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Hyundai HBF 20-7 Operation Manual

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Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17
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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
Group 3 Test and adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19
Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Electric components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
CONTENTS

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Summary of Contents for Hyundai HBF 20-7

  • Page 1: Table Of Contents

    CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17 SECTION 2 REMOVAL &...
  • Page 2 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11...
  • Page 3 This section explains how to verify the performance of the machine and adjust the major parts of each component for stable operation and maintenance. 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 4 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 5 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 6 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 7 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 8 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 9 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 10 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 11: Section 1 General

    SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17...

  • Page 12: 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 13 ・ 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 14 ・ 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 15 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 16: Group 2 Specifications

    GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS B207GEN01 Mast Dash board 11 Seat Lift cylinder Frame 12 Steering wheel Backrest Steering axle 13 Overhead guard Forks Counterweight Drive axle 10 Battery...
  • Page 17 2. SPECIFICATIONS HBF20/25-7 B207SP01 Model Unit HBF 20-7 HBF 25-7 Capacity 2000 2500 ← Load center Weight(Unloaded) 3920 4285 Lifting height ← 3300 Free lift ← Lifting speed(Unload/Load) Fork 580/370 580/350 mm/sec Lowering speed(Unload/Load) ← 460/510 mm/sec L×W×T L,W,T ←...
  • Page 18 HBF30/32-7 B207SP01 Model Unit HBF 30-7 HBF 32-7 Capacity 3000 3200 Load center ← Weight 4635 4730 Lifting height 3300 3200 Free lift ← Lifting speed(Unload/Load) Fork ← mm/sec 550/300 Lowering speed(Unload/Load) ← mm/sec 450/500 L×W×T L,W,T ← 1050×125×45 Tilt angle forward/backward C/C’...
  • Page 19 HBF20/25/30C-7 B207SP01 Model Unit HBF 20C-7 HBF 25C-7 HBF 30C-7 Capacity 2000 2500 3000 ← ← Load center Weight(Unloaded) 3940 4280 4735 Lifting height ← ← 3300 Free lift ← ← Lifting speed(Unload/Load) Fork 580/370 580/360 460/270 mm/sec Lowering speed(Unload/Load) ←...
  • Page 20 Type DC Series, self ventilated Rated voltage Output 10.3 15.5 Brush size 16×28×45 14×25.3 Insulation Class H B B ATTERY HBF 20-7(OPT) HBF 30/32-7 HBF 30/32-7 Item Unit HBF 20-7(STD) HBF 25-7(STD) (STD) (OPT) Type VCE 660 VCE 715 VCE 740...
  • Page 21 GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity 29.0 cc/rev Maximum operating pressure Rated speed(max/min) 3000/500 M M AIN CONTROL VALVE Item Unit Specification Type 3 spool, 4 spool Operating method Mechanical Main relief valve pressure D D RIVE AXLE Item Unit Specification...
  • Page 22 HBF20/25/30C-7 MOTOR Item Unit Drive motor Hydraulic pump motor Model KUDF 4001 KKDG 4005 Type DC Series, self ventilated Rated voltage Output 10.3 15.5 Brush size 16×28×45 14×25.3 Insulation Class H B B ATTERY Item Unit HBF20/25C-7 HBF 30C-7 Type VCI 740 VCI 845 Rated voltage...
  • Page 23 GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity 29.0 cc/rev Maximum operating pressure Rated speed(max/min) 3000/500 M M AIN CONTROL VALVE Item Unit Specification Type 3 spool, 4 spool Operating method Mechanical Main relief valve pressure D D RIVE AXLE Item Unit Specification...
  • Page 24 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS HBF20/25/30/32-7 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 M10×1.5 4.8±0.5 34.7±3.6 system Steering motor mounting bolt M10×1.5 6.9±1.4 50±10 Hydraulic pump mounting bolt M10×1.5 5±1.0 36.5±7.2 MCV mounting bolt, nut...
  • Page 25 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 26 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 27 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. 。 C(。 F) ℓ (U.S. gal) Capacity Ambient temperature Service Kind of HBF20/25/30/32-7 point fluid HBF20/25/30C-7 (-4) (14) (32) (50) (68) (86) (104) Axle Gear oil SAE 80W-90LSD/API GL-5 (1.2)

  • Page 28: 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 29: 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 30: Group 1 Structure

    SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE GROUP 1 STRUCTURE B207RE01 Lift cylinder Drive motor 15 Battery Mast Priority valve 16 Counterweight Backrest 10 Hydraulic pump 17 Overhead guard Tilt cylinder 11 Pump motor 18 Seat Forks...

  • Page 31: Group 2 Removal And Installation Of Unit

    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. Remove and install following units as explained in the flow chart. 1. MAST 1. MAST REMOVAL REMOVAL 1) 1)
  • Page 32 ② While supporting lift chains, remove the split pins and slide out chain anchor pins Lift chain from the chain anchors of stationary Outer mast upright. B207RE05 ③ Pull the chains out of the sheaves and Mast drape them over the front of the carriage. Carriage &...
  • Page 33 PIPING ① Remove the return hoses and clamps attached to the cylinder. ② Remove the return hoses from the Band connector. clamp Hose ③ clamp Remove hose assembly, connector, Return down safety valve from the lift cylinder. hose ④ Disconnect hose assembly from the flow regulator.
  • Page 34 INNER MAST ① Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. Inner mast Outer mast D255RE10 TILT CYLINDER PIN MAST SUPPORT CAP ①...
  • Page 35 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. ※ Installation procedure for each of mast component is the reverse of the removal procedure. MAST SUPPORT CAP ① Check the mast support cap and spring pin for wear. ②...
  • Page 36 2. POWER TRAIN ASSEMBLY REMOVAL B153RE00 Mast and counterweight Refer to section on mast(Page 2-2) ※ After removing mast, remove the counterweight to prevent the truck from turning over. B207RE12 Brake piping Brake Brake pipe Disconnect the brake piping from the master cylinder wheel cylinder end.
  • Page 37 Drive axle Crane ① Attach a crane to the tilt cylinder notches on the dashboard and raise the machine enough for truck to slide under drive axle- transmission-drive motor assembly. ② Put the block between the truck and drive axle assembly. Drive motor ③...
  • Page 38 3. ELECTRICAL COMPONENTS Before removing each component, disconnect cables and earth lines attached to the component. REMOVAL B153RE001 BATTERY Before pulling out the battery plug, tilt the mast forward a little, and lower the fork to the lowest position. The batteries for the HBF series weigh from around 1090kg to 1370kg so the extreme care must be taken when handling them.
  • Page 39 ② Using a battery hanger, carefully raise the Hanger battery assembly. ※ Be careful not to damage overhead guard or control system. Battery cover B207RE18 DRIVE MOTOR Drive motor ① Drain out oil from differential case. Mag plug Drain plug B207RE19 ②...
  • Page 40 ③ Disconnect drive motor wiring from Motor wiring terminal. Drive motor B207RE21 ④ Pass wire rope under the drive motor, Rope Drive motor then remove the tightening bolts.(5 bolts) Torque wrench B207RE22 ⑤ Pull out drive motor about 100mm to right side.
  • Page 41 PUMP MOTOR ① Lower the fork to floor. B207RE24 ② Disconnect the battery connector and remove battery from chassis. Hanger ③ Remove the driver’s compartment floor plate. Battery cover B207RE18 ④ Remove the left hand side cover B207RE27 2-12...
  • Page 42 ⑤ Disconnect the wiring of pump motor and remove the gear pump from pump motor. Disconnect wiring B207RE28 Pump motor Pump B207RE29 ⑥ Remove the tightening bolts of the motor mounting bracket. Pump motor Frame B207RE30 ⑦ Remove the motor from mounting bracket.
  • Page 43 4. WHEEL BRAKE REMOVAL B153RE002 Front wheel Put a block under the mast and tilt forward, or jack up the bottom of the frame to raise the front wheels off the ground, then remove the front wheels. Fork down Drive bolt shaft Block...
  • Page 44 INSTALLATION Installation is in the reverse order to removal, but be careful of the following points. Coat the mounting bolts with loctite and tighten to 26kgf・m(188lbf・ft) Fork down Block B207RE34 When replacing the oil seal inside the hub, be careful to install the seal facing in the correct direction (Lip on outside) and knock into place.
  • Page 45 6. REAR AXLE REMOVAL Counter Rear wheel Mounting Hose weight (Left side) bolt D35ARE37 B207RE36 Counterweight Install a lifting tool in the counterweight, and raise with a crane. Remove the mounting bolts, raise slightly and move to the rear. ・ Weight of counterweight(standard) HBF20-7 : 650kg(1433lb) HBF20C-7 : 600kg(1323lb) HBF25-7 : 920kg(2028lb)
  • Page 46 Mounting bolt Put a block under the rear axle, support on a truck, and raise the frame with a crane. Remove the mounting bolts installed to the frame, and pull out to the rear. There are shims between the support and rear axle to prevent play. B207RE40 INSTALLATION Support...

  • Page 47: Section 3 Power Train System

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

  • Page 48: Group 1 Structure And Operation

    SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. DRIVE AXLE UNIT STRUCTURE 1 B153PT01 Case 10 Spring washer 18 Drive shaft Case 11 Bolt 19 Washer 12 Spring washer 20 Side gear Case Air breather 13 Dowel pin 21 Pinion gear shaft Plug 14 Magnetic plug...
  • Page 49 STRUCTURE 2 GEAR 4 DIFFERENTIAL CASE CASE 35 36 CASE DRIVE SHAFT 47,48 B153PT02 35 Liner 44 Lock washer 26 Ball bearing 27 Gear 1 36 Lock nut 45 Oil seal 28 Ball bearing 37 Drum brake 46 Hub bolt 29 Gear 3 38 Oil seal 47 Wheel brake-LH...
  • Page 50 2. SPECIFICATION HBF20/25/30/32-7 Item Unit Specification Max input torque Max input rpm 3500 G2 : G1 44 : 17(2.588 : 1) 49 : 22(2.227 : 1) G3 : G2 Gear ratio 50 : 13(3.846 : 1) G4 : G3 Total 22.172 Quantity of oil HBF20/25/30/32C-7...

  • Page 51: Group 2 Troubleshooting

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

  • Page 52: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY DRIVE AXLE Remove the drive tires from wheel hub. B153DAD001 Remove the drain plug and drain gear oil. B153DAD002 Pull out the drive shaft with universal puller. B153DAD003...
  • Page 53 Remove the outer nut by straightening the locking part of the outer nut. When loosening the nut, use special tool and do not use improper method to loosen this nut. B153DAD004 Remove the inner nut by straightening the locking part of the inner nut. When loosening the nut, use special tool and do not use improper method to loosen this nut.
  • Page 54 Remove the brake bolts. B153DAD008 Separate the brake from drive axle. B153DAD009 (10) Separate the drive support (righthand) from drive axle. B153DAD010 (11) Separate the T/M case from drive axle. B153DAD011...
  • Page 55 (12) Pull out the differential case assembly. B153DAD012 (13) Remove T/M case bolts. B153DAD013 (14) Separate the T/M case. B153DAD014 (15) Pull out the gear. B153DAD015...
  • Page 56 (16) Pull out the gear. B153DAD016 (17) Pull out the bearing with universal puller. B153DAD017 (18) Remove the locking nut. B153DAD018 (19) Pull out the distance piece. B153DAD019...
  • Page 57 (20) Separate the gear from differential case with rubber mallet. B153DAD020 (21) Pull out the gear. B153DAD021 (22) Remove the tapered roller bearing, if needed. B153DAD022 (23) Remove the bearing cup. B153DAD023 3-10...
  • Page 58 (24) Remove the opposite bearing cup. B153DAD024 HUB DRUM Remove the bolts. B153DAD025 Separate drum and wheel hub. B153DAD026 Replace a worn wheel bolts. B153DAD027 3-11...
  • Page 59 Hub will come off together with brake drum. Tapered roller bearing will come out with the hub. Replace oil seal, O-ring and retainer. B153DAD028 Separate tapered roller bearing and retainer. B153DAD029 Remove the opposite bearing cup. B153DAD030 3-12...
  • Page 60 DIFFERENTIAL ASSEMBLY Remove the gear from differential case and bolt. B153DAD031 Extract the spring pin. B153DAD032 Pull out the pinion gear shaft. B153DAD033 Separate the pinion gear(2pcs) from differential assembly. B153DAD034 3-13...
  • Page 61 Pull out the side gear from differential. B153DAD035 Extract the side gear washer. B153DAD036 Put disassembled parts in order(by groups) and be careful not to lose bulk parts such as bolts, washers and snap ring etc. B153DAD037 3-14...
  • Page 62 2. ASSEMBLY DIFFERENTIAL SUB ASSEMBLY Install the washer(2pcs) to the case assembly, putting the grease. B153DAA001 Install the side gear(2pcs) to the case assembly. B153DAA002 Install the pinion gear(2pcs) to the case assembly. B153DAA003 After adjusting the hole of spring. B153DAA004 3-15...
  • Page 63 Insert the spring pin to shaft. B153DAA005 Install the gear to case assembly. B153DAA006 After putting loctite #277, secure them by tightening the bolts to specified torque. Tightening torque : 10.9~15.1kgf m (79~109lbf ft) B153DAA007 Install the ball bearing(2pcs) to case assembly.
  • Page 64 HUB DRUM SUB ASSEMBLY Press the bearing cup. B153DAA009 Press the opposite bearing cup. B153DAA010 Install the tapered roller bearing to the wheel hub. B153DAA011 After putting the TB #1102, install the oil seal retainer to the wheel. B153DAA012 3-17...
  • Page 65 After putting the TB #1102, install the oil seal to the wheel hub. B153DAA013 Fill a wheel hub center about 50~70% full with grease. B153DAA014 Install the brake drum and the wheel hub. B153DAA015 After putting loctite #277, secure them by tightening the bolts to specific torque.
  • Page 66 DRIVE AXLE ASSEMBLY Press the taper roller bearing to a gear. B153DAA017 Press the bearing cup. B153DAA018 Install the gear to case. B153DAA019 Insert the gauge for a gap measurement to a gear. B153DAA020 3-19...
  • Page 67 Install gauge to case. B153DAA021 Measure a gap between the case and gauge. B153DAA022 Press the bearing cup. B153DAA023 Insert the distance piece (the same thickness and number as those removed during disassembly). B153DAA024 3-20...
  • Page 68 Install the nut Tightening torque : 18~22kgf m (130~159lbf ft) B153DAA025 (10) Measure the tightening torque of taper roller bearing. Pre-load Torque : 0.04~0.06kgf m (0.3~0.43lbf ft) B153DAA026 (11) Secure it with nut tightening to specified torque, lock the nut. B153DAA027 (12) Install the ball bearing to the gear.
  • Page 69 (13) Install the ball bearing on the opposite side. B153DAA029 (14) Install the ball bearing to the gear. B153DAA030 (15) Install the differential subassembly to the case. B153DAA031 (16) Confirm a attachment condition of the ball bearing. B153DAA032 3-22...
  • Page 70 (17) Put the liquid gasket(TB #1215) on both side of packing for the case. B153DAA033 (18) Install the case assembly to the case. B153DAA034 (19) Install the bolts after putting the loctite #227. Tightening torque : 0.9~13.3kgf m (6.5~96.2lbf ft) B153DAA035 (20) Insert the dowel pin to the case.
  • Page 71 (21) Install the gear to the case. B153DAA037 (22) Install the gear to the case. B153DAA038 (23) Put the liquid gasket(TB #1215) on both side of packing for the case. B153DAA039 (24) Install the case fitting into the dowel pin. B153DAA040 3-24...
  • Page 72 (25) Install the bolts after putting the loctite. Tightening torque : 11~15kgf m (79~108lbf ft) B153DAA041 (26) Install the bolts after putting the loctite (#277). Tightening torque : 11~15kgf m (79~108lbf ft) B153DAA042 (27) Install the oil seal on both sides. (Put the liquid gasket on the circumfe- rence section and the grease on the lib) B153DAA043...
  • Page 73 (29) Install the drive support to the case tube. B153DAA045 (30) Install the righthand and lefthand brake respectively. B153DAA046 (31) After putting the loctite #277, install the bolt and plane washer. B153DAA047 (32) Install the hub drum sub. B153DAA048 3-26...
  • Page 74 (33) Insert the taper roller bearing to the hub drum. B153DAA049 (34) Install the adjust nut on both sides. Tightening torque : 3~5kgf m (21.7~36lbf ft) B153DAA050 (35) Measure the pre-load torque of taper roller bearing. B153DAA051 (36) If it satisfy the preload, secure the lock washer to nut groove.
  • Page 75 (37) Install the outer nut. B153DAA053 (38) Bend the lock washer to outer side. B153DAA054 (39) Put the liquid gasket(TB #1215) B153DAA055 (40) Install the shaft to distinguish between the two shaft. (Righthand : long, lefthand : short) B153DAA056 3-28...
  • Page 76 (41) Install the drain plug. Put loctite #572 B153DAA057 (42) Fill in the gear oil(SAE 85W/140) until flat part of check plug. After putting the loctite #572, install the check plug. B153DAA058 (43) After putting the loctite #572, install the air breather(PT1/2).

  • Page 77: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6 Group 3 Test and adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9...
  • Page 78 SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE There are two brake systems, the foot brake system and the hand brake system. In the foot brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
  • Page 79 3. BRAKE PEDAL AND PIPING The brake system provides two systems, a foot brake and a parking brake. In the foot brake system, the oil pressure which is generated in the master cylinder when the brake pedal is depressed is transmitted to the wheel cylinders. The piston of the wheel cylinder presses the brake shoes and then moves outward causing contact with the drums and braking force is obtained.
  • Page 80 4. WHEEL BRAKE STRUCTURE The wheel brake assembly mounts to the flange on the drive axle housing casting and is basically contained within the hub assembly. The inside of the hub is machined and acts as the brake drum. 10 3 31 161713 28,29 Section A-A 5 12...
  • Page 81 5. BRAKE VALVE STRUCTURE B207BS04 Body Spring seat Key wire Secondary cup Spring Boot Piston Check valve assembly Plate Spacer Union bolt Primary cup Gasket Union...
  • Page 82 DISASSEMBLY AND ASSEMBLY Remove the boot(12) and push rod. Take out the snap ring. Take out the piston(3), secondary cup(2), spacer(4), primary cup(5), spring sheet96), spring(7) and check valve assembly(8) from cylinder. Perform assembly in reverse order of disassembly and add special working. ・Body and metallic parts should be washed and cleaned with petroleum solvents then dry the parts by air.
  • Page 83 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS 1) 1) BRAKE PIPING BRAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed.
  • Page 84 . TROUBLESHOOTING Problem ause Remedy Insufficient braking force ・Hydraulic system leaks oil. ・Repair and add oil. ・Hydraulic system leaks air. ・Bleed air. ・Lining surface soiled with water or oil. ・Clean or replace. ・Lining surface roughened or in poor ・Repair by polishing or replace. contact with drum.
  • Page 85 Problem ause Remedy Brake squeaks ・Lining surface roughened. ・Repair by polishing or replace. ・Lining worn. ・Replace. ・Poor shoe to lining contact. ・Replace. ・Excessively large friction between ・Clean and apply brake grease. shoe and back plate. ・Foreign matter on drum sliding surfa- ・Clean ・Drum sliding surface damaged or di- ・Replace.
  • Page 86 GROUP 3 TESTS AND ADJUSTMENTS 1. ADJUSTMENT OF WHEEL BRAKE Adjust with engine stopped. Jack up truck. Extend adjustment screw by Adjustment wheel Lever clicking adjustment wheel teeth with a screwdriver until wheel(mounted on brake drum being adjusted) offers a light resistance when turned by hand.
  • Page 87 3. ADJUSTMENT OF PEDAL BRAKE PEDAL Pedal height from floor plate Adjust with stopper bolt. ・Pedal height : 130~135mm(5.1~5.3in) 130~135 mm Adjust with rod of master cylinder ・Play : 15~25mm(0.6 ~ 1in) B207BS05 4-10...

  • Page 88: Section 5 Steering System

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

  • Page 89: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Hydraulic gear pump Steering unit Steering cylinder Steering wheel Steering axle Oil filter Hyd tank B207SS01 The steering system for this machine is composed of steering wheel assembly(4), steering unit(2), steering cylinder(3), trail axle(5) and pipings.
  • Page 90 2. HYDRAULIC CIRCUIT 90kg/cm B207SS02 Hydraulic gear pump Steering cylinder Steering pump Return filter Steering unit 12 Hydraulic tank...
  • Page 91 NEUTRAL 90kg/cm B207SS03 The steering wheel is not being operated so control spool(G) does not move. The oil from hydraulic tank(11) enters to hydraulic gear pump(1) and pressurized so that the oil flows into the inlet port(P) of steering unit(3). Oil flows out of T port to the hydraulic tank(11).
  • Page 92 LEFT TURN 90kg/cm B207SS04 When the steering wheel is turned to the left, the spool(G) within the steering unit(3) connected with steering column turns in left hand direction. As this time, the oil discharged from hydraulic gear pump(1) flows into the spool(G) of the steering unit(3) through the inlet port(P) and flows to gerotor(H).
  • Page 93 RIGHT TURN 90kg/cm B207SS05 When the steering wheel is turned to the right, the spool(G) within the steering unit(4) connected with steering column turn in right hand direction. As this time, the oil discharged fromhydraulic gear pump(1) flows into the spool(G) of the steering unit(3) through the inlet port(P) and flows to gerotor(H).
  • Page 94 3. STEERING UNIT STRUCTURE SPLINE HYD CIRCUIT 22 6 28-2 28-1 SUCTION VALVE 27-4 27-3 27-1 27-2 SECTION "K-K" SECTION "X-O-X" B207SS06 Dust seal 13 Gerotor set 24 Plate spring Retaining ring 14 Bearing race 25 Plug Cap seal 15 Bore screw 26 O-ring Thrust bearing 16 Drive shaft...
  • Page 95 OPERATION The steering unit is composed of the control valve(rotary valve) and the metering device. The control valve controls the flow of oil from the pump in the interior of the unit depending on the condition of the steering wheel. The metering device is a kind of hydraulic motor composed of a stator and a rotor. It meters the required oil volume, feeds the metered oil to the power cylinder and detects cylinder’s motion value, that is, cylinder’s motion rate.
  • Page 96 4. STEERING AXLE STRUCTURE 1-12 1-17 1-12 1-32 1-16 1-15 1-33 1-14 1-30 1-18 1-31 1-30 1-13 1-35 1-31 1-36 1-28 1-29 1-37 1-34 1-15 1-16 1-17 1-14 1-13 1-35 1-36 1-19 1-11 1-37 1-23 1-21 1-28 1-20 1-29 1-22 1-24 1-25 1-26...
  • Page 97 TIGHTENING TORQUE AND SPECIFICATION Stroke 89 Apply loctite #277 49~67 kgf m (357~483 26.6~36.0 kgf m (192~260 lbf Greasing Fill 70% of the space in the hub with lithium Bearing end should grease be leveled with boss end Apply loctite #277 5.5~8.3 kgf m (40~60 Fix with split pin...

  • Page 98: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS Check item Checking procedure Steering wheel ・ Set rear wheels facing straight forward, then turn steering wheel to left and right. Measure range of steering wheel movement before rear wheel starts to move. 30-60mm (1.2-2.4 in) Range should be 30~60mm at rim of steering wheel.
  • Page 99 Problem ause Remedy Steering wheel turns unstea- ・Lockout loosening. ・Retighten. dily. ・Metal spring deteriorated. ・Replace. Steering system makes abn- ・Gear backlash out of adjustment. ・Adjust. ormal sound or vibration. ・Lockout loosening. ・Retighten. ・Air in oil circuit. ・Bleed air. Abnormal sound heard when Valve ・Faulty.
  • Page 100 OWER STEERING UNIT Problem ause Remedy Oil leakage ・Fittings loose, worn, or damaged. ・Check and replace the damaged parts. ・Deteriorated seals by excessive heat. ・Replace the seals. ・Loose screw or its deteriorated ・Replace the sealing and tighten sealing. screw appropriately. ・Internal seals worn or damaged.

  • Page 101: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 28-2 28-1 27-2 27-4 27-3 27-1 B207SS10 Dust seal 13 Gerotor set 24 Plate spring Retaining ring 14 Bearing race 25 Plug Cap seal 15 Bore screw 26 O-ring Thrust bearing 16 Drive shaft 27 Check valve Ball...
  • Page 102 TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-14...
  • Page 103 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1kgf・m (0~54.4lbf・ft) 13mm socket spanner 6, 8mm and 12mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 5-70(2) TIGHTENING TORQUE L : Left port R : Right port T : Tank P : Pump...
  • Page 104 DISASSEMBLY Disassemble steering column from steering unit and place the steering unit in the holding tool. Screw out the screws in the end cover(6- off plus one special screw). 5-72(1) Remove the end cover, sideways. 5-72(2) Lift the gearwheel set(With spacer if fitted) off the unit.
  • Page 105 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball and suction valve pins and balls. D353SE09 5-17...
  • Page 106 Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and thrust bearing will be pushed out of the housing together.
  • Page 107 (12) Carefully press the spool out of the sleeve. 5-74(4) (13) Press the neutral position springs out of their slots in the spool. 5-75(1) (14) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (14) Screw out the plug using an 8mm hexagon socket spanner.
  • Page 108 (15) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (16) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (17) The pressure relief valve is now disassem- bled. D353SE13 5-20...
  • Page 109 ASSEMBLY Assemble spool and sleeve. ※ When assembling spool and sleeve only one of two possible ways of positioning the spring slots is correct. There are three slots in the spool and three holes in the sleeve in the end of the spool / sleeve opposite to the end with spring slots.
  • Page 110 Press the springs together and push the neutral position springs into place in the sleeve. 5-77(2) Line up the springs and center them. 5-77(3) Guide the ring down over the sleeve. ※ The ring should be able to rotate free of the springs.
  • Page 111 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) ※ Assembly pattern for standard bearings Outer bearing race Thrust bearing Inner bearing race Spool Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 112 (11) Grease O-ring with hydraulic oil and place them on the tool. 5-79(1) 5-79(2) (12) Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.
  • Page 113 (14) Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore. 5-80(1) Installation instructions for lip seal (15) Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 114 (17) Press and turn the lip seal into place in the housing. 5-81(1) (18) With a light turning movement, guide the spool and sleeve into the bore. ※ Fit the spool set holding the cross pin horizontal. 5-81(2) (19) The spool set will push out the assembly tool guide.
  • Page 115 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20° C. 5-82(2) (23) Place the distributor plate so that the...
  • Page 116 (25) Place the cardan shaft as shown - so that it is held in position by the mounting fork. 5-83(1) (26) Grease the two O-rings with mineral oil approx. viscosity 500 cSt at 20° C and place them in the two grooves in the gear rim.
  • Page 117 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ・Tightening torque : 4.0±0.5kgf・m (28.9±3.6lbf・ft) 5-84(3)
  • Page 118 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. ※ Do not use a hammer! 5-85(2) 5-30...
  • Page 119 2. STEERING CYLINDER STRUCTURE B207SE21 Tube assembly Rod seal O-ring Rod assembly Back up ring 10 O-ring Gland Dust wiper 11 Piston seal Bushing Snap ring 12 Bushing 5-31...
  • Page 120 DISASSEMBLY ※ Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in a vice. Remove the gland by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube.
  • Page 121 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Set a special tool the cylinder, gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland assembly, and tighten it with torque 40±4kgf・m (289±29lbf・ft).
  • Page 122 3. TRAIL AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 1-12 1-17 1-12 1-32 1-16 1-15 1-33 1-14 1-30 1-18 1-31 1-30 1-13 1-35 1-31 1-36 1-28 1-29 1-37 1-34 1-15 1-16 1-17 1-14 1-13 1-35 1-36 1-19 1-11 1-37...
  • Page 123 CHECK AND INSPECTION B207SS13 mm(in) Criteria Remedy Check item Standard size Repair limit Diameter of king pin 35(1.38) 34.8(1.370) Replace Vertical play of knuckle 0.2(0.008) Adjust with shims Diameter of center pin 50(2.0) 49.5(1.9) Replace ・Damage, wear Rear axle, hub, knuckle, bearing Replace ・Seizure, abnormal noise, defective rotation 5-35...
  • Page 124 DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the balance weight part of the truck. Loosen the hub nut and take off the steering wheel tire.
  • Page 125 Loosen special bolt(1-5) and nut(1-6). 1-17 1-16 Remove retaining ring(1-17), oil seal(1-34). 1-15 1-14 (10) Push out the king pin(1-18) without damaging 1-13 1-18 the knuckle arm (1-2). 1-12 (11) Pull out the thrust bearing (1-14). If any defect is observed in needle bearing(1-15), 1-28 1-29 pull it out by using extractor.

  • Page 126: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19...

  • Page 127: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT TILT LIFT 90kg/cm 190kg/cm 140kg/cm B207HS01 Hydraulic gear pump(W/Priority valve) Suction strainer Main control valve Down control valve Steering unit Down safety valve Steering cylinder 10 Return filter Tilt cylinder 11 Hydraulic oil tank Lift cylinder...
  • Page 128 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION TILT LIFT Return line Steering system 190kg/cm 140kg/cm B207HS02 When the lift control lever is pulled buck, the spool on the first block is moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of lift cylinder(6) by pushing the load check valve of the spool.
  • Page 129 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION TILT Return line Steering system LOWER 190kg/cm 140kg/cm B207HS03 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 130 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION TILT LIFT Return line Steering system 190kg/cm 140kg/cm B207HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position. The oil from hydraulic gear pump(1) flows into main control(2) and then goes to the large chamber of tilt cylinder(5) by pushing the load check valve of the spool.
  • Page 131 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION TILT LIFT Return line Steering system 190kg/cm 140kg/cm B207HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the small chamber of tilt cylinder(5) by pushing the load check valve of spool.
  • Page 132 2. HYDRAULIC GEAR PUMP STRUCTURE D207HS06 Flange 16 Screw 27 Seal Priority valve 17 Nut 28 Seal Body 18 Cap screw 29 Seal Floating gear 21 Lip seal 31 Name plate 22 Circlip 32 Screw Drive gear 23 Bushing 34 O-ring 10 Driven gear 25 Center plate 35 O-ring...
  • Page 133 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 134 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 135 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 136 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 137 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 138 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 139 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 140 4. LIFT CYLINDER D255HS18 Tube assembly Wear ring 11 O-ring Retaining ring 12 Guide Piston Gland 13 DU bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 5. TILT CYLINDER 19,20,21 11,12 13,14 18 17 16 3 4 6 5 D255HS19 Tube assembly...

  • Page 141: 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 142 . 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 143 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 144 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 145: 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 146 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 147 (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 148 (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 149 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 150 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 151 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 152 (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 housing...
  • Page 153 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. ・Tighten torque : 11.1~11.8kgf・m (80~85lbf・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 154 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 155 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 156 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 157 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 158 TEST OF MAIN CONTROL VALVE Checking spool operation ① Spool moves smoothly. ② Spool comes back to neutral position by spring tention. Checking the pressure of relief valve ① Install a gauge to gauge port of inlet block to check out pressure and then. Checking the pressure of main relief valve ①...
  • Page 159 3. LIFT CYLINDER STRUCTURE ・ I.D ×O.D×Stroke (standard) 50×58×1655mm (2×2.3×65 in) ・ Rod O.D : 40mm (1.6 in) B153HS14 Tube assy Wear ring 11 O-ring Stop 12 Stopper Piston Rod cover 13 Du-bushing U-packing Dust wiper 14 Spacer Back up ring 10 U-packing 15 O-ring 6-33...
  • Page 160 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 161 4. TILT CYLINDER STRUCTURE B153HS15 Tube assy O-ring 15 Du bushing U-packing 16 Knuckle Rod cover 10 Piston 17 Hexagon bolt Dust wiper 11 Back up ring 18 Spring washer Du bushing 12 O-ring 19 Hexagon nut U-packing 13 Hexagon nut 20 O-ring Back up ring 14 Spring pin...
  • Page 162 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 163: Section 7 Electrical System

    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 164: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION HBF20/25/30/32-7 ONLY B207EL01 Combination switch Flash unit 15 Start key assy DC-DC converter Relay 16 Monitor panel Parking switch assy 10 Controller assy 17 Switch assy High horn assy 11 Back buzzer 18 Beacon switch Drive motor 12 License lamp...

  • Page 165: Group 2 Electrical Circuit

    SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT B207EL02...

  • Page 166: 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 167 2. BATTERY STRUCTURE B207EL03 Cells Negative leading cable Steel box Positive leading cable Cell connector Connector Row connector...
  • Page 168 Therefore, be sure to check and maintain the battery so that it may be kept best. B207EL04 SPECIFICATION AND SERVICE DATA HBF20/25/30/32-7 HBF 20-7(OPT) HBF 30/32-7 HBF 30/32-7 Item Unit HBF 20-7(STD) HBF 25-7(STD)
  • Page 169 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 170 Performance and maintenance of batteries ① 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 171 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 172 (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 173 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 174 TROUBLESHOOTING Nature of trouble ymptoms Causes Repair Deformation ・Deformation of container, ・Excessive temperature ris- ・Replace lid or one touch cap ing or external impact Breakage ・Electrolyte leakage acco- ・External impact, improper ・Replace or install a new rding to breakage of cont- handling, excessive vibrat- ainer, lid or one touch cap ・Termination of connector...
  • Page 175 3. DRIVE MOTOR STRUCTURE B207EL07 Armature assembly Spring washer 16 Thermostat assy Field assembly Socket bolt 17 Cross screw Endbell comm assembly 10 Spring washer 18 Spring washer Endbell de assembly 11 Brush kit 19 Name plate Wave washer 13 Spring brush 20 Setting pin Oil seal 14 Fan cover...
  • Page 176 SPECIFICATION Item Unit Specification Model KUDF4001 Type D.C. series, self ventilated Rated voltage Rated output 10.3 Brush size 16×28×45 Insulation Class H EXTERNAL INVOLUTE SPLINE DATA (Unit : mm) Involute spline shaft 30×22×1.25 Adendum modification +0.800 Number of teeth 22EA Pitch circle dia Ø27.50 ooth...
  • Page 177 DISASSEMBLY Before starting disassembly, measure the insulation resistance of armature, field coil by insulation resistance(500MΩ). 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 178 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 179 Remove BWI lead wire from commutator side endbell. B153EL079 (10) Picture after disassembly ① Field & frame assembly B153EL080 ② Brush holder assembly B153EL081 7-16...
  • Page 180 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 181 TROUBLE SHOOTING Problem robable 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 182 INSPECTION Armature inspection ① 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 183 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 184 4. PUMP DRIVE MOTOR STRUCTURE B153EL18 Armature assy Brush cover Field assy 10 Name plate Endbell comm assy 11 Setting pin Endbell de assy 12 Thermostat assy Socket bolt 13 Cross screw Socket bolt 14 Spring washer Spring washer 15 Brush kit Wave washer 7-21...
  • Page 185 SPECIFICATION Item Unit Specification Model KKDG 4005 Type D.C. series, self ventilated Rated voltage Rated output 15.5 Brush size 14×25.3 Insulation Class H INTERNAL INVOLUTE SPLINE DATA Item Unit Specification Flat root side fit Class 4 No of teeth Spline pitch 16/32 Pressure angle Degree...
  • Page 186 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 187 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 188 Remove 4 bolts on the commutator side endbell. (below) B153EL091 ① Brush holder assembly B153EL092 ② Frame and field assembly. B153EL093 7-25...
  • Page 189 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. ① Are the bolts, nuts, and other fasteners tightened properly? ②...
  • Page 190 5. CONTROLLER SYSTEM STRUCTURE B153EL28 Traction controller Pump controller Specifications Model Logic Application Type Power Actual value Medium I/O Logic Traction SERIES 24-48V, 650A 650A HBF20/25/30/32-7 HBF20/25/30C-7 Pump I/O Logic Pump SERIES 24-48V, 650A 650A 7-27...
  • Page 191 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 192 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 193 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 194 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 195 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 196 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 197 (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 198 ⑤ Storage temperature -40。 C to +70。 C ⑥ ⑥ umidity 95% maximum, non-condensing ⑦ Humidity resistance No functional defects after controller is left at 60。 C and 100% humidity for one hour after freezer use(-30。 C minimum) ⑧ ⑧ Powerpak has been highly accelerated life tested.
  • Page 199 CONTROLLER WIRING AND CONNECTIONS Wiring ① ① Power connections See power wiring diagrams for specific connections. ② 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 200 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 201 Traction Controller Personalities(Controller Adjustments) ① ① 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...
  • Page 202 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 203 ② ② Cal. Min adjust Max. adjust Step size *Actual *Actual Parameter Adjusted (all units) (350A unit) all units value 1 value 2 1.1.1A Current limit armature 350A 350A 350A/420A 1.1.1F Current limit field 1.1.2 Acceleration delay 0.1S 5.0S 0.1S 3.0S 1.0S 1.1.3...
  • Page 204 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 205 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。...
  • Page 206 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 207 ④ ④ 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 208 TRACTION SETUP MENU(ENABLES/DISABLES FEATURES) ① ① 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...
  • Page 209 ② ② 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 1.6.3 Analogue IP 24V / On / Off 1.6.4 Contactor chopping Linear / Curved / 2* Slope / Crawl 1.6.5 Accelerator type...
  • Page 210 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 2.1.2...
  • Page 211 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。...
  • Page 212 (13) Pump setup menu enables / disables features ① Setup Logic Cal. ref Feature Actual value type 2.6.1 Mode CAN bus 2.6.2 Accelerator type Curved 2.6.3 Accelerator 2 Lift 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.SW 6...
  • Page 213 (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 214 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 215 8 8 ) 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 216 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 217 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 218 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 219 ・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 220 ⑤ ⑤ 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. ⑥...
  • Page 221 ⑨ ⑨ 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.
  • Page 222 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 223 ⑭ ⑭ 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 224 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 225 Pump operation ① ① 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 226 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 227 Nominal Under-voltage Under-voltage Over-voltage Over-voltage battery cutout start start cutout voltage 65.0V 70.0V ⑤ ⑤ 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...
  • Page 228 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11...
  • Page 229 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) TILT CYLINDER LIFT CYLINDER CARRIAGE B207MS01 Outer mast Mast support metal 10 Chain wheel bearing Shim(0.5, 1.0t) Inner mast 11 Roller Roller Lift chain 12 Back up liner Tilt cylinder pin Anchor bolt 13 Shim(0.5, 1.0t) Mast support cap...
  • Page 230 2. 2 STAGE MAST(VF- MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE B207MS02 Outer mast Anchor bolt 10 Rataining ring Inner mast Sheave bracket 11 Mast support cap Roller Chain guard 12 Mast support metal Shim(0.5, 1.0t) Sheave 13 Tilt cylinder pin Lift chain...
  • Page 231 3. 3 STAGE MAST(TF MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE B207MS03 Outer mast Lift chain 11 Retaining ring Middle mast Anchor bolt 12 Mast support cap Inner mast Sheave bracket 13 Mast support metal Roller Chain guard 14 Tilt cylinder pin Shim(0.5, 1.0t) 10 Sheave...
  • Page 232 4. CARRIAGE, BACKREST AND FORK B207MS04 Backrest Side roller Carriage Fork assy Load roller Extension fork...
  • Page 233 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=900mm(35.4in) EX : mm(in) STD Fork assy Applicable model Standard Limit Thickness F173796-01 HBF20(C)-7 45(1.8) 41(1.6) B207FK01 Set forks in middle and measure out of...
  • Page 234 2. TROUBLESHOOTING MAST Problem ause 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 235 FORKS roblem ause 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 236 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V, VF 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 237 . 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 238 ARRIAGE 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 239 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 240 SIDE ROLLER Remove carriage as outlined in the carriage Side roller assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. ※...
  • Page 241 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Chain ① Remove the carriage assembly and Stud move them to one side. bolt ② Loosen and remove hexagon bolts and Inner mast washers securing lift cylinders to inner mast.
  • Page 242 2 stage mast(VF mast) ① Remove free lift chain connected between carriage and free lift cylinder. Chain ② Remove the carriage assembly and move them to one side. Stud ③ Loosen and remove hexagon bolts and bolt Inner washers securing lift cylinders to inner mast mast.
  • Page 243 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. ③ Loosen and remove bolts and special washers securing lift cylinders to middle mast. ④...
  • Page 244 ELEVATING MAST Inner mast (V, VF mast) ① 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. ② Lift inner mast upright straight up and out of outer mast section. ③...
  • Page 245 CHAIN Chain sheave(V, VF mast) Chain Outer mast ① Place a sling around carriage and attach Sheave to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 246 Chain wheel bearing support(TF mast) 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 247 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 248 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 249 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.

This manual is also suitable for:

Hbf 25-7Hbf 30-7Hbf 32-7Hbf 20c-7Hbf 25c-7Hbf 30c-7

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