check if the failure disappears :
a) Running microswitch or handle microswitch
if this happens, replace the logic.
stuck.
PAY ATTENTION : the contactors connected to
b) Error in sequence made by the operator, pedal
the controller must not have arc suppressers on
pressed at the key on.
the contactor coils because these are inside
c) Incorrect wiring if there is not any defect
the controller and then the external ones
externally is necessary to replace the logic.
modify the contactor opening times.
11) FORW - BACK
6) VMN HIGH
The test is carried out continuously. An alarm is
Test carried out in standby. if the VMN voltage is
signalled when two requests for running are made
greater than 2/3 VBATT, an alarm is shown. simultaneously. Possible causes:
Possible causes: a) Defective wiring.
a) Contactor stuck(only standard traction). b) Running microswitch stuck.
b) Short circuit between + BATT and VMN, please c) Incorrect manoeuvre.
check if there are any metallic parts causing short d) If there is not external defects, replace the logic.
circuit in the contactor board.
c) Logic failure, probably the braking diode are
12) VACC NOT OK
broken, replace the power.
The test is made in standby.
7) NO FULL COND. The alarm indicates that the accelerator voltage is
greater than 1V with respect to the minimum
The test is carried out in full conduction. If, in this value stored. Possible causes:
condition, the VMN is found to be greater than 1/3 a) A potentiometer wire is interrupted or the
VBATT, the diagnostic circuit is faulty, causing a potentiometer negative has not been connected
safety risk, and thus machine operation is inhibited. to the PIN DC-2 of the logic board, In this case
If the defect persists, replace the logic. it is generated an alarm because the logic don't
find the load to pin DC-2.
8) THERMAL PROTECTION b) The potentiometer is not correctly calibrated.
An indication that the controller temperature has c) The potentiometer is defective(interrupted).
exceeded 80˚C. The maximum current is gradually
reduced, reaching 0 at a temperature of 85˚C. 13) I HIGH AT STAND
a) If the alarms occurs while cold, the most
Test carried out in standby. Checks that the
probably reason is the failure of the thermic
current is nil.
diagnosis circuit on the power or on the logic
If this is not verified, an alarm is signalled.
board, replace on of the two parts or replace the
This alarms inhibits machine operation.
complete controller.
Possible cause:
b) If the alarm often occurs after short time the
a) Current sensor broken and logic failure.
machine is working, probably it is due to
First replace the logic, and if the defect persists,
inadequate heat sink, check the fixing nuts
replace the power unit.
tightening and the correct installation.
14) I=0 EVER
9) BATTERY LOW
Test carried out in running.
The battery charge is low. Checks that the current during running is greater
The alarm is signalled only if the “battery check” than a minimum value. If not, an alarm is signalled
option has been selected from the serial console and the machine is shut down. Possible causes:
(default). When this alarm occurs, the maximum a) The current sensor is faulty. Replace the power
current is reduced to 50%. unit.
b) Wrong connections of the motor cables to the
power bars SH- and SH+.

15) EEPROM PAR.KO b) Short circuit with +BATT of the wiring that
comes from the contactor connector.
Fault in the area of memory in which the
The alarm indicates the occurrence of an
adjustment parameters are stored. This alarm
overload, not the breakdown of a chopper
inhibits machine operation. If the defect persists
component. Once the external cause is
when the key is switched off and on again,
removed, the chopper can be restarted.
replace the logic. If the alarm disappears,
remember that the parameters stored previously
have been cancelled and replaced by the default 22) DRIVER SHORTED
values. The test is carried out in standby, and checks that
the voltage of the drivers that control the contactors
16) EEPROM CONF.KO is consistent with the preset value.
Possible cause:
Fault in the area of memory in which the special
a) Logic failure.
chopper configuration data is stored. If the defect
b) Driver breakdown caused by overvoltage in the
persists when the key is switched off and on
contactor negative wiring. Replace the logic
again, replace the logic. Otherwise, keep in mind
after having removed the cause.
that the chopper configuration has been reset to
the default values(regeneration version, etc.); thus
it must be reprogrammed.
Consult the console manual.
Pump controller
17) EEPROM DATA KO
1) STAND BY VMN LOW
The data in the area of memory for the hour-metre
is incorrect. This alarm does not shut down the The test is carried out in standby. If the VMN
machine. If the alarm disappears when the key is voltage is lower than 1/3 of the battery voltage, an
switched off and on again, keep in mind that alarm is signalled. Possible causes:
hour-meter data has been reset to zero. a)Check the motor wiring to make sure it is correct.
b)Chopper broken, replace.
18) EEPROM OFF LINE
2) NO FULL COND.
Fault in the nonvolatile memory that contains data
relative to the area for the hour-metre, the alarm The test is carried out in full conduction.
stored and the programming parameters. If, in this condition, the VMN is found to be greater
If the alarm persists when to key is switched off than 1/3 VBATT, the diagnostic circuit is faulty,
and on again, replace the logic. causing a safety risk, and thus machine operation
is inhibited. If the defect persists, replace the logic.
19) CHOP NO CONF.
3) TH.PROTECTION
An alarm similar to no 16, except that here, even
though the data is correct, it does nit correspond An indication that the chopper temperature has
to a hardware configuration recongnised by the exceeded 80°C. The maximum current is gradually
H2B. The considerations are the same as for alarm reduced, reaching 0 at a temperature of 85°C.
16 “EEPROM CONF.KO”. If the alarm occurs while cold:
a) Check the thermal sensor connection.
20) WATCHDOG b) Thermal sensor failure.
c) Connection on the power interrupted(check the
The test is made in both running and standby. connector that connects the logic to the power
It is a self-diagnosis test within the logic. If an unit).
alarm should occur, replace the logic. d) Logic failure.
21) SHORTED COIL 4) BATTERY

An overload or a shot circuit toward +BATT on The battery charge is low.
the contactor negative driver outputs. The alarm is signalled only if the BATTERY CHECK
Possible causes: option has been selected.
a) The contactor coils are short circuited or All functions except hydrdrive are inhibited.
absorb more than 6A continuous.

5) INCORRECTSTART 11) EEPROM OFF LINE
A running request is present on key startup. Fault in the non-volatile memory that contains
Possible causes: data relative to the area for the hour-meter, the
a) Operator error. alarms stored and the programming parameters.
b) Request microswitch stuck. If the alarm persists when the key is switched off
and on again, replace the logic.
6) I HIGH AT STAND
12) CHOP. NO CONF.
Test carried out in standby, checks that the current
is nil. If this is not verified, an alarm is signalled. An alarm similar to no.9, except that here, enen
This alarm shuts down the machine. though the data is correct, it does not correspond
Possible causes: to a hardware configuration recognised by the H2.
a) Current sensor broken and logic failure. The considerations are the same as for alarm 9
First replace the logic, and if the defect persists, “EEPROM CONF. KO”.
replace the power unit.
13) WATCH-DOG
7) I=0 EVER The test is made in both running and standby.
Test carried out in running. It is a self-diagnosis test within the logic.
Checks that the current during running is greater If an alarm should occur, replace the logic.
than a minimum value. If not, an alarm is signalled
and the machine is shut down. Possible causes:
a) The current sensor is faulty. Replace the power
unit.
8) EEPROM PAR.KO
Fault in the area of memory in which the
adjustment parameters are stored. This alarm
inhibits machine operation.
If the defect persists when the key is switched off
and on again, replace the logic.
If the alarm disappears, remember that the
parameters stored perviously have been cancelled,
and replaced by the default values.
9) EEPROM CONF.KO
Fault in the area of memory in which the special
chopper configuration data is stored. If the defect
persists when the key is switched off and on again,
replace the logic. Otherwise, keep in mind that the
chopper configuration has been reset to the default
values(regeneration voltage, etc.); thus it must be
re-programmed. Consult the console manual.
10) EEPROM DATA KO

The data in the area of memory that handles the
hour-meter is incorrect. This alarm does not shut
down the machine. If the alarm disappears when
the machine is switched off and on again, keep in
mine that the hour-meter data has been reset to
zero.

Troubleshooting Problem List
TROUBLESHOOTING PROBLEM LIST

Problem # CENTRAL VEHICLE MONITORING SYSTEM (CVMS) PROBLEMS
1 CVMS does not work, with no lift truck operation.
2 CVMS does not work at all, lift truck operation normal.
Display portion of CVMS seems random or wrong.
3
Lift truck operation normal.
Display all symbols two times after key switch and seat switch closed then blank,
4
no lift truck drive or pump motor operation.
“SELF” DIAGNOSTIC PROBLEMS
5 Display = “F”, no lift truck operation
6 Display = “A3” and “ accelerator symbols”, no lift truck operation.
7 Seat switch circuit defect.
8 Direction switch circuit defect.
9 Lift switches circuit defect.
10 Tilt switch circuit defect.
11 Auxiliary switch circuit defect.
12 Park brake switch circuit defect.
13 Pedal brake switch circuit defect.
14 Accelerator circuit defect.
15 Incorrect contactor operation.
“RUN TIME” DIAGNOSTIC PROBLEMS
16 Display = “EE”, no lift truck drive operation.
17 Display = “EE” (Flashing), no lift truck drive operation.
18 Display = “E1” lift truck operation normal.
Overtemperature is ON and display = and EC or Ec. Lift truck accelerates slower than normal
19
or lifting speed is slower than normal.
Overtemperature is ON and display = and Ed.
20
Pump and steering operation normal. Acceleration slow.
Overtemperature is ON and display = and EP. Lifting speed slow.
21
Drive and power steering operation normal.
22 Display = “EL”. No hydraulic (lift and tilt). Steering normal.
23 Hourmeter does not work.
24 Normal hydraulic operations, display is normal and drive current limit is half.
Drive motor does not operate or operates with low power or is erratic.
25
Pump and power steering systems operation normal.
26 Horn does not function correctly. Lift and drive operation normal.
Auxiliary lighting and/or alarm does not function correctly.
27
Lift and drive operation normal.
MicroController Control System 52 Troubleshooting

TROUBLESHOOTING PROBLEM LIST
Problem # FAILURE CODE PROBLEMS
28 Display = “F0”, no lift truck operation
29 Display = “F1”, no drive operation, pump and steering operation normal
30 Display = “F2” no lift truck operation
31 Display = “F3”, no lift truck operation
32 Display = “F4”, no lift truck operation.
36 Display = “FA”, no lift truck operation.
37 Display = “Fb”, no lift truck operation.
38 Display = “Fc”, no lift truck operation.
39 Display = “FL”, no pump and steering operation, drive operation normal.
40 Display = “FF”, serial failure.

PROBLEM 1
Central Vehicle Monitoring System (CVMS) does

not work, with no lift truck operation.
POSSIBLE CAUSE
Battery polarity not correct on control panel;

Key fuse open circuit; Key switch defect;
Logics defect.
CHECKS
With battery connected, check control panel battery connections for correct polarity.
Positive battery connected to line fuse and negative battery connected to B - on controller.
If correct If not correct
Push horn buttton to close horn switch. Make correction to cables.
Horn work Horn does not work
Disconnnect battery and check the horn

fuse for continuity.
Continuity No continuity
Check for shorts and

replace fuse.
Close key switch. Measure voltage on DD-1 Measure voltage on horn (wire #90) with
depressing the horn switch.
Battery Less than Check continuity the negative wire of horn
Voltage Battery voltage
Battery Less than
Voltage Battery voltage
Replace logics.
Replace horn or Repair or replace
check the battery. open wire.
Replace key switch or repair broken

wire #5 between key switch and DD-1.

PROBLEM 2
CVMS does not work at all, lift truck operation normal.

If only part of CVMS works.
POSSIBLE CAUSE
Open circuit from PB-6 to CVMS connector PIN 1;

Open circuit from PB-5 to CVMS connector PIN 5;
CVMS defect.
CHECKS
Make sure CVMS connector is connected to CVMS.
If connected If not connected
Connect multimeter positive lead to PB-6 Connect CVMS connector.

and negative lead to PB-5.
Measure the voltage.
12 volts 0 volts
Replace the CVMS module. Repair or replace open circuit between 5 wires
from controller to CVMS.

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

(wire RD / WH / GN / YL / BK).
Check for shorts to battery negative from Repair or replace open wire.
PIN 1 to PIN 5 on CVMS connector.
No shorts found Shorted
Replace logics. Repair or replace shorted wire.

PROBLEM 4
Display all symbols two times when the drection lever is

selected and accelerator is depressed and then blank,
no lift truck drive or pump motor operation.
POSSIBLE CAUSE
Line contactor defect; Drive fuse open circuit;

Regen contactor defect;Logics defect.
CHECKS
Does the line contactor close and remain closed ?
Yes No
Check for open the Drive fuse See Problem 15. Incorrect
contactor operation.
Normal Open
Check the regen contactor activity with Replace the fuse.

direction lever and accelerator
Yes No
Repair or replace Measure voltage between coil terminal X and Y

line contactor tips
or power connections. 48 Volts No Voltage
Replace the regen contactor.
Measure voltage between pin 4 and pin 6 of

connector DG.
48 Volts No Voltage
Repair the controller harness. Replace logic of

drive controller.

PROBLEM 5
Display = “F”, no lift truck operation.
POSSIBLE CAUSE
Wiring defect; Logics defect.
CHECKS
With the key on, check the voltage at logic DD-1, wire #5.
Battery voltage No voltage
Check continuity from control panel battery Repair or replace open wire.
negative to battery negative.
Replace logics. Repair or replace open cable.

PROBLEM 6
Display = “A3” and “ accelerator symbols”,

no lift truck operation.
POSSIBLE CAUSE
The truck goes into Quick Diagnostic.
CHECKS
Release the accelerator pedal and move direction switch to

neutral. Key switch off and on.
Still problem Normal
Check voltage from logic DE-3 to battery

negative.
No voltage Battery voltage
Replace direction switch.
Check voltage from logic DC-1 to battery

negative.
Above 4volts
Replace accelerator.

PROBLEM 7
Seat switch circuit defect.
POSSIBLE CAUSE
Seat switch defect; Wiring to seat defect;

Logics defect.
CHECKS

Disconnect DD or DE connector. Check continuity from DD-2
harness connector to DE-4. Should be closed circuit when
seat is pressed on and open circuit when seat is released.
No continuity Constant continuity Check OK
Disconnect seat switch connector. Push Replace logics.

on the seat and check the continuity
across the seat switch.
Disconnect seat switch connector. Push
on the seat and check the continuity
across the seat switch.
Replace seat switch.
Check wiring for open circuits between

harness connector DD-2 and DE-4.
Repair any open circuit found. Replace seat switch.
Check wiring for short circuits

between harness connector DD-2
and DE-4. Repair any short circuit
found.

PROBLEM 8
Direction switch circuit defect.
POSSIBLE CAUSE
Direction switch defect; Wiring to direction

switch defect; Logics defect..
CHECKS

Disconnect DD or DE connector.
Check continuity from DD-2 to DE-3 harness connector;
With direction lever in forward should have a closed circuit,
in neutral should be open.
Check OK Check failed
Check continuity from DD-2 to DE-6. Disconnect direction switch connector.

With direction lever in reverse should have a Check continuity between Pin2 and Pin3.
closed circuit, in neutral should be open.
Replace logics. Repair or replace direction switch.
Check wiring for open/short circuits

Check wiring for open/short circuits
between harness connector DD-2 and DE-6.
between harness connector DD-2 and DE-3
Repair any open/short circuit found.
Repair any open/short circuit found.
Replace direction switch.

PROBLEM 9
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 quick diagnostics.

Circuit passes Circuit fails
“Quick-Diagnostics” “Quick-Diagnostics”
Perform Problem 11,12 Tilt or Key switch ON.

auxiliary circuit defect. Connect multimeter negative lead to Pin5
and the positive lead to Pin1 and Pin2.
Battery Voltage 0 Volt
Repair or replace broken wire

Measure voltage from Pin7 to Pin5 battery between PD-2 and Pin1(wire #44)
negative as the lever is pulled and released. or key switch and Pin2(wire #5) or
between Pin5 and battery
9.0 to 11.0 and .2v 9.0 to 11.0 and .2V negative(-).
Measured NOT measured
Replace logics. Replace Valve Control Card.
NOTE : Before lift truck is placed into operation, connect tilt and auxliary switches and verify proper adjustment.
Refer to Valve Control Card Adjustments.

PROBLEM 10
Tilt switch circuit defect.
POSSIBLE CAUSE
Tilt switch defect; Wiring defect; Logics defect.
CHECKS
Disconnect PD or PE connector. Pull tilt lever to maximum.

Check continuity from PD-2 to PE-5.
Replace logics. Check continuity of wire #89.
Check continuity from PD-2 of wire #44 to Pin1 of Repair or replace wire.
valve board connector.
Replace tilt switch. Repair or replace wire.

PROBLEM 11
Auxiliary switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Auxiliary switch defect; Logics defect.
CHECKS
Disconnect PD or PE connector. Pull auxiliary lever to

maximum. Check continuity from PD-2 to PE-2 or PE-3.
Replace logics. Check continuity of wire #88 or #87.
Check continuity from PD-2 of wire #44 to Pin1 of Repair or replace wire.
valve board connector.
Replace AUX. switch. Repair or replace wire.

PROBLEM 12
Park brake switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Park brake switch defect; Logics defect.
CHECKS
Disconnect DD or DE connector. Release park brake lever.

Check continuity from DD-2 to DE-1.
Check continuity from DD-2 of wire #4 to Repair or replace wire.

terminal of park brake switch.
Replace park brake switch. Repair or replace wire.

PROBLEM 13
Pedal brake switch circuit defect.
POSSIBLE CAUSE
Wiring defect; Pedal brake switch defect; Logics defect.
CHECKS
Disconnect DD or DE connector. Push down the brake pedal.

Check continuity from DD-2 of wire #4 to Repair or replace wire.

Pin2 of pedal brake switch.
Replace pedal brake switch. Repair or replace wire.

PROBLEM 14
Accelerator circuit defect.
POSSIBLE CAUSE
Wiring defect; Accelerator defect; Logics defect.
CHECKS
With the key switch on, the seat switch closed,

park brake released and connect multimeter
positive lead to DC-3, negative lead to DC-2.
8~12 volts Other voltage
Connect multimeter positive lead to DC-1, Replace logics.

negative lead to DC-2. Measure the voltage;
accelerator pedal released : 0 volt.
Press accelerator pedal to max. : 7 to 11 volts.
Disconnect DD and DE connector. Replace accelerator.

Push down the accelerator pedal.
Check continuity of wire #7.

Repair or replace wire.
Check continuity from Pin6 of accelerator Repair or replace wire.

harness connector to DD-2(wire #4).
Replace accelerator. Repair or replace wire.

PROBLEM 15
Incorrect line contactor operation.
POSSIBLE CAUSE
Wiring defect; Line contactor defect; Logics defect.
Disconnect the battery. Check for free

mechanical movement of contactor tips
Movement OK Movement not free
Connect the battery. Key switch ON. Replace contactor.

Measure voltage between coil terminal
X and Y.
48 Volts Other Voltage
Replace contactor. Repair or replace wire.

PROBLEM 16
Display = “EE”, no lift truck drive operation.
POSSIBLE CAUSE
Static Return to Off (SRO) circuit activated by

improper operation sequence; Direction switch defect;
Accelerator linkage not fully released;
Accelerator control defect; Logics defect.
CHECKS
Check for SRO by release of accelerator, release

park brake, move the direction lever to neutral,
reselect direction and press the accelerator.
No change Lift Truck Operation OK
Run “Quick-Diagnostics” to find Inform operator of correct start–up procedure.

faulty circuit or component. Also, that the direction lever must be left
in neutral when leaving the truck.
If no faulty component is found,

replace logics.

PROBLEM 17
Display = “EE” (Flashing),

no lift truck drive operation.
POSSIBLE CAUSE
No opterator in seat; Seat switch defect;

Open wiring; Logics defect.
CHECKS
See Problem 7, seat switch circuit defect.

PROBLEM 18
Display = “E1” lift truck operation normal.
POSSIBLE CAUSE
Worn brushes; Short wiring; Display defect.
CHECKS
Disconnect the respective wire from the motor.

Wire #31 for drive motor or wire #72 for pump motor.
Connect the battery and close the key switch and
seat switch.
Does the LCD go out ?
No Yes
Disconnect the battery. Check continuity of Check the brushes and replace
the respective wires to the controller. as necessary.
Repair or replace wires.
Check continuity from Batt.+ on controller

to wire#31 and wire#72 or PE-6 (wire #73).
Shorted Opened
Repair wires. Replace logics.

PROBLEM 19
Overtemperature is ON and Display = and EC or Ec.

Lift truck accelerates slower than normal or lifting speed
is slower than normal. Power steering operation normal.
POSSIBLE CAUSE
Control panel overheated; Control thermostat (thermal

senders) defect; Logics defect.
CHECKS
Let the truck cool for 15 minutes.

(EC = Drive controller, Ec = Pump controller)
Overtemperature indicator ON Normal display
Check the cooling fan for Control panel was overheated, resume normal
controller after key on operation. If repeats occur, check
drive and pump motors current draw or
Fail Normal operating cycle for excessive ramp
climbing, towing or excessive lifting.
Replace the fan. Replace drive (EC) or

pump (Ec) controller.

PROBLEM 20
Overtemperature is ON and Display = and Ed.

Pump and power steering operation normal.
Acceleration slow.
POSSIBLE CAUSE
Drive motor overheated; Drive motor thermostat (thermal

switch) defect; Open wiring; Display defect;
Logics defect.
CHECKS
Disconnect the battery. With the drive motor Drive motor was overheated, resume normal
at close to room temperature, disconnect the operation. If repeats occur, check drive motors
drive motor thermal switch connector. current draw or operating cycle for excessive
Check continuity of thermal switch. ramp climbing or towing.
Should have continuity below 123°C (253°F)
Check continuity of wire #43 between drive Repair or replace switch.

motor thermal switch to DE-2.
Check continuity of wire #4 between drive motor Repair or replace wire.

thermal switch to DD-2.
Replace logics. Repair or replace wire.

PROBLEM 21
Overtemperature is ON and Display = and EP.

Lifting performance slow. Drive and power steering
operation normal.
POSSIBLE CAUSE
Pump motor overheated; Pump motor thermostat (thermal

switch) defect; Open wiring; Display defect;
Logics defect.
CHECKS
Disconnect the battery. With the pump motor Pump motor was overheated, resume normal
at close to room temperature, disconnect the operation. If repeats occur, check pump motor
pump motor thermal switch connector. current draw or operating cycle for excessive
Check continuity of thermal switch. lifting and tilting.
Should have continuity below 123°C (253°F).
Check continuity of wire #42 between pump Repair or replace switch.

motor thermal switch to PE-1.
Check continuity of wire #44 between pump Repair or replace wire.

motor thermal switch connector to PD-2.

PROBLEM 22
Display = “EL”. No hydraulic (lift and tilt).

Steering normal.
Battery discharge indicator (BDI) circuit defect.
POSSIBLE CAUSE
Battery discharged or has a defect; Logics defect.
CHECKS
Connect battery, turn on key switch, close seat switch

and measure voltage from BATT+ to BATT- on
controller. Voltage must be greater than 45 volts.
Voltage OK Voltage low
With key ON, seat switch and line contactor Check battery connections;
closed, measure voltage at BATT+ on Charge or replace battery.
controller.
Battery voltage Less than battery
Replace logics. Repair shorted wire or high resistance

connection causing the improper voltage.

PROBLEM 23
Hourmeter does not work.
POSSIBLE CAUSE
Key switch and seat switch ON.

The hourmeter requires battery voltage to run.
Measure voltage at hourmeter to ensure that it is
battery voltage.
No voltage Battery voltage
Check continuity from seat switch to Replace hourmeter.

hourmeter positive (+) terminal.
Check continuity from hourmeter negative (-) to Replace hourmeter.

battery negative.
No continuity
Repair or replace wire.

PROBLEM 24
Normal hydraulic operations, display is normal and

drive current limit is half.
POSSIBLE CAUSE
Pedal brake switch shorted.
Disconnect wire from pedal switch. Replace logics.

Check pedal brake switch.
Shorted
Replace switch.

PROBLEM 25
Drive motor does not operate or operates with

low power or is erratic. Pump and power steering
systems operation normal.
POSSIBLE CAUSE
Accelerator defect; Direction control circuit defect ;

Current limit set too low; Wiring defect ;
Logics defect.
CHECKS
Perform Quick-diagnostics.
Passed Does not pass
Readjust current limit to specifications. See respective problem for

defective circuit.
In specification
Check drive motor and cables (A1, A2).
Check OK Open circuit
Replace logics. Repair open circuit or replace drive motor.

PROBLEM 26
Horn does not function correctly. Lift and drive

operation normal.
POSSIBLE CAUSE
Open fuse; Faulty wiring; Defective horn switch;

Horn defect.
CHECKS
With the faulty horn circuit activated, check for

voltage on the load side of the horn fuse.
Battery voltage No voltage
Check for voltage on the load side of Check for short circuits;
the horn switch. Replace horn fuse.
Battery voltage 0 volt
Check for continuity of wire #1 Repair or replace open wire from fuse
from horn. or replace defective switch.
Replace horn. Repair or replace open wire going to battery

negative.

PROBLEM 27
Auxiliary lighting and/or alarm does not function

correctly. Lift and drive operation normal.
POSSIBLE CAUSE
Open fuse; Faulty wiring; Defective switch; Shorted

load; Open load; Loss of input voltage to DC-DC
converter; Defective DC-DC converter.
CHECKS
Connect the battery and close the key switch.

Measure from the DC-DC converter 12V positive
terminal to the 12V negative terminal.
No voltage Voltage Voltage Voltage

output above 13V below 11V 11 to 13V
Con’d Con’d Con’d With the faulty auxiliary circuit

Next Next Next activated, check for voltage on
Page Page Page load side of the auxiliary fuse.
11 to 13 volts No voltage
Check for voltage on the load Check for short

side of the auxiliary switch. circuits; Replace
auxiliary fuse.
11 to 13 volts 0 volts
Check for voltage at the negative connection Repair or replace open wire from
of the load. fuse or replace detective switch.
0 volts 11 to 13 volts
Repair or replace open wire from Repair or replace open wire going
the auxiliary switch or replace the to battery negative.
defective auxiliary component.

Problem 27 (continued)
No voltage output.
Measure the voltage from (POS INPUT) to (NEG INPUT).
Batteryvoltage 0 volt
Replace the DC-DC converter. Measure the voltage from the B+

cable at the line contactor to the (NEG INPUT)
terminal of the DC-DC converter.
Battery voltage 0 volt
Check for open fuse or wiring between the line Repair open negative
contactor and the (POS INPUT) terminal of the connection from converter
DC-DC converter. (NEG INPUT) to battery
negative.
Open fuse Open wiring
Replace fuse and check wiring for shorts. If no Repair or replace faulty wiring.
shorts are found and the fuse continues to fail,
replace the DC-DC converter.

Problem 27 (continued)
Voltage bellow 11 volts.
Measure the voltage from the (+IN) terminal to (-IN)

terminal of the DC-DC converter.
28.8 volts or above Below 28.7 volts
Remove all connections at the (+OUT) and (-OUT) Check the battery and DC-DC converter
terminals of the DC-DC converter. Measure the input connections from the battery.
voltage from the (+OUT) to (-OUT).
Battery low Poor connection
11 to 13 volts Below 11 volts
Charge or replace battery.
Repair or replace faulty wiring or

Check for a short or low resistance connections.
in the auxiliary circuits and loads.
NOTE : Excessive loading places the

DC-DC converter faulty.
converter into current limit
Replace converter.
(15A maximum).
Voltage above 13 volts.
Remove all connections at the (+OUT) and (-OUT)

terminals of the DC-DC converter. Measure the voltage
from the (+OUT) to (-OUT).
11 to 13 volts Above 13 volts
Check the output load circuits for DC-DC converter faulty.

incorrect wiring or shorts to battery Replace converter.
negative.

PROBLEM 28
Display = “F0”, no lift truck operation.
POSSIBLE CAUSE
Excessive drive motor currents due to pushing or ramp

application. Failed drive motor. Failed logics.
Weak or discharged battery.
CHECKS
Measure the maximum drive current at A2 cable in stall

condition.
Key switch and seat switch ON. Direction switch to
forward and depress the accelerator over than half
position.
The current should be 650A for 5 seconds.
Also the 650A current will be flowed 5 seconds more
and then display F0.
OK Below 500A
Place lift truck into operation. Set the “IMAX.” to level 9 in

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

PROBLEM 29
POSSIBLE CAUSE
Accelerator circuit defect; Logics defect.
CHECKS
Key to ON, close seat switch, release park brake and

accelerator, direction lever to neutral. Display should
show battery charge. Place in forward, and depress
accelerator.
Display = “F&1” Drive operation nomal
Measure the voltage of DE-7 with accelerator operating.
0V 48V 0V
Set again the accelerator Check the continuity of wire #7

signal (min. & max.) continuity No continuity
according to P113.
Replace accelerata Repair wire #7

PROBLEM 30
POSSIBLE CAUSE
Opened the motor cable (A1, A2, S1, S2).

Opened the armature coil or field coil in drive motor.
Contactor failure. Shorted MOSFET TD in Drive Module.
CHECKS
Check conditions under which faults is detected.

Running with
As soon as the accelerator pedal
At the keyon contactors on running
is completely released for doing
positions
Disconnect the motor cable See point G). See point F).
connected to the battery and
then verity if the alarm
still present
Yes No
See point F).
A running contactor is
locked in working position
Yes No
The stuck contactor See point C), D), E).

coil is supplied?
Yes No
See point A). See point B).
Points
A) If the running contactor remains stuck, you can verify :
1) if the wire going from FWD contactor coil to REV contactor coil is casually in short with a metallic part connected to the
battery negative :
2) disconnecting the contactor wire always exited from board connactor if the contactor is no longer exited, replace the logic
board.
B) A running contactor is stuck on working position, unlock the contact, it could be possible to replace the contactor.
C) Wrong connections of the motor cables. The field and the armature are crossed.
D) There is a current dispersion on the motor between the field winding and the armature one otherwise there are some electric
parts of these windings that makes a contact inside the motor.
E) Check that there are not metallic parts inside the contactor board that cause a short towards the negative in the points
connected to SH- and SH+.
F) The most probably reason is that the failure is inside the controller, replace it.
G) If there’s the bypass contactor check that it is not stuck or it is too much slow in opening. For verifying this possibility, disconnect the
bypass and check if the failure disappears : if this happens, replace the logic.

PROBLEM 31
POSSIBLE CAUSE
Pump fuse open.

Shorted MOSFET TP in Pump Module.;
Open the pump motor cable (P1, P2) during the operation.
Open the armature coil or the field coil in pump motor
during operation.
Logics defect.
CHECKS
Check the pump fuse open.
Yes No
Replace the pump fuse. Check the continuity of P1, P2 cables.
Measure the resistance between Repair or replace

P1 and P2 terminals on pump motor. the cables.
0 ohm Opened
Remove the pump controller from frame Replace the armature AS or field AS.
and replace the pump controller.

PROBLEM 32
POSSIBLE CAUSE
Shorted MOSFET TD in Drive Module and

MOSFET TP in Pump Module.
CHECKS
See Problems 30 and 31, Display = “F2” and “F3”.

Do both procedures.

PROBLEM 33
POSSIBLE CAUSE
Opened the MOSFET TD in Drive controller;

Frame voltage on S1 or S2 drive motor cable.
CHECKS
Disconnect the battery, and disconnect the S1, S2 cables from

the drive controller and measure the voltage of S1 terminal.
Frame Voltage 0V
Replace the drive controller.
Check continuity from frame to S1 or S2

terminal of the drive motor.
Replace the motor. Investigate voltage present on

S1 or S2 cable.

PROBLEM 34
POSSIBLE CAUSE
Opened the P1, P2 cables when the key switch turn to on.
Opened the MOSFET TP in Pump Module;
Opened armature or field coil in pump motor when the key
key switch turn to on.
CHECKS
Check the continuity of P1, P2 cables.
Repair or replace the cables.
Measure the resistance between P1 and P2

terminals on pump motor.
0 ohms Opened
Remove the controller from frame. Replace the Armature AS or Field AS.
Replace the Pump controller.

PROBLEM 35
Display = “F7”, no lift truck operation, line

contactor closes and opens.
POSSIBLE CAUSE
Failure in both the drive and pump circuits.
CHECKS
See Problem 33 and 34, Display = “F5” and

Display = “F6”. Do both procedures.

PROBLEM 36
Display = “FA”, no lift truck operation.
POSSIBLE CAUSE
Welded regen contactor tips ;

Shorted wire #15 to negative ;
Logics defect.
CHECKS
Disconnect the battery, check regen contactor for welded

tips. Check contactor for free tip movement.
Not welded Welded
Check for a short of wire #15 to negative. Repair or replace contactor tips.
Shorts founds Not shorts founds
Repair or replace Replace the logics

faulty wire. of drive controller.

PROBLEM 37
Display = “Fb”, no lift truck operation.
POSSIBLE CAUSE
Battery defect; Logics defect.
CHECKS
Disconnect battery, measure voltage at battery

connector terminal. Voltage must be higher
than 40 volts or lower than 60 volts.
Voltage OK Wrong voltage
With key on, seat switch and line contactor Check battery connections;
closed, measure voltage at DP-1. Replace battery.
Battery voltage No battery voltage

PROBLEM 38
Display = “Fc”, no lift truck operation.
POSSIBLE CAUSE
Direction contactor defect;

Drive motor defect;
Power connection defect;
Faulty of contactor coil wire;
Logic defect ;
CHECKS
Check conditions under which fault is detected.
Only at forward Only at reverse at both running

running request running request request
You see forward contator closing You see reverse contator closing You see forward or reverse contator
for 0.3 sec then opening? for 0.3 sec then opening? closing for 0.3 sec then opening?
Yes No Yes No Yes No
See point A). When requesting See point B). When requesting See point C). When requesting
forward running reverse running forward running
you find any you find any you find any
voltage at coil voltage at coil voltage at a coil's
contactor for contactor for contact (or at
0.3 sec? 0.3 sec? reverse contactor
coil’s contacts) for
Yes No Yes No
0.3 sec?
Yes No
See point D). See point G). See point E). See point H).
See point F). See point I).
Points
A) There is not good contact either on normally open of forward contactor or on normally closed of reverse contactor, due to
dust, dirt or any particles which prevent a valid contact. Clean contacts by means of compressed air ; if necessary remove dirt
applying a soft abrasive movement. It could be necessary changing both contactors.
B) There is not a good contact either on normally open of reverse contactor or on normally closed of forward contactor, due to
dust, dirt or any particles which prevent a valid contact. clean contacts by means of compressed air ; if necessary remove dirt
applying a soft abrasive movement. It could be necessary changing both contactors.
C) The most probably reason is that the normally closed contact of the braking contactor doesn't make a good contact towards
the battery negative for dust, dirt or because the contact doesn't lean completely for a mechanical defect of the contactor.
It may be due to 1 of follawing causes of motor connecting interruption :
1) brushes lift up from commutator
2) brushes cable burn up
3) Interruption either on motor winding or on motor itself cabling.
D) Forward contactor is supplied with a correct voltage but it doesn't close.
Possible causes:
1) contactor coil is interrupted, verify its resistance using an multimeter.
2) contact can't move due to mechanic block.
3) Nominal working coil voltage is greater than battery one.

E) Reverse contactor is supplied with a correct voltage but it doesn't close : everything said at point D) for forward contactor is
valid here.
F) Reverse and forward contactor are supplied with a correct voltage but they doesn’t close ; See point D).
G) Supply don’t come up to forward contactor, please check cabling and connections from forward contactor coil to connectors
X and Y.
H) Supply don’t come up to reverse contactor, please check cabling and connections from reverse contactor coil to connectors
X and Y.
I) Supply don’t come up to forward contactor and reverse contactor, please check cabling and connections from the coils to
connectors X and Y.
For points G), H), I) replacing controller may be necessary.

PROBLEM 39
Display = “FL”, no hydraulic operation, but

drive operation and steering is normal.
POSSIBLE CAUSE
Valve control card defect ; wiring defect ;

Logics defect.
CHECKS
Key switch ON. Seat switch ON.

Measure voltage at PC-1.
Over than 0.1V No voltage
Adjust the value control card.(P113) Replace logics.

Refer to “Valve Control Card
Adjustment” in this manual.
Still “FL”
Replace valve control card.
PROBLEM 40
Display = “FF”, no lift truck operation.
POSSIBLE CAUSE
Serial communication failure between

drive controller and pump controller.
CHECKS
Disconnect the battery, replace logics.

System Tests and Adjustments Potentiometer Adjustment Tool -Trimmer
Available from most electronic suppliers, this

Test Equipment insulated tool allows for fast and easy adjustments of
potentiometers.
Hydrometer
Hydrometers are usually available from any battery

supplier. Battery maintenance is a crucial part of
maintaining the electric vehicle. The ability to
measure specific gravity and adjust the battery
discharge indicator to match battery manufacturers
specifications is an important part in the total
maintenance of the electric vehicle.
Discharging Head Capacitors

There are various pieces of electric truck test (HEAD CAP)
equipment that Daewoo recommends for all service
personnel. This equipment is available from a
number of world wide manufacturers and local
electronic suppliers. Contact your Daewoo dealer or WARNING
the factory for further recommendations.
Injury to personnel is possible. Disconnect the
Handheld Multimeter battery and discharge the head capacitor (HEAD
CAP) before any contact is made with the control
A digital multimeter that measures DC voltage, panel.
resistance, and has a diode tester, is required. It is
recommended that a high quality meter that is drop
protected, or comes with a drop proof case, be
purchased. Autoranging features, fast becoming an 1
industry standard, are convenient for the service
personnel, but are not required for servicing the lift
truck. A variety of miniature test leads, alligator clips,
and needle probes are also useful, and some of
these usually come with the multimeter.
2
Clamp-on Current Probe
The electric lift truck testing and adjusting procedures

require the measurement of average DC currents.
Currents in excess of 600 amps may be present, so
Discharging Head Capacitor (HEAD CAP)
a clamp-on meter that will exceed this level is (1) Positive terminal. (2) Negative terminals.
required. It is also highly recommeded that a device
that has a voltage output, as well as a visible display, 1. Disconnect the battery and discharge the head
be used. This makes viewing and adjusting currents capacitor.
from the operator's seat possible. The jaws of the
current probe should be able to accept at least a 2. Put a 82 ohm, 80 watt resistor Part No.
19mm (.75 inch) cable diameter. 929315, in position between the positive (1) and
negative (2) terminals. Hold the resistor in position
for 10 seconds. This will discharge the capacitor
below 5 volts.

Logics Removal 4. Loosen 6 screws (8) that hold logic cover.
WARNING
Injury to personnel is possible. Disconnect the
battery and discharge the head capacitor (HEAD
panel.
<Drive Controller>
1. Disconnect the battery and discharge the head 5. Loosen 4 screws and remove the side cover (9)
capacitor. and connector DG (10).
6. Remove the plate (11).
7. Remove logics to right.
<Pump Controller>
1. Disconnect the battery and discharge the head

capacitor.
1 5
Component Location 3
(1) B+ Cable, (2) B- Cable, (3) A1 Cable, (4) A2 Cable,
(5) S1 Cable, (6) S2 Cable, (7) POS Cable, (8) Bolts 2
4
2. Disconnect 8 (1), (2), (3), (4), (5), (6), (7) cables
from the controller ass’y and disconnect 4 connectors
and 4 terminals from the controller. Component Location
(1) POS Cable, (2) B- Cable, (3) P1 Cable, (4) P2 Cable,
3. Loosen 5 bolts (8) that hold the controller ass’y and
remove the controller ass’y.
2. Disconnect 4 cables (1), (2), (3), (4) from the
controller ass’y and 5 connectors from the controller.
3. Loosen 4 bolts (5) that hold the controller ass’y.

4. Remove the controller ass’y.
5. Loosen 4 screws (6) that hold logic cover and

remove the side cover (7) & connector PG (8).
6. Remove the plate (9).
7. Remove logics to right.

“Run Time” Tests
Static Return to off (SRO), Display = “EE”

WARNING
1. Connect the battery and sit on the seat.
Battery voltage and high amperage are present. Injury
to personnel is possible. Disconnect the battery and 2. Select a direction before turning key to ON.
discharge the head capacitor (HEAD CAP) before any
contact is made with the control panel. 3. Turn key to ON. An “EE” should appear on the
display and the drive system should not operate.
4. Return the direction lever to neutral, then back to

WARNING forward or reverse. The “EE” should disappear from
the display and the drive system should operate.
The lift truck can move suddenly. Battery voltage
and high amperage are present. Injury to
5. Turn key to OFF. Depress and hold the accelerator
personnel or damage to the lift truck is possible.
pedal.
Safely lift both drive wheels off the floor. Put
blocks of wood under the frame so the drive
6. Turn the key to ON. An “EE” should appear on the
wheels are free to turn. During any test or
display and the drive system should not operate.
operation check, keep away from drive wheels.
7. Release the accelerator padal. The “EE” should

disappear from the display and the drive system
should operate.
Key ON, No Operator Warning, Display =“EE”
(Flashing)
2. Turn key to ON with no one on the seat.
3. The display should show the letter “EE” flashing on

and off.
4. With an operator on the seat or by pressing on the

seat the letter “EE” should disappear from the
display and the drive system should operate.

Component Tests Conductor and Switch Continuity
1. Set the multimeter to the 200 Ω range.
WARNING 2. Use the multimeter to perform the continuity test. lf

continuity exists, the measurement will be less
Battery voltage and high amperage are present. than 1 ohm. lf the measurement is more than this,
Injury to personnel is possible. Disconnect the continuity does not exist and the problem will have
battery and discharge the head capacitor (HEAD to be repaired.
panel.
NOTICE
Do not use steam or solvent to clean the controls.
Damage can be caused to the control panel. Use
pressure from an air hose with a maximum
pressure of 205 kPa (30 psi) to clean the control
panel when necessary. The air supply must be
equipped with a water filter.
NOTE: When control wires and power cables or bus

bars are to be connected to the same bolt or
stud, place all control wires together on the
top of the bus bar or power cable.
Use the electrical schematic (located inside rear

panel cover) to locate components referred to by
name and number in the procedures that follow.
All wires must be located as shown on the schematic.
Refer to SB4087E00 schematic(A174502) as
attached.

Contactor
Coil Resistance
WARNING
2. Disconnect all leads to both terminals of the coil.
The lift truck can move suddenly. Injury to
personnel or damage to the lift truck is possible. 3. Set the multimeter to the 200Ω range.
Safely lift the drive wheels off the floor. Put blocks
of wood under the frame so both drive wheels are 4. Measure the resistance of the coil at both
free to turn. Keep away from drive wheels that teminals. If must be within specifications.
turn. See Component Measurements in Specifications
section.
5. If the coil is not within specifications, the contactor

assembly will be replaced.
WARNING
Coil Pulsing
Injury to personnel is possible. Disconnect the 2. With the contactor coil leads, set the multimeter to
battery and discharge the head capacitor (HEAD the 200 volts DC range.
panel. 3. Connect the multimeter negative lead to the
negative coil terminal Y and the meter positive lead
to the coil positive terminal X wire #15 or #16.
NOTICE 4. Connect the battery and activate the controls

Damage can be caused to the control panel. Do not necessary for the contactor to be activated.
switch the direction lever from one direction to
the other (plug the lift truck) when the drive wheels 5. After the contactor activates the multimeter must
are off the ground and in rotation at full speed. indicate 48 volts. If the voltage is not correct
and the contactor passed the Coil Resistance test,
the logics must be replaced.

capacitor. Contactor Tips
2. Visually inspect the tips to verify they are not

welded, melted, burned, or pitted.
3. Pull and release the tips quickly to verify there is no

binding.
4. Visually inspect the contactor assembly.

Verify foreign objects don't interfere with normal
contactor operation.

Electrical System Adjustments
Accelerator Control Linkage Parking Brake Switch
Method A (Mechanical)
WARNING

4 1 personnel or damage to the lift truck is possible.
Safely lift the drive wheels off the floor. Put blocks
of wood under the frame so both drive wheels are
free to turn. Keep away from drive wheels that
turn.
2
80
3 1
(1) Rod As. (2) Nut. (3) Stopper. (4)Pedal.
3
capacitor.
2
2. Adjust length of Rod (1) to 80 ± 2 mm and tighten
the nut (2). Fully depress accelerator pedal (4) until
stopped by accelerator stopper (3).
Parking Brake Switch Adjustment
3. Release accelerator pedal (4). Check for (1) Switch. (2) Plate. (3) Bolts.
dimension.
1. Close the seat switch and turn the key to ON.
Method B (Electrical)
2. Release the parking brake and put the truck in
1. Enter Quick diagnostics, through the specified forward.
procedure, the display is an “A0”. 3. Reposition plate (2) so the switch (1) actuator is
against the bracket. Tighten bolts (3).
2. Depress the accelerator slowly to stop. The speed
symbols will increase from 0 to 10 on LCD. 4. Engage the parking brake and the park brake
symbol will be displayed. Repeat the procedure
until adjustment is correct.

Lift Sensor Valve Control Card Adjustment

capacitor.
WARNING

1 personnel or damage to the lift truck is possible.
Safety lift the drive wheels off the floor. Put blocks
of wood under the frame so both drive wheels are
3 free to turn. Keep away from drive wheels that turn.
4
1. Verify the lift sensor clearance is adjusted correctly.
2. Disconnect all tilt and auxiliary switch connectors.
2 3. Place the lift truck in “Quick” diagnostics so that the

display shows the lift speed.
Lift Sensor Adjustment

(1) Lift Sensor(transducer) (2) Magnet. (3) Screw.
(4) Setscrew. (A) 1.0 mm (.039 in) Clearance.
NOTICE
Lift sensor may be damaged. Do not allow the magnet
(2) to make contact with the plastic bracket when the
lift lever is activated.
2. Loosen setscrew (4).

1 2
3. Adjust screw (3) to make clearance (A) 1.0mm
(.039 in) between lift sensor (1) and magnet (2) Valve Control Card Adjustment
when the lift lever is activated fully (pulled all the (1) P1 Potentiometer. (2) P2 Potentiometer.
way back).
4. Turn potentiometer P1 (1) fully counterclockwise
4. Tighten setscrew (4). Check lift sensor circuit. The unitl a clicking sound is heard (roughly 20 turns).
valve control card may need adjusting.
5. Turn potentiometer P2 (2) fully counterclockwise
until a clicking sound is heard (roughly 20 turns).
6. Turn potentiometer P2 (1) 15 full turns clockwise.
7. Position the lift lever just prior to the hydraulic valve

opening. Adjust P1(1) clockwise until a “1” is
obtained on the display.

8. Pull the lift lever all the way back. A “10” must be Tilt and Auxiliary Switch Adjustment
displayed.
Because each tilt and auxiliary switch can turn on the
9. If a “10” is not displayed, adjust P2 (2) clockwise pump motor, it is recommended that only one be
until it is. connected to start with. After adjusting the first switch
proceed with the next one.
10. Release the lift lever and adjust P1
counterclockwise until a “A0” is displayed. 1. Disconnect the battery and discharge the head
capacitor. Disconnect all but one switch connector.
11. Repeat steps 9 and 10 until “A0” to “10” speeds
correct.
12. Put the lift truck back in the run mode so the
actual hydraulics can be tested.
13. Connect the battery, close the seat switch and

turn the key to ON.
14. Pull the lift lever back until the pump motor turns
on. The forks must not move. Adjust P1 so the
motor starts just before the valve opens.
If the valve opens before the motor turns on, adjust

P1 (1) clockwise. 1
If the motor turns on too far in advance of the valve 2

opening, adjust P1 (1) counterclockwise.
Tilt and Auxiliary Switch Adjustment

(1) Screw. (2) Screws.
2. With valve spool in neutral position, loosen screws

(2) and adjust screw (1) to center the switch roller
on cam.
3. After adjusting switch in or out to obtain correct

switch point, tighten screws (1) and (2) to lock
switch into position.
4. Connect the battery, close the seat switch and turn

the key to on. Readjust switch if needed, so that
the pump motor turns on before the control valve
opens.
This must be adjusted for each lever direction
(pushed or pulled).
5. Connect the next switch and repeat this proccdure.

Digital Console
CONSOLE CONNECTOR
DISPLAY
A284220
1 PARM.
2 TESTER
3 SAVE
4 RESTORE
I MOX V.POT
TEMP V.BATT
5 ALARMS V.MOT VMN.MOT
M.SW.TEST
6 ACCELERATOR
7 MOTOR DATA
ROLL ENTER PARAM.

BUTTONS
ROLL OUT SET

Using Digital Console
VIEW A
CONNECTOR B
VIEW A
<Drive controller (A174900)> <Pump controller (A174950)>
1. Key switch off. 1. Key switch off.
2. Open the rear controller room door. 2. Open the side controller room door.
3. Remove the connector DB of Harness As. 3. Remove the connector PB of Harness As.
4. Connect the console connector. 4. Key switch on.

Make sure the correct position of connector.
5. Connect the console connector.
5. Key switch on, the display will show the HEADING. Make sure the correct position of connector.
Description
H2 ofREG
Standard
DHConsole
X.XX Menu
48V 600A XXXXXX
HP P.S TD DH X.XX
48V 600A XXXXXX

Description of Standard Console Menu
<DRIVE CONTROLLER>
HEADING
MAIN MENU CONFIG. MENU
PARAMERER ACCELER. DELAY 0~9

CHANGE INVERS BRAKING 0~9
RELEASE BRAKING 0~9 SET MODEL MODEL TYPE REGENERATIVE TR.
PEDAL BRAKING 0~9 / NONE /
BREAKING 0~9 STANDARD PUMP /
BREAKING MODUL. 0~9 PUMP + HYDRO
CURVE BRAKING 0~9
CURVE TIME 0~9
CUT BACK SPEED 1 0~9
COMPENSATION 0~9 SET OPTIONS BYPASS CONTACTOR BYPASS/
WEAK DROPOUT 0~9 WEAKENING
MAXIMUM CURRENT 0~9 SPEED CONTROL ON/OFF
CREEP SPEED 0~9 BATTERY CHECK ON/OFF
MAX SPEED FORW 0~9 ANTIROLLBACK ON/OFF
MAX SPEED BACK 0~9 RELEASE BRAKING ON/OFF
HOUR COUNTER RUNNING /
KEYON
SAFETY SWITCH SEAT /
HANDLE
TESTER VMN % SOFT BRAKING ON / OFF
MOTOR VOLTAGE V AUX FUNCTION NONE /
MOTOR CURRENT A HYDRO CONTACTOR
BATTERY VOLTAGE V / BIMOTOR CONTACT.
TEMPERATURE ˚C
ACCELERATOR V-%
FORWARD SWITCH ON/OFF ADJUSTMENTS SET BATTERY TYPE
BACKWARD SWITCH ON/OFF ADJUST BATTERY
CUT BACK SWITCH ON/OFF
ENABLE SWITCH ON/OFF
HANDBRAKE ON/OFF
BRAKE SWITCH ON/OFF
HANDLE/SEAT SW. ON/OFF
MOTOR TEMPERAT. ON/OFF
SAVE
PARAM.
RESTORE
PARAM.
CODE,
ALARMS
h, N˚, ˚C
PROGRAM VACC VACC SETTING MIN / MAX
MOTOR DATA NOT AVAILABLE!

<PUMP CONTROLLER>
HEADING
MAIN MENU CONFIG. MENU
PARAMERER ACCELER. DELAY 0~9

CHANGE DECELER. DELAY 0~9
EV. ACCELER. DEL 0~9 SET MODEL MODEL STANDARD PUMP /
EV. DECELER. DEL 0~9 PUMP + HYDRO
HYD SPEED COARSE 0~9
HYD SPEED FINE 0~9
HYDRO COMPENS 0~9
HYDRO TIME 0~9
SPEED LIMIT 0~9
1ST SPEED COARSE 0~9
1ST SPEED FINE 0~9 SET OPTIONS BYPASS CONTACTOR BYPASS/
1ST SPEED COMP. 0~9 WEAKENING
2ND SPEED COARSE 0~9 BATTERY CHECK ON/OFF
2ND SPEED FINE 0~9 HOUR COUNTER RUNNING /
2ND SPEED COMP. 0~9 KEYON
3RD SPEED COARSE 0~9 MAIN CONTACTOR RUNNING STATUS
3RD SPEED FINE 0~9 / PRESENT
3RD SPEED COMP. 0~9 AUX FUNCTION RUNNING STATUS
4TH SPEED COARSE 0~9 / HYDRO CONTACTOR
4TH SPEED FINE 0~9 / EXCLUSIVE HYDRO
4TH SPEED COMP. 0~9
CREEP SPEED 0~9
MAXIMUM CURRENT 0~9
MIN VALVE VOLT. 0~9 ADJUSTMENTS SET BATTERY TYPE
MAX VALVE VOLT. 0~9 ADJUST BATTERY
AUX FUNCTION 1 0~6
TESTER VMN %
MOTOR VOLTAGE V
MOTOR CURRENT A
BATTERY VOLTAGE V
TEMPERATURE ˚C
LIFTING CONTROL V-%
LIFTING SWITCH ON/OFF
DIGITAL INPUT #1 ON/OFF
1ST SPEED SWITCH ON/OFF
2ND SPEED SWITCH ON/OFF
3RD SPEED SWITCH ON/OFF
MOTOR TEMPERAT. ON/OFF
HYDRO SPEED REQ. ON/OFF
SAVE
PARAM.
RESTORE
PARAM.
CODE,
ALARMS
h, N˚, ˚C
PROGRAM VACC VACC SETTING MIN / MAX
MOTOR DATA NOT AVAILABLE!

Description of SET OPTIONS Functions
The options can be set on the “SET OPTIONS” Menu.
Function Option Meaning

1. HOUR COUNTER RUNNING Hour meter enabled when running.
KEY ON Hour meter enabled when the key is on.
2. BATTERY CHECK ON Battery voltage check activated on stand by. When the charge is
lower than 60%,the maximum current is reduced by 50% .
OFF Battery discharge is not checked.
Flow chart showing how to make changes to Option Menu.
DISPLAY H2 REG DHX.XX

1. Opening HEADING. 48V 600A XXXXXX
2. Press Top Left & Right Buttons together to enter KEYBOARD

CONFIG. MENU.
CONFIG. MENU
3. The Display will show : SET MODEL SET MODEL
4. Press ROLL UP or ROLL DOWN buttons until SET

OPTIONS Menu appears.
CONFIG. MENU
5. SET OPTIONS appears on the display. SET OPTIONS
6. Press ENTER to go into the SET OPTIONS Menu.
7. The display will shows the first OPTION. HOUR COUNTER

RUNNING
8. Press ROLL UP or ROLL DOWN buttons until desired

OPTION appears.
9. Desired OPTION appears. HOUR COUNTER
KEY ON
10. Press PARAM or SET DOWN buttons in order to

modify the changes.
11. New OPTION appears. BATTERY CHECK

ON
12. Press OUT to exit the Menu.
13. Confirmation request appears. ARE YOU SURE?

YES = ENTER NO = OUT
14. Press ENTER to accept the changes, or Press OUT

if you do not accept the changes.
CONFIG. MENU
15. SET OPTIONS Menu appears. SET OPTION
16. Press OUT again. Display now show the Opening HEADING.

Description of SET OPTIONS Functions
<DRIVE CONTROLLER>

BYPASS Bypass contactor adopted.
1. BYPASS CONTACTOR
WEAKENING NOT AVAILABLE
2. SPEED CONTROL - NOT AVAILABLE
Activates the check that reads the battery voltage in standby.
ON When the residual charge is less than 10%, the maximum
3. BATTERY CHECK
current is reduced by 70% and the LED blinks continuously.
OFF No low battery charge alarm.
ON Activates anti-rollback function.
4. ANTIROLLBACK
OFF No anti-rollback
Braking active at the moment of accelerator pedal release with
ON
5. RELEASE BRAKING increment of the braking current by means of the brake pedal.
OFF No regenerative braking at accelerator pedal release.
RUNNING Hour meter only active when running.
6. HOUR COUNTER
KEY ON Hour meter active with the key on.
Interrupt function for the truck when the key switch turn on
SEAT without an operator on the seat or while no one is on the seat
7. SAFETY SWITCH
during 6 sec. under the key on.
HANDLE NOT AVAILABLE
8. SOFT BRAKING - NOT AVAILABLE
9. AUX FUNCTION - NOT AVAILABLE
<PUMP CONTROLLER>

1. BYPASS CONTACTOR - NOT AVAILABLE
Activates the check that reads the battery voltage in standby.
ON When the residual charge is less than 10%, the maximum
2. BATTERY CHECK
current is reduced by 70% and the LED blinks continuously.
OFF No low battery charge alarm
RUNNING Hour meter only active when running.
3. HOUR COUNTER
KEY ON Hour meter active with the key on.
4. MAIN CONTACTOR - NOT AVAILABLE
5. AUX FUNCTION - NOT AVAILABLE

ADJUSTMENTS : SET BATTERY TYPE (Drive and Pump Controller)
Using this function it is possible store the nominal value of the battery.
How to execute SET BETTERY TYPE with the console.
DISPLAY HP P.STD DHX.XX
KEYBOARD
2. Press Top Left & Right Buttons to enter CONFIG. MENU.
CONFIG. MENU
4. Press ROLL UP BUTTON until ADJUSTMENTS Menu

appears.
CONFIG. MENU
ADJUSTMENTS
5. ADJUSTMENTS appears on the display.
6. Press ENTER to go into the ADJUSTMENTS Menu.
SET BATTERY TYPE

7. The display will shows. SET BATTERY TYPE. 26V
+
8. Press PARAM. or SET buttons to choose nominal value of the battery. -
9. New battery value appears on the display. ADJUST BATTERY

48V
11. Confirmation request appears. ARE YOU SURE?

12. Press ENTER to accept the changes, or press OUT

13. ADJUSTMENTS Menu appears. CONFIG. MENU

ADJUSTMENTS
14. Press OUT. Display now show the Opening HEADING.

ADJUSTMENTS : ADJUST BATTERY (Drive and Pump Controller)
Using this function it is possible to calibrate the internal voltmeter to a fine level. lt is necessary to input the battery
voltage value after measurement using an external calibrated digital voltmeter.
Procedure showing how to carry out ADJUST BATTERY operation by console.
DISPLAY HP P.STD DHX.XX
KEYBOARD
2. Press Top Left & Right Buttons to enter CONFIG. MENU.
CONFIG. MENU
4. Press ROLL UP BUTTON until ADJUSTMENTS Menu

appears.
CONFIG. MENU
5. ADJUSTMENTS appears on the display. ADJUSTMENTS
6. Press ENTER to go into the ADJUSTMENTS Menu.
SET BATTERY TYPE

7. The display will shows SET BATTERY TYPE. 48V
8. Press ROLL UP or ROLL DOWN buttons until desired

OPTION appears.
ADJUST BATTERY
9. ADJUST BATTERY appears. 56.0V
10. Press PARAM. or SET buttons in order to increase +

or decrease respectively. Set the valus read by an external -
calibrated digital voltmeter.

ADJUST BATTERY
11. Battery value appears on the display. 48.6V
ARE YOU SURE?

13. Confirmation request appears. YES = ENTER NO = OUT
14. Press ENTER to accept the changes, or press OUT

CONFIG. MENU
ADJUSTMENTS
15. ADJUSTMENTS Menu appears.
16. Press OUT. Display now show the Opening HEADING.

Description of PROGRAM VACC Function (Drive and Pump)
This function looks for and remembers the minimum and maximum accelerator output voltage over the full
mechanical range of the pedal or lift lever. It enables compensation for non symmetry of the mechanical system.
The operation is performed by operating the pedal or lift lever after entering the PROGRAM VACC function.
Flow Chart showing how to use the PROGRAM VACC function of the Digital Console.
DISPLAY H2 REG. DHX.XX

2. Press ENTER to go into the MAIN MENU. KEYBOARD
3. The Display will show : MAIN MENU

PARAMETER CHANGE
4. Press ROLL UP or ROLL DOWN button until

PROGRAM VACC appears on the display.

PROGRAM VACC
6. Press ENTER to go into the PROGRAM VACC routine.
7. The Display will show the minimum and maximum

values of accelerator or valve board output. VACC SETTINGS
0.4 8.7
8. Press ENTER to clear these values. Display will show 0.0.
9. Select Forward Direction (only for drive controller).

MIN VACC MAX
0.0 - 0.0
10. Slowly depress the accelerator pedal or pull the lift lever to its maximum
value. The new minimum and maximum voltages will be displayed
on the Console plus an arrow indicating the direction.
11. When finished, still depressing accel pedal or pulling lift lever.
Press OUT.
12. The Display will ask : ARE YOU SURE?
13. Press ENTER for yes, or OUT for NO. ARE YOU SURE?
14. Release the accel pedal and select neutral direction or release the
lift lever.
15. Press OUT again to return to the Opening HEADING.

Description of TESTER Functions 13. HANDLE/SEAT SW. = the level of the Seat
microswitch.
ON/ +VB = active entry of the Seat microswitch.
The most important input or output signals can be OFF/ GND = non active entry of the Seat
measured in real time using the TESTER function of microswitch.
the console. The Console acts as a multimeter able to
14. MOTOR TEMPERAT. = the level of the Drive
read voltage, current and temperature. The following
Motor temp. switch.
listing shows the measurements that may be made :
ON/ GND = active entry of the Motor temp. switch.
OFF/ +VB = non active entry of the Motor temp.
switch.
< DRIVE CONTROLLER > < PUMP CONTROLLER >
1. VMN : the voltage effectively dropped across the 1. VMN : the voltage effectively dropped across the
MOSFET. It is measured between BATT-and VMN. MOSFET. It is measured between BATT-and VMN.
2. MOTOR VOLTAGE : level of traction motor voltage 2. MOTOR VOLTAGE : level of traction motor voltage
measured between S2 and BATT+. measured between P2 and BATT+.
3. MOTOR CURRENT: the current flowing in the 3. MOTOR CURRENT: the current flowing in the pump
traction motor armature. motor armature.
4. BATTERY VOLTAGE : level of battery voltage 4. BATTERY VOLTAGE : level of battery voltage
measured at the input to the key switch. measured at the input to the key switch.
5. TEMPERATURE : the temperature measured on the 5. TEMPERATURE : the temperature measured on the
aluminum heat skin holding the MOSFET devices. aluminum heat skin holding the MOSFET devices.
6. ACCELERATOR : the voltage of the accelerator 6. LIFTING CONTROL : the voltage of the lifting
potentiometer’s wiper(CPOT). The voltage level potentiometer's wiper(CPOT). The voltage leve
is shown on the Left Hand Side of the Console is shown on the Left Hand Side of the Console
Display and the value in percentage is shown Display and the value in percentage is shown on the
on the Right Hand Side. Right Hand Side.
7. FORWARD SWITCH : the level of the Forward 7. LIFTING SWITCH : Not used
direction digital entry. 8. DIGITAL INPUT #1 : Not used
ON/ +VB = active entry of closed switch.
OFF/ GND = non active entry of open switch. 9. 1ST SPEED SWITCH : the level of the Tilt speed
microswitch.
8. BACKWARD SWITCH : the level of the Reverse ON/ +VB = active entry, microswitch closed.
direction digital entry. OFF/ GND = non active entry, microswitch open.
ON/ +VB = active entry of closed switch.
OFF/ GND = non active entry of open switch. 10. 2ND SPEED SWITCH : the level of the Aux1
speed microswitch.
9. CUTBACK SWITCH : Not used ON/ +VB = active entry, microswitch closed.
10. ENABLE SWITCH : the level of Enable switch OFF/ GND = non active entry, microswitch open.
digital input. 11. 3RD SPEED SWITCH : the level of the Aux2
ON/ +VB = active entry of closed switch. speed microswitch.
OFF/ GND = non active entry of open switch. ON/ +VB = active entry, microswitch closed.
11. HANDBRAKE : the level of the Handbrake OFF/ GND = non active entry, microswitch open.
microswitch. 12. MOTOR TEMPERAT : the level of the Pump Motor
ON/ GND = active entry of the Handbrake switch. temp. switch.
OFF/ +VB = non active entry of the Handbrake switch. ON/ GND = active entry of the Motor
12. BRAKE SWITCH : the level of the Pedal brake OFF/ +VB = non active entry of the Motor temp.
microswitch. switch
ON/ +VB = active entry of the Pedal brake switch. 13. HYDRO SPEED REQ. : Not used
OFF/GND = non active entry of the Pedal brake
switch.

How to use the TESTER Functions
Flow Chart showing how to use the TESTER function of the Digital Console.
1. Opening HEADING.
48V 600A XXXXXX
2. Press ENTER to go into the MAIN MENU.
KEYBOARD
3. The Display will show :

MAIN MENU
PARAMETER CHANGE
4. Press ROLL UP or ROLL DOWN button until TESTER menu
appear on the display.
5. The Display shows : MAIN MENU

TESTER
6. Press ENTER to go into the TESTER function.
7. The first variable to be tested is shown on the Display.

VMN
50%
8. Press either ROLL UP or ROLL DOWN buttons.
9. Next variable for measurement appears

MOTOR CURRENT
0V
10. When you have finished, Press OUT.
11. The Display shows :

MAIN MENU
TESTER
12. Press OUT again and return to Opening HEADING.
Remember it is not possible to make any changes using
TESTER. All you can do is measure as if you were using
a pre-connected multimeter.

Description of ALARMS Functions
The microprocessor in the chopper remembers the last five Alarms that have occurred. Items remembered
relative to each Alarm are : the code of the alarm, the number of times the particular Alarm occurred, the
Hour Meter count, and the chopper temperature. This function permits deeper diagnosis of problems as the
recent history can now be accessed.
Flow Chart showing how to use the ALARMS function via Digital Console.
KEYBOARD

PARAMETER CHANGE

ALRAMS appears on display.
MAIN MENU
5. The Display will show : ALARMS
6. Press ENTER to go into the ALARMS function.
7. The Display will show the most recent Alarm.
8. Each press of the ROLL UP button brings up following

Alarms. Pressing ROLL DOWN returns to the most recent.
9. If an Alarm has not occurred, the Display will show : NONE.
10. When you have finished looking at the Alarms,

Press OUT to exit the ALARMS menu.
CLEAR LOGBOOK?
11. The Display will ask CLEAR LOGBOOK?
12. Press ENTER for YES, or OUT for NO.
13. The Display will ask “ARE YOU SURE”. ARE YOU SURE?
Press ENTER for YES, or OUT for NO.
LOGBOOK CLEARED!
14. The Display show : (PRESS OUT)
15. Press OUT to return to the Opening HEADING.

Description of SAVE PARAM. Function
The SAVE PARAM. function allows the operator to transmit the Parameter values and Configuration data of
the chopper into the Console memory. It is possible to load 32 different programms.
The information saved in the Console memory can then be reloaded into another chopper using the
RESTORE function. The data that is available via the SAVE function is as follows:
- All Parameter Values (PARAMETER CHANGE).

- Options (SET OPTIONS).
- The Level of the Battery (ADJUST BATTERY).
Flow Chart showing how to use the SAVE function of the Digital Console.

KEYBOARD

PARAMETER CHANGE

SAVE PARAM. appears on the display
MAIN MENU
5. The Display will show : SAVE PARAM.
6. Press ENTER to go into the SAVE function.
7. If this facility has been used before, the type of chopper SELECT : Mod.00
COMBISEM 3 DH
data stored appears on the top Main with a 2 digit reference.
8. Keep pressing either ROLL UP or ROLL DOWN keys until

SELECT : Mod.01
the second Main indicates a FREE storage facility. FREE
9. Press ENTER to commence SAVE routine.

READING...
10. You can see the items that are being stored whilst ACCELER. DELAY (ETC.)
the SAVE routine is happening.
MAIN MENU
SAVE PARAM.
11. When finished, the Console shows :

Description of RESTORE PARAM. Function
The RESTORE PARAM. function allows transfer of the Console’s stored data into the memory of the
chopper. This is achieved in a fast and easy way using the method previously used with the SAVE PARAM.
function. The data that is available via the RESTORE PARAM. function is as follows :
- All Parameter Values (PARAMETER CHANGE).

- Options (SET OPTIONS)
- The level of the Battery (ADJUST BATTERY)
ATTENTION : When the RESTORE operation is made, all data in the chopper memory will be written
over and replaced with the data being restored.
Flow Chart showing how to use the RESTORE function of the Digital console.

2. Press ENTER to go into the MAIN MENU. KEYBOARD

PARAMETER CHANGE

RESTORE PARAM. appears on the display.
MAIN MENU
5. The Display will show : RESTORE PARAM.
6. Press ENTER to go into RESTORE PARAM. function.
7. The Display shows the type of Model stored, SELECT : Mod.00

COMBISEM 3 DH
with a Code Number.
8. Keep pressing either ROLL UP and ROLL DOWN buttons
until the desired model appears on the Display.
SELECT : Mod.01
B1 ZAPI V1
9. Press ENTER to commence the Restore operation.
10. The Display will ask "ARE YOU SURE".

ARE YOU SURE?
Press ENTER for YES, or OUT for NO. YES = ENTER NO = OUT
11. You can see the items that are being stored in the chopper
STORING...
memory whilst the RESTORE routine is happening. ACCELER. DELAY(ETC)
12. When finished the Console displays : MAIN MENU

RESTORE PARAM.

Description of PARAMETER CHANGE 11. WEAK DROPOUT = threshold of current for
Menu That may be Programmed opening the weakening contactor (if programmed
as such and not as bypass, in which case the
(PARAMETER CHANGE MENU)
output threshold is fixed and not programmable.
The Parameters can be modified with the chopper in 12. MAXIMUM CURRENT = define the maximum
standby or running. In the letter case, you must return current of the chopper both when running and in
to standby before switching off the chopper so that braking. All the current adjustments are expressed
the modifications are stored in nonvolatile memory. as a pecentage of this value. The adjustment
interval is from 50% (level 0) to 100% (level 9).
DRIVE CONTROLLER
13. CREEP SPEED = define the maximum voltage
applied to the motor with the running request
NOTICE activated. Provides a more immediate response
in starting off.
Connection of the CONSOLE to the Drive Controller
must be made with the key switch turned off. 14. MAX SPEED FORW = max speed with forward
direction on. This speed reduction goes under
The following Parameters can be modified: adjustable compensation with the COMPENSATION
parameter.
1. ACCELER. DELAY = acceleration time, i.e. the
minimum time during which the motor voltage varies 15. MAX SPEED BACK = max speed with backward
from 0V to the maximum. direction on. This speed reduction goes under
adjustable compensation with the COMPENSATION
2. INVERS BRAKING = basic braking current in parameter.
direction inversion. A value is added to this value
based on the accelerator puls a fixed increment
every second. PUMP CONTROLLER
3. RELEASE BRAKING = release braking current

NOTICE
4. PEDAL BRAKING = release braking current with
brake pedal pressed. Connection of the CONSOLE to the Pump Controller
must be made after the key switch turned on.
5. BRAKING = the plugging current when the
regenerative braking isn’t selected. The following Parameters can be modified:
6. BRAKING MODULE = define the maximum 1. ACCELER. DELAY = Pump motor acceleration time.
current in inversion braking with the accelerator
pedal pressed. When the accelerator is pressed 2. DECELER. DELAY = Deceleration time, i.e. to
all the way down in inversion, braking becomes annual the motor.
more brusque the higher the value of the parameter.
3. EV. ACCELER. DEL = Acceleration time relative to
7. CURVE BRAKING = current for curve braking, descent (proportional solenoid valve).
activated with speed reduction request
(CUT BACK SPEED 1), if the PWM is greater than 4. EV. DECELER. DEL = Deceleration time relative to
80% and the motor current less than 40% lmax. descent (proportional solenoid valve).
8. CURVE TIME = curve braking time associated to 5. HYD SPEED COARSE = Coarse hydrodrive speed
CUT BACK SPEED 1. If 0, braking is not carried out. (from 0 to 100% Vbatt on the motor).
9. CUT BACK SPEED 1 = reduction of speed (relative 6. HYD SPEED COARSE = Fine hydrodrive speed
to DB -7). (a value from 0 to 100% Vbatt is added to the coarse
speed value).
10. COMPENSATION = compensation of the speed The speed is given by :
(motor voltage) on the basis of the current when motor voltage=(coarse speed + fine speed)xVbatt/100.
the speed reduction is active.

7. HYDRO COMPENS. = Compensation in current
for hydrodrive request.
8. HYDRO TIME = Idle off delay.
9. SPEED LIMIT = Maximum pump speed.
10. 1ST SPEED CORSE = Tilt speed coarse.
11. 1ST SPEED FINE = Tilt speed fine.
12. 1ST SPEED COMP. = Tilt speed compensation.
13. 2ND SPEED CORSE = Aux1 speed coarse.
14. 2ND SPEED FINE = Aux1 speed fine.
15. 2ND SPEED COMP. = Aux1 speed compensation.
16. 3RD SPEED CORSE = Aux2 speed coarse.
17. 3RD SPEED FINE = Aux2 speed fine.
18. 3RD SPEED COMP. = Aux2 speed compensation.
19. 4TH SPEED CORSE = Pump 4th speed coarse.

(Not used)
20. 4TH SPEED FINE = Pump 4th speed fine.

(Nor used)
21. 4TH SPEED COMP. = Pump 4th speed

compensation. (Nor used)
22. CREEP SPEED = define the minimum value of

voltage applied to the motor with running request
active. Allows a more immediate reponse.
23. MAXIMUM CURRENT = define the maximum

chopper current. All current adjustments are
expressed as a percentage of this value. The
adjustment range is from 50% (level 0) to 100%
(level 9).
24. MIN VALVE VOLT. = Minimum voltage applied on

the proportional solenoid valve.
25. MAX VALVE VOLT. = Maximum voltage applied on

the proportional solenoid valve.
26. AUX FUNCTION 1 = Discharged battery reset value.

PARAMETER Settings
< DRIVE CONTROLLER >
PROGRAMMED LEVEL
NO. PARAMETERS UNIT 0 1 2 3 4 5 6 7 8 9
1 ACCELER. DELAY sec.(1) 0.2 0.41 0.82 1.2 1.6 2.0 2.4 3.0 3.5 4.0
2 INVERS BRAKING %IMAX(2) 18 23 27 32 36 41 45 50 54 58
3 RELEASE BRAKING %IMAX(2) 15 19 23 27 31 34 38 42 46 50
4 PEDAL BRAKING %IMAX(2) 25 31 37 43 49 56 62 68 74 80
5 BRAKING %IMAX(2) 10 20 30 40 50 60 70 80 90 100
6 BRAKING MODUL %IMAX(2) 0 3 5 8 11 14 17 20 22 25
7 CURVE BRAKING %IMAX(2) 15 19 23 27 31 34 38 42 46 50
8 CURVE TIME sec. 0 0.2 0.3 0.4 0.6 0.8 1 1.2 1.6 2
9 CUT BACK SPEED 1 %VBATT 10 22 33 45 53 60 69 78 86 100
10 COMPENSATION K(I) (3) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
11 WEAK DROPOUT %IMAX 10 20 30 40 50 60 70 80 90 100
12 MAXIMUM CURRENT amp. 300 333 367 400 433 467 500 533 567 600
13 CREEP SPEED %VBATT 0 0.9 1.9 2.9 4.5 5.9 7.8 9.8 11.7 13.7
14 MAX SPEED FORW %VBATT 20 29 38 47 56 64 73 82 91 100
15 MAX SPEED BACK %VBATT 20 29 38 47 56 64 73 82 91 100
< PUMP CONTROLLER >

PROGRAMMED LEVEL
NO. PARAMETERS UNIT 0 1 2 3 4 5 6 7 8 9
1 ACCELER. DELAY sec. 0.15 0.24 0.39 0.50 0.63 0.74 0.86 0.97 1.09 1.22
2 DECELER. DELAY sec. 0.06 0.13 0.19 0.25 0.31 0.38 0.44 0.50 0.56 0.62
3 EV. ACCELER. DEL sec. 0.39 0.63 0.71 0.81 0.97 1.05 1.27 1.36 1.46 1.54
4 EV. DECELER. DEL sec. 0.30 0.60 0.70 0.78 0.95 1.04 1.26 1.36 1.43 1.53
5 HYD SPEED COARSE %VBATT 0 11 22 33 44 55 66 77 88 100
6 HYD SPEED FINE %VBATT 0 1.2 2.4 3.6 4.8 6.05 7.3 8.5 9.7 10.9
7 HYDRO COMPENS K(I)(3) 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
8 HYDRO TIME sec. 0 0.5 2 4 6 9 12 14 17 20
9 SPEED LIMIT %VBATT 50 55 60 66 72 78 84 90 96 100
10 1ST SPEED COARSE %VBATT 0 11 22 33 44 55 66 77 88 100
11 1ST SPEED FINE %VBATT 0 1.2 2.4 3.6 4.8 6.05 7.3 8.5 9.7 10.9
12 1ST SPEED COMP. K(I)(3) 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
13 2ND SPEED COARSE %VBATT 0 11 22 33 44 55 66 77 88 100
14 2ND SPEED FINE %VBATT 0 1.2 2.4 3.6 4.8 6.05 7.3 8.5 9.7 10.9
15 2ND SPEED COMP. K(I)(3) 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
16 3RD SPEED COARSE %VBATT 0 11 22 33 44 55 66 77 88 100
17 3RD SPEED FINE %VBATT 0 1.2 2.4 3.6 4.8 6.05 7.3 8.5 9.7 10.9
18 3RD SPEED COMP. K(I)(3) 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
19 4TH SPEED COARSE %VBATT 0 11 22 33 44 55 66 77 88 100
20 4TH SPEED FINE %VBATT 0 1.2 2.4 3.6 4.8 6.05 7.3 8.5 9.7 10.9
21 4TH SPEED COMP. K(I)(3) 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
22 CREEP SPEED %VBATT 0 1.9 3.9 5.9 7.8 9.8 11.7 13.7 16.6 17.6
23 MAXIMUM CURRENT amp. 300 333 367 400 433 467 500 533 567 600
24 MIN VALVE VOLT. %VBATT 7.4 113 15.2 19.2 23.1 27.0 31. 35 39 43
25 MAX VALVE VOLT %VBATT 56 60 64.5 70 74 78.5 83.5 88 92.5 97.5
26 AUX. FUNCTION 1 %VBATT (4) “1” 1 2 3 4 5 6 - - -
(1) = When reduction speed is activated, this value is increased of 100%.

(2) = If the braking parameter increases, the braking time decreases. This adjustment provides gradual and smooth
braking. The braking time depends on the type of motor and the operating conditions(laden, unladen, on
plane, on gradient).
(3) = Maximum compensation for the motor at current equal to IMAX.

How to use the PARAMETER CHANGE Menu
Flow Chart showing how to make Programme changes using Digital Console.
1. Opening HEADING.
48V 600A XXXXXX
KEYBOARD
3. The Display will show : PARAMETER CHANGE.

MAIN MENU
PARAMETER CHANGE
4. Press ENTER to go into the Parameter Change facility.
5. The Display will show the first Parameter.

ACCELER. DELAY
LEVEL = 4
6. Press either ROLL UP and ROLL DOWN to display the next
parameter.
7. The names of the Parameters appear on the Display.

RELEASE BRAKING
8. When the desired Parameter appears, the Display will show LEVEL = 5
a Level Number that will be between 0 and 9. Press either PARAM.

(Top Right) or SET(Bottom Right) buttons to change the Level value.
9. The Display will show the New Level. RELEASE BRAKING

LEVEL = 6
10. When you are satisfied with the results of the changes
you have made, Press OUT.
11. The Display asks “ARE YOU SURE?”

ARE YOU SURE?
12. Press ENTER to accept the changes, or Press OUT YES = ENTER NO = OUT
if you do not wish to accept the changes and wish
to make further modifications to the parameters.
13. The Display will show : PARAMETER CHANGE
MAIN MENU
PARAMETER CHANGE
14. Press either ROLL UP and ROLL DOWN to display
other parameters or press OUT.
Activating Default Settings
All of the parameter values can be set to the factory defanlt settings by the follawing procedure.
1. Enter the “Quick Diagnostics” mode. (refer to P44)

2. Remove all switches to neutral (include accelerator) position to display “AO”.
3. Direction lever FWD NEUTRAL Pull & Redease the tilt lever
Direction lever FWD NEUTRAL Pull & Redease the tilt lever (A0 A3 A0 A6 A0; 2times)
4. And then “d” will be displayed on the instrument.
5. Key switch OFF.

Service Manual Contents Notice: For Use in Service Manual Form SB4080E SB4081E00 D e C - 2 0 0 2

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SERVICE MANUAL CONTENTS

TITLE FORM NUMBER

Service Manual Contents SB4081E00

DRIVE & CONTROL SYSTEM

MicroController Control System SB4082E00

Power Train SB4083E00

Vehicle Systems SB4084E00

OPERATION & MAINTENANCE

Operation & Maintenance Manual SB2329E00

Models ; B20S-3, B25S-3, B30S-3

Foreword ...............................................................2 Inspection, Maintenance and Repair of Lift Truck

Environment Protection Section

This manual contains information necessary for

WARNING Operating techniques outlined in this publication are

Maintenance Environment Management

Perform service on items at multiples of the original

Important Safety Information

The meaning of this safety alert symbol is as follows :

Attention ! Become Alert ! Your Safety is Involved.

The most effective method of preventing serious

Do not operate a lift truck if in need of repair, IC6O002P

This also provides allowable lift truck capacity

No Riders Warning No Standing on Forks Warning, No

Do not stand or ride on the forks. Do not stand

Located on the right side of the operator station.

Hard Placement Warning

Load Backrest Must Be In Place

(No hands. Do not place hands in this area. Do WARNING

Located on the mast

Apply Parking Brake Warning Battery Disconnect Before Servicing

Located on the top left side of the cowl.

Overhead Guard Must Be In Place

Located on the logic unit cover behind the control

Located outside top frame member of overhead

General Hazard Information

In the USA, please refer to current revisions of :

• 29 Code Federal Register, 1910.178 Powered

WARNING • American National Standard, ANSI B56.1 Safety

IA1O1010 • Other OSHA Regulations which may be applicable

Do not operate a lift truck if in need of repair,

Do not start or service the lift truck when a “DO NOT

Wear a hard hat, protective glasses and other

Do not wear loose clothing or jewelry that can catch

Keep the lift truck, especially the deck and steps,

If the lift truck must be operated without the

Do not raise loads any higher than necessary and

Do not drive lift truck up to anyone standing in front

Obey all traffic rules and warning signs.

Know the appropriate work-site hand signals and who

Operation Information Starting the Lift Truck

Make sure no one is standing and/or working on,

Refer to the topic “Start the Lift Truck” in the

Before Operating the Lift Truck

Operate the lift truck and controls only from the

loosely stacked loads. Refer to load capacity plate floor.

• Do not stunt ride or indulge in horseplay. Engage the parking brake.

• Stay in designated travel path, clear of dock edges,

• Slow down and use extra care through doorways,

• Slow down and avoid pedestrians, other vehicles,

Refer to the topic “Operating Techniques” in the

Loading or Unloading Trucks/Trailers

• Do not operate lift trucks on trucks or trailers which