Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16

SECTION 2 REMOVAL & INSTALLATION

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6

SECTION 4 BRAKE SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

SECTION 5 STEERING SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2

Group 3 Electric components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3

SECTION 8 MAST

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-3

Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-6

Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-9

CONTENTS

Table of Contents

Troubleshooting

Summary of Contents for Hyundai 14BRJ-7

Page 1: Table Of Contents
CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16 SECTION 2 REMOVAL &...
Page 2 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 3 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 4 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 5 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 6 Liter to U.S. Gallon 1ℓ = 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...
Page 7 kgf·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 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
Page 8 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 9 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 10: Section 1 General
SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16...
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 · Unless you have special instructions to the contrary, maintenance should always be carried out with the machine stopped. maintenance is carried out with the machine running, there must be two men present : one sitting in the operator's seat and the other one performing the maintenance.
Page 14 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 15: Group 2 Specifications
GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS BRJ7RE01 Mast Drive motor 17 Start key Lift cylinder 10 Drive wheel 18 Battery trolley Carriage and backrest 11 Load wheel & brake 19 Seat Forks 12 Accelerator pedal 20 Hood Drive unit 13 Brake pedal 21 Pedal switch Dash board 14 Overhead guard...
Page 16 2. SPECIFICATIONS 14/16BRJ-7 14BRJ7SP01 Model Unit 14BRJ-7 16BRJ-7 Capacity 1400 1600 Load center Weight 2946 3048 Lifting height 5306 Free lift(Without backrest) 1724 Lifting speed(Unload/load) Fork mm/sec 580/370 Lowering speed(Unload/load) mm/sec 450/500 L W T L,W,T 1200 100 40 1200 100 40 Tilt angle forward/backward C/C’...
Page 17 20/25BRJ-7 14BRJ7SP01 Model Unit 20BRJ-7 25BRJ-7 Capacity 2000 2500 Load center Weight 3515 3711 Lifting height 5305 Free lift(Without backrest) 1709 Lifting speed(Unload/load) Fork mm/sec 580/370 Lowering speed(Unload/load) mm/sec 450/500 L W T L,W,T 1200 100 45 1200 125 45 Tilt angle forward/backward C/C’...
Page 18 TSA 200-160-104 TSA 170-210-009 G104087A Type Rated voltage Output 15.8 Insulation Class F Class F Class H BATTERY Item Unit 14BRJ-7 16BRJ-7 Rated voltage ← ← Dimension(W×L×H)(OPT) 1223×283(353)×787 Min. Battery weight(OPT) 710(890) ← Max. Battery weight(OPT) 790(990) ← SBE 320...
Page 19 GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Displacement 19.6 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 Proportional Main relief valve pressure D D RIVE UNIT Item Unit Specification...
Page 20 20/25BRJ-7 CONTROLLER Item Unit Drive&Pump motor controller EPS motor controller Fingertip controller Model AC-2 EPS-AC0 Mhyrio CB ← ← Type MOSFET 200×250×147.5 180×144×64.8 Dimension 197×82×73 Current limit 450A ← ← Communication M M OTOR Item Unit Traction Pump Model TSA 200-160-104 TSA 170-210-009 G104087A Type...
Page 21 GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity 19.6 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 Proportional Main relief valve pressure D D RIVE UNIT Item Unit Specification...
Page 22 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS 14/16BRJ-7 Items Size kgf·m lbf·ft Hyd pump motor mounting bolt M10×1.5 6.9±1.4 50±10 Electric system Traction motor mounting bolt M 8×1.25 2.5±0.5 18.1±3.6 Hydraulic pump mounting bolt M10×1.5 5±1 36±7.2 Hydraulic MCV mounting bolt, nut M 8×1.25 2.5±0.5 18.1±3.6...
Page 23 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT - Coarse thread Bolt size kgf·m lbf·ft kgf·m lbf·ft 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7 M10×1.5...
Page 24 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat(mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 130.2 1" 151.9 1-1/4" 253.2 IPE AND HOSE(ORFS TYPE) Thread size(UNF) Width across flat(mm) kgf·m lbf·ft 9/16-18 28.9 11/16-16 36.2 13/16-16 68.7 1-3/16-12 130.2 1-7/16-12...
Page 25 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. ℓ (U.S. gal) 。 C(。 F) Capacity Ambient temperature Service Kind of point fluid 14/16BRJ-7 20/25BRJ-7 (-31) (-4) (14) (32) (50) (68) (86) (104) Drive Gear oil SAE 80W/90...
Page 26: 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 27: Section 2 Removal & Installation
SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
Page 28: Group 1 Structure
SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE GROUP 1 STRUCTURE BRJ7RE01 Mast Drive motor 17 Start key Lift cylinder 10 Drive wheel 18 Battery trolley Carriage and backrest 11 Load wheel & Brake 19 Seat Forks 12 Accelerator pedal...
Page 29: 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 Carriage Piping Mast Backrest & fork Backrest Backrest ① Remove bolts securing backrest to fork carriage. Lift backrest straight up and remove it from carriage.
Page 30 ② While supporting lift chains, remove the Lift chain split pins and nuts from anchor bolts of stationary upright. Outer mast Split pin BRJ7RE05 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain...
Page 31 PIPING ① Remove the return hoses and clamps Inner mast attached to the cylinder. ② Remove the return hoses from the connector. ③ Return Remove hose assembly, connector, hose down safety valve from the lift cylinder. Band clamp Hose ④ Disconnect hose assembly from the flow clamp regulator.
Page 32 M M AST REMOVAL Crane ① Pass wire rope around the inner and outer masts to allow lifting them out with a hoist. ② Remove the stopper pin at the end of Mast reach cylinder and then remove the stopper bolt at the end of guide rail. Wire rope ③...
Page 33 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. LIFT CYLINDER INSTALLATION AND ADJUSTMENT ① Assemble the lift cylinder inside the outer mast, then tighten the stopper bolt.
Page 34 2. POWER TRAIN ASSEMBLY REMOVAL BRJ7RE001 Disconnect the battery cable. d i s b l e t t e 14BRJ7OM121 Remove seat and hood. Bolt Hood BRJ7RE13 Disconnect the hose, pipe and wiring from Pump motor assembly Wiring pump & motor assembly. Loosen mounting nuts from frame and To MCV then take out the assembly.
Page 35 Disconnect the wiring. Drive motor ① Drive motor wiring ② EPS motor wiring. Loosen mounting bolts from frame and then take out drive unit assembly. EPS motor Mounting bolt BRJ7RE17 Lift up the frame and support both side of frame on wood block. Hook Wood block BRJ7RE18...
Page 36 INSTALLATION Drive motor Installatron is in the reverse order to removal, but be careful of following points. Drive unit mounting bolts : 6EA ·Tightening torque : 12.8~14.0kgf·m (92.6~101.3lbf·ft) EPS motor Drive unit bracket mounting bolt : 9EA ·Tightening torque : 12.8~14.0kgf·m Mounting bolt (92.6~101.3lbf·ft) BRJ7RE17...
Page 37 3. ELECTRICAL COMPONENTS Before removing each component, disconnect cables and earth lines attached to the component. REMOVAL BRJ7RE002 PUMP MOTOR ① Disconnect the battery cable. d i s b l e t t e 14BRJ7OM121 ② Remove seat and hood. Bolt Hood BRJ7RE13...
Page 38 ③ Disconnect the hose, pipe and wiring Pump motor assembly Wiring from pump & motor assembly. Loosen mounting nuts from frame and To MCV then take out the assembly. Pipe ④ Remove 2 mounting bolts fastening the pump & motor and then disengage the Pump Mounting nut pump from motor.
Page 39 ④ Remove bolts connecting the motor and drive unit. Bolt BRJ7RE22 ⑤ Tie wire rope around the drive motor and lift up slowly. rope BRJ7RE23 ⑥ Put the motor on the clean work bench. BRJ7RE24 2-12...
Page 40 EPS MOTOR ① Disconnect the battery cable. d i s b l e t t e 14BRJ7OM121 ② Remove seat and hood. Bolt Hood BRJ7RE13 ③ Disconnect wirings. EPS motor BRJ7RE25 ④ Loosen bolts and remove EPS motor assembly. EPS motor Bolt BRJ7RE26 2-13...
Page 41 BATTERY REMOVAL ① Forward Turn on the key. r a m ② Foot on the battery unlock lever to unlock S i d the battery trolley assembly.. Backward ③ Pull the reach lever until it is relief. Battery unlock lever ④...
Page 42 INSTALLATION Installation is in the reverse order to removal, but be careful of following points. PUMP MOTOR Pump motor assembly Wiring ① Pump motor mounting nut. ·Tightening torque : 2.0~3.0kgf·m To MCV (14.5~21.7lbf·ft) Pipe ② Hydraulic pump mounting bolt ·Tightening torque : 4.0~6.0kgf·m (28.9~43.4lbf·ft) Pump Mounting nut...
Page 43 BATTERY INSTALLATION ① Using a battery hanger, carefully put the battery assembly on the battery trolley between mast and frame. ② Connect the battery connector. ③ Turn on the key. ④ Pull the reach lever until it sounds locked. (Auto lock) 14BRJ7OM122 ⑤...
Page 44 4. TIRE & WHEEL ASSEMBLY REMOVAL DRIVE TIRE & WHEEL ASSEMBLY ① Lift up the frame ※ Lift up until the tire clear off the ground. Hook Wood block BRJ7RE18 ② Remove wheel nuts attaching the drive wheel and take off the drive wheel assembly.
Page 45 INSTALLATION Installation is in the reverse order to removal, but be careful of the following points. Drive wheel nuts ·Tightening torque : 13.5~15.5kgf·m (98~112lbf·ft) Wheel nut BRJ7RE34 Load wheel special bolts ·Tightening torque : 13~15kgf·m Flat head bolt (94~108lbf·ft) Special Load wheel flat head socket bolts bolt ·Tightening torque : 7~8kgf·m...
Page 46: 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6...
Page 47: Group 1 Structure And Operation
SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. DRIVE UNIT STRUCTURE 14/16BRJ-7 BRJ7DU101 Hexagon screw 14 Slotted pin 27 Protection cap Turntable bearing 15 Retaining ring 28 Bearing ball Steering gear 16 Taper roller bearing 29 Housing Breather valve 17 Shim 30 Shim...
Page 48 20/25BRJ-7 BRJ7DU103 Turntable bearing 13 Slotted pin 25 Input pinion Hexagon screw 14 Retaining ring 26 Protection cap Steering gear 15 Taper roller bearing 27 Housing Breather valve 16 Shim 28 Shim Protection cap 17 O-ring 29 Seal ring Hexagon nut 18 Housing cover 30 Plug Spur gear...
Page 49 2. SPECIFICATION 14/16BRJ-7 Item Unit Specification Gear ratio Total 14.5 ℓ Oil Quantity 20/25BRJ-7 Item Unit Specification Gear ratio Total 20.2 ℓ Oil Quantity...
Page 50: Group 2 Troubleshooting
GROUP 2 TROUBLESHOOTING Problem Cause Remedy 1. Noise · 1) Loud, beating noise Check tooth flanks of the drive pinion Gearing of helical gear stage damag- and the helical gear for damage. In ed, indentations. case of damage always replace both components.
Page 51 Fault Probable cause Remedy · · Oil leakage on oil filler or oil Dirt between sealing ring and Cleaning required. drain plug housing. · · Old sealing ring was used. Use new sealing ring · · Bolts not tightened according to the Tighten bolts with the specified specified tightening torque.
Page 52: Group 3 Disassembly And Assembly
GROUP 3 DISASSEMBLY AND ASSEMBLY INSTRUCTION Pay attention to cleanliness and expert like manner for all work to be carried out. Transmission removed from the vehicle has therefore to be cleaned prior to opening. Both utmost care and cleanliness are essential conditions for a correct disassembly and reassembly of the transmission as well as for the installation of each spare part.
Page 53 NECESSARY SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Reference number Description Is necessay for : 225296 Extracting fixture Removal of drive pinion - 14/16/20/25BRJ-7 62519 Holding fixture Loosening of taper press fit - 14/16BRJ-7 62513 Holding fixture Loosening of taper press fit - 20/25BRJ-7 62507-1 Counter holder Determination of shim thickness - 14/16/20/25BRJ-7...
Page 54 Modifications and changes without the proper permission are affecting the safety of the transmission and are not allowed. Only original spare parts from Hyundai are allowed to be used. It is explicitly pointed out to the fact that spare parts and accessories, which were not supplied by Hyundai are not checked and approved by us either.
Page 55 4. COMPLETE DISASSEMBLY GENERAL INSTRUCTIONS DISASSEMBLY Prior to dismantling the transmission is to be cleaned carefully. Parts which are only available as assemblies will not be dismantled further. It is recommendable to install a locating fixture as shown in Figure 44. It serves to rotate the unit and offers easy working for disassembly and BRJ7DU044...
Page 56 REMOVAL OF DRIVE PINION With a screwdriver press the radial sealing ring (item 2) upwards from the bore seat of the housing and remove it. Dispose of the radial sealing ring according to chapter 6. BRJ7DU045 Unsnap and remove the retaining ring (item 3) from the housing bore by means of flat-head pliers.
Page 57 Handle the extracting fixture "S" as shown on the right. Move the handle on the bar upwards strongly several times until the drive pinion is loosened from the bearing seat completely. Do not damage the gearing of the drive pinion at the next work step! Damages might cause louder running noises and consequential damages! BRJ7DU049...
Page 58 REMOVAL OF GEAR RING AND PIVOTED BOGIE BEARING Loosen the 12 hexagon screws (item 1) on the pivoted bogie bearing (item 2), remove and dispose them of acc. to chapter 6. BRJ7DU053 With a dead-blow soft-face hammer slightly beat against the gear ring (item 3) from the bottom to loosen it from the connecting construction.
Page 59 DISASSEMBLY OF TRANSMISSION HOUSING WITH TRANSMISSION COMPONENTS Removal of sealing cap The surface (item 1) where the sealing cap is located must not be damaged. The sealing cap itself is destroyed and cannot be reused. ① Insert a screwdriver (item 2) into the sealing cap (item 3) beating cautiously and press it off or by using the lever effect upwards and scrap it.
Page 60 ② Loosen the housing cover (item 2) by tapping against the outer edges and remove it. Use the two recesses in the housing. BRJ7DU059 ③ With a three-armed puller (item 4) pull the taper roller bearing inner ring (item 3) over the bearing seat of the wheel shaft and remove it.
Page 61 Loosening of taper press fit ※ For work at high oil pressures to loosen the taper press fit there is the danger of eye and skin injuries, if oil would come out under high pressure. Always wear goggles and safety gloves! Observe and follow the instructions of the pressure oil device manufacturer.
Page 62 ④ Connect the flexible high-pressure pipe (item 4) from the pressure oil device into the connecting bore provided in the wheel shaft (item 5). Fixedly tighten the connecting nipple with an openjaw spanner. Pay attention for pressing-off that there is sufficient clearance in pressing-off direction avoiding that the wheel shaft BRJ7DU065 is bottoming.
Page 63 ⑧ Loosen the cap screws (item 10), take off and remove the holding fixture "S" from the housing. BRJ7DU069 ⑨ Pressing-off by means of 2nd hand pump Alternatively the wheel shaft can be pressed off with a second press-out cylinder, e.g. in the mobile area. It is to be proceeded as follows: Connect the dis- and assembly fixture with the press-out cylinder for the wheel...
Page 64 ⑫ Take the wheel shaft out of the transmission. BRJ7DU073 ⑬ Unscrew the hydraulic hose from cylinder 1 of the wheel shaft. Wipe off excessive oil. BRJ7DU074 ⑭ Unscrew the dis- and assembly fixture from the transmission When the gearing is damaged, running noises and consequential damages might occur, so that the bevel gear set has to be replaced.
Page 65 Then remove the following parts from the housing (item 12): ·14/16BRJ-7 : Shims and taper roller bearing ·20/25BRJ-7 : Shims, spacer ring and taper roller bearing BRJ7DU077 Removal of bevel pinion shaft ① Put the gear lock "S" into the housing bearing bore of the drive pinion and block the helical gear with it.
Page 66 ⑤ Pull out, remove and keep the helical gear (item 3) from the cover opening of the housing. BRJ7DU081 ⑥ Take out and remove the taper roller bearing inner ring (item 4) upwards from the bearing bore: BRJ7DU082 ⑦ ·14/16BRJ-7 Take off and remove the spacer bush (item 5) from the bevel pinion shaft.
Page 67 Removal of thread protective shield and radial sealing ring ① By means of a hammer remove the thread protective shield (item 1) from the glued joint on the housing. Do not damage the housing and supporting face! BRJ7DU085 ② With a screwdriver and a hammer expel and remove the radial sealing ring (item 2) cautiously from the housing seat.
Page 68 isassembly bearings bevel pinion shaft ① Expel the outer rings of the taper roller bearings (item 2) on both sides from the housing seat cautiously. ② Shims which were damaged have to be replaced by new shims of the same size. BRJ7DU088 Disassembly bearings wheel shaft ①...
Page 69 5. COMPLETE REASSEMBLY GENERAL INSTRUCTIONS FOR REASSEMBLY Clean components by means of cleaning agent if necessary and remove the loctite residues. Check all components for wear, damage and cracks, if necessary components have to be replaced. All connection faces and plan face clean and steadly smoothing. CONSUMABLES Suitable cold cleaners, e.g.
Page 70 USE OF REMOVED SHIMS AS BASIS FOR REASSEMBLY The bevel gear set, consisting of bevel pinion shaft and crown gear, has fixed installation dimensions. However the transmission housing and the taper roller bearings have to be measured. If the removed shims are used as basis it is not necessary to measure the transmission housing. If all of the removed components are to be reused, the original shim thickness has also to be used again.
Page 71 DETERMINATION OF BEARING WIDTH DIFFERENCE OF A TAPER ROLLER BEARING Determination of bearing width general ① Zeroize depth gauge (item 1) by means of gauge blocks (item 2). BRJ7DU091 ② Put the new bearing on both gauge blocks and roll it as shown. BRJ7DU092 ③...
Page 72 DETERMINATION OF BASIC INSTALLATION DIMENSIONS Determination of the necessary shim thickness for the exact installation dimension setting of the bevel pinion shaft The correct position of the bevel pinion shaft is required for an optimum service life of the transmission. Thickness of the shim (Item 1) and the correct setting of the bevel pinion shaft respectively will be determined acc.
Page 73 BRJ7DU096 BRJ7DU095 BRJ7DU097 At zero position of the dial gauge the following can be taken as basis: 14/16BRJ-7 Dimension "1" = 111.50 mm 20/25BRJ-7 Dimension "1" = 117.00 mm Determine Dimension "2" in housing bearing bore L3 (see figure 94) and add it to the respective Dimension "1".
Page 74 Determination of necessary shim thickness for optimum setting of torsional backlash of the crown Gear Correct setting of the crown gear is necessary to obtain an optimum torsional backlash of the bevel gearing. Bearing width "B" for the taper roller bearing on the crown gear can be measured according to chapter 5) at page 3-25 "Determination of bearing width and difference of a taper roller bearing".
Page 75 Schematic sketch 14/16BRJ-7 By means of the equation X = G – E – B – K1 the required thickness of the shim (Item 3) can be calculated, i.e. with Dimension "E" 14/16BRJ-7 = 46.00 mm Example 14/16BRJ-7 : Dimension "G" 68.53 mm Dimension "B"...
Page 76 INSTALLATION OF BEARING FOR BEVEL PINION SHAFT AND EXACT SETTING OF THE BEARING PRELOAD Preassembly of bevel pinion shaft with bearing ① Use a hand-lever press for pressing the taper roller bearing inner ring (item 1) with the press-in sleeve "S" cautiously on the bevel pinion shaft (item 2) until contact is obtained.
Page 77 Calculation of distance dimension between collar bevel pinion shaft and housing ① Install the preassembled bevel pinion shaft (item 1) from the bottom into the housing. BRJ7DU105 ② By means of the counter holder "S" preload the bearing outer ring in the housing hand-tight.
Page 78 14/16BRJ-7 : Determine distance dimension "D" from the spacer bush (item 2) to contact of the bearing outer ring in the housing. (item 3 is the required shim thickness) BRJ7DU108 20/25BRJ-7 : Determine distance dimension "D" by means of depth gauge from the collar of the bevel pinion shaft to contact of the bearing outer ring in the housing.
Page 79 Measure the bearing slack "H" with a measuring fixture gauge blocks/measuring ledge in the following steps : ① Zeroizing of depth gauge (item 1) by means of gauge blocks (item 2). BRJ7DU111 ② Rolling-in of bearing. BRJ7DU112 ③ Measuring of bearing slack H. Example : Dimension "H"...
Page 80 Calculation of shims required for upper bevel pinion shaft bearing By means of the equation X = D – H the required thickness of the shim (Item 3 figure 108 or 109) can be calculated, i.e. with Dimension "D" on 14/16BRJ-7 : Distance from spacer bush on 20/25BRJ-7 : Distance from collar of bevel pinion shaft Dimension "H"...
Page 81 ③ Put the bearing inner ring (item 3) into the outer ring of the taper roller bearing. BRJ7DU116 Installation of grooved ball bearing for drive pinion ① Install the grooved ball bearing (item 1) with the striking mandrel "S" into the bearing seat of the housing until contact is obtained.
Page 82 ③ Install the bevel pinion shaft (item 3, on 14/16BRJ-7 with spacer bush) from the bottom into the housing and assemble is through the profiled seat of the helical gear bore. BRJ7DU123 ④ Preload the bevel pinion shaft (item 3) with the counter holder "S"...
Page 83 ⑧ Place the hexagon nut M16× 1.5 (14/16BRJ-7) and M20×1.5 (20/25BRJ- 7) onto the bevel pinion shaft and tighten it with a torque spanner (item 4). Tightening torque : 14/16BRJ-7 : 100 Nm 20/25BRJ-7 : 150 Nm Do not yet peen the hexagon nut with the bevel pinion shaft! The hexagon nut must only be peened after setting BRJ7DU127...
Page 84 INSTALLATION OF CROWN GEAR AND WHEEL SHAFT INTO THE HOUSING Installation of thread protective shield and radial sealing ring ① Wet the thread protective shield (item1) on the bore seat evenly with LOCTITE 270 and install it until contact by means of the striking mandrel "S".
Page 85 nstallation of taper roller bearing into the housing ① By means of striking mandrel "S" drive the bearing outer ring into the bearing seat of the housing until contact is obtained. (S) Striking mandrel 62542 BRJ7DU132 ② Insert the bearing inner ring (item 1) into the outer ring of the taper roller bearing.
Page 86 Pay attention not to damage the gearing, when the crown gear is assembled. BRJ7DU135 ① Assemble the crown gear (item 4) into the housing carefully and insert it into the gearing of the bevel pinion shaft at the same time. Pay attention that the crown gear is aligned centrally to the shim and the bush.
Page 87 Pressing-on wheel shaft Taper press fit must be grease- and oilfree. Pay attention to an impeccable surface of the press fit. In case of damage use a new wheel shaft. All components must be aligned and centered for the press-on procedure. For this installation procedure a press with a controllable press-on force is required.
Page 88 Determination of seat The seat must be 10 to 15 mm. ① Measure Dimension A from plane face/wheel shaft to face/crown gear once again (see chapter 9) (3) at page 3-39 “Determination of control dimension for seat“). Dimension "A" e.g. 44.34 mm BRJ7DU140 Example: Dimension "A"...
Page 89 INSTALLATION OF BEARING FOR WHEEL SHAFT Determination of required shim thickness for exact bearing preload of the wheel shaft Thickness of the shim (item 4) to be added can be determined with the following method: BRJ7DU142 Measuring ledge Housing cover Dim.
Page 90 Calculation of shim required Thickness of shim can be calculated with the dimensions determined. Example for 14/16BRJ-7 : Cover dimension : Dim. C measured on housing cover 0.85 mm Housing dimension : Dim. F measured on housing 23.01 mm Bearing dimension : Dim. B measured on bearing under preloading force 21.85 mm X1 = F - (C + B) X1 = 23.01 - (0.85 + 21.85) = 0.31 mm...
Page 91 ④ Place counter holder "N" into the assembly fixture and preload it hand-tight against the wheel shaft (cf. figure 124). (N) Counter holder 62507-1 ⑤ Mount the taper roller bearing inner ring (item 2) by means of striking mandrel "S" onto the bearing seat of the wheel shaft (item 3) until contact is obtained.
Page 92 Checking of bearing friction torque on wheel shaft Rolling For measuring of the bearing friction torque place tool "S" on the wheel shaft congruent with the wheel bolts and by means of the torque spanner turn the wheel shaft several times. (S) : Measuring fixture 62532 : 14/16BRJ-7 BRJ7DU150 (S) : Measuring fixture 62515 : 20/25BRJ-7...
Page 93 Installation of side cover Prior to the installation of the side cover clean the sealing surface on the housing and remove the oil residues. The sealing surface must not be damaged. Wear safety gloves for working with adhesives and observe the LOCTITE instructions. The following step must be carried out within 10 minutes since the LOCTITE hardens.
Page 94 Do not yet tighten the cap screws with the corresponding tightening torque. Tighten the 10 cap screws evenly only in the tightening sequence shown in Figure 156. Sequence of tightening : Number 1 beginning ..Number 10 end Tightening torque of the cap screws : 9.5 Nm BRJ7DU156 REASSEMBLY AND INSTALLATION OF DRIVE PINION Installation of ball bearing...
Page 95 Mounting of sealing cap For sealing of the bore in the drive pinion a sealing cap (item 5) must be mounted. This requires the following sealing application: ① LOCTITE 5910 : Product application as adhesive application onto the supporting BRJ7DU158 face and around the bore in the drive pinion as sealing function by excessive product.
Page 96 ③ Snap the retaining ring (item 2) by means of flat-head pliers into the groove of the housing bore and install it until contact is obtained. BRJ7DU162 ④ Wet the sealing lip of the radial sealing ring with grease (e.g. Shell Alvania R3) slightly.
Page 97 Attachment of pivoted connection geared steering ① Place the gear ring (item 2) and turn it so that the bolt holes match the threaded holes of the connecting construction. ② Install the gear ring with a dead-blow soft face hammer until contact is obtained. BRJ7DU166 ③...
Page 98 6. DISPOSAL Disposal of the replaced components, materials and substances adequately, environmentally friendly and in accordance with the legal regulations for disposal for the respective material : Component Consisting of Disposal acc. to the regulations : Transmission oil Waste oil Side cover Sheet Radial sealing ring...
Page 99: Section 4 Brake System
SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1...
Page 100: Group 1 Structure And Function
SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. STRUCTURE BRJ7SM128 Magnet & coil sub-assembly Socket head cap screw Armature JPT pin housing Self lubricating bush Intermediate seal Auto adjust mechanism JPT contact Conical damper spring 10 Single wire seal 2.
Page 101 3. PRE-INSTALLATION CHECKS Check that in the process of unpacking and subsequent handling prior to assembly, the mounting features and parts of the brake are undamaged. Prior to fitting, remove and clean off any foreign matter which may have found its way into the assembly during transit, also ensure that the interfaces to which the brake is mounted are clean and free from burrs or swellings.
Page 102 7. REASSEMBLY AND INSTALLATION Load tire LOAD TIRE Clean all parts thoroughly and pay particular attention to remove any dust from the auto adjust mechanism and magnet pole faces. ※ Clean only with a dry cloth. Carefully fit the self lubricating bushes (3) to the load wheel as shown in part section 'A- A', ensuring the step of dimension B as BRJ7RE40...
Page 103 Install the magnetic assembly on the frame with bolt 12 and 13(Apply one drop of loctite HARNESS 277 onto threads of bolts). MAGNETIC ·Tightening torque : Bolt 12 : 7.5±0.5kgf·m Bolt 13 : 14±1.0kgf·m Check the electrical supply is appropriate to the brake(48 volts D.C.) and connect to the DISC leads of the magnet &...
Page 104: Section 5 Steering System
SECTION 5 STEERING SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1...
Page 105: Group 1 Structure And Function
SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. STRUCTURE 11-1 11-2 11-5 11-4 11-3 11-6 Steering wheel Stepping motor Main harness Controller sub assy EPS motor Pinion & steering gear Traction motor Position sensor assy Drive unit 10 Drive tire 11 Steering panel assy 11-1 Steering panel 11-2 Panel bracket...
Page 106 2. FUNCTION BRJ7SE13 Steering wheel It decides the direction of rotation of the truck. It transmits the handling of operator. Stepper motor It is sensing the operation of steering wheel. It is transmits the output signal to controller. Controller It decides the torque and the direction of rotation of motor. It supplied power to motor.
Page 107: Section 6 Hydraulic System
SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24...
Page 108: Group 1 Structure And Function
SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT (14/16BRJ-7) BRJ7HS01 Hydraulic pump Reach cylinder Main control valve Return filter Lift cylinder Suction strainer Down safety valve Hydraulic tank Tilt cylinder...
Page 109 HYDRAULIC CIRCUIT (20/25BRJ-7) BRJ7HS10 Hydraulic pump Reach cylinder Main control valve Return filter Lift cylinder Suction strainer Down safety valve Hydraulic tank Tilt cylinder...
Page 110 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION (14/16BRJ-7) emergency lowering 130bar 130bar BRJ7HS02 When the lift control lever is pulled back, the m1 valve on the lift block is moves to open position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of lift cylinder(3).
Page 111 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION (20/25BRJ-7) BRJ7HS08 When the lift control lever is pulled back, the m1 valve on the lift block is moves to open position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of lift cylinder(3).
Page 112 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION (14/16BRJ-7) emergency lowering 130bar 130bar BRJ7HS03 When the lift control is pushed forward, the m2 valve on the lift block is moved to open position. The work port(H) and the large chamber are connected to the return passage, so the lift will be lowered due to its own weight.
Page 113 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION (20/25BRJ-7) emergency lowering 130bar 130bar BRJ7HS09 When the lift control is pushed forward, the m2 valve on the lift block is moved to open position. The work port(H) and the large chamber is connected to the return passage, so the lift will be lowered due to its own weight.
Page 114 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION emergency lowering 130bar 130bar BRJ7HS04 When the tilt control lever is pulled backward, 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 large chamber of tilt cylinder(5).
Page 115 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 14/16BRJ ONLY 190 bar emergency (at 40lpm) lowering 130bar 130bar BRJ7HS05 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
Page 116 WHEN THE REACH CONTROL LEVER IS IN THE FORWARD (REACH OUT) POSITION 14/16BRJ ONLY 190 bar emergency (at 40lpm) lowering 130bar 130bar BRJ7HS06 When the reach control lever is pushed forward, the spool on the third block is moved to reach out position.
Page 117 WHEN THE REACH CONTROL LEVER IS IN THE BACKWARD (REACH IN) POSITION BRJ7HS07 When the reach control lever is pulled backward, the spool on the third block is moved to reach in position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the small chamber of reach cylinder(6).
Page 118 2. HYDRAULIC GEAR PUMP STRUCTURE BRJ7HS19 Mounting frange Bearing block 11 Dowel pin End cover Backup ring 12 Start ring Gear housing Seal 13 Socket head bolt Drive gear O-ring 14 Spring washer Idler shaft 10 Shaft seal OPERATION This pump comprises of an rear cover, a body, bushings and a housing bolted together with bolts. The gear journals are supported in side plate within pressure balanced bushings to give high volumetric and mechanical efficiencies.
Page 119 3. MAIN CONTROL VALVE STRUCTURE (3 Spool) Port name Size Port Inlet port 1 1/16-12UN Outlet port 1 1/16-12UN Work port 1 1/16-12UN Work port 9/16-18 UNF A, B BRJ7HS12A Main block 4-2 Disc 11 Adapter Solenoid valve (Lift) 4-3 Circlip 12 Head screw 2-1 EVI coil 4-4 Black plug...
Page 120 STRUCTURE(4 Spool, Option) Port name Size Port Inlet port 1 1/16-12UN Outlet port 1 1/16-12UN Work port 1 1/16-12UN Work port 9/16-18 UNF A, B BRJ7HS12 Main block 4-2 Disc 11 Adapter Solenoid valve (Lift) 4-3 Circlip 12 Head screw 2-1 EVI coil 4-4 Black plug 13 End block...
Page 121 EMERGENCY LOWERING In case of the mast cannot be lowered due to a problem in the controller, active the emergency lowering valve on the valve block with hexagonal wrench. Turn off the electric emergency switch. Open the lowering valve using the 5mm hexagonal wrench.
Page 122 4. LIFT CYLINDER 14/16BRJ-7 BRJ7HS21 Tube assy Stop ring 13 Rod bush Cushion seal 14 Rod cover Piston Retaining ring 15 U-packing U-packing 10 Spacer 16 Dust wiper Back up ring 11 O-ring 17 O-ring Wear ring 12 Stopper 6-15...
Page 123 20/25BRJ-7 BRJ7HS22 Tube assy Spacer 15 Dust wiper Retaining ring 16 Retaining ring Piston 10 Stop ring 17 Wear ring U-packing 11 Cushion seal 18 Dust ring Back up ring 12 Retaining ring 19 O-ring Wear ring 13 Rod cover 20 Stop ring Check 14 U-packing...
Page 124 5. FREE LIFT CYLINDER 14/16/20/25BRJ-7 BRJ7HS23 Tube assy Check valve 11 Dust wiper Retaining ring 12 Retaining ring Piston Set screw 13 O-ring Piston seal Rod cover 14 Back up ring Wear ring 10 U-packing 6-17...
Page 125 6. TILT CYLINDER 14/16/20/25BRJ-7 BRJ7HS25 Tube assy Nylon nut 11 O-ring Gland 12 O-ring O-ring DU bushing 13 O-ring Piston Rod seal Piston seal 10 Dust wiper 6-18...
Page 126 7. REACH CYLINDER 14/16/20/25BRJ-7 BRJ7HS27 Tube assy Rod cover 13 Back up ring Spherical bearing Rod bush 14 O-ring Retaining ring U-packing 15 Piston Spherical bearing 10 Back up ring 16 Piston seal Retaining ring 11 Dust wiper 17 O-ring Rod assy 12 O-ring 18 Hex nut...
Page 127: 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. Load maximum load, set mast vertical and raise 1m from ground. Wait for 10 minutes measure hydraulic drift(amount forks move down and amount mast tilts forward).
Page 128 . 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 129 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 130 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 131: Group 3 Disassembly And Assembly
GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP ※ Tools required ·Metric socket set ·Internal snap ring pliers ·Shaft seal sleeve ·Torque wrench It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
Page 132 Lift and remove end cover. PUMP 03 Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts. PUMP 04 (10) Remove rear bearing block from drive and idler shafts. PUMP 05 (11) Remove idler shaft from bearing block.
Page 133 (12) Remove drive shaft from mounting flange. There is no need to protect the shaft seal as it will be replaced as a new item. PUMP 07 (13) Remove the front bearing block. PUMP 08 (14) Turn mounting flange over, with shaft seal up, and remove the retaining ring with proper snap ring pliers.
Page 134 (17) Remove seals from both bearing blocks and discard. PUMP 11 INSPECT PARTS FOR WEAR Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be replaced as new items. Check drive shaft spline for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway.
Page 135 Inspect bearing blocks for excessive wear or scoring on the surfaces which are in contact with the gears. Also inspect the bearings for excessive wear or scoring. Inspect the area inside the gear housing. It is normal for the surface inside the gear housing to show a clean "wipe"...
Page 136 ASSEMBLY ※ New seals should be installed upon reassembly of pump. Install new shaft seal in mounting flange with part number side facing outboard. Press the seal into the seal bore until the seal reaches the bottom of the bore. Uniform pressure must be used to prevent misalignment or damage to the seal.
Page 137 Insert the drive end of the drive shaft through the bearing block with the seal side down, and the open side of the E- seal pointing to the intake side of the pump. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal.
Page 138 (13) Gently slide the gear housing over the rear bearing block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place with hands, do not force or use any tool. Check to make sure the intake port in the housing in on the same side as the open end of the E-seal and that the marked lines on the mounting flange and gear...
Page 139 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. ·Tighten torque : 6~7kgf·m (43.4~50.6lbf·ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
Page 140 2. MAIN CONTROL VALVE Lock washer Washer O-ring Coil O-ring Cartridge Lock washer Washer O-ring Solennoid valve for lift Coil Tightening torque : 4.0kgf.m (40Nm) Lift section block Cartridge Solennoid valve for tilt Tightening torque : 1.0kgf.m (10Nm) Tilt section block Roll pin Solennoid valve for reach Reach section block...
Page 141 Lift block solenoid assembly ① The solenoid is installed upper side and below side cavities in lift block. Torque to 4.1kgf·cm (40Nm) ② Install the O-ring, coil, O-ring and washer to the assemblied cartridge. ③ Insert the lock washer to the groove of the cartridge. ilt &...
Page 142 3. LIFT CYLINDER STRUCTURE BRJ7HS21 Tube assy Stop ring 13 Rod bush Cushion seal 14 Rod cover Piston Retaining ring 15 U-packing 16 Dust wiper U-packing 10 Spacer Back up ring 11 O-ring 17 O-ring Wear ring 12 Stopper 6-35...
Page 143 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 144 4. TILT CYLINDER STRUCTURE BRJ7HS25 Tube assy Nylon nut 11 O-ring Gland 12 O-ring O-ring DU bushing 13 O-ring Piston Rod seal Piston seal 10 Dust wiper 6-37...
Page 145 CHECK AND INSPECTION mm(in) Check item Standard size Repair limit Remedy Clearance between 0.072~0.288 Replace bushing cylinder rod & bushing (0.003~0.011) (0.020) Clearance between rod 0.10~0.35 Replace bushing head bushing & pin (0.004~0.014) (0.024) 6-38...
Page 146 5. REACH CYLINDER STRUCTURE BRJ7HS27 Tube assy Rod cover 13 Back up ring Spherical bearing Rod bush 14 O-ring Retaining ring U-packing 15 Piston Spherical bearing 10 Back up ring 16 Piston seal Retaining ring 11 Dust wiper 17 O-ring Rod assy 12 O-ring 18 Hex nut...
Page 147 CHECK AND INSPECTION mm(in) Check item Standard size Repair limit Remedy Clearance between 0.072~0.288 Replace bushing cylinder rod & bushing (0.003~0.011) (0.020) Clearance between rod 0.10~0.35 Replace bushing head bushing & pin (0.004~0.014) (0.024) 6-40...
Page 148: 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 149: Group 1 Component Location
SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 10 12 BRJ7EL01 Relay 11 Pump motor 21 Cabin tilt switch Back buzzer 12 EPS motor 22 Beacon lamp Can tiller card 13 Fuse box assy 23 Control sub assy DC converter 14 Stepping &...
Page 150: Group 2 Electrical Circuit
GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT 1. B+ : BATTERY POSITIVE B- : BATTERY NEGATIVE C+ : CONVERTER OUTPUT POSITIVE C- : CONVERTER OUTPUT NEGATIVE E+ : EPS POSITIVE KI : KEY SWITCH IN KO : KEY SWITCH OUT BR+ : BUZZER RELAY POSITIVE BR- : BUZZER RELAY NEGATIVE 2.
Page 151: 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 152 2. BATTERY STRUCTURE BRJ7EL03 Cells Plug Steel box Spacer Cell connector Handle (Red) Row connector 10 Screw Positive leading cable 11 Spring washer Negative leading cable...
Page 153 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 154 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 155 Performance and maintenance of batteries ① 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 156 ④ 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。...
Page 157 (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 158 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 159 TROUBLESHOOTING Nature of trouble ymptoms Causes Repair Deformation ·Deformation of container, ·Excessive temperature ris- ·Replace lid or one touch cap ing or external impact ·Electrolyte leakage acco- ·External impact, improper ·Replace or install a new Breakage rding to breakage of cont- handling, excessive vibrat- ainer, lid or one touch cap ·Termination of connector...
Page 160 3. DRIVE MOTOR STRUCTURE BRJ7EL06 Rotor Tab housing amp 16 Distance ring Stator 10 Bearing ring 17 Locking ring Hexagon socket screw 11 Screw 18 Brake warner Hexagon nut 12 End shield 19 Screw Disc 13 Sensor bearing 20 Key round ends Terminal board bottom 14 Locking ring Cabelstrips...
Page 161 SPECIFICATION Item Unit Specification Type TSA200-160-104 Rated voltage Rated output 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 162 4. PUMP MOTOR STRUCTURE BRJ7EL07 End shield Stator CPL 11 Screw O-ring Ball bearing 12 Cabelstrips MEDI-200B Spring washer waved End shield drive end 13 Spring washer Sensor bearing Screw 14 Hexagon nut Rotor CPL 10 Terminal CPL with high nut 7-14...
Page 163 SPECIFICATION Item Unit Specification Type TSA170-210-009 Rated voltage Rated output 15.8 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 16.535 Form diameter 15.977 Minor diameter 12.9286...
Page 164 5. EPS MOTOR STRUCTURE BRJ7EL08 Rotor Screw 17 Screw Stator 10 Screw 18 Washer Flange 11 Thickness ring 19 Bakelite washer Flange 12 Flange nut 20 Sensor support Casing 13 Bakelite pipe 21 Magnet Super seal 14 Thermal 22 Screw Gear 15 Screw 23 Sensor card...
Page 165 SPECIFICATION Item Unit Specification Type G104087A Rated voltage Rated output Insulation Class H 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 6. CONTROLLER SYSTEM STRUCTURE BRJ7EL11 Specifications Model Model Application Type Power Current limit Traction 36-48V, 450A 450A/3min 14/16/20/25BRJ-7 Pump 36-48V, 450A 450A/3min 7-18...
Page 167 O O PERATIONAL FEATURES Features ① Speed control. ② 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 168 DESCRIPTION OF THE CONNECTORS Traction controller BRJ7EL12 No. of Pin Function Description PCLRXD Positive serial reception. NCLRXD Negative serial reception. PCLTXD Positive serial transmission. NCLTXD Negative serial transmission. Negative console power supply. Positive console power supply. It must be connected to A8 for the flash memory programming. FLASH It must be connected to A7 for the flash memory programming.
Page 169 Function No. of Pin Description REVERSE Reverse direction request input. It must be connected to the reverse direction microswitch, active high. Brake request input. It must be connected to the brake pedal switch, active high. Brake potentiometer wiper. CPO TB -BATT.
Page 170 Encoder installation ① Traction controller card is fit for different types of encoder. To control AC motor with a 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. D1 : +12V - Positive of encoder power supply.
Page 171 Pump controller BRJ7EL12 No. of Pin Function Description PCLRXD Positive serial reception. NCLRXD Negative serial reception. PCLTXD Positive serial transmission. Negative serial transmission. NCLTXD Negative console power supply. Positive console power supply. It must be connected to A8 for the flash memory programming. FLASH It must be connected to A7 for the flash memory programming.
Page 172 Function Description No. of Pin Incremental ENCODER connector. D1÷D6 TILT DOWN Tilt down analog input Positive of height limit microswitch TILT UP Tilt up analog input HEIGHT LIMIT Speed reduction input. Active low (switch opened). Connected to the power supply through a microswitch (CH) with a 10A fuse in series.
Page 173 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" ① Hour counter - RUNNING : The counter registers travel time only. - KEY ON : The counter registers when the "key"...
Page 174 ⑨ - ON : If this option is set to ON, electric power steering function is used. - OFF : If this option is set to OFF, electric power steering function isn't used. ⑩ Display If this option is set to on the communication with the graphic display is enabled. ⑪...
Page 175 ⑤ Throttle 0 zone It establishes a deadband in the accelerator input curve (see also curve below). ⑥ Throttle X point This parameter changes the characteristic of the accelerator input curve. ⑦ Throttle Y point This parameter changes the characteristic of the accelerator input curve. SPEED f(Hz) MAX SPEED TROTTLE Y...
Page 176 ⑪ PWM on main contactor - OFF : The inverter applies the battery voltage to the coil on F8 output. - ON : The PWM reduces the voltage to the set value. ⑫ PWM on aux output - OFF : The inverter applies the battery voltage to the coil on F9 output. - ON : The PWM reduces the voltage to the set value.
Page 177 standard acceleration ramp Stop Smooth BRJ7EL14A Seat delay time : It sets the delay time after the seat switch is off. Sequence delay : It sets the delay from the accelerator enable to direction signal input. Chat time : It sets the time from the time main contactor is on to the time seat switch is on. Curve cutback : Speed reduction when the truck is doing a curve.
Page 178 ⑥ Lifting Cutback If the mast is lifted preset height, Lift speed reduction is working depends on the setting status of this function. - ON : If set to on this function, Lift speed control is performed. - OFF : If set to off this function, Lift speed control isn't performed. ⑦...
Page 179 ⑫ Min lower(Option): Volts. It sets the minimum value for the lowering sensor. ⑬ Max lower(Option): Volts. It sets the maximum value for the lowering sensor. ⑭ Min reach in(Option): Volts. It sets the minimum value for the reach in sensor. ⑮...
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 ① Traction controller FORWARD BRJ7EL15 7-33...
Page 182 ② Pump controller SET TEMPERATURE ANALOG / DIGITAL BRJ7EL16 7-34...
Page 183 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 184 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: ①...
Page 185 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. ①...
Page 186 ⑭ Brake pedal pot. Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if the PEDAL BRAKING parameter is set ANALOG. ⑮ Hand brake The level of the handbrake microswitch. - ON / GND = Input active, switch opened. - OFF / +VB = Input non active, switch closed.
Page 187 ⑩ Tilt up switch Status of the tilt up switch of the pump. - ON / +VB = Active entry of closed switch. - OFF / GND = Non active entry of open switch. ⑪ Tilt down switch Status of the tilt down switch of the pump. - ON / +VB = Active entry of closed switch.
Page 188 Cutback switch The level of the speed reduction microswitch. - ON / GND = Input active, switch opened. - OFF / +VB = Input non active, switch closed. Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Page 189 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 190 7. EPS CONTROLLER STRUCTURE BRJ7EL51 Specifications Model Model Application Type Power Current limit 14/16/20/25BRJ-7 36-48V, 45A 45A/2min 7-42...
Page 191 OPERATIONAL FEATURES Features A list of eps-ac0 operational features follows below: ① Static sensitivity boost in open loop (steering sensitivity increases for a slow moving steering wheel). ② Static numbness in closed loop (steering sensitivity decreases for handle steer close to the straight-ahead direction).
Page 192 DESCRIPTION OF CONNECTORS EPS controller EP S - A C BRJ7EL52 No. of Pin Function Description SW 2 2nd toggle switch (90 degrees). SW 1 1st toggle switch (0 degrees). -BATT. Safety switch lower voltage point. Safety switch higher voltage point. SAFETY Can bus low.
Page 193 No. of Pin Function Description PCLRXD Positive serial reception. NCLRXD Negative serial reception. PCLTXD Positive serial transmission. NCLTXD Negative serial transmission. Negative console power supply. Positive console power supply. FLASH It must be connected to A8 for the flash memory programming. FLASH It must be connected to A7 for the flash memory programming.
Page 194 FUNCTION CONFIGURATION Using the config menu of the programming console, the service engineer can configure the following functions. Submenu "SET OPTIONS" ① HOUR COUNTER RUNNING : The counter registers travel time only. KEY ON : The counter registers when the "key" switch is closed. ②...
Page 195 ⑦ AUX FUNCTION 1 This option sets the steering mode after the feedback sensor has reached the commanded position (it is used only in closed loop configurations (i.e. automatic centering). It can be set one of three: - LEVEL 0 : The steering control is always active when a travel demand is active. The steer control is turned off when the travel demands are deactivated (after a 3 sec delay).
Page 196 ⑨ MAXIMUM SLIP (Factory adjusted). MAXIMUM SLIP modifies the acceleration and deceleration ramp for the frequency in the motor. Higher MAXIMUM SLIP gets faster acceleration and deceleration ramp. If the encoder is used for the motor control (ENCODER CONTROL is On), MAXIMUM SLIP has another meaning: it is the slip to be applied when the control is sourcing the maximum current.
Page 197 SET ENC AT 360 This adjustment is used to acquire the encoder counting corresponding to a full steered wheel revolution. It is an important setting especially for applications without steered wheel angle limitation. Procedure for SET ENC AT 360 consists of collecting the encoder counting corresponding to a full steered wheel revolution on the tester reading ENC COUNT AT 360.
Page 198 ④ AUX FUNCTION #2 Level 0 to 9. This setting performs the dynamic numbness compensation: it consists of a reduction in the steer sensitivity when the truck is driving at high speed. To get this goal, it is necessary to attenuate the scaling factor between the speed of the steering wheel and the speed of the steering motor.
Page 199 ⑨ DYNAM NUMB ANG Level 0 to 9. This parameter handles the Dynamic Numbness vs. the Steering Error for AUTC functions. This functions applies a linear correspondence between the steering motor speed and the angle error between the actual commanded position and the latest steady state position of the steered wheel: when this angle error is wider than the angle specified with this setting, there will be no clamp on the steering motor speed (full speed steering motor is SET SAT FREQ plus OVERSAT FREQ);...
Page 200 LAG FB REGULAT Level 0 to 9. It is used to set the integral (lag) contribution to a PID algorithm for AUTC functions. The integral contribution is applied to the FEEDBACK ENC value only. It works like a low pass filter to get smooth the pursuing next to the commanded position.
Page 201 Alignment at the rest position In the open loop applications (i.e. when the stepper motor is used in the steering wheel or the steer command is a speed information coming via CAN bus) an alignment at the rest position is automatically performed when the steered wheel has a drift with a released steering wheel.
Page 202 PROGRAMMING & ADJUSTMENTS There are two ways to adjust parameter via a console or a buttons on a display. ※ Adjustments via buttons on a display, please refer to the display section. ADJUSTMENTS VIA CONSOLE (Option) Adjustment of Parameters and changes to the inverter¡¯s configuration are made using the Digital Console.
Page 203 Description of standard console menu BRJ7EL53 7-55...
Page 204 TESTER MENU 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. Stepper motor Voltage value with 2 decimal digit.
Page 205 (12) Endstroke ACW Provides real time the active state (ON) or not of the CCW toggle switch (connected to CNA#2). It is On when CNA#2 is low. (13) CW limit level When the maximum angle limitation via feedback sensors is enabled (option LIMIT DEVICE to ON) and the FEEDBACK ENC overtakes the superior limit for the steered wheel angle limitation, the steered wheel angle will be limited and CW LIMIT LEVEL turns ON (active).
Page 206 When the special adjustments DEBUG OUTPUT is Level 12, SLOPE PEAK supplies the slope peak of the CPOC2 set point potentiometer (CNA#8). The SLOPE PEAK measurement is the difference between two AD conversions of the selected potentiometer picked up with 16 msec long interval. The SLOPE PEAK reading can be converted in a Voltage change (V in volts) of the wiper voltage in an interval 16 msec long, with the formula: V = SLOPE PEAK*5/1024 = Voltage change in Volts in 16 msec (e.g.
Page 207 8. FINGERTIP CONTROLLER INTRODUCTION OF FINGER TIP The general forklift performs lifting and tilting using the mechanical lever mounted on MCV (Main Control Valve) by an operator. A new system is designed in order to improve operator's convenience and match up with marketing trend.
Page 208 STRUCTURE BRJ7EL61 7-60...
Page 209 Description of connectors No. of Pin Function Description PCLRXD Serial communication interface NCLRXD Serial communication interface PCLTXD Serial communication interface NCLTXD Serial communication interface Negative supply. +12V supply. Mhyrio CB positive power supply +KEY Input of valves positive power supply PAUX Mhyrio CB negative supply -BATT...
Page 210 Type Function Description SET BATTERY 12/24/36 This parameter sets the battery nominal voltage, that is the key input voltage TYPE /48/72/80 (MHYRIO supply) V valves coil This parameter sets the ON/OFF valves coil nominal voltage. 12/24/36 /48/72/80 Valves supply 12/24/36 This parameter sets the voltage of the valve's coil positive supply.
Page 211 ADJUSTMENTS & FUNCTION There are two ways to adjust parameter via a console or buttons on a display. Adjustments via console or buttons on a display Adjustment of Parameters and changes to the controller's configuration are made using the Digital Console or buttons on a display.
Page 212 Description of parameters that may be programmed (parameter change) In addition to the configuration, parameter settings can be factory set (default parameters), or the customer can make changes according to the application, using a digital console or a display. During the setting up procedure on the machine, the console can remain connected to the controller during travel.
Page 213 ⑭ Max EVP6 This parameter adjusts the maximum current of valve 6, if it is set as proportional (see "set option menu"). ⑮ Min EVP7 This parameter adjusts the minimum current of valve 7, if it is set as proportional (see "set option menu").
Page 214 EVP5 Open delay EVP5 proportional valve current ramping up time: this parameter sets the EVP5 valve current ramp, to change from 0 A to operating current. EVP5 Close delay EVP5 proportional valve current ramping down time: this parameter sets the EVP5 valve closing ramp, to change the coil current from operating current to 0 A.
Page 215 (3-1) Description to change parameters by a console The flow chart shows how to change parameters by a console. ① Opening finger tip controller menu (MHY CB) ② Press ENTER to go into the GENERAL MENU. ③ The display will show: PARAMETER CHANGE. ④...
Page 216 (3-2) Description to change parameters by a display The flow chart shows how to change parameters by buttons on a display. ① Press to enter password for 2~3 seconds. The display will show: ENTER PASSWORD. ② Enter the password using After finishing entering it, press for 2~3 sec ③...
Page 217 ① When the desired parameter appears, the display will show a level number that will be between 0 and 9. Press either to change the level value ② The display will show the new level. ③ When you are satisfied with the results of the changes you have made, press ④...
Page 218 ⑩ Input 2 Level of digital input 2 : - ON / +VB : input active, switch closed - OFF / COND : input not active, switch open. ⑪ Analog input 1 Voltage of the analog input. (4-1) escription to check data by a console The flow chart shows how to use the TESTER function of the digital console.
Page 219 (4-2) Description to check data by a display The flow chart shows how to use the TESTER function of buttons on a display. ① Press to enter password for 2~3 seconds. The Display will show: ENTER PASSWORD. ② Enter the password using After finishing entering it, press for 2~3 sec ③...
Page 220 ① The first variable to be tested is shown on the display ② Press either ③ Next variable for measurement appears. ④ When you have finished, press ⑤ The display shows : TESTER ⑥ Press again and return to MHY CB HY. BRJ7EL68 ANALYSIS OF ALARMS ①...
Page 221 ⑧ EV driver short One of the on/off valves driver is shorted; check the external connection, if it is ok the driver is probably damaged. ⑨ EVP driver short The single proportional valve driver is shorted; check the external connection, if it is ok the driver is probably damaged.
Page 222 9. 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 223 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 224 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 225 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 ≤...
Page 226 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 227 DESCRIPTION OF PROGRAMMABLE FUNCTIONS Menu set model ① 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 228 ⑦ 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 ⑧ aintenance done It can be ON/OFF.
Page 229 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 230 low chart showing how to make changes to option menu: ① Opening Zapi menu. ② Press ROLL UP & SET UP Buttons to enter CONFIG MENU. ③ The display will show: SET MODEL. ④ Press ROLL UP or ROLL DOWN until SET OPTIONS appears.
Page 231 low chart showing how to use the TESTER function of the digital console: ① Opening Zapi menu. ② Press ENTER to go into the MAIN MENU. ③ The display will show: PARAMETER CHANGE. ④ Press ROLL UP or ROLL DOWN until TESTER menu appears on the display.
Page 232 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 233 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 234 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...
Page 235 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 236 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 237 ANALYSIS OF GRAPHIC SMART DISPLAY RELATED ALARMS Graphic Smart Display alarms ① 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 238 ⑥ 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 239 1 1 0) DIAGNOSTIC FAULT CODES Pump Mhyrio Traction Code Description Alarm SERIAL ERR#1 Main uC and Slave uC communicate via a local serial interface. This alarm occurs when the slave uC does not receive the communication from the main uC through ○...
Page 240 Pump Mhyrio Traction Code Alarm Description VMN HIGH The test is carried out during initial diagnosis and in standby. Possible causes: A) Problem with the motor connections or the motor ○ ○ power circuit; check if the 3 phases are correctly connected;...
Page 241 Pump Mhyrio Traction Code Description Alarm HIGH Inverter temperature is greater than 75° C. The maximum TEMPERATURE current is reduced proportionally to the temperature increase. The inverter stops at 100° C. If the alarm is ○ signalled when the inverter is cold: ○...
Page 242 Pump Mhyrio Traction Code Alarm Description COIL When the key is switched ON the μ P checks the MC SHORTED driver FF SR. If it does not react in a correct way to the μ P stimulus, the alarm is signalled. Replace the logic board.
Page 243 Pump Mhyrio Traction Code Alarm Description INPUT It occurs when the voltage on CNA#4 (NK1: Lower ERROR #1 potential terminal of the safety contacts is higher than 12 V before to turn the safety contacts closed. When the safety contacts are open, the voltage on CNA#4 is expected to be close to 0 Vdc and this is independent ○...
Page 244 Pump Mhyrio Traction Code Alarm Description MICRO It occurs in one of the following conditions : If the slave SLAVE #4 uC detects the stator voltage phasor rotates in the opposite direction respect to the sign of the stepper ○ motor speed, this alarm occurs.
Page 245 Pump Mhyrio Traction Code Alarm Description POSITION This alarm occurs for an error in the redundant test of the ERROR feedback sensors. Here we have an encoder and two toggle switches. This alarm occurs whether the sector (toggle switches configuration) and the encoder counting are not matched.
Page 246 Pump Mhyrio Traction Code Alarm Description LIFT FUCNT Potentiometer lift value and its complementer are not ○ matched EVP DRIVER One of the on/off valves driver is shorted; check the SHORT ○ external connection, if it is ok the driver is probably damaged.
Page 247 Pump Mhyrio Traction Code Alarm Description CAN BUS KO There is a problem related to the CAN-BUS line. The error is signalled if the MHYRIO controller does not ○ receive any message from the CAN-BUS line. First of all, check the wiring. If it is ok, the problem is on the logic board, which must be replaced.
Page 248 Pump Mhyrio Traction Code Alarm Description GAIN The parameters to compensate for the gain of the EEPROM KO current amplifiers (ADJUSTMENT #03 and ADJUSTMENT #04) are recorded in a not volatile memory (eeprom) with a redundant handling. In fact ○ every adjustment is recorded in three eeprom locations.
Page 249 Pump Mhyrio Traction Code Alarm Description DISPLAY Comunication with display ok but waiting for display ○ ENABLE message UNDER This fault is signalled if an undervoltage condition is ○ VOLTAGE detected in the MHYRIO power supply S.P OUT OF This alarm occurs for a fault on the command RANGE potentiometer (CPOC1 on CNA#9, CPOC2 on CNA#8).
Page 250 Pump Mhyrio Traction Code Alarm Description ○ CHAT MODE No command(traction or pump) for CHAT TIME minutes ○ PROTECTION FF VALVES Flip-flop circuit, that manages on/off valve drivers short- ○ circuit protection, does not reset in the correct way. The problem is probably in the hardware circuit.
Page 251 0. 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 252 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 7-104...
Page 253 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 254 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 255 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 256 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 257 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 258 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 259 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 260 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 261 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 262 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 263 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 264 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 265 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 266 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 267 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 268: Section 8 Mast
SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-3 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-6 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-9...
Page 269: Group 1 Structure
SECTION 8 MAST GROUP 1 STRUCTURE 1. 3 STAGE MAST(TF MAST) 14/16/20/25BRJ-7 LIFT CYLINDER CARRIAGE FREE LIFT CYLINDER BRJ7MS03 Outer mast Shim(0.5, 1.0t) Chain sheave Middle mast Retaining ring 10 Back up liner Inner mast Lift chain 11 Clamp Roller Anchor bolt...
Page 270 2. CARRIAGE, BACKREST AND FORK 14/16/20/25BRJ-7 BRJ7MS05 Backrest Side roller Carriage Fork assy Load roller Extension fork...
Page 271: 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. ℓ=1050mm(41.3in) EX : mm(in) STD Fork assy Applicable model Standard Limit 64HM-11060 14/16BRJ-7 40(1.6) 36(1.4) 45(1.8) 40(1.6) 20BRJ-7...
Page 272 . 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 273 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 274: 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 275 . 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 276 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 277: Group 4 Removal And Installation
GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are Anchor pin approximately 25mm(1inch) from the floor. Release fork anchor pins and slide forks, one by one, toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
Page 278 3. CARRIAGE ASSEMBLY CARRIAGE With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor.
Page 279 CARRIAGE LOAD ROLLER Remove carriage as outlined in the carriage assembly removal paragraph. Loosen and remove flat head bolts and plain washers from top load roller bracket. Using a pryer, remove load rollers from load roller bracket. Reverse the above procedure to assemble. Refer to MAST ROLLER ADJUSTMENT Carriage paragraph.
Page 280 MAST LOAD ROLLER AND BACK UP LINER 3 stage mast(TF mast) ① Remove the carriage assembly and move to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. Load ③ Loosen and remove bolts and special roller washers securing lift cylinders to middle Lift chain...
Page 281 ELEVATING MAST Inner and middle mast(TF mast) ① After completing all necessary steps for load rollers and back up liner removal. Remove rear chains and sheave support if not already done. ② Disconnect free lift cylinder hose. Drain hose into a suitable pan or container and cap hose. ③...
Page 282 Chain wheel bearing support(TF mast) ① Remove the carriage assembly and move to one side. ② 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 283 ② 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 284 ⑧ 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 285 ③ ③ 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. ④ 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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16brj-7

Hyundai 14BRJ-7 Operation Manual

Section 1 General

Section 2 Removal & Installation

Section 3 Power Train System

Section 4 Brake System

Section 5 Steering System

Section 6 Hydraulic System

Section 7 Electrical System

Section 8 Mast

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