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Hyundai 20BC-7 Service Manual

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FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section gives the general information of the machine and explains the safety hints for
maintenance.
SECTION 2 REMOVAL & INSTALLATION OF UNIT
This section explains the procedures and techniques of removal and installation of each component.
SECTION 3 POWER TRAIN SYSTEM
This section explains the structure of the transmission as well as control valve and drive axle.
SECTION 4 BRAKE SYSTEM
This section explains the brake piping, each component and operation.
SECTION 5 STEERING SYSTEM
This section explains the structure of the steering unit, priority valve, trail axle as well as steering
circuit and operation.
SECTION 6 HYDRAULIC SYSTEM
This section explains the structure of the gear pump, main control valve as well as work equipment
circuit, each component and operation.
SECTION 7 ELECTRICAL SYSTEM
This section explains the electrical circuit and each component.
It serves not only to give an understanding electrical system, but also serves as reference material for
troubleshooting.
SECTION 8 MAST
This section explains the structure of mast, carriage, backrest and forks.
The specifications contained in this service manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
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  • Page 1 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
  • Page 2 When a manual is revised, an edition mark is Any additions, amendments or other changes will recorded on the bottom outside corner of the be sent to HYUNDAI distributors. pages. Get the most up-to-date information before you start any work.
  • Page 3 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 4 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 5 Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
  • Page 6 m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 7 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 8 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 9: Table Of Contents

    CONTENTS FOREWORD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-1 SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4...

  • Page 10: Section 1 General

    SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12...

  • Page 11: Group 1 Safety Hints

    GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
  • Page 12 Hand a caution sign in the operator's compartment (For example Do not start or Maintenance in progress). This will prevent anyone from starting or moving the machine by mistake. D50ASF07 When inspecting running parts or near such parts, always stop the machine first. Before checking or servicing accumulator or piping, depress brake pedal repeatedly to release pressure.
  • Page 13 Way to use dipstick Push the dipstick fully into the guide, and then pull out. Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request the HYUNDAI Forklift distributor to carry out...

  • Page 14: Group 2 Specifications

    GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS 20BC7OM113 Mast Dash board 11 Seat Lift cylinder Frame 12 Steering wheel Carriage and backrest Steering axle 13 Overhead guard Forks Counterweight Drive unit 10 Battery cover...
  • Page 15 2. SPECIFICATIONS 20BC7SP01 Model Unit 20BC-7 25BC-7 30BC-7 32BC-7 Capacity 2000 2500 3000 3200 Load center Weight 4027 4362 4870 5042 Lifting height 3300 3200 Free lift Lifting speed[Unload/Load] Fork mm/sec 610/420 610/410 500/340 500/330 Lowering speed[Unload/Load] mm/sec 450/500 L W T...
  • Page 16 3. SPECIFICATION FOR MAJOR COMPONENTS CONTROLLER Item Unit Traction Pump Model AC 3 Type MOSFET 250 300 177 Dimension Current limit 600A Communication M M OTOR Item Unit Traction Pump Model TSA 270-210 TSA 200-230 Type Rated voltage Output 14.2 Insulation Class F Class F...
  • Page 17 GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity 30.8 cc/rev Maximum operating pressure Rated speed(max/min) 3000/500 M M AIN CONTROL VALVE Item Unit Specification Type 3 spool, 4 spool Operating method Mechanical Main relief valve pressure D D RIVE AXLE Item Unit Specification...
  • Page 18 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Items Size kgf m lbf ft Hyd pump motor mounting bolt 6.9 1.4 50 10 Electric system Traction motor mounting bolt M10 1.5 6.9 1.4 50 10 Hydraulic pump mounting bolt M10 1.5 36 7.2 MCV mounting bolt, nut M 8 1.25 2.5 0.5...
  • Page 19 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT Coarse thread Bolt size kgf m lbf ft kgf m lbf ft 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8 1.25...
  • Page 20 PIPE AND HOSE(FLARE TYPE) Thread size Width across flat kgf m lbf ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" IPE AND HOSE(ORFS TYPE) Thread size Width across flat kgf m lbf ft 9/16-18 28.9 11/16-16 36.2 13/16-16 68.7 1-3/16-12 1-7/16-12...
  • Page 21 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature C( F) Capacity (U.S. gal Service Kind of point fluid 20/25/30/32BC-7 (104) (-4) (14) (32) (50) (68) (86) SAE 80W/90 Axle Gear oil (1.4) SAE 75W/90 (-35 ISO VG 22...

  • Page 22: Group 3 Periodic Replacement

    GROUP 3 PERIODIC REPLACEMENT For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time of periodic maintenance;...

  • Page 23: Section 2 Removal & Installation Of Unit

    SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Major components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...

  • Page 24: Group 1 Major Components

    SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 MAJOR COMPONENTS 20BC7RE02 Lift cylinder Drive unit 17 Counterweight Mast 10 Drive motor 18 Traction controller Steering unit 11 Hyd gear pump 19 Pump controller Backrest 12 Pump motor 20 Seat Tilt cylinder 13 Battery 21 Overhead guard...

  • Page 25: Group 2 Removal And Installation Of Unit

    GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Forks Backrest Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Turn knob up and slide one fork at a time toward the center of the carriage where a Knob notch has been cut in the bottom plate for...
  • Page 26 While supporting lift chains, remove the split pins and nuts from anchor pins of Lift chain stationary upright. Outer mast Split pin 22B7RE05 Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain Block...
  • Page 27 Piping Remove the return hoses and clamps attached to the cylinder. Remove the return hoses from the connector. Remove hose assembly, tee, velocity fuse valve(1) from the lift cylinder. Disconnect hose assembly from the flow regulator(2). 20BC7RE08 Lift cylinder Loosen hexagonal bolts and remove spacers securing the lift cylinders to outer mast.
  • Page 28 Inner mast Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. 20BC7RE10 Tilt cylinder pin Mast support cap Attach a crane to the stay at the top of the outer mast, and raise enough to sustain jacked up machine.
  • Page 29 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. Installation procedure for each of mast component is the reverse of the removal procedure. Mast support cap Check the mast support cap and spring pin for wear. Jack up the machine so that the front is raised and then using an overhead hoist assemble outer mast to drive axle unit.
  • Page 30 2. POWER TRAIN ASSEMBLY REMOVAL B153RE00 Mast and counterweight Refer to section on mast(Page 2-2) After removing mast, remove the counterweight to prevent the truck from turning over. 20BC7RE17 Brake piping Disconnect the brake piping from the wheel brake assembly. Brake Brake pipe master...
  • Page 31 Drive axle and motor assy Crane Attach a crane to the tilt cylinder notches on the dashboard and raise the machine enough for truck to slide under drive axle- transmission-drive motor assembly. Put the block between the truck and drive Drive axle &...
  • Page 32 3. ELECTRICAL COMPONENTS Before removing each component, disconnect cables and earth lines attached to the component. REMOVAL 22B7RE29 BATTERY Before pulling out the battery plug, tilt the mast forward a little, and lower the fork to the lowest position. The batteries weigh from around 1130kg to 1600kg so the extreme care must be taken when handling them.
  • Page 33 Pump motor Lower the fork to floor. 20B7RE21 Remove the left hand side cover. Side cover-LH 22B7RE22 Disconnect the wiring of pump motor and remove the gear pump from pump motor. Pump motor Gear pump 22B7RE23 Remove the tightening bolts of the pump motor mounting bracket.
  • Page 34 4. WHEEL BRAKE REMOVAL B153RE002 Front wheel Put a block under the mast and tilt forward, or jack up the bottom of the frame to raise the front wheels off the ground, then remove the front wheels. Fork down Drive bolt shaft Block...
  • Page 35 INSTALLATION Installation is in the reverse order to removal, but be careful of the following points. Coat the mounting bolts with loctite and tighten to 26kgf m(188lbf ft) Fork down Block B207RE34 When replacing the oil seal inside the hub, be careful to install the seal facing in the correct direction (Lip on outside) and knock into place.
  • Page 36 Counterweight Install a lifting tool in the counterweight, and raise with a crane. Remove the mounting bolts, raise slightly and move to the rear. Weight of counterweight(standard) 590kg (1300lb) 1080kg (2380lb) 20BC-7 30BC-7 925kg (2040lb) 1250kg (2760lb) 25BC-7 32BC-7 Tightening torque : 70~90 kgf m (506~651lbf ft). Apply loctite #277.
  • Page 37 Mounting bolt Put a block under the rear axle, support on a truck, and raise the frame with a crane. Remove the mounting bolts installed to the frame, and pull out to the rear. There are shims between the support and rear axle to prevent play. B207RE40 INSTALLATION Support...

  • Page 38: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5...

  • Page 39: Group 1 Structure And Operation

    SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. DRIVE AXLE UNIT STRUCTURE 1 B153PT01 Case 10 Spring washer 18 Drive shaft Case 11 Bolt 19 Washer 12 Spring washer 20 Side gear Case Air breather 13 Dowel pin 21 Pinion gear shaft Plug 14 Magnetic plug...
  • Page 40 STRUCTURE 2 GEAR 4 DIFFERENTIAL CASE CASE 35 36 CASE DRIVE SHAFT 47,48 B153PT02 35 Liner 44 Lock washer 26 Ball bearing 27 Gear 1 36 Lock nut 45 Oil seal 28 Ball bearing 37 Drum brake 46 Hub bolt 29 Gear 3 38 Oil seal 47 Wheel brake-LH...
  • Page 41 2. SPECIFICATION Item Unit Specification Max input torque Max input rpm 3500 43 : 24(1.792 : 1) G2 : G1 49 : 22(2.227 : 1) G3 : G2 Gear ratio 50 : 13(3.846 : 1) G4 : G3 15.348 Total Quantity of oil...

  • Page 42: Group 2 Troubleshooting

    G G ROUP 2 TROUBLESHOOTING Problem robable cause Remedy 1. Continuous metallic groan 1) During acceleration - Adjust back-lash or replace gears. Worn out gears. Pinion and bevel gear meshed too deeply. 2) During travelling at - Refill Lack of gear oil. uniform speed - Replace Worn out gears.

  • Page 43: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY DRIVE AXLE Remove the drive tires from wheel hub. B153DAD001 Remove the drain plug and drain gear oil. B153DAD002 Pull out the drive shaft with universal puller. B153DAD003...
  • Page 44 Remove the outer nut by straightening the locking part of the outer nut. When loosening the nut, use special tool and do not use improper method to loosen this nut. B153DAD004 Remove the inner nut by straightening the locking part of the inner nut. When loosening the nut, use special tool and do not use improper method to loosen this nut.
  • Page 45 Remove the brake bolts. B153DAD008 Separate the brake from drive axle. B153DAD009 (10) Separate the drive support (righthand) from drive axle. B153DAD010 (11) Separate the T/M case from drive axle. B153DAD011...
  • Page 46 (12) Pull out the differential case assembly. B153DAD012 (13) Remove T/M case bolts. B153DAD013 (14) Separate the T/M case. B153DAD014 (15) Pull out the gear. B153DAD015...
  • Page 47 (16) Pull out the gear. B153DAD016 (17) Pull out the bearing with universal puller. B153DAD017 (18) Remove the locking nut. B153DAD018 (19) Pull out the distance piece. B153DAD019...
  • Page 48 (20) Separate the gear from differential case with rubber mallet. B153DAD020 (21) Pull out the gear. B153DAD021 (22) Remove the tapered roller bearing, if needed. B153DAD022 (23) Remove the bearing cup. B153DAD023 3-10...
  • Page 49 (24) Remove the opposite bearing cup. B153DAD024 HUB DRUM Remove the bolts. B153DAD025 Separate drum and wheel hub. B153DAD026 Replace a worn wheel bolts. B153DAD027 3-11...
  • Page 50 Hub will come off together with brake drum. Tapered roller bearing will come out with the hub. Replace oil seal, O-ring and retainer. B153DAD028 Separate tapered roller bearing and retainer. B153DAD029 Remove the opposite bearing cup. B153DAD030 3-12...
  • Page 51 DIFFERENTIAL ASSEMBLY Remove the gear from differential case and bolt. B153DAD031 Extract the spring pin. B153DAD032 Pull out the pinion gear shaft. B153DAD033 Separate the pinion gear(2pcs) from differential assembly. B153DAD034 3-13...
  • Page 52 Pull out the side gear from differential. B153DAD035 Extract the side gear washer. B153DAD036 Put disassembled parts in order(by groups) and be careful not to lose bulk parts such as bolts, washers and snap ring etc. B153DAD037 3-14...
  • Page 53 2. ASSEMBLY DIFFERENTIAL SUB ASSEMBLY Install the washer(2pcs) to the case assembly, putting the grease. B153DAA001 Install the side gear(2pcs) to the case assembly. B153DAA002 Install the pinion gear(2pcs) to the case assembly. B153DAA003 After adjusting the hole of spring. B153DAA004 3-15...
  • Page 54 Insert the spring pin to shaft. B153DAA005 Install the gear to case assembly. B153DAA006 After putting loctite #277, secure them by tightening the bolts to specified torque. Tightening torque : 10.9~15.1kgf m (79~109lbf ft) B153DAA007 Install the ball bearing(2pcs) to case assembly.
  • Page 55 HUB DRUM SUB ASSEMBLY Press the bearing cup. B153DAA009 Press the opposite bearing cup. B153DAA010 Install the tapered roller bearing to the wheel hub. B153DAA011 After putting the TB #1102, install the oil seal retainer to the wheel. B153DAA012 3-17...
  • Page 56 After putting the TB #1102, install the oil seal to the wheel hub. B153DAA013 Fill a wheel hub center about 50~70% full with grease. B153DAA014 Install the brake drum and the wheel hub. B153DAA015 After putting loctite #277, secure them by tightening the bolts to specific torque.
  • Page 57 DRIVE AXLE ASSEMBLY Press the taper roller bearing to a gear. B153DAA017 Press the bearing cup. B153DAA018 Install the gear to case. B153DAA019 Insert the gauge for a gap measurement to a gear. B153DAA020 3-19...
  • Page 58 Install gauge to case. B153DAA021 Measure a gap between the case and gauge. B153DAA022 Press the bearing cup. B153DAA023 Insert the distance piece (the same thickness and number as those removed during disassembly). B153DAA024 3-20...
  • Page 59 Install the nut Tightening torque : 18~22kgf m (130~159lbf ft) B153DAA025 (10) Measure the tightening torque of taper roller bearing. Pre-load Torque : 0.04~0.06kgf m (0.3~0.43lbf ft) B153DAA026 (11) Secure it with nut tightening to specified torque, lock the nut. B153DAA027 (12) Install the ball bearing to the gear.
  • Page 60 (13) Install the ball bearing on the opposite side. B153DAA029 (14) Install the ball bearing to the gear. B153DAA030 (15) Install the differential subassembly to the case. B153DAA031 (16) Confirm a attachment condition of the ball bearing. B153DAA032 3-22...
  • Page 61 (17) Put the liquid gasket(TB #1215) on both side of packing for the case. B153DAA033 (18) Install the case assembly to the case. B153DAA034 (19) Install the bolts after putting the loctite #227. Tightening torque : 0.9~13.3kgf m (6.5~96.2lbf ft) B153DAA035 (20) Insert the dowel pin to the case.
  • Page 62 (21) Install the gear to the case. B153DAA037 (22) Install the gear to the case. B153DAA038 (23) Put the liquid gasket(TB #1215) on both side of packing for the case. B153DAA039 (24) Install the case fitting into the dowel pin. B153DAA040 3-24...
  • Page 63 (25) Install the bolts after putting the loctite. Tightening torque : 11~15kgf m (79~108lbf ft) B153DAA041 (26) Install the bolts after putting the loctite (#277). Tightening torque : 11~15kgf m (79~108lbf ft) B153DAA042 (27) Install the oil seal on both sides. (Put the liquid gasket on the circumfe- rence section and the grease on the lib) B153DAA043...
  • Page 64 (29) Install the drive support to the case tube. B153DAA045 (30) Install the righthand and lefthand brake respectively. B153DAA046 (31) After putting the loctite #277, install the bolt and plane washer. B153DAA047 (32) Install the hub drum sub. B153DAA048 3-26...
  • Page 65 (33) Insert the taper roller bearing to the hub drum. B153DAA049 (34) Install the adjust nut on both sides. Tightening torque : 3~5kgf m (21.7~36lbf ft) B153DAA050 (35) Measure the pre-load torque of taper roller bearing. B153DAA051 (36) If it satisfy the preload, secure the lock washer to nut groove.
  • Page 66 (37) Install the outer nut. B153DAA053 (38) Bend the lock washer to outer side. B153DAA054 (39) Put the liquid gasket(TB #1215) B153DAA055 (40) Install the shaft to distinguish between the two shaft. (Righthand : long, lefthand : short) B153DAA056 3-28...
  • Page 67 (41) Install the drain plug. Put loctite #572 B153DAA057 (42) Fill in the gear oil(SAE 85W/140) until flat part of check plug. After putting the loctite #572, install the check plug. B153DAA058 (43) After putting the loctite #572, install the air breather(PT1/2).

  • Page 68: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5 Group 3 Test and adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8...

  • Page 69: Group 1 Structure And Function

    SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE There are two brake systems, the foot brake system and the hand brake system. In the foot brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
  • Page 70 3. BRAKE PEDAL AND PIPING The brake system provides two systems, a foot brake and a parking brake. In the foot brake system, the oil pressure which is generated in the master cylinder when the brake pedal is depressed is transmitted to the wheel cylinders. The piston of the wheel cylinder presses the brake shoes and then moves outward causing contact with the drums and braking force is obtained.
  • Page 71 4. WHEEL BRAKE STRUCTURE The wheel brake assembly mounts to the flange on the drive axle housing casting and is basically contained within the hub assembly. The inside of the hub is machined and acts as the brake drum. 10 3 31 161713 28,29 Section A-A 5 12...
  • Page 72 5. BRAKE MASTER CYLINDER(DRY TYPE) STRUCTURE D255BS04 Body Spacer 13 Rod 18 Band bolt Piston Plate 14 Yoke 19 Band plate Primary cup Key wire 15 Nut 20 Band washer Secondary cup 10 Boot 16 Nipple 21 Cap Spring 11 Check valve 17 Band 22 Cap Spring seat...

  • Page 73: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS RAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. WHEEL BRAKE Compact wheel base chassis Measure lining at point with most wear, and check that lining thickness is at least 2.0mm(0.08in).
  • Page 74 . TROUBLESHOOTING Problem ause Remedy Insufficient braking force Hydraulic system leaks oil. Repair and add oil. Hydraulic system leaks air. Bleed air. Lining surface soiled with water or oil. Clean or replace. Lining surface roughened or in poor Repair by polishing or replace. contact with drum.
  • Page 75 Problem ause Remedy Brake squeaks Lining surface roughened. Repair by polishing or replace. Lining worn. Replace. Poor shoe to lining contact. Replace. Excessively large friction between Clean and apply brake grease. shoe and back plate. Foreign matter on drum sliding surfa- Clean Drum sliding surface damaged or di- Replace.

  • Page 76: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS 1. ADJUSTMENT OF WHEEL BRAKE Adjustment wheel Lever Adjust with engine stopped. Jack up truck. Extend adjustment screw by clicking adjustment wheel teeth with a screwdriver until wheel(mounted on brake drum being adjusted) offers a light Adjustment screw resistance when turned by hand.
  • Page 77 3. ADJUSTMENT OF PEDAL BRAKE PEDAL Pedal height from floor plate Adjust with stopper bolt. 140~145mm Pedal height : 140~145mm(5.5~5.7in) Adjust with rod of master cylinder Play : 8~12mm(0.31 ~ 0.47in) Floor plate 22B7BS07...

  • Page 78: Section 5 Steering System

    SECTION 5 STEERING SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13...

  • Page 79: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Steering cylinder Steering axle Steering unit Hyd oil filter Test coupling Hyd tank Hyd gear pump 20BC7SS01 The steering system for this machine is composed of hydraulic gear pump, steering wheel assembly, steering unit, steering cylinder, steering axle and pipings.
  • Page 80 2. HYDRAULIC CIRCUIT 10MPa Return line 22B7SS02 Hydraulic gear pump with priority valve Suction strainer Steering unit 10 Return filter Steering cylinder 11 Hydraulic oil tank...
  • Page 81 NEUTRAL 10MPa Return line 22B7SS03 The steering wheel is not being operated so control spool(G) does not move. The oil from hydraulic tank(11) enters to hydraulic gear pump(1) and pressurized so that the oil flows into the inlet port(P) of steering unit(3) and the spool(K) moves to the right. Most of pump oil flows to MCV through the EF port and partially flows into the hydraulic tank(11) through the spool(K).
  • Page 82 LEFT TURN 10MPa Return line 22B7SS04 When the steering wheel is turned to the left, the spool(G) within the steering unit(3) connected with steering column turns in left hand direction. As this time, the oil discharged from hydraulic gear pump(1) flows into the spool(G) of the steering unit(3) through the inlet port(P) and flows to gerotor(H).
  • Page 83 RIGHT TURN 10MPa Return line 22B7SS05 When the steering wheel is turned to the right, the spool(G) within the steering unit(3) connected with steering column turn in right hand direction. As this time, the oil discharged from hydraulic gear pump(1) flows into the spool(G) of the steering unit(3) through the inlet port(P) and flows to gerotor(H).
  • Page 84 3. STEERING UNIT STRUCTURE 29-4 29-5 29-6 29-3 29-1 29-2 27-3 27-2 27-4 27-1 22B7SS08 Dust seal 13 Gerotor set 27 P-port check valve Retaining seal 14 Bearing race 27-1 Plug 27-2 Poppet Cap seal 15 Bore screw Thrust bearing 16 Drive 27-3 Spring seat Ball...
  • Page 85 OPERATION The steering unit is composed of the control valve(rotary valve) and the metering device. The control valve controls the flow of oil from the pump in the interior of the unit depending on the condition of the steering wheel. The metering device is a kind of hydraulic motor composed of a stator and a rotor. It meters the required oil volume, feeds the metered oil to the power cylinder and detects cylinder’s motion value, that is, cylinder’s motion rate.
  • Page 86 4. STEERING AXLE STRUCTURE 1-12 1-31 1-12 1-26 1-12 1-29 1-25 1-30 1-23 1-32 1-29 1-17 1-24 1-30 1-16 1-21 1-15 1-20 1-35 1-14 1-34 1-13 1-18 1-36 1-22 1-17 1-16 1-15 1-27 1-28 1-18 1-33 1-15 1-16 1-17 1-11 1-34 1-35 1-33...
  • Page 87 TIGHTENING TORQUE AND SPECIFICATION 55~61kg m(398~441lb ft) Stroke 85mm Stroke 85mm Apply loctite #277. 27~36kg m(195~260lb ft) Apply loctite #277. 20BC7SS09 Center pin support Type Unit single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of degree...

  • Page 88: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS Check item Checking procedure Steering wheel Set rear wheels facing straight forward, then turn steering wheel to left and right. Measure range of steering wheel movement before rear wheel starts to move. 30-60mm (1.2-2.4 in) Range should be 30~60mm at rim of steering wheel.
  • Page 89 Problem ause Remedy Steering wheel turns unstea- Lockout loosening. Retighten. dily. Metal spring deteriorated. Replace. Steering system makes abn- Gear backlash out of adjustment. Adjust. ormal sound or vibration. Lockout loosening. Retighten. Air in oil circuit. Bleed air. Abnormal sound heard when Valve steering wheel is turned fully Faulty.
  • Page 90 OWER STEERING UNIT Problem ause Remedy Oil leakage Fittings loose, worn, or damaged. Check and replace the damaged parts. Deteriorated seals by excessive heat. Replace the seals. Loose screw or its deteriorated Replace the sealing and tighten sealing. screw appropriately. Internal seals worn or damaged.

  • Page 91: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 29-4 29-5 29-6 29-3 29-1 29-2 27-3 27-2 27-4 27-1 22B7SS08 Dust seal 13 Gerotor set 27 P-port check valve Retaining seal 14 Bearing race 27-1 Plug Cap seal 15 Bore screw 27-2 Poppet Thrust bearing 16 Drive...
  • Page 92 TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-14...
  • Page 93 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1kgf (0~54.4lbf ft) 13mm socket spanner 6, 8mm and 12mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 5-70(2) TIGHTENING TORQUE L : Left port R : Right port T : Tank...
  • Page 94 DISASSEMBLY Disassemble steering column from steering unit and place the steering unit in the holding tool. Screw out the screws in the end cover(6- off plus one special screw). 5-72(1) Remove the end cover, sideways. 5-72(2) Lift the gearwheel set(With spacer if fitted) off the unit.
  • Page 95 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball. B20H7SS09 5-17...
  • Page 96 Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and thrust bearing will be pushed out of the housing together.
  • Page 97 (12) Carefully press the spool out of the sleeve. 5-74(4) (13) Press the neutral position springs out of their slots in the spool. 5-75(1) (14) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (15) Screw out the plug using an 8mm hexagon socket spanner.
  • Page 98 (16) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (17) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (18) The pressure relief valve is now disassem- bled. D353SE13 5-20...
  • Page 99 ASSEMBLY Assemble spool and sleeve. When assembling spool and sleeve only one of two possible ways of positioning the spring slots is correct. There are three slots in the spool and three holes in the sleeve in the end of the spool / sleeve opposite to the end with spring slots.
  • Page 100 Press the springs together and push the neutral position springs into place in the sleeve. 5-77(2) Line up the springs and center them. 5-77(3) Guide the ring down over the sleeve. The ring should be able to rotate free of the springs.
  • Page 101 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) Assembly pattern for standard bearings Outer bearing race Thrust bearing Inner bearing race Spool Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 102 (11) Grease O-ring with hydraulic oil and place them on the tool. 5-79(1) 5-79(2) (12) Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.
  • Page 103 (14) Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore. 5-80(1) Installation instructions for lip seal (15) Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 104 (17) Press and turn the lip seal into place in the housing. 5-81(1) (18) With a light turning movement, guide the spool and sleeve into the bore. Fit the spool set holding the cross pin horizontal. 5-81(2) (19) The spool set will push out the assembly tool guide.
  • Page 105 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20 5-82(2) (23) Place the distributor plate so that the channel holes match the holes in the...
  • Page 106 (25) Place the cardan shaft as shown - so that it is held in position by the mounting fork. 5-83(1) (26) Grease the two O-rings with mineral oil approx. viscosity 500 cSt at 20 C and place them in the two grooves in the gear rim.
  • Page 107 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. Tightening torque : 4.0 0.5kgf m (28.9 3.6lbf ft) 5-84(3)
  • Page 108 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. Do not use a hammer! 5-85(2) 5-30...
  • Page 109 2. STEERING CYLINDER STRUCTURE B207SE21 Tube assembly Rod seal O-ring Rod assembly Back up ring 10 O-ring Gland Dust wiper 11 Piston seal Bushing Snap ring 12 Bushing 5-31...
  • Page 110 DISASSEMBLY Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in a vice. Remove the gland by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube. Check wear condition of the sealing parts.
  • Page 111 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Set a special tool the cylinder, gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland assembly, and tighten it with torque 40 4kgf m (289 29lbf ft).
  • Page 112 3. STEERING AXLE STRUCTURE Do not remove the stopper bolt unless necessary. 1-12 1-31 1-12 1-26 1-12 1-29 1-25 1-30 1-23 1-32 1-29 1-17 1-24 1-30 1-16 1-21 1-15 1-20 1-35 1-14 1-34 1-13 1-18 1-36 1-22 1-17 1-16 1-15 1-27 1-28 1-18...
  • Page 113 CHECK AND INSPECTION 20BC7SS13 mm(in) Criteria Remedy Check item Standard size Repair limit Diameter of king pin 35(1.38) 34.8(1.370) Replace Vertical play of knuckle 0.2(0.008) Adjust with shims Diameter of center pin 50(2.0) 49.5(1.9) Replace Damage, wear Rear axle, hub, knuckle, bearing Replace Seizure, abnormal noise, defective rotation 5-35...
  • Page 114 DISASSEMBLY Servicing work on the knuckle part can be carried Tire out without removing the axle assy from chassis. The work can be done by jacking up the balance Taper roller bearing weight part of the truck. Castle nut Remove hub cap. Split pin Pull out split pin and remove castle nut and plain Plain washer...
  • Page 115 Loosen set screw(1-5) and nut(1-6). 1-17 Remove retaining ring(1-17), oil seal(1-33). 1-15 (10) Push out the king pin(1-18) without damaging 1-12 the knuckle arm (1-2). 1-18 (11) Pull out the needle bearing (1-15). If any defect is observed in needle bearing(1-15), pull it out by using extractor.

  • Page 116: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-16 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20...

  • Page 117: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 10 MPa LIFT TILT AUX 1 AUX 2 22B7HS01 Hydraulic gear pump with priority valve Suction strainer Main control valve Down control valve Steering unit Down safety valve Steering cylinder 10 Return filter Tilt cylinder...
  • Page 118 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION Load check valve LIFT Steering system Return line 22B7HS02 When the lift control lever is pulled back, the spool on the first block is moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of lift cylinder(6) by pushing the load check valve of the spool.
  • Page 119 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION LOWER Steering system Return line 22B7HS03 When the lift control lever is pushed forward, the spool on the first block is moved to lower position. The work port(1A) and the small chamber and the large chamber are connected to the return passage, so the forks will be lowered due to its own weight.
  • Page 120 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION Load check valve TILT Steering system FORWARD Return line 22B7HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position. The oil from hydraulic gear pump(1) flows into main control valve (2) and then goes to the large chamber of tilt cylinder(5) by pushing the load check valve of the spool.
  • Page 121 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION Load check valve Steering system TILT BACKWARD Return line 22B7HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the small chamber of tilt cylinder(5) by pushing the load check valve of spool.
  • Page 122 2. HYDRAULIC GEAR PUMP STRUCTURE 21 20 14 11 22B7HS19 Gear housing 13 Throttling screw 24 Filter Body 14 Washer 25 Steel flange Rear end cover 15 Seal 26 Spring seat Front cover 16 Seal 27 Splined conn shaft Half thrust plate 17 Seal 28 Spring Half thrust plate...
  • Page 123 3. MAIN CONTROL VALVE STRUCTURE (4 Spool, without OPSS) INLET LIFT TILT AUX1 AUX2 OUTLET 3A 3B 4A 4B 2A 2B VIEW A Port name Size Port Inlet port 7/8-14UNF Outlet port 7/8-14UNF Work port 7/8-14UNF Work port 3/4-16UNF 2A, 2B, 3A, 3B, 4A, 4B 22B7HS07 Inlet block assy Outlet block assy...
  • Page 124 STRUCTURE(4 Spool, with mast tilting, lifting and lowering OPSS) INLET LIFT TILT AUX1 AUX2 OUTLET 3A 3B 4A 4B 2A 2B VIEW A Port Port name Size Inlet port 7/8-14UNF Outlet port 7/8-14UNF Work port 7/8-14UNF 2A, 2B, 3A, 3B, 4A, 4B Work port 3/4-16UNF 22B7HS08...
  • Page 125 INLET SECTION Operation The inlet section contains the pump inlet connection and main relief valve. INLET 190bar 22B7HS09 Operation of relief valve at setting pressure When the pressure at inlet reaches to setting pressure, the pilot poppet which is in the main relief valve is opened by pressure.
  • Page 126 LIFT SECTION Operation The lift section has a single work port to direct flow to the lift cylinder. Only one work port is used, because the lift cylinder is single-acting(gravity returns the mast to the lowered position). The lift section also contains part of the components which comprise the safety features. There is a lift lock check valve.
  • Page 127 TILT SECTION Operation The tilt spool contains an internal plunger which acts to stop tilt forward actuation when the battery power is off. Tilt forward When the seated operator shifts the lever forward, pressure is applied to the head of the tilt cylinder, and the forks tilt forward.
  • Page 128 AUXILIARY SECTIONS Operation Many different functions can be controlled by the auxiliary spool sections. In general, one work port is pressurized by high pressure oil from the parallel passage, past the load check valve, past the metering notches, and to the cylinder. Simultaneously, oil from the other work port is directed across the spool metering notches to tank.
  • Page 129 OUTLET SECTION Operation The outlet section contains the tank port and the secondary relief valve(with built-in anti-cavitation feature). OUTLET 130bar 22B7HS17 Operation of relief valve at setting pressure When the pressure at outlet reaches to setting pressure, the pilot poppet which is in the main relief valve is opened by pressure.
  • Page 130 MAIN RELIEF VALVE This valve is a type of pilot piston to prevent hydraulic components and pipes from being broken by high pressure so, it keeps under pressure limited. Relief valve pressure varies by 130kgf/cm in accordance with 1 revolution of adjust bolt. 22B7HS20 Pilot seat Main spring...
  • Page 131 4. LIFT CYLINDER D255HS18 Tube assembly Wear ring 11 O-ring Retaining ring 12 Guide Piston Gland 13 DU bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 5. TILT CYLINDER 23 18 19 20,21,22 12,13 8 17 16 11,10 15,14 9 1 2 6 20BC7HS24 Tube assembly Du bushing...

  • Page 132: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1m from ground. Wait for 10 minutes and measure hydraulic drift(amount forks move down and amount mast tilts forward). heck condition 20B7HS08 - Hydraulic oil : Normal operating temp...
  • Page 133 . TROUBLESHOOTING SYSTEM Problem ause Remedy Large fork lowering speed Seal inside control valve defective. Replace spool or valve body. Oil leaks from joint or hose. Replace. Seal inside cylinder defective. Replace packing. Large spontaneous tilt of mast Tilting backward : Check valve defec- Clean or replace.
  • Page 134 HYDRAULIC GEAR PUMP Problem ause Remedy Pump does not develop full System relief valve set too low or Check system relief valve for proper pressure leaking. setting. Oil viscosity too low. Change to proper viscosity oil. Pump is worn out. Repair or replace pump.
  • Page 135 LIFT CYLINDER Problem ause Remedy Oil leaks out from rod cover Foreign matters on packing. Replace packing. through rod Unallowable score on rod. Smooth rod surface with an oil stone. Unusual distortion of dust seal. Replace dust seal. Chrome plating is striped. Replace rod.

  • Page 136: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP DISASSEMBLY Clean the pump externally with care. 22B7HS30 Loosen and remove the clamp bolts. Coat the sharp edges of the drive shaft with adhesive tape and smear a clean grease on the shaft end extension to avoid any damaging lip of the shaft seal when removing the mounting flange.
  • Page 137 Ease the drive gear up to facilitate removal the front plate. 22B7HS33 Remove driven gear and pressure plate also keeping all as straight as possible. And now, 1st section is completely disassembled. 22B7HS34 After removing intermediate section, disassemble 2nd section following same ways for 1st section.
  • Page 138 REPLACING SHAFT SEAL Take off snap-ring with proper tool. 22B7HS37 Remove old shaft seal from the cover with not sharp-end rod while paying attention not to give any scratch on the surface of shaft seal. 22B7HS38 Clean surface contact shaft seal. 22B7HS39 Smear grease on the hole for shaft seal before fitting shaft seal into it to prevent...
  • Page 139 Insert the shaft seal carefully and fit it inside of mounting flange with proper tool. 22B7HS41 Fit the snap ring in pre-arranged position with proper tool. 22B7HS42 REPLACING SEALS FOR PRESSURE PLATE Before replacing seals for pressure plate, make it sure that rubber spring is in right position.
  • Page 140 Smear grease little bit before locate O-ring and back-up ring. 22B7HS45 22B7HS46 ASSEMBLING LS-BLOCK Prepare all components needed to assemble LS-Block. Pay attention the position of each component. 22B7HS47 Insert the spool into the body with care not to make any scar on the surface of spool. 22B7HS48 6-24...
  • Page 141 Tighten both caps with torque wrench. Tightening torque : 10.2kgf m(73.8lbf ft) 22B7HS49 SSEMBLING COMPLETE UNIT Locate 2nd section prearranged square ring on both side on the LS-block. 22B7HS50 Insert pressure plate and to the end very carefully while pushing two rubber springs. O-ring side should face covers, not gears.
  • Page 142 Insert preassembled pressure plate with same way for 2nd section. 22B7HS53 Locate driving and driven gears at right position and pressure plate and mounting flange also. 22B7HS54 Tighten the bolts with washer in a crisscross pattern. Tightening torque : 4.59kgf m(33.2lbf ft) 22B7HS55 Check that the pump rotate freely when the drive shaft is turned by hand.
  • Page 143 2. MAIN CONTROL VALVE ASSEMBLY General Ensure that the assembly area will be clean and free of contamination. Use a flat(within 0.2mm) work surface when bolting the valve sections together. Use calibrated torque wrenches and instrumentation. Additional auxiliary valve sections may be added to the main control valve in a similar manner as indicated below.
  • Page 144 Lift lock check valve 4.5~5.0 kgf m (32.5~36.2 lbf ft) Plug 4.5~5.0 kgf m Load check valve (32.5~36.2 lbf ft) 3.5~4.0 kgf m (25.3~30 lbf ft) Dust wiper Seal Main relief valve 4.5~5.0 kgf m (32.5~36.2 lbf ft) Seal plate Bolt : M6X1.0 Bolt : M6X1.0 Secondary main relief valve...
  • Page 145 Lift lock check valve 4.5~5.0 kgf m (32.5~36.2 lbf ft) Plug 4.5~5.0 kgf m Load check valve (32.5~36.2 lbf ft) 3.5~4.0 kgf m (25.3~30 lbf ft) Dust wiper Seal Main relief valve 4.5~5.0 kgf m (32.5~36.2 lbf ft) Seal plate Bolt : M6X1.0 Bolt : M6X1.0 Secondary main relief valve...
  • Page 146 Lift lock check valve 4.5~5.0 kgf m (32.5~36.2 lbf ft) Plug 4.5~5.0 kgf m Load check valve (32.5~36.2 lbf ft) 3.5~4.0 kgf m (25.3~30 lbf ft) Dust wiper Seal Main relief valve 4.5~5.0 kgf m (32.5~36.2 lbf ft) Seal plate Bolt : M6X1.0 Bolt : M6X1.0 Secondary main relief valve...
  • Page 147 DISASSEMBLY General Subassemblies (such as relief valves, check valves, and spools) may be removed without having to loosen the tie rods and disassembling the entire valve. Disassemble the valve sections on a flat working surface. Ensure that the disassembly area will be clean and free of contamination. Keep the disassembly area neat to avoid loss or damage of parts.
  • Page 148 3. LIFT CYLINDER STRUCTURE Down control valve Down safety valve 22B7HS26 Tube assy Wear ring 11 O-ring Rod assy Retaining ring 12 Guide Piston Gland 13 Du bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 6-32...
  • Page 149 DISASSEMBLY Hold the cylinder tube in a vice, loosen the Guide cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn. Lever up the edge of the guide, then turn the guide in again and the guide can be removed.
  • Page 150 4. TILT CYLINDER STRUCTURE 22B7HS23 Tube assy Du bushing 17 Lock washer 10 Rod seal 18 Rod eye Piston 11 Back up ring 19 Spherical bearing Piston seal 12 Dust wiper 20 Hexagon bolt Wear ring 13 Snap ring 21 Spring washer O-ring 14 O-ring 22 Hexagon nut...
  • Page 151 DISASSEMBLY Hold the parallel parts of the cylinder tube bottom in a vice and mark the rod head end to show how much it is screwed in, then remove the rod head. Next, hook a wrench into the notch at the cylinder head and remove the cylinder head from cylinder tube.

  • Page 152: Section 7 Electrical System

    SECTION 7 ELECTRICAL SYSTEM Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2 Group 3 Electric components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3...

  • Page 153: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 20BC7EL02 Combination switch Fuse box assy 15 Beacon lamp(opt) Parking switch Contactor 16 Accelerator assy High horn 10 Pump controller 17 DC-DC converter Drive motor 11 Back up alarm 18 Display Pump motor 12 Traction controller 19 Working lamp switch(opt) Flasher unit...

  • Page 154: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT FUSE BOX ASSY HEAD LAMP 24 24A SWITCH BRAKE FLAS LAMP -HER SWITCH UNIT LAMP RELAY INPUT OUTPUT LAMP FAN- FAN- FAN- FAN- INV. * NOTE DC-DC CONVERTER B+ : Battery positive B- : Battery negative C- : Converter negative (IN) (OUT)

  • Page 155: Group 3 Electric Components

    For the monitoring system, there are many sensors such as current sensors, hydraulic pressure sensors, and temperature sensors. The HYUNDAI Battery forklift trucks are equipped with the most advanced DRIVING CONTROL SYSTEM currently available world-widely. The operator friendliness features enable him to set the truck conditions properly according to each working circumstance easily on his seat, and the SELF- DIAGNOSTIC function displays current status of truck in working.
  • Page 156 2. BATTERY STRUCTURE Protective tube 9,10,11,12 20BC7EL03 Cells Negative leading cable Steel box Plug Cell connector Handle (Red) Common connector 10 Screw Row connector 11 Spring washer Positive leading cable 12 Nut...
  • Page 157 GENERAL As in the battery forklift, the battery is an energy source, the handling of the battery is very important. The life and performan- ce of the battery greatly depend on the ordinary handling and maintenance. Therefore, be sure to check and maintain the battery so that it may be kept best.
  • Page 158 SAFETY PRECAUTIONS When a sulfuric acid contact with skin For acid contact with skin, eye or clothing, flush with water immediately. If swallowed, drink a large amount of water or milk. Seek medical attention immediately. When handling acid, always wear eye goggles or a face shield and rubber gloves.
  • Page 159 Performance and maintenance of batteries Initial charge Wet-charged battery gradually decrease its capacity during storage. In order to provide sufficient discharge capacity in the first discharge, the good initial charge is required. The conditions of initial charging are seen as below at room temperature. By modified constant voltage charger Connect the battery to the charger and turn on the equalizing charge “ON”.
  • Page 160 Normal charge Charge the discharged batteries as quickly as possible. The temperature of electrolyte before starting the charging operation shall preferably be below 45 C, and the temperature during the charge should be maintained at no higher than 55 C. (Under any unavoidable situations, it should never be above 55 C).
  • Page 161 (for the purpose of uniform stirring of electrolyte by charging). If the electrolyte level is improper after completion of charging, you may topping up the electrolyte level to the maximum level . Determination of replenishment time and methods(cell with ONE TOUCH CAP) Confirm the electrolyte level by looking at the float in the ONE TOUCH CAP.
  • Page 162 You must make sure to clear of explosive hydrogen gas in the cells before repairs. Be careful not to drill to far into the cell and damage the unit. During drilling operation make sure lead curls produced do not contact opposite cell poles and cause a spark. Upon completion of drilling the intercell connectors, can be lifted off.
  • Page 163 TROUBLESHOOTING Nature of trouble ymptoms Causes Repair Deformation Deformation of container, Excessive temperature ris- Replace lid or one touch cap ing or external impact Breakage Electrolyte leakage acco- External impact, improper Replace or install a new rding to breakage of cont- handling, excessive vibrat- ainer, lid or one touch cap Termination of connector...
  • Page 164 3. DRIVE MOTOR STRUCTURE 20BC7EL07 Rotor Disc 15 Commutator end plate Circlip Terminal base 16 Sensor bearing Stator 10 End shield 17 Spring washer Terminal board 11 Ball bearing 18 O-ring Screw 12 Circlip 19 Cable Hexagon nut 13 Oil seal 20 Cylinder screw Hexagon nut 14 Screw...
  • Page 165 SPECIFICATION Item Unit Specification Type TSA270-210 Rated voltage Rated output 14.2 Insulation Class F MAINTENANCE INSTRUCTION Before starting the maintenance please disconnect the power supply. Ball bearing Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of repair, they should be replaced.
  • Page 166 4. PUMP MOTOR STRUCTURE 22B7EL08 Rotor End shield drive end 12 Screw Stator Oil seal 13 End shield non drive end Terminal Ball bearing 14 Sensor bearing Screw 10 Locking ring 15 Spring washer Hexagon nut 11 Locking ring 16 O-ring Crinkle washer 7-14...
  • Page 167 SPECIFICATION Item Unit Specification Type TSA200-230 Rated voltage Rated output Insulation Class F INTERNAL INVOLUTE SPLINE DATA Item Unit Specification Flat root side fit Class 7 No of teeth Spline pitch 16/32 Pressure angle Degree Major diameter 19.7104 Form diameter 19.1516 Minor diameter 16.0274...
  • Page 168 5. CONTROLLER SYSTEM STRUCTURE 20BC7EL10 Specifications Model Model Application Type Power Current limit Traction MOSFET 36-48V, 600A 600A/3min 20/25/30/32BC-7 Pump MOSFET 36-48V, 600A 600A/3min 7-16...
  • Page 169 O O PERATIONAL FEATURES Features Speed control. Optimum behavior an a slope due to the speed feedback: The motors speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set-point. The system can perform an electrical stop on a ramp (the machine is electrically hold on a slope) for a programmable time.
  • Page 170 DESCRIPTION OF THE CONNECTORS Traction controller Rubber cap (No. of pin B1~B8) VIEW A 35B7EL14 No. of pin Function Description +12V Positive of encoder power supply. ENC GND Negative of encoder power supply. SEAT Seat presence signal; Active HIGH. FORWARD Forward direction request signal;...
  • Page 171 No. of pin Function Description CAN H High level CAN-BUS voltage I/O. CAN L Low level CAN-BUS voltage I/O. NTHERM-L Negative of traction motor temperature sensor. PTHERM-L Positive of traction motor temperature sensor. Output of main contactor coil driver(drives to -BATT) Positive of main contactor coil.
  • Page 172 Encoder installation Traction controller card is fit for different types of encoder. To control AC motor with Zapi inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90 . The encoder power supply can be +12V. It can have different electronic output. A1 : +12V : Positive of encoder power supply.
  • Page 173 Pump controller Rubber cap (No. of pin B1~B8) VIEW A 35B7EL14 Function Description No. of pin +12V Positive of encoder power supply. ENC GND Negative of encoder power supply. PPOT Lift potentiometer positive: 10V output; keep load > 1k SEAT Seat presence signal;...
  • Page 174 Function Description No. of pin CAN H High level CAN-BUS voltage I/O. CAN L Low level CAN-BUS voltage I/O. -BATT -Batt. MOT TH Input for motor temperature sensor. Negative of the low lock valve. Positive of the low lock valve. SAFETY OUT If not connected to SAFETY, the MC coil power output will be disabled.
  • Page 175 FUNCTION CONFIGURATION TRACTION CONTROLLER Using the CONFIG MENU of the programming console, the user can configure the following functions (see "OPERATIONAL FEATURE" chapter for an explanation of "hydraulic steering function") : Submenu "SET OPTIONS" Hour counter - RUNNING : The counter registers travel time only. - KEY ON : The counter registers when the "key"...
  • Page 176 S.R.O. If this option is set to on the static return to off is requested for starting the truck. The required sequence is : Seat-direction lever-accelerator pedal or : Seat-accelerator pedal-direction lever within the seq. delay time If this option is set to off the required sequence to start the truck is : Direction lever-accelerator pedal or : Accelerator pedal-direction lever within the seq.
  • Page 177 Throttle 0 zone It establishes a deadband in the accelerator input curve (see also curve below). Throttle X point This parameter changes the characteristic of the accelerator input curve. Throttle Y point This parameter changes the characteristic of the accelerator input curve. SPEED f(Hz) MAX SPEED TROTTLE Y...
  • Page 178 PUMP CONTROLLER Using the config menu of the programming console, the user can configure the following functions. Submenu "SET OPTIONS" Hour counter - RUNNING : The counter registers travel time only. - KEY ON : The counter registers when the "key" switch is closed. Set temperature - DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to A25 input.
  • Page 179 Submenu "ADJUSTMENTS" Set battery type : Selects the nominal battery voltage. Adjust battery : Fine adjustment of the battery voltage measured by the controller. Throttle 0 zone : Establishes a deadband in the accelerator input curve (see also curve below). Throttle X zone : This parameter changes the characteristic of the accelerator input curve.
  • Page 180 PROGRAMMING & ADJUSTMENTS There are two ways to adjust parameter via a console or buttons on a display. Adjustments via buttons on a display, please refer to the display section. (page 7-44) ADJUSTMENTS VIA CONSOLE (Option) Adjustment of parameters and changes to the inverter's configuration are made using the digital console.
  • Page 181 Description of standard console menu Traction controller 20BC7EL18 7-29...
  • Page 182 Pump controller 20BC7EL20 7-30...
  • Page 183 Display 20B7EL27 7-31...
  • Page 184 Description of ALARMS menu The microprocessor in the controller records 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 inverter temperature. This function permits a deeper diagnosis of problems as the recent history can now be accessed.
  • Page 185 Description of console PROGRAM VACC function This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal. It enables compensation for non symmetry of the mechanical system between directions. The operation is performed by operating the pedal after entering the PROGRAM VACC function. Flow chart showing how to use the PROGRAM VACC function of the digital console: AC3 ZAPI V0.0 Opening Zapi display.
  • Page 186 TESTER MENU Traction controller The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to read voltage, current and temperature. In the following chapter a list of relative measurements for different configurations. Motor voltage This is the voltage supplied to the motor by the inverter;...
  • Page 187 Seat switch The level of the seat microswitch digital input. - ON / +VB = Input active, switch closed. - OFF / GND = Input non active, switch open. Cutback switch The level of the speed reduction microswitch. - ON / GND = Input active, switch opened. - OFF / +VB = Input non active, switch closed.
  • Page 188 Pump controller The most important input or output signals can be measured in real time using the TESTER function of the console. The console acts as a multimeter able to read voltage, current and temperature. The following definition listing shows the relative measurements : Motor voltage This is the voltage supplied to the motor by the inverter;...
  • Page 189 Aux in switch: Status of the aux in switch of the pump. - ON / +VB = Active entry of closed switch. - OFF / GND = Non active entry of open switch. Aux out switch: Status of the aux out switch of the pump. - ON / +VB = Active entry of closed switch.
  • Page 190 GENERAL SUGGESTION FOR SAFETY For a proper installation take care of the following recommendations: After operation, even with the key switch open, the internal capacitors may remain charged for some time. For safe operation, we recommend that the battery is disconnected, and a short circuit is made between battery positive and battery negative power terminals of the inverter using a resister between 10 ohm and 100 ohm.
  • Page 191 6. DISPLAY STRUCTURE The instrument panel has six built-in red LED, which provide the operator with an easy information about the status of some truck devices. H Y U N D A I 15B7OM65 Oil level warning lamp (option) Key 2 button Wrench warning lamp Key 3 button Thermometer warning lamp...
  • Page 192 WARNING LAMP When the key switch is OFF, the display makes a general test lighting and switching OFF all the LED in sequence. Oil level warning lamp (Option) This LED lights when the measured oil level of the hydraulic circuit is under the minimum acceptable mark. To connect the oil sensor output to the Analogue Input #1.
  • Page 193 TESTER MENU Status of keyboard buttons can be monitored in real time in the TESTER menu. Key 1 button Status of keyboard button: ON = Input active, button pushed OFF = Input not active, button released 16B7OM67 Key 2 button Status of TURTLE keyboard button: ON = Input active, button pushed...
  • Page 194 LCD FUNCTION 15B7OM77 Battery's state of charge The battery's state of charge indication is displayed on the left side of the unit (1); it is shown by ten notches. Each notch represents the 10% of the battery charge. As the battery becomes discharged, the notches turn off progressively, one after the other, in proportion to the value of the residual battery charge.
  • Page 195 Turtle The turtle symbol (3) is normally off; when it appears (fixed) it shows activation of the "soft" mode of the truck, in which maximum speed and acceleration are reduced. The "soft" mode can be activated pressing button Hour meter The number displayed on the bottom right side of the unit (4) shows the Hours Worked.
  • Page 196 DESCRIPTION OF PROGRAMMABLE FUNCTIONS Menu set model Connect to Using CANBUS link, every module connected to can net can act as the "access node" to the canbus net for the external world. For example the ZAPI hand console (or the PC-Win console) can be physically connected to one module and, by the canbus, virtually connected to any other module of the net.
  • Page 197 Maintenance The options are : PRESENT : A maintenance hour-counter is incremented with key ON. When the hours elapsed reach the programmed value with the display the warning SERVICE REQUIRED is shown. ABSENT : No SERVICE REQUIRED warning aintenance done It can be ON/OFF.
  • Page 198 DESCRIPTION OF CONSOLE USING Access to SET MODEL menu. The only parameter present in SET MODEL function is CONNECTED TO. By setting this parameter, operator can connect ZAPI console to every ZAPI product connected to CAN-BUS line. This functionality allows completely control of every ZAPI product without changing the position of the console connector.
  • Page 199 low chart showing how to make changes to option menu: Opening Zapi menu. Press ROLL UP & SET UP Buttons to enter CONFIG MENU. The display will show: SET MODEL. Press ROLL UP or ROLL DOWN until SET OPTIONS appears. SET OPTIONS menu appears.
  • Page 200 low chart showing how to use the TESTER function of the digital console: Opening Zapi menu. Press ENTER to go into the MAIN MENU. The display will show: PARAMETER CHANGE. Press ROLL UP or ROLL DOWN until TESTER menu appears on the display. The display will show: TESTER.
  • Page 201 DESCRIPTION OF ALARM MENU The microprocessor in the controller records 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 and the hour meter count. This function permits deeper diagnosis of problems as the recent history can now be accessed.
  • Page 202 Graphic Smart Display menu structure by the six operator buttons integrated in a membrane keyboard. At turn on the display shows the HYUNDAI logo for some seconds, then asks the starting password to have access to the main page (if "USER PASSWORD" option is ON), otherwise it shows directly the main page (if "USER PASSWORD"...
  • Page 203 ENTER PASSWORD ENTER USER PASSWORD SERVICE / ENGINEERING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 PERFORMANCE ROLLING D 247 :...
  • Page 204 ZAPI CONSOLE TRUCK MENU The display will act like a Zapi console. MAINTENANCE HOURS MAINTENANCE 00000 CHANGE PASSWORD ENTER OLD PASSWORD - - - - 1 2 3 4 5 6 7 8 9 ENTER OLD PASSWORD ENTER NEW PASSWORD - - - - 1 2 3 4 5 6 7 8 9 PASSWORD HAS...
  • Page 205 Performance rolling From MAIN PAGE using membrane keyboard numbers, it is possible to select the performance mode which must be used in traction and pump controllers. Performance can be chosen with button 4, and it is displayed in the top right side of the unit. When one performance is selected, the related information will be sent via canbus to traction and pump controllers that will manage this data.
  • Page 206 ANALYSIS OF GRAPHIC SMART DISPLAY RELATED ALARMS Graphic Smart Display alarms WATCHDOG Cause: At start-up the watch dog signal is already active before the software has generated it. At standby or running condition the watch dog signal is not active (in alarm status). Troubleshooting: The WD hardware circuit or microcontroller output port are damaged.
  • Page 207 CAN BUS KO Cause: Graphic Smart Display doesn't receive messages from canbus line or the hour meter synchronization at key-on fails. Troubleshooting: A) If this fault code is displayed together with other alarm messages, the fault is probably to be looked for in the Graphic Smart Display can interface, since the display seems to be unable to receive any can message.
  • Page 208 DIAGNOSTIC FAULT CODES Condition that has to occur Code Alarm string Description Traction Pump to come out from alarm status WATCHDOG Alarm : The Watchdog If the alarm is present in circuit been Init status, remove the triggered. alarm condition If the alarm has occurred in standby or running mode, it is necessary to remove...
  • Page 209 Condition that has to occur Code Alarm string Description Traction Pump to come out from alarm status DRIVER Alarm: Line contac- If the alarm is present in SHORTED tor coil driver is Init status, remove the shorted alarm cause If the alarm has occurred in standby or running mode, it is necessary to remove alarm cause and to...
  • Page 210 Condition that has to occur Code Alarm string Description Traction Pump to come out from alarm status AUX OUTPUT Alarm: EB coil driver If the alarm is present in shorted or open Init status, remove the alarm cause If the alarm has occurred in standby or running mode, it is necessary to remove alarm cause and to...
  • Page 211 Condition that has to occur Code Alarm string Description Traction Pump to come out from alarm status MOTOR Warning: The encoder To recycle the key STALL signal is constantly zero when the maxi- mum torque is applied to the motor SEQUENCE Warning: An incorrect To remove warning cause...
  • Page 212 . BATTERY CHARGER This explains basic information related to charger to help you easily understand and use it. This includes the contents from the way to install a charger to tips for emergency situations. This is focused on practices aiming to be usefully utilized in the field. BASIC INFORMATION What is charger Charger is a device which makes a battery accept D.C electricity under optimal condition as it...
  • Page 213 Names of each part (independent items) BR7BAT30 Main PCB board Shunt Resistance (RD) Main trans (Class H) 10 Resistance (DR) Cooling fan MG S/W 11 TAP changer SCR module Assistant trans 7-61...
  • Page 214 CHARGER INSTALLATION METHOD Location for charger installation Dry and well ventilated place. No inflammable and B7 fire are near by. Safe place where no collision possibility with people or equipment is. Check points before installing charger Enough capacity of AC input power source to operate charger.
  • Page 215 Equalized charging Equalized charging is Equalized charging is to correct the battery when it does not normally perform its functions as the voltage differences are too big between cells of a battery. When equalized charging is required? When re-operates the battery after having left the battery for a long time.
  • Page 216 HOW TO CHECK THE CHARGER'S NORMAL OPERATION After changing SCR module or PCB (SE- 5000SN), the charger's normal operation should be checked. Checking order Separate the charger and battery connector. Separate lower cover in the front of the charger. Check the AV input voltage used from the input switch terminal in the lower left side of the inside of the charger.
  • Page 217 Convert the automatic / manual switch to manual. The automatic/manual switch is located in the lower left part of the PCB Be sure to check if battery connector is separated in advance. MG/SW operation (This switch is operated automatically.) Check the charging voltage soft start BR7BAT08 function (refer to the monitor) After 5 seconds next to turn the manual...
  • Page 218 If charger's out voltage is under 60V, it is abnormal. Please refer to the error sheet. When the charging voltage is indicated as normal condition (63V), convert automatic / manual switch to automatic and start charging. Display error code on the front cover as BR7BAT11 following table.
  • Page 219 CHECK POINTS BEFORE APPLYING AC input power source switch is input. Check if the battery connector of the forklift truck and charger's connector are connected. Check points when "Error" lamp is on in the front monitor of the charger. Check the front cover indicator. BR7BAT10 A.F : Input three phase power source continuity check = Check if input three...
  • Page 220 ERROR DETECTION Error list Only floating charge lamp is on in the monitor but it is not charged. ON and OFF is repeated with a few minutes intervals even after starting charging. Charger TRIP is occurred after abnormality lamp is on. In case error code is "O.V"...
  • Page 221 Troubleshooting Only floating charge lamp is on after indicating "A.O", It's not charged. 220/380V Model : Measure the TB.4 (380V) TB.8(220V) voltage between input voltage change over tabs 2-4 2-6 4-6 220,380,410,440V Model : Measure the voltage in front of In front of MS Manual/Auto TAP Changer AC INPUT MS S/W...
  • Page 222 ON and OFF is repeated with a few minutes intervals after starting charging. Indicate "O.C" on the monitor. - TH is operated (AC input over-current TRIP). OUTPUT CURRENT CREASE CREASE Serious trans noisy Measure output Exceed Adjust output current Current under the current using DC value : 15~20A...
  • Page 223 Charger TRIP is occurred after abnormality lamp is on. In case error code is "O.V" Over-voltage output / Set at 66Vdc (In case of BATT 48V) Turning charging voltage volume in Check After separating the battery connecter, the center of the right-hand side of the voltage of the turn on MS as converting PCB anti-clockwise rotation...
  • Page 224 Charger TRIP is occurred after abnormality lamp is on. In case error code is "O.C" Output over current, established as 120% of the rated current. crease crease Measure Re-establish the charging current Restart the charger as pushing the output current by volume in the center of PCB as turning reset switch in the monitor.
  • Page 225 Charger TRIP is occurred after it started charging and charging completion lamp is on. (In case input voltage is normal - Refer to the error detection No. 1) Restore the charger as pushing reset switch. Measure After separating battery connector, the output current by Measure the output put the automatic/manual selection...
  • Page 226 Charger has no response even if the battery connector is connected. - In case only floating LED is on, charger input power is cut off or doesn't connect. (In case the input voltage is normal - Refer to the error detection No. NO Charger BATTERY Connector contact fault Battery...
  • Page 227 HOW TO CHECK THE SCR MODULE Circuit Real diagram * Before checking SCR MODULE, be sure to disconnect bus bar and wire on the terminal. Measuring point SURGE PCB Measure value (Real diagram) No.1 ~ No.3 Forward : Under 100 k ohm ∞...
  • Page 228 PCB MAJOR PARTS NAME AND LOCATION 9 10 BR7BAT24 Micro control unit #1 Over voltage 13 Set input over current Micro control unit #2 Monitor level yellow 14 Auto/manual switch CN6 voltage detect Monitor level green 15 SCR control connector SH current detect 10 Under current 16 CN4 RY contact point...

  • Page 229: Section 8 Mast

    SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...

  • Page 230: Group 1 Structure

    SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) 20BC7MS01 Outer mast Chain sheave 13 Clamp Inner mast Lift chain 14 Back up liner Roller Anchor bolt 15 Shim(0.5, 1.0t) Tilt cylinder pin 10 Roller 16 Shim(0.5, 1.0t) Mast support cap 11 Retaining ring Bushing...
  • Page 231 2. 3 STAGE MAST(TF MAST) 20BC7MS02 Outer mast Lift chain 10 Chain sheave Middle mast Anchor bolt 11 Retaining ring Inner mast Sheave bracket 12 Mast support cap Roller Chain guard 13 Tilt cylinder pin Shim(0.5, 1.0t)
  • Page 232 3. CARRIAGE, BACKREST AND FORK 22BHA7MS20 Backrest Load roller Fork assembly Carriage Side roller Extension fork...
  • Page 233 4. INTEGRAL SIDE SHIFT, BACKREST AND FORK 22BHA7MS21 Backrest Load roller Fork assembly Integral side shift Side roller Extension fork...

  • Page 234: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. EX : =1050mm(41.3in) mm(in) STD Fork assy Applicable model Standard Limit F173796-02 20/25BC-7 45(1.8) 40(1.6) 30/32BC-7 40(1.6) 64FG-31020...
  • Page 235 . TROUBLESHOOTING MAST Problem Cause Remedy Forks fail to lower. Deformed mast or carriage. Disassemble, repair or replace. Fork fails to elevate Faulty hydraulic equipment. See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. Deformed mast assembly. Disassemble mast and replace damaged parts or replace complete mast assembly.
  • Page 236 ORKS Problem Cause Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear wear and reduces the thickness of the limit, replace fork. fork. Inspection for thickness is needed. Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...

  • Page 237: Group 3 Adjustment

    GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V MAST) INNER/OUTER MAST ROLLER CLEAR- ANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the roller side face and mast at the closest position on the opposite side to the...
  • Page 238 . MAST LOAD ROLLER(TF MAST) INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast and the middle mast, and adjust the clearance between the roller side face and mast at the closest position on the 15L7MS06...
  • Page 239 ARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, lower rollers after loosen the adjust screws from the side rollers. Shift the carriage to one side to bring the roller into contact with the inner mast, and measure the clearance between the roller side face and mast at...

  • Page 240: Group 4 Removal And Installation

    GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1inch) from the floor. Knob Turn the knob up and slide forks, one by Spring one, toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 241 SIDE ROLLER Side roller Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. Adjustment Once carriage is properly installed, loosen nuts and adjust screws, (if not...
  • Page 242 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Remove the carriage assembly and move them to one side. Loosen and remove bolts and spacer securing lift cylinders to outer mast. Loosen and remove hexagon bolts and nuts securing lift cylinders to inner mast. Attach chains or sling to the inner mast section at top crossmember.
  • Page 243 3 stage mast(TF mast) Remove the carriage assembly and move it to one side. Loosen and remove hexagon bolt securing bottom cylinder from outer mast. Loosen and remove band and special washers securing lift cylinders to middle mast. Remove the spring pin. Attach chains or sling to the inner and middle mast section at top crossmember.
  • Page 244 ELEVATING MAST Inner mast (V mast) After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. Lift inner mast upright straight up and out of outer mast section. Replace and reverse above procedure to install.
  • Page 245 CHAIN Chain sheave(V mast) Place a sling around carriage and attach Chain Outer mast to an overhead hoist. Lift carriage high Sheave enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 246 Chain wheel bearing support(TF mast) Remove the carriage assembly and move to one side. After removing bolt to securing chain wheel bearing support assembly to free lift cylinder. After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 247 Rust and corrosion Chains used on lift trucks are highly stressed precision components. It is very important that the “as-manufactured” ultimate strength and fatigue strength be maintained throughout the chain service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or roller chain because corrosion causes side plate cracking.
  • Page 248 Chain wear scale The chain can be checked for wear or stretching with the use of a chain wear scale. Stretching of a chain is due to the elongation of the pitch holes and wearing of the pin O.D. The greatest amount of stretching occurs at the areas of the chain that flex over the sheaves most frequently.
  • Page 249 Adjustment Chain adjustments are important for the following reasons : Equal loading of chain. Proper sequencing of mast. Prevent over-stretching of chains. Prevent chains from jumping off sheaves if they are too loose. djustment procedure With mast in its fully collapsed and vertical position, lower the fork to the floor. Adjust the chain length by loosening or tightening nut on the chain anchor.

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