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Hyundai HBR 14-7 Operation Manual

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Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
Group 3 Test and adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-11
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-18
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22
Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Electric components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-6
Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-9
Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-12
CONTENTS

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Summary of Contents for Hyundai HBR 14-7

  • 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 = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
  • Page 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...
  • 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 BR147GEN01 Head guard Reach lever 17 Drive motor Monitor panel 10 Attachment lever 18 Drive unit Key switch 11 Accelerator 19 Drive wheel Head lamp switch 12 Dircection indication lamp switch 20 Hydraulic oil tank Work lamp switch(Opt) 13 Hazard lamp switch 21 Brake pedal...
  • Page 16 2. SPECIFICATIONS HBR14/15/18-7 BR147SP01 Model Unit HBR 14-7 HBR 15-7 HBR 18-7 Capacity 1350 1500 1800 Load center Weight(Unloaded, with battery) 2210 2290 2350 Lifting height 3000 Free lift Lifting speed(Unload/Load) Fork 480/300 480/290 480/280 mm/sec Lowering speed(Unload/Load) 450/500 mm/sec...
  • Page 17 HBR20/25-7 BR147SP01 Model Unit HBR 20-7 HBR 25-7 Capacity 2000 2500 Load center Weight(Unloaded, with battery) 2920 3010 Lifting height 3000 Free lift Lifting speed(Unload/Load) Fork mm/sec 430/280 430/260 Lowering speed(Unload/Load) mm/sec 450/500 L W T L,W,T 1050 100 45 Tilt angle(Forward/backward) C/C’...
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS HBR14/15/18-7 MOTOR Item Unit Drive motor Hydraulic pump motor Model KNAS4003 KNAQ4004 Type SEM, self ventilated DC series, self ventilated Rated voltage Output Brush size 16 32 30 16 20 25 Insulation Class H BATTERY HBR14/15-7(OPT) Item Unit...
  • Page 19 GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity cc/rev Maximum operating pressure Rated speed(max/min) 3000/500 MAIN CONTROL VALVE Item Unit Specification Type 3 spool, 4 spool Operating method Mechanical Main relief valve pressure DRIVE UNIT Item Unit Specification G2 : G1 35 : 8 (4.375 : 1)
  • Page 20 HBR20/25-7 MOTOR Item Unit Drive motor Hydraulic pump motor Model KNAS4005 KNAQ4004 Type SEM, self ventilated DC Series, self ventilated Rated voltage Output Brush size 16 32 30 16 20 25 Insulation Class H BATTERY Item Unit HBR20/25-7 Model(Type) VCI 335 Rated voltage Capacity 335/5...
  • Page 21 GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity cc/rev Maximum operating pressure Rated speed(max/min) 3000/500 MAIN CONTROL VALVE Item Unit Specification Type 3 spool, 4 spool Operating method Mechanical Main relief valve pressure DRIVE UNIT Item Unit Specification Max input torque 2200...
  • Page 22 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS HBR14/15/18-7 kgf m lbf ft Items Size Hyd pump motor mounting bolt M10 1.5 6.9 1.4 50 10 Electric Drive motor mounting bolt M 8 1.25 2.0 0.2 14.4 1.4 system Steering motor mounting bolt M10 1.5 6.9 1.4 50 10...
  • 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 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7...
  • Page 24 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat 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...
  • Page 25 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Capacity (U.S. gal Ambient temperature C( F) Service Kind of point fluid 14/15/18-7 20/25-7 (-31) (-4) (14) (32) (50) (68) (86) (104) SAE 80W/90 Drive Gear oil unit...

  • 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 B147RE01 Mast Load wheel 15 Steering wheel Lift cylinder Reach cylinder 16 Control levers Main control valve 10 Drive wheel 17 Accelerator EPS filter 11 EPS motor...

  • 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 Remove bolts securing backrest to fork carriage. Lift backrest straight up and remove it from carriage.
  • Page 30 While supporting lift chains, remove the Lift chain split pins and slide out chain anchor pins Outer mast from the chain anchors of stationary upright. BR147RE05 Pull the chains out of the sheaves and Mast drape them over the front of the carriage. Carriage Lift chain Block...
  • Page 31 PIPING Remove the return hoses and clamps Inner mast attached to the cylinder. Remove the return hoses from the connector. Return Remove hose assembly, connector, hose down safety valve from the lift cylinder. Band clamp Hose Disconnect hose assembly from the flow clamp regulator.
  • Page 32 MAST REMOVAL Crane Pass wire rope around the inner and outer masts to allow lifting them out with a hoist. Remove the stopper pin at the end of reach cylinder and then remove the stopper bolt at the end of guide rail. Mast Draw out the mast from the guide rail with Wire rope...
  • 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 Assemble the lift cylinder inside the outer mast, then tighten the stopper bolt.
  • Page 34 2. POWER TRAIN ASSEMBLY REMOVAL BR147RE001 Disconnect the battery cable and then pull out the battery to battery stand or carrier. Battery Disconnect battery cable Battery stand or carrier BR147RE12 Remove steering joint parts. Sprocket Universal joint BR147RE13 Disconnect the hose, pipe and wiring from Pump &...
  • Page 35 Remove brake cable. Brake cam Wrench Brake cable BR147RE16 Disconnect the wiring. Drive motor Drive motor wiring EPS motor wiring. motor BR147RE17 Jack up the frame and support both side of frame on wood block. BR147JB09 Remove the support bolts and pull out the link pins.
  • Page 36 Remove drive unit assembly from frame Wire rope by lifting. Drive unit assembly BR147RE19 INSTALLATION Installatron is in the reverse order to removal, but be careful of following points. Link pin support bolts. Link pin Tightening torque : 4.0~6.0kgf m Link pin Wrench (28.9~43.4lbf ft)
  • Page 37 3. ELECTRICAL COMPONENTS Before removing each component, disconnect cables and earth lines attached to the component. REMOVAL BR147RE002 PUMP MOTOR Disconnect the battery cable and then pull out the battery to battery stand or carrier. Battery Disconnect battery cable Battery stand or carrier BR147RE12...
  • Page 38 Disconnect the hose, pipe and wiring Pump & motor assembly from pump & motor assembly. Loosen mounting nuts from the bracket Wiring and then take out the assembly. Hose Pipe To hyd tank To MCV Mounting nut BR147RE15 Remove 2 socket bolts fastening the Pump &...
  • Page 39 Remove brake cable. Brake cam Wrench Brake cable BR147RE16 Disconnect wirings. Drive motor a. Drive motor wiring b. EPS motor wiring motor BR147RE17 Remove bolts connecting the motor and drive unit. Bolt BR147RE22 Tie wire rope around the drive motor and Wire rope lift up slowly.
  • Page 40 Put the motor on the clean work bench. BR147RE24 EPS MOTOR Disconnect the battery cable and then pull out the battery to battery stand or carrier. Battery Disconnect battery cable Battery stand or carrier BR147RE12 Remove side door. Side door BR147RE20 Disconnect wirings.
  • Page 41 Loosen bolts and remove EPS motor assembly. motor BR147RE26 BATTERY ASSEMBLY When the spare battery is used for continuous operation or it is required to check the battery, motor, etc., remove the battery through the following procedure: Disconnect Disconnect the battery connector. BR147OM120 Put the battery stand to the battery stopper side.
  • Page 42 Adjust the height of the roller of the stand to that of the roller of the vehicle. Slide the battery to the stand. Battery Battery stand BR147OM139 The same procedure is applied when the optional battery carrier is used. Battery Battery carrier BR147OM135...
  • Page 43 INSTALLATION Installation is in the reverse order to removal, but be careful of following points. PUMP MOTOR Pump & motor assembly Pump motor mounting nut. Tightening torque : 4.0~6.0kgf m (28.9~43.4lbf ft) Hydraulic pump mounting bolt Tightening torque : 4.0~6.0kgf m (28.9~43.4lbf ft) Socket bolt BR147RE21...
  • Page 44 4. CASTER LINK ASSEMBLY BR147RE003 REMOVAL Disconnect the battery cable and then pull out the battery to battery stand or carrier. Battery Disconnect battery cable Battery stand or carrier BR147RE12 Remove floor mat and floor plate. Floor mat Floor plate BR147RE28 Remove inspection cover by loosening the screw.
  • Page 45 Remove bolt, pin, spring and brake cable to remove the brake pedal assembly. Brake cable Spring Brake Bolt pedal BR147RE30 Remove lock nut from the top end of Lock support bolt for spring at caster side(lower side). Spring and support bolts are dropped Caster down.
  • Page 46 INSTALLATION Installation is in the reverse order to removal, but be careful of the following points. No.3 link pin(lowest one) fixing bolt. Tightening torque : 2.0~3.0kgf m Bolt (14.5~21.7lbf ft) No.3 Link pin Caster assy BR147RE32 Lock nut fixing the support bolt. Lock Tightening torque : 12~15kgf m (87~109lbf ft)
  • Page 47 5. TIRE & WHEEL ASSEMBLY REMOVAL DRIVE TIRE & WHEEL ASSEMBLY Jack up the frame Jack up until the tire clear off the ground. BR147JB09 Remove 6 flange bolts attaching the drive wheel and take off the drive wheel assembly. Flange bolt Drive wheel assy...
  • Page 48 Remove bolt and take out the steering shaft & caster wheel assembly from axle fork. Bolt Axle fork Steering shaft & caster wheel assy BR147RE35 Remove remained bearing from the axle fork. Axle fork Bearing Bearing Bearing cover BR147RE36 LOAD WHEEL ASSEMBLY Jack up the reach legs and fix the machine with blocks.
  • Page 49 INSTALLATION Installation is in the reverse order to removal, but be careful of the following points. Drive wheel flange bolts Tightening torque : HBR14/15/18-7 : 19~22kgf m (137~159lbf ft) HBR20/25-7 : 13.5~15.5kgf m (98~112lbf ft) Flange bolt Drive wheel assy BR147RE33 Caster wheel bolts.

  • Page 50: 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 51: Group 1 Structure And Operation

    SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. DRIVE AXLE UNIT STRUCTURE HBR14/15/18-7 51 52 VIEW B 11 12 10 2 14 15 49 48 51 50 52 51 SECTION A - A BR147DU100 Gear case cover 14 Bearing lock nut 27 Idler gear shaft 40 Case...
  • Page 52 HBR20/25-7 29-1 29-3 29-2 26 25 28 15 14 SECTION A-A BR147DU103 10 Housing 25 Cover 39 Wheel shaft 11 Cover 26 Seal ring 40 Bevel gear set 12 Hexagon screw 27 O-ring 41 Taper roller bearing 13 Ring gamma 28 Circlip 42 Taper roller bearing 14 Magnet plug...
  • Page 53 2. SPECIFICATION HBR14/15/18-7 Item Unit Specification Max input torque Kgf m Max input rpm G2 : G1 35 : 8(4.375 : 1) G3 : G2 46 : 10(4.6 : 1) Gear ratio Total 20.125 Quantity of oil HBR20/25-7 Item Unit Specification Max input torque 2200...

  • Page 54: Group 2 Troubleshooting

    GROUP 2 TROUBLESHOOTING Problem Probable cause Remedy Continuous metallic groan 1) During acceleration - Adjust back-lash or replace gears. Worn out gears. Pinion and bevel gear meshed too deeply. - Refill Lack of gear oil. 2) During travelling at - Replace Worn out gears.
  • Page 55 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 56: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HBR14/15/18-7 DISASSEMBLY Before starting disassembly check the backlash and tooth contact for use as reference during assembly. Stabilize the drive unit assembly by using wooden block. BR147DU101 Remove the plug and drain out the oil. Remove the gear case cover and drain out the oil.
  • Page 57 Remove the end cover(29, 30). (10) Remove the bearing(16, 20) installed on the side of spiral bevel gear(6) for pinion shaft(26). Loose the nut for spiral bevel gear(6) by straightening the locking of the washer and remove the nut(21) and the washer(22).
  • Page 58 INSPECTION Inspect the gear case for cracks, bearing insertion parts for injuries, oil seals for damage and for other defects. Replace if found defective. Inspect for gear case cracks visually and by use of flaw penetrants. Inspect the drive unit bracket for cracks, bearing insertion parts for injuries, bushings for damage, and other defects.
  • Page 59 ASSEMBLY Assemble the oil seal to the cover of gear case, assemble the bearing to spiral bevel pinion shaft. Assemble the spiral bevel pinion shaft bearing, washer and nut to the cover of gear case, and screw on the locking nut. Tighten the locking nut while measuring starting torque required to start the bevel pinion turning.
  • Page 60 INSTALLATION Perform the removal in reverse order. LBRICATION PROCEDURES Lubrication of drive unit gear case is performed as follows : Cover the brakes and drive motor with waste to prevent the gear oil from splashing on these parts. Fill in oil through the filler hole A. After operating the vehicle for several hours, remove plug B and check the oil level.
  • Page 61 2. HBR20/25-7 STANDARD TOOLS Open jaw spanner 10, 13, 30mm. BR147DU03 Allen wrench 6, 10mm. BR147DU04 Torque spanner Adjustable from 9.5 to 300Nm. BR147DU05 Hexagonal socket spanner. BR147DU06/07 3-11...
  • Page 62 Plastic hammer(1000g). Steel hammer(250g). Stable screwdrivers or levers. BR147DU08 Two-armed or three-armed puller. BR147DU09 Grease gun With adapter for hydraulic-type lubricating nipple acc. to DIN 71412-M8 1. BR147DU10 3-12...
  • Page 63 MEASURING TOOLS Dial gauge with magnetic stand. BR147DU11 Micrometer depth gauge Measuring depth up to 70mm. BR147DU12 Micrometer Measuring range up to 25mm. BR147DU13 Measuring device For determination of installation dimens- ion for bevel pinion shaft. BR147DU14 3-13...
  • Page 64 SPECIAL TOOLS Assembly plate(A) If no assembly fixture is available. BR147DU15 Bush(B) To press off bearing inner ring from bevel pinion shaft. BR147DU16 Bush(C) To press bearing inner ring onto bevel pinion shaft. BR147DU17 Measuring bush(D) For determination of installation dimens- ion for bevel pinion shaft.
  • Page 65 Clamping fixture(F) To clamp bevel pinion shaft into the housing. BR147DU19 Bush(G) To press bearing inner ring onto bevel pinion shaft. BR147DU20 Sleeve(H) To press bearing inner ring onto wheel shaft and onto crown gear. BR147DU21 3-15...
  • Page 66 Puller(M) To pull off bearing inner rings from the wheel shaft and the crown gear. BR147DU22 Clamping pliers BR147DU23 Pressure piece(N) To pull off bearing inner ring from the crown gear. BR147DU24 (10) Assembly drift(S) Install protective shield. BR147DU25 3-16...
  • Page 67 (11) Assembly drift(T) Install radial shaft seal. BR147DU26 (12) Assembly drift(U) To install breather filter. BR147DU27 (13) Assembly drift(V) To install grooved ball bearings into the housing seat. BR147DU28 3-17...
  • Page 68 DISASSEMBLY Prior to disassembly clean drive unit carefully. A great help is a bright, spacio- us working place, free of dirt and chips. The necessary working steps are described and illustrated in the correct sequence. Parts only available as assembly groups will not be stripped any further.
  • Page 69 This drive unit has the housing top section additionally fastened to the housing by means of 2 socket head bolts( ), hexagon nuts( ) and washers ( ). BR147DU32/33 For motor fixing the centering ring( ) is bolted onto the pivoting bearing( ). Two final stops( ) on the chain tread and the lock plate( ) connected with the centering ring are required for the...
  • Page 70 Remove input from the housing top section and dismantle it By means of two assembly levers press cover assy( ) cautiously against the bearing outer ring(With radial shaft seal, grooved ball bearing, O-ring and input pinion) out of the bearing bore. Do not damage the input pinion toothing.
  • Page 71 Remove radial shaft seal( ) from the cover, only if unavoidable. Radial shaft seal will be destroyed at removal. Use new radial shaft seal for reassembly. By means of bush press radial shaft seal and grooved ball bearing( ) out of the cover( ) and remove them.
  • Page 72 REMOVE HOUSING COVER Remove hexagon bolts( ) in the housing cover. Loosen and remove housing cover( ) from the housing by slightly beating with a plastic hammer against the outer edge. BR147DU43 REMOVE WHEEL SHAFT AND CROWN GEAR Place drive unit into the fixture and fasten it with screws.
  • Page 73 REMOVE BEARING INNER RINGS FROM WHEEL SHAFT AND CROWN GEAR If the taper roller bearings are to be reused, we recommend to use puller M. (See page 3-16 special tools) Remove bearing inner ring from wheel shaft Place clamping pliers of the puller onto the rollers of the bearing inner ring.
  • Page 74 PRESS WHEEL BOLTS OUT OF THE WHEEL SHAFT Wheel bolts( ) can only be pressed out at removed wheel shaft. Make these 2 steps only in case of emergency. Do not damage wheel bolt threads at pressing-out. Place wheel shaft( ) into a suitable bush and press out wheel bolts with a press.
  • Page 75 Press off taper roller bearing inner ring from the bevel pinion shaft By means of bush B press off the bearing inner ring( ) from the bevel pinion shaft( ). BR147DU51 REMOVE TAPER ROLLER BEARING OUTER RINGS AND RADIAL SHAFT SEAL Cautiously drive the bearing outer rings(...
  • Page 76 REASSEMBLY Clean all parts with a suitable cleaning agent and remove residues of LOCTITE. Keep away cleaning agent from your skin, do not drink it or inhale its vapours. Wear safety gloves and goggles. In case of skin contact rinse immediately with a lot of water. If by mistake the cleaning agent was swallowed, call medical aid immediately.
  • Page 77 DETERMINATION OF INSTALLATION DIMENSION FOR BEVEL PINION SHAFT The bevel gear set, consisting of bevel gear shaft and bevel gear, is provided with certain installation dimensions. The installation dimension of the bevel pinion shaft is 100.00mm. The correct adjustment of the bevel pinion shaft is required for an exact setting of the contact pattern and the torsional backlash of the gearing.
  • Page 78 PREASSEMBLE HOUSING Bearing for bevel pinion shaft Shim ring thickness determined in page 3-27 has to be obtained by combining shim rings of variable thicknesses. Place shim rings( ) into the bearing seat. Install bearing outer ring( ) into bearing seat in the housing. A tolerance of 0.05 from the determ- ined dimension is permissible.
  • Page 79 Install sealing ring and bearing inner ring onto the wheel shaft Push sealing ring( ) on the wheel shaft( ). By means of sleeve H press bearing inner ring( ) onto the wheel shaft until contact. Only when the bearing is adjusted, the sealing and the taper roller bearing can be filled with grease SHELL Alvania R3.
  • Page 80 INSTALL BEVEL PINION SHAFT INTO THE HOUSING Wet cage and space between rollers of the bearing inner ring with transmission oil. Insert preassembled bevel pinion shaft from the bottom into the housing and by means of clamping fixture F apply a slight preload to the bearing outer ring in the housing.
  • Page 81 A bearing preload of 0.07mm shall be achieved. Shim ring thickness(thickness Z) determined has to be obtained by combining shim rings of variable thicknesses. Place shim ring(s) ( ) into the bearing seat. Install bearing outer ring( ) by means of a copper mandrel and a hammer into bearing seat of the housing until contact with the shim ring.
  • Page 82 Press bevel pinion shaft down by hand and rotate it several times, so that the taper rollers in the bearing rings are aligned. Position dial gauge as shown in right figure and put the dial gauge indicator to Zero. Mark position of the dial gauge on the helical gear with a colour pencil.
  • Page 83 MOUNT WHEEL SHAFT AND CROWN GEAR INTO THE HOUSING Radial shaft seal between the taper roller bearings has to be installed into the housing, only when bearing preload of the wheel shaft was determined. Insert crown gear( ) into the housing. Cautiously install the wheel shaft( ) into the crown gear toothing.
  • Page 84 (10) CONTACT PATTERN CHECK For a contact pattern check it is necessary to apply marking ink onto 3~4 tooth flanks of the crown gear. Have the ink-marked tooth flanks get into mesh with the bevel pinion several times. A better recognition of the contact pattern is possible, when the bevel pinion is braked slightly.
  • Page 85 (11) MEASURE BEARING PLAY ON WHEEL SHAFT AND ADJUST BEAR- ING PRELOAD Press wheel shaft down by hand and rotate it several times, so that the taper rollers in the bearing rings are aligned. Position dial gauge as shown in right figure and put the dial gauge indicator to Zero.
  • Page 86 (12) INSTALL THREAD PROTETIVE SHIELD(GAMMA RING) Spray seat for thread protective shield with LOCTITE fast cleaner. Have fast cleaner work and thoroughly remove the dissolved dirt with a clean cloth. Spray surface again and have it dried. Hazardous when breathed swallowed.
  • Page 87 Fill sealing ring and taper roller bearings on the wheel shaft( ) with SHELL Alvania R3 grease. Cautiously install wheel shaft( ) into the crown gear toothing. Remove excess LOCTITE with a clean cloth. Bolt together the crown gear and the wheel shaft with hexagon bolt( ) and washer( ).
  • Page 88 (15) CHECK PIVOTING BEARING(HOUS- ING TOP SECTION) The housing top section has to be replaced, if : The peened cover disc on the pivoting bearing has loosened. The pivoting bearing is difficult to rotate or sticking. The cage segments or balls are damag- The maximum bearing play is exceed- The housing top section can only replaced completely.
  • Page 89 Install breather valve Drive breather valve( ) by means of press-in mandrel U carefully into the housing top section. Take care for mounting that the cap of the breather valve can still move freely. Install hydraulic-type lubricating nipple Screw in hydraulic-type lubricating nipple( ) with an open-jaw spanner into the housing top section until contact.
  • Page 90 Preassemble cover( ) as follows : Install radial shaft seal( ) by means of an assembly drift V with the correct side until contact. Do not damage sealing lip of the shaft seal. Apply a thin layer of grease onto the sealing lip.
  • Page 91 Install housing top section Provide sealing surface of the housing with a thin layer of LOCTITE 574. Plane faces of the housing and the housing top section have to be cleaned carefully before with LOCTITE fast cleaner and must be free of grease. BR147DU92 Place housing top section onto the housing, so that the cylinderical pins in...
  • Page 92 Check axial play of the input in housing top section Have wheel shaft rotated several times. For measurement of the axial play of the input, a dial gauge with a magnetic stand is to be positioned right-angled onto the plane face of the input pinion and the dial indicator must be put to Zero.
  • Page 93 (17) RELUBRICATION OF PIVOTING BEARING Under normal operating conditions the pivoting bearing has to be relubricated once a year. After cleaning with a steam jet device or similar, the pivoting bearing has to be relubricated. For the operation in a heavily dust-loaded or humid environment(e.g.

  • Page 94: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9 Group 3 Test and adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-11...

  • Page 95: Group 1 Structure And Function

    SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Brake shoe Brake cam Drive motor Brake switch Brake cable Brake cable Drive unit Stopper bolt & nut Brake pedal Floor mat BR147BS01 2. SPECIFICATION Item HBR14/15/18-7 HBR20/25-7 Type Center brake Material Rubber mould...
  • Page 96 3. BRAKE PEDAL AND PIPING STRUCTURE BR147BS02 Brake cam Spring Brake switch Brake pedal Bracket Brake cable Stopper bolt...
  • Page 97 DISASSEMBLY AND ASSEMBLY Floor mat Disassembly Remove floor mat and floor plate. Floor plate BR147RE28 Remove inspection cover Inspection cover Screw BR147RE29 Remove bolt, pin, spring and brake cable to remove brake pedal assembly. Brake cable Spring Brake Bolt pedal BR147RE30 Assembly Perform disassembly in reverse order.
  • Page 98 4. BRAKE SYSTEM STRUCTURE DRIVE MOTOR BR147BS03 Drive motor Cam bolt 17 Brake rod Brake drum Hexagon nut 18 Spring Brake shoe pin 10 Bracket 19 Plain washer Lock plate 11 Spring washer 20 Hexagon nut Plain washer 12 Hexagon bolt 21 Low castle nut Hexagon nut 13 Brake cam...
  • Page 99 DISASSEMBLY AND ASSEMBLY Disassembly Remove the brake cable from brake cam. Brake cable Wrench BR147BS04 Remove spring and support bolts after removing lock nut of brake spring. Wrench Spring Support Lock bolt BR147BS05 Remove lock nut for adjusting bolt. Wrench Lock nut BR147BS06 Remove lock nut of brake shoe support...
  • Page 100 Take off brake shoe lifting up straightly. Brake shoe BR147BS08 Remove the split pin from the bracket of Brake cam cam and remove the cam. Split pin BR147BS09 Remove 3 bolts attached on bracket and take off brake cam bracket. Bolt Brake cam bracket...
  • Page 101 Assembly Assembly is in the reverse order to disassembly but be careful of following points. Brake cam bracket mounting bolts. Tightening torque : 1.6~1.9kgf m Bolt (12~14lbf ft) Apply loctite #277 Brake cam bracket BR147BS10 Brake shoe support pin mounting. Tightening torque : 14.6~16kgf m Lock nut Lock plate...
  • Page 102 5. INSPECTION Lining inspection Contact normally? Any injuries? Any one sided contact? Service limit : 1.5mm(0.059") Lining should be replaced together with brake shoe. Brake drum inspection Any damage or wear? If so, plane the drum for revising. Drum die should not exceed ; under 3mm(0.012") Spring inspection Are the springs weakened or damaged?

  • Page 103: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS BRAKE PEDAL OPERATION Once the pedal released, the machine must remain stopped. Check the free play of pedal is 10~15mm(0.4~0.6in). Check the pedal height is 58~63mm(2.3~2.5in). BRAKE SYSTEM OPERATION Check the operation of brake cam. Measure lining at point with most wear, and check that lining thickness is at least 2.0mm(0.08in).
  • Page 104 2. TROUBLESHOOTING Problem Cause Remedy Brake drags Brake spring out of adjustment. Check and adjust. Brake spring broken. Replace. Brake drum worn or rusted. Check, and replace if defective. Brake switch defective. Check, and replace if defective. Brake pedal play excessive. Adjust brake pedal play.

  • Page 105: Group 3 Test And Adjustment

    GROUP 3 TEST AND ADJUSTMENT 1. BRAKE PEDAL AND CABLE Check the pedal height and adjust the stopper bolt if the height is too high or too low. H : 58~63mm(2.3~2.5in) Brake switch After adjusting the pedal height set vertically Adjust cable the brake cam and set the brake cable.

  • Page 106: Section 5 Steering System

    SECTION 5 STEERING SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3...

  • Page 107: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 18-1 18-2 20-6 20-7 20-5 20-3 20-1 20-4 20-3 19-5 20-2 19-3 19-1 U-joint assy 19-4 1-1 Straight pin 19-3 1-2 Snap ring Roller chain 10 Hexagon bolt 13 Hexagon nut 14 Spring washer 19-2 15 Plain washer...
  • Page 108 2. SPECIFICATIONS AND SERVICE STANDARD 1st stage Chain Type 2st stage Gear Steering wheel diameter (mm) 25~50 Steering wheel free play (mm) Steering chain slack (mm) Right turn Steering angle Left turn HBR 14 1550 HBR 15 1640 Minimum turning radius HBR 18 1775 (mm)

  • Page 109: Group 2 Disassembly And Assembly

    GROUP 2 DISASSEMBLY AND ASSEMBLY 1. TOOL Standard tool 18-1 Universal puller 18-2 Vernier caliper 2. DISASSEMBLY 20-6 Remove the cap of steering wheel(18-2) 20-7 20-5 and remove the hexagon nut(20-6) by 20-3 Cover means of box spanner. 20-1 Remove the steering wheel(18-2). 20-4 Loosen the nut(13) fixing the steering 20-3...
  • Page 110 4. INSPECTION Inspect the steering chain for extension, cracks and damage and replace if defective. L1 + L2 Standard : L = 76.20mm(3.00in) Limit : L = 77.34mm(3.04in) Inspect the sprockets assy and steering wheel shaft for cracks and damage, and replace if defective.

  • Page 111: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-18 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22...

  • Page 112: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT BR147HS01 Hydraulic tank Down control valve Hydraulic pump Tilt cylinder Main control valve Reach cylinder Lift cylinder Return filter Down safety valve...
  • Page 113 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION BR147HS02 When the lift control lever is pulled back, the spool on the first block is moves to lift position. The oil from hydraulic gear pump(2) flows into main control valve(3) and then goes to the large chamber of lift cylinder(4) by pushing the load check valve of the spool.
  • Page 114 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION BR147HS03 When the lift control is pushed forward, the spool on the first block is moved to lower position. The work port(1B) and the small chamber and the large chamber are connected to the return passage, so the lift will be lowered due to its own weight.
  • Page 115 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION BR147HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position. The oil from hydraulic gear pump(2) flows into main control valve(3) and then goes to the large chamber of tilt cylinder(7) by pushing the load check valve of the spool.
  • Page 116 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION BR147HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position. The oil from hydraulic gear pump(2) flows into main control valve(3) and then goes to the small chamber of tilt cylinder(7) by pushing the load check valve of spool.
  • Page 117 WHEN THE REACH CONTROL LEVER IS IN THE BACKWARD POSITION BR147HS06 When the reach control lever is pushed backward, the spool on the third block is moved o reach backward position. The oil from hydraulic gear pump(2) flows into main control valve(3) and then goes to the small chamber of reach cylinder(8) by pushing the load check valve of spool.
  • Page 118 WHEN THE REACH CONTROL LEVER IS IN THE FORWARD POSITION BR147HS07 When the reach control lever is pushed forward, the spool on the third block is moved to reach forward position. The oil from hydraulic gear pump(2) flows into main control valve(3) and then goes to the large chamber of reach cylinder(8) by pushing the load check valve of spool.
  • Page 119 2. HYDRAULIC GEAR PUMP STRUCTURE BR147HS08 Front cover Bushing block 11 Dowel pin Rear cover Dry bearing 12 Snap ring Gear housing Channel seal 13 Socket head bolt Drive gear Square seal 14 Spring washer Driven gear 10 Lip seal OPERATION This pump comprises of an rear cover, a body, bushings and a housing bolted together with socket bolts.
  • Page 120 3. MAIN CONTROL VALVE STRUCTURE (3 Spool) 9 10 Port name Size Inlet port PF 1/2 Outlet port PF 1/2 Gauge port PF1/4 Work port 2 - PF 3/8 B207HS07 Inlet block assy Relief valve assy Lift block assy Tilt block assy Aux 1 block assy Outlet block assy 10 Nut...
  • Page 121 STRUCTURE(4 Spool) 9 10 Port name Size Inlet port PF 1/2 Outlet port PF 1/2 Gauge port PF1/4 Work port 2 - PF 3/8 B207HS08 Inlet block assy Relief valve assy Lift block assy Tilt block assy Aux 1 block assy 10 Rod Aux 2 block assy 11 Nut...
  • Page 122 INLET SECTION OPERATION Structure and description D155HS09 When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the flow into lift cylinder port(1B). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 123 Lower position D155HS10 When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (1B) T. In lift lower position the fork drops due to its own weight.
  • Page 124 TILT SECTION OPERATION Tilt forward position D155HS11 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The oil supplied from the pump and flow into tilt cylinder port(2A). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage.
  • Page 125 Tilt backward position D155HS12 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flows into tilt cylinder port(2B).
  • Page 126 MAIN RELIEF VALVE This valve is a type of pilot piston to prevent hydraulic components and pipes from being broken by high pressure so, it keeps under pressure limited. Relief valve pressure varies by 130kgf/cm in accordance with 1 revolution of adjust bolt. 15 16 17 18 D155HS22...
  • Page 127 4. LIFT CYLINDER D155HS13 Tube assy Wear ring 11 O-ring Retaining ring 12 Stopper Piston Rod cover 13 Du bushing U-packing Dust wiper 14 Spacer Back up ring 10 U-packing 15 O-ring 5. TILT CYLINDER D255HS19 Tube assembly Piston seal Rod seal Rod assembly Nylon nut...
  • Page 128 5. REACH CYLINDER BR147HS14 Tube assembly Dust wiper 11 O-ring Rod assembly O-ring 12 Nylon nut Gland O-ring 13 O-ring DU bushing Piston 14 Spacer Rod seal 10 Piston seal 6-17...

  • Page 129: 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 2 minutes and measure hydraulic drift(amount forks move down and amount mast tilts forward).
  • Page 130 2. TROUBLESHOOTING SYSTEM Problem Cause 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 131 HYDRAULIC GEAR PUMP Problem Cause 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 132 LIFT CYLINDER Problem Cause 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 133: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP DISASSEMBLY Put the unit back side down to your work place. B207PMP01 Remove all fasteners, bolts and nuts. B207PMP02 Put all removed parts on a safe place. B207PMP03 Remove the mounting flange. B207PMP04 6-22...
  • Page 134 Remove the gear set and remove the balance plate from bottom of the body. B207PMP05 Remove the snap ring(located in front of the shaft seal ring). B207PMP06 Use proper and safe tools for this operation. B207PMP07 Push out the shaft seal. B207PMP08 6-23...
  • Page 135 Check balance plates, the mid plate and the sealing parts. B207PMP09 (10) Assemble new sealing parts, the rubber seal first, the plastic seal on top. B207PMP10 (11) Check all parts of the gear set including the key for the split gear. B207PMP11 (12) Remove the section seal from mounting...
  • Page 136 ASSEMBLY Clean all mounting faces of the mounting flange from sealant and dirt. B207PMP13 Be careful, avoid mechanical surface damages. B207PMP14 Clean all mounting faces of the body from sealant and dirt. B207PMP15 Assemble the lower balance plate into the body, sealing parts can be fixed with grease.
  • Page 137 Assemble the basic gears into the body, journals and other contact faces should be oiled with clean hydraulic fluid. B207PMP17 Assemble the mid plate to the gear set. The center plate is not rotation sensitive. B207PMP18 Fit the key to the drive shaft. The key should be fixed with grease.
  • Page 138 Put the upper balance plate on top of the gear set. Position is rotation sensitive. B207PMP21 (10) Prepare the shaft seal for assembly. Use a proper assembly fixture. B207PMP22 (11) The shaft seal should be packed with some grease. B207PMP23 (12) Press in the shaft seal to bottom of the shaft seal bore.
  • Page 139 (13) Assemble the snap ring. B207PMP25 (14) Check the section seal. Use of a new one is recommended in each case. B207PMP26 (15) Clean all assembly faces again. B207PMP27 (16) Put a rope of loctite sealant out side the interlock track on the body(it's for corrosion protection).
  • Page 140 (17) Fit an assembly fixture for shaft seal protection to the drive shaft. B207PMP29 (18) The assembly fixture should be oiled with clean hydraulic fluid to lubricate the shaft seal lip during assembly. B207PMP30 (19) Fit the mounting flange careful from top down to the body.
  • Page 141 (21) Fit fasteners, bolts or nuts with correct assembly torque, according to values shown on unit assembly drawing. B207PMP33 6-30...
  • Page 142 2. MAIN CONTROL VALVE DISASSEMBLY Remove spool cap. Put disassembled parts orderly on the clean work bench. B207CVD01 Remove socket bolts from the opposite side. B207CVD02 Disassemble spool assembly carefully from the section body. In case of not being pulled out easily, push it into body again and then pull out smoothly by rotating the assembly.
  • Page 143 Disassembly of main relief valves(2EA). B207CVD05 Remove tightening nut of stud bolt. Do not untighten stud bolt but replacing of O-ring or load check poppet. B207CVD06 Put each section orderly on the clean work bench. Place the O-rings between sections near section block.
  • Page 144 ASSEMBLY Assembly of load check valve. Install check poppet, spring, O-ring orderly to each section. B207CVA01 Array inlet, lift, tilt, aux and outlet block orderly and assemble them with stud bolts so that the O-rings and springs are not to fall off.
  • Page 145 Install return cap to the return spring side of spool assembly and then tighten socket bolts at following torque. Tightening torque 0.9~1.1kgf m (6.5~8.0lbf ft) B207CVA05 Install O-ring, dust wiper, seal plate orderly to the opposite side of return cap. Install dust wiper with its wing side facing outside.
  • Page 146 TEST OF MAIN CONTROL VALVE Checking spool operation Spool moves smoothly. Spool comes back to neutral position by spring tention. Checking the pressure of relief valve Install a gauge to gauge port of inlet block to check out pressure and then. Checking the pressure of main relief valve Make relief by tilting in.
  • Page 147 3. LIFT CYLINDER STRUCTURE I.D O.D Stroke : 45 55 1245mm (1.7 2.2 49~108in) Rod O.D : 35mm (1.4 in) D155HS16 Tube assy Wear ring 11 O-ring Rod assy Retaining ring 12 Stopper Piston Rod cover 13 Du bushing U-packing Dust wiper 14 Spacer Back up ring...
  • Page 148 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 149 4. TILT CYLINDER STRUCTURE BR147HS15 Tube assy Piston seal Rod seal 10 Dust wiper O-ring Gland 11 O-ring Piston DU bushing 12 O-ring 6-38...
  • Page 150 DISASSEMBLY Hold the parallel parts of the cylinder tube bottom in a vice and mark the rod head end to show how much it is screwed in, then remove the rod head. Next, hook a wrench into the notch at the cylinder head and remove the cylinder head from cylinder tube.
  • Page 151 5. REACH CYLINDER STRUCTURE BR147HS21 Tube assy Dust wiper 11 O-ringl Rod assy O-ring 12 Nylon nut Gland O-ring 13 O-ring DU bushing Piston 14 Spacer Rod seal 10 Piston seal 6-40...
  • Page 152 DISASSEMBLY Hold the parallel parts of the cylinder tube bottom in a vice and mark the rod head end to show how much it is screwed in, then remove the rod head. Next, hook a wrench into the notch at the cylinder head and remove the cylinder head from cylinder tube.

  • Page 153: 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 154: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION BR147EL01 Head lamp EPS motor 17 Start switch Flasher lamp 10 Drive motor 18 Monitor panel Relay assy 11 Static chain 19 Switch assy Fuse box 12 Control panel assy 20 Micro switch EPS controller 13 Battery assy 21 Back buzzer...

  • Page 155: Group 2 Electrical Circuit

    SECTION 7 ELECTRICAL SYSTEM GROUP 2 ELECTRICAL CIRCUIT HBR14-7(-#0006), HBR15-7(-#0018), HBR18-7(-#0022) HBR20-7(-#0023), HBR25-7(-#0010) FUSE BOX ASSY PUMP TRACTION PUMP LOGIC "A" TRACTION LOGIC "A" MOTOR MOTOR B.W.I B.W.I FLAS HORN BUZZER HEAD -HER SWITCH RELAY LAMP UNIT INPUT OUTPUT (20A) CALIBRATOR (20A) TRAC.
  • Page 156 HBR14-7(#0007-), HBR15-7(#0019-), HBR18-7(#0023-) HBR20-7(#0024-), HBR25-7(#0011-) BR147EL02-1 7-2-1...

  • Page 157: Group 3 Electric Components

    For the monitoring system, there are many sensors such as current sensors, hydraulic pressure sensors, and temperature sensors. The HYUNDAI HBF series are equipped with the most advanced DRIVING CONTROL SYSTEM currently available world-widely. The operator friendlyness features enable him to set the vehicle conditions properly according to each working circumstance easily on his seat, and the SELF-DIAGNOSTIC function displays current status of vehicle in working.
  • Page 158 2. BATTERY STRUCTURE BR147EL03 Cells Negative leading cable Steel box Positive leading cable Cell connector Connector Row connector...
  • Page 159 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 160 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 161 Performance and maintenance of batteries Initial charge Dry-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 162 Normal charge Charge the discharged batteries as quickly as possible. The temperature of electrolyte before starting the charging operation shall preferably be below 45 C, and the temperature during the charge should be maintained at no higher than 55 C. (Under any unavoidable situations, it should never be above 55 C).
  • Page 163 (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 164 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 165 TROUBLESHOOTING Nature of trouble Symptoms Causes Repair Deformation Deformation of container, Excessive temperature ris- Replace lid or one touch cap ing or external impact Breakage Electrolyte leakage acco- External impact, improper Replace or install a new rding to breakage of cont- handling, excessive vibrat- ainer, lid or one touch cap Termination of connector...
  • Page 166 3. DRIVE MOTOR STRUCTURE BR147EL07 Armature assy 3-3 Retaining ring 10 Hexagon bolt 1-1 Fan Endbell comm assy 11 Spring washer 1-2 Bearing Brush kit 12 Hexagon bolt Field & frame assy Thermostat 13 Spring washer Endbell de assy Headband assy 3-1 Endbell de Terminal 3-2 Bearing...
  • Page 167 SPECIFICATION Item Unit HBR14/15/18-7 HBR20/25-7 Model KUDF4003 KNAS4005 Type SEM, self ventilated Rated voltage Rated output Brush size 16 32 30 Insulation Class H EXTERNAL INVOLUTE SPLINE DATA (Unit : mm) Item HBR14/15/18-7 HBR20/25-7 Involute spline shaft 25 13 1.667 DIN5480-25.1 1.25 30 18 Adendum modification +0.800...
  • Page 168 DISASSEMBLY Before starting disassembly, measure the insulation resistance of armature, field coil by insulation resistance(500M ). Punch alighning marks on drive side endbell and frame. B153EL071 Remove the commutator side cover. B153EL072 Remove 4 brush springs and 4 brushes. B153EL073 Remove screws and brushes from brush holder assembly.
  • Page 169 Remove 4 bolts on the drive side endbell, using L wrench. B153EL075 Remove armature and drive-side endbell by lifting up straightly. B153EL076 Armature assembly, drive side endbell and field & frame assembly after disassembling from motor. B153EL077 Remove 4 bolts on the commutator side endbell.
  • Page 170 Remove BWI lead wire from commutator side endbell. B153EL079 (10) Picture after disassembly Field & frame assembly B153EL080 Brush holder assembly B153EL081 7-16...
  • Page 171 ASSEMBLY AND INSTALLATION Perform the assembly in the reverse order of disassembling. The motor is composed of four parts. armature assembly, field & frame assembly, endbell commutator assembly, etc. B153EL082 After removing the field coil from frame, distance between core and core should be Adjust to equal interval adjusted equally at disassembly.
  • Page 172 TROUBLE SHOOTING Problem Probable cause Remedy 1. Motor fails to start. Brush contact faulty. Check brush to commutator contact. Wire breakage of faulty connection. Check connections. Field coil shorted or open. Replace winding. armature coil shorted or open. Check armature winding. 2.
  • Page 173 INSPECTION Armature inspection Check for roughness commutator, high mica, coil insulation, etc. If commutator surface is rough correct it with sandpaper (about No. 400) and throughly clean around the commutator with compressed air. If severely roughened, correct it by machining on lathe. Commutator diameter New part size 82.5mm...
  • Page 174 Brush inspection Check the brushes to see if worn or contacting improperly. Brush wear limit : 20mm New brush length : 40mm Brush holder and brush pressure inspection Check the brush holders for loose mounting bolts. And spring for breakage, etc. hook on spring scale to the brush holder spring and measure the spring tension pressing down the brush.
  • Page 175 4. PUMP DRIVE MOTOR STRUCTURE BR147EL18 Armature assy 3-3 Retaining ring 10 Wave washer 1-1 Fan Endbell comm assy 11 Hexagon bolt 1-2 Bearing Brush kit 12 Hexagon bolt Field & frame assy Thermostat 13 Spring washer Endbell de assy Headband assy 3-1 Endbell de Terminal...
  • Page 176 SPECIFICATION Item Unit Specification Model KNAQ 4004 Type D.C. series, self ventilated Rated voltage Rated output Brush size 16 20 25 Insulation Class H INTERNAL INVOLUTE SPLINE DATA Item Unit Specification Flat root side fit ANSI B92.1 - 970 No of teeth Spline pitch 16/32 Pressure angle...
  • Page 177 DISASSEMBLY Before starting disassembly, measure the insulation resistance of armature, field coil by insulation resistance(500V Megger). Punch alighning marks on the commutator side cover. B153EL083 Remove the commutator side cover. B153EL084 Remove 8 brushes. B153EL085 Remove the wiring (+) and (-) from brush holder assembly.
  • Page 178 Remove 4 bolts on the drive side endbell, using L wrench. B153EL087 Remove armature and drive side endbell by lifting up straightly. (below) B153EL088 Armature assembly and drive side endbell. B153EL089 B153EL090 7-24...
  • Page 179 Remove 4 bolts on the commutator side endbell. (below) B153EL091 Brush holder assembly B153EL092 Frame and field assembly. B153EL093 7-25...
  • Page 180 ASSEMBLY AND INSTALLATION Perform the assembly in the reverse order of disassembly. The motor is composed of three parts, armature assembly, frame and field assembly and endbell commutator assemby. B153EL094 After completing assembly, perform the following check. Are the bolts, nuts, and other fasteners tightened properly? Are there any errors in wiring, and are the connections tight? Are the insulation resistance more than 1M ? Are the brushes making good contact with the commutator?
  • Page 181 5. CONTROLLER SYSTEM STRUCTURE BR147EL28 Traction controller Pump controller Specifications Model Logic Application Type Power Actual value HBR14/15/18-7 SEM low I/O Logic Traction 24-48V, 350A/50A 350A HBR20/25-7 SEM low I/O Logic Traction 24-48V, 425A/50A 420A HBR14/15/18-7 Pump I/O Logic Pump SERIES 24-48V, 450A 400A...
  • Page 182 VARIANTS Suffix B153EL028 3rd digit 1st digit 2nd digit Suffix (Controller type) (Voltage range) SERIES 2 = Traction 4 = 24 - 48V 3 = 300A 3 = 350A/50A* L = Low I/O, Traction 3 = Pump 8 = 72 - 80V 4 = 450A 4 = 425A/50A* M = Medium I/O, Traction...
  • Page 183 CONTROLLER FEATURES WITH THE DIFFERENT LOGIC VARIANTS SERIES Logic Feature Pump Low I/O Logic Traction Med. I/O Logic Number of connectors Number of digital switch inputs Number of analogue inputs Number of contactor drive outputs(2 Amps) 24V - 80V operation Can cater for current limit range of 300A to 650A Logic case enclosed to IP65, power case to IP55 Microprocessor control...
  • Page 184 Logic Feature Pump Low I/O Logic Traction Med. I/O Logic Inching and timed burst inching facilities Economy pot input Short circuit and open circuit contactor detect 3 traction cutback speeds with independent accel delays 6 Pump speeds with additive, priority & compensation Input to disable pump operation Independent power steer speed and compensation settings Hardware and software fail-safe systems...
  • Page 185 Logic Feature PowerpaK Logic Separate Number of connectors Number of digital switch inputs Number of analogue inputs Number of contactor drive outputs Voltage operation range 24-80V Armature current limit range 350-500A Field current limit range 30-50A Armature and field currents independently measured Solid state direction control Good speed regulation without speed sensor Motor curve setup menu...
  • Page 186 Logic Feature PowerpaK Power steer contactor driver and timer Electric brake driver for walkies Regenerative braking down to zero speed Braking proportional to accelerator position Braking in neutral and with brake pedal Under and over-voltage protection Accelerator wire off detect Inching and timed burst inching facilities Economy pot input 2 traction cutback speeds with independent accel delays...
  • Page 187 SAFETY Electric vehicles can be dangerous. All testing, fault-finding and adjustment should be carried out by competent personnel. The drive wheels should be off the floor and free to rotate during the following procedures. The powerpak controller contains a tripple fail-safe system to give a high level of safety. If the diagnostic LED is not illuminated or flashes, the safety circuit may have tripped and the truck may not drive.
  • Page 188 (14) The controller must be used with a line contactor as indicated in the wiring diagrams. (15) As blow-out magnets are fitted to contactors(except 24V) ensure that no magnetic particles can accumulate in the contact gaps and cause malfunction. Ensure that contactors are wired with the correct polarity to their power terminals as indicated by the + sign on the top moulding.
  • Page 189 Storage temperature -40 C to +70 C Humidity 95% maximum, non-condensing Humidity resistance No functional defects after controller is left at 60 C and 100% humidity for one hour after freezer use(-30 C minimum) Halt Powerpak has been highly accelerated life tested. Mechanical Unit size (all units) Length 142mm, width 142mm, height 140mm with logic fitted.
  • Page 190 CONTROLLER WIRING AND CONNECTIONS Wiring Power connections See power wiring diagrams for specific connections. Power wiring Minimum cable sizes : Current limits up to 500A 35mm and 650A 50mm for SERIES. Current limits up to 270A 25mm and 500A 35mm for SEM.
  • Page 191 Panel connector socket C Communications connector socket A POWERPAK Traction Med. I/O Logic All logics. Communications connector socket A 10way molex connector 6 way molex connector RS232 & CAN 6 way molex connector CAN 5 cont . Drives (External module allows RS232 connection to PC) Cont.
  • Page 192 Traction Controller Personalities(Controller Adjustments) SERIES Cal. Min adjust Max adjust Step size Actual Parameter Adjusted Logic : (all units) 650A unit (all units) value 1.1.1 Current limit Med i/o 650A 650A 1.1.2 Acceleration delay Med i/o 0.1S 5.0S 0.1S 1.0S 1.1.2a Current ramp delay Med i/o...
  • Page 193 Cal. Min adjust Max adjust Step size Actual Parameter Adjusted Logic : (all units) 650A unit (all units) value 1.1.34 O.Temp pot zero level Med i/o 5.0V 0.02V 3.00V 1.1.35 O.Temp pot full level Med i/o 5.0V 0.02V 4.50V 1.1.36 Speed limit Med i/o 2kPH(0 disables)
  • Page 194 Cal. Min adjust Max. adjust Step size *Actual *Actual Parameter Adjusted (all units) (350A unit) all units value 1 value 2 350A/420A 1.1.1A Current limit armature 350A 350A 1.1.1F Current limit field 1.1.2 Acceleration delay 0.1S 5.0S 0.1S 3.0S 1.0S 1.1.3 Deceleration delay 0.1S...
  • Page 195 Cal. Min adjust Max. adjust Step size *Actual *Actual Parameter Adjusted (all units) (350A unit) all units value 1 value 2 1.1.36 Speed proportional 0(0 disables) 1.1.37 Brake proportional 0(0 disables) 1.1.38 Speed integral 0(0 disables) 1.1.39 Brake integral 0(0 disables) 1.1.40 Low voltage init 14.5V...
  • Page 196 Traction Controller Status Information Cal. Parameter Logic Step Max display ref. displayed type display size info. 1.2.1 Battery voltage Med i/o 127V 0.1V 1.2.2 Traction motor voltage Med i/o 127V 0.5V 1.2.3 Traction motor current Med i/o 1200A 1.2.4 Traction controller temp Med i/o -30 C +225 C...
  • Page 197 BDI Adjustments(if enabled in setup menu) Logic Min. Max. Actual Cal. Ref. Parameter adjusted/displayed Step size type setting setting value SERIES SEM 1.4.1 1.4.1 xxx % Charge left L, M, H, P Display only 1.4.2 Battery volt xx V L, M, H, P Nominal V 1.4.3 1.4.2...
  • Page 198 Empty level The battery discharging indication will fully depend on this threshold value. The controller uses this threshold value and internal timer to decrease the indication level. The discharge timer only counts “moderate discharge”. i.e. when the battery voltage is below a discharge threshold. This threshold is calculated by adding an offset to the empty cell voltage.
  • Page 199 TRACTION SETUP MENU(ENABLES/DISABLES FEATURES) SERIES CONTROLLER Cal. Ref. Feature Logic type Default 1.6.1 Contactor chopping L, M, H 1.6.2 Accelerator type L, M, H Curved 1.6.3 L, M, H 1.6.4 Power steer trigger L, M, H FS1+dir 1.6.5 Economy cuts traction current M, H 1.6.6 Bypass in current limit...
  • Page 200 SEM CONTROLLER Cal. Ref. Feature Options Standalone / Master / Slave / Dual traction / Traction + pump / 1.6.1 System setup Dual + pump 1.6.2 Digital IO 13, 14(#0007-, #0019-, #0023-, #0024-, #0011-) 1.6.3 Analogue IP 24V / On / Off 1.6.4 Contactor chopping Linear / Curved / 2* Slope / Crawl...
  • Page 201 Pump controller personalities(controller adjustments) Logic Min adjust Max.adjust Step size *Actual *Actual *Actual Cal. ref. Parameter adjusted type (all units) 650A unit (all units) value 1 value 2 value 3 2.1.1 Current limit 50 A 650 A 10 A 650A 400A 400A 0.1 S...
  • Page 202 Pump controller status information Logic Cal. ref. Parameter displayed Step size Default type setting setting 2.2.1 Battery voltage 127V 0.5V 2.2.2 Pump motor voltage 127V 2.2.3 Pump motor current 1200A 2.2.4 Pump mosfet voltage 127V 0.5V 2.2.5 Pump controller temp. -30 C +225 C 2.2.6...
  • Page 203 (13) Pump setup menu enables / disables features Setup Logic Cal. ref Feature Actual value type CAN bus mode 2.6.1 Mode 2.6.2 Accelerator type Linear 2.6.3 Accelerator 2 Economy 2.6.4 2.6.5 Fault log 2.6.6 Service log 2.6.7 Seat and pump 2.6.8 Pin 5 P.Switch 6...
  • Page 204 (14) Traction and Pump adjustment descriptions Adjustment Logic type Description (T=Affects traction, P=Affects pump) Current limit L, M, H, P Maximum allowable motor current. Acceleration delay L, M, H, P Time taken to ramp up from 0 to 100% on. Current Ramp delay L, M, H Time taken to ramp up current in plugging and drive.
  • Page 205 Adjustment Logic type Deseription (T=Affects traction, P=Affects pump) High voltage cutback L, M, H, P Voltage at which contactors will open, to prevent high voltage damage. Battery protection L, M, H, P Voltages below this level cause a battery low 7 flash fault. Protection delay L, M, H, P Length of time the voltage can fall below the battery protection...
  • Page 206 DIAGNOSTICS Traction and pump fault messages and LED status/number of flashes. Calibrator Standard Full Feature Description and how to clear Check message display display OK(lowest priority) Traction operational and OK. No action required. Testing... Run Tests Only displayed briefly at power up. No action required.
  • Page 207 Diagnostic/status text messages The controller can transmit text messages for diagnostic and status indication. On the standard display these appear over the status area, and on the full-feature display, they also overwrite the hours counter until the fault condition has cleared.
  • Page 208 Message Symbols displayed Fault description Contactor has bad contact or didn’t close, motor o/c. Recycle FS1 & Dir. CONTACT FAULT Contactor didn’t open or is welded. Recycle FS1 and direction switch. CONTACT FAULT Direction or FS1 switch at power up. Recycle Direction FS1 or both.
  • Page 209 Message Symbols displayed Fault description Bypass contactor S/C or MOSFET S/C Recycle FS1 or direction. MOSFET & FAIL Traction motor too hot. & Pump motor too hot. & If any of these messages is displayed then the controller has failed one of its FAIL &...
  • Page 210 6 flash faults Not Logged(Potentiometer wire off type faults) 7 flash faults Logged(Battery low or high faults) 8 flash faults Not Logged(Thermal cutback faults) 9 flash faults Logged(Contactor coil S/C type faults) Each of the above logged categories contains the total number of faults of this type, the key hours count of the most recent fault and a text description of the fault.
  • Page 211 Deceleration delay This is an adjustable delay to ramp down the pulsing from 100% on to 0% on, and can be used to limit the inherent truck lurch when acceleration is interrupted. When neutral is selected, contactors are only opened when the % on has ramped down to 0. Creep The creep speed is adjustable and is used to select a minimum pulsing level as soon as drive is requested, to minimize delays and dead-bands.
  • Page 212 Power steer, traction controller A contactor drive is available to control a separate power steer motor. An adjustable delay allows the motor to operate for a set time, after the power steer trigger or power steer demand has been removed. SEVCON’s standard trigger, i.e. when the contactor is closed, is when either FS1 or the footbrake switch is closed, or the traction unit is pulsing.
  • Page 213 Regen braking is not possible at low speeds depending on the motor characteristics. To help minimize delays attempting to regen, a regen time adjustment is offered which can be set so that regen is only attempted for a short period of time, which is sufficient to initiate regen at medium to high speeds but not to cause unnecessarily long delays at very slow speeds where regen is not possible.
  • Page 214 Traction accelerator When drive is elected and the accelerator is first pressed, pulsing will commence at the creep speed setting increasing towards the maximum % on. If the accelerator is depressed at power up, pulsing will be inhibited and a 6 flash fault will be indicated, until the pedal is released.
  • Page 215 On pump controllers the line contactor also gives a mechanical break. Under normal operating conditions contractors will operate without arcing. However, under certain fault conditions, contractors may arc when opening. The bypass contactor may also arc during bypass over-current drop out conditions. Contactor chopping This feature allows 24V contactors to be used at all battery voltages 24V-80V, by continuously monitoring the battery voltage and chopping the contactor output pins accordingly, to present an...
  • Page 216 Pump operation Pump Operation There is no start-up sequence, so pulsing will be initiated after a small delay at power-up if one or more of the pump switches is selected. There are adjustable ramp up and ramp down delays. A pump contactor can be specified as an option.
  • Page 217 Set up Procedure-Set both the base speed and the compensation factor to 0. Activate the pump switch associated with the speed to be compensated. Ensure that the motor has its minimum load. Increase the base speed until the correct operation speed at minimum load is achieved.
  • Page 218 Nominal Under-voltage Under-voltage Over-voltage Over-voltage battery cutout start start cutout voltage 65.0V 70.0V Diagnostic LED This is mounted between the connectors on the front of the controller. It serves as a simple diagnostic tool as explained below : Constant illumination -No fault, normal condition LED extinguished -Internal controller fault 1 flash...

  • Page 219: Section 8 Mast

    SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-6 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-9 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-12...

  • Page 220: Group 1 Structure

    SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) HBR14/15/18-7 CARRIAGE LIFT CYLINDER BR147MS01 Outer mast Retaining ring Retaining ring Inner mast Lift chain 10 Back up liner Roller Anchor bolt 11 U-bolt Shim(0.5, 1.0t) Chain sheave 12 Inner support...
  • Page 221 HBR20/25-7 CARRIAGE LIFT CYLINDER BR147MS02 Outer mast Retaining ring Retaining ring Inner mast Lift chain 10 Back up liner Roller Anchor bolt 11 U-bolt Shim(0.5, 1.0t) Chain sheave 12 Inner support...
  • Page 222 2. 3 STAGE MAST(TF MAST) LIFT CYLINDER CARRIAGE FREE LIFT CYLINDER BR147MS03 Outer mast Shim(0.5, 1.0t) Chain sheave Middle mast Retaining ring 10 Back up liner Inner mast Lift chain 11 U-bolt Roller Anchor bolt 12 Inner support...
  • Page 223 3. CARRIAGE, BACKREST AND FORK HBR14/15/18-7(SHAFT TYPE) BR147MS04 Backrest Side roller Carriage Fork assy Load roller...
  • Page 224 HBR20/25-7(HOOK TYPE) BR147MS05 Backrest Side roller Carriage Fork assy Load roller Extension fork...

  • Page 225: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. EX : =900mm(35.4in) mm(in) STD Fork assy Applicable model Standard Limit Thickness 64FP-11030 HBR14/15/18-7 35(1.4) 31(1.2) HBR20/25-7 45(1.8)
  • Page 226 2. 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 damag-ed parts or replace complete mast assembly.
  • Page 227 FORKS 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 228: Group 3 Adjustment

    GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V MAST) INNER/OUTER MAST ROLLER CLEAR- ANCE ADJUSTMENT Outer mast Bring into Inner mast contact 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, Bring into contact...
  • Page 229 2. MAST LOAD ROLLER(TF MAST) INNER AND MIDDLE MAST ROLLER Outer mast Inner mast Bring into CLEARANCE ADJUSTMENT Middle mast contact 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 Bring into and the middle mast, and adjust the...
  • Page 230 CARRIAGE LOAD ROLLER Bring into Outer mast Measure the clearance when the center of contact the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, middle and lower rollers after loosen the adjust Bring into screws from the side rollers.

  • Page 231: 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 232 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 233 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. Carriage Refer to MAST ROLLER ADJUSTMENT load roller...
  • Page 234 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Remove the carriage assembly and move them to one side. Lift chain Loosen and remove hexagon bolts and washers securing lift cylinders to inner Stud bolt Inner mast mast. Loosen and remove hexagon bolts and nuts securing lift cylinders to inner mast.
  • Page 235 3 stage mast(TF mast) Remove the carriage assembly and move to one side. Loosen and remove hexagon bolt securing bottom cylinder from outer mast. Loosen and remove bolts and special Load Lift chain roller washers securing lift cylinders to middle mast.
  • Page 236 ELEVATING MAST Inner mast (V mast) After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. Lift inner mast upright straight up and out of outer mast section. Replace and reverse above procedure to install.
  • Page 237 CHAIN Chain sheave(V mast) Lift chain Place a sling around carriage and attach to an overhead hoist. Lift carriage high Outer mast enough so that the tension on the chain Sheave over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 238 Chain wheel bearing support(TF mast) Remove the carriage assembly and move to one side. After removing bolt to securing chain wheel bearing support assembly to free lift cylinder. After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 239 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 240 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 241 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. Adjustment 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.

This manual is also suitable for:

Hbr 15-7Hbr 18-7Hbr 20-7Hbr 25-7

Table of Contents