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

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

Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14

SECTION 2 REMOVAL & INSTALLATION OF UNIT

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

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

SECTION 3 POWER TRAIN SYSTEM

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

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

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4

SECTION 4 BRAKE SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6

Group 3 Test and adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

SECTION 5 STEERING SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14

SECTION 6 HYDRAULIC SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-16

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20

SECTION 7 ELECTRICAL SYSTEM

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

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

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

CONTENTS

Summary of Contents for Hyundai HBF15T-5

Page 1 CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14 SECTION 2 REMOVAL &...
Page 2 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...
Page 3 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 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 = 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 8 m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
Page 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 Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14...
Page 12 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 1. GENERAL LOCATIONS B15T5GEN01 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 B15T5SP01 Model Unit HBF15T-5 HBF18T-5 Capacity 1500 1750 Load center Weight 2915 3100 Lifting height 3300 Free lift Lifting speed[Unload/Load] Fork mm/sec 480/330(375/240) 480/310(375/220) Lowering speed[Unload/Load] mm/sec 450/500 L W T L,W,T 900 100 40 Tilt angle forward/backward C/C’...
Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS CONTROLLER Item Unit Drive motor controller Hydraulic pump motor Model PP743 PP344P Type MOSFET 142 142 135 Dimension Current limit SEM 350A/50A Series 450A Communication M M OTOR Item Unit Drive motor Hydraulic pump motor Model 203-19-4001 KKDG 4006...
Page 19 GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity cc/rev Maximum operating pressure Rated speed(max/min) 3000/500 S S TEERING HYDRAULIC MOTOR Item Unit Specification Model OMRA NA125 Max oil flow /min Displacement 125.7 Max pressure Connector size PF 1/2 M M AIN CONTROL VALVE Item Unit...
Page 20 W W HEELS Item Specification Type(front and rear) Solid(Cushion), Lug, Smooth, Non-marking Quantity(front/rear) Front-drive 7-8(18 7 12.125) Rear-steering 16 6-8(16 6 10.5) STEERING Item Specification Type Full hydraulic, power steering Steering Steering angle to both right and left angle, respectively RAKE Item Criteria...
Page 21 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Items Size kgf m lbf ft 6.9 1.4 50 10 Hyd pump motor mounting bolt Electric system M14 2.0 19.3 3.0 140 22 Drive motor mounting bolt M10 1.5 36 7.2 Hydraulic pump mounting bolt M 8 1.25 2.5 0.5 18.1 3.6...
Page 22 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 23 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 24 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 HBF15/18T-5 (-4) (14) (32) (50) (68) (86) (104) Drive axle 0.35 Axle ATF DEXRON III (0.1) ISO VG 32...
Page 25 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 26 SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
Page 27 SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE GROUP 1 STRUCTURE B15T5RE01 Lift cylinder Drive motor 15 Hydraulic pump Mast Priority valve 16 Seat Backrest 10 Battery 17 Overhead guard Tilt cylinder 11 Rear wheel 18 Main control valve Forks...
Page 28 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Forks Backrest Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Anchor pin Release fork anchor pins and slide one fork at a time toward the center of the Carriage carriage where a notch has been cut in...
Page 29 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. B15T5RE05 Pull the chains out of the sheaves and drape them over the front of the carriage. LIft chain Carriage &...
Page 30 PIPING Remove the return hoses and clamps 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 Disconnect hose assembly from the flow regulator. Return hose Lift...
Page 31 INNER MAST Inner mast Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. Outer mast B15T5RE10 TILT CYLINDER PIN MAST SUPPORT CAP Attach a crane to the stay at the top of the outer mast, and raise enough to sustain jacked up machine.
Page 32 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. Installation procedure for each of mast component is the reverse of the removal procedure. MAST SUPPORT CAP Check the mast support cap and spring pin for wear. Jack up the machine so that the front is raised and then using an overhead hoist assemble outer mast to drive axle unit.
Page 33 2. POWER TRAIN ASSEMBLY REMOVAL B153RE00 Mast Brake master Refer to section on mast(Page 2-2). cylinder Brake piping Disconnect the brake piping from the wheel cylinder end. Drive line assembly(LH) Drive line assembly(RH) B15T5RE13 Parking brake cable Parking brake Disconnect parking brake cable from the lever wheel brake assembly.
Page 34 Loosen seven bolts on the vehicle frame and carefully take out the drive unit. Frame Motor wiring Mounting bolt B15T5RE22 Drive motor Remove three hexagon bolts holding the drive motor in place. Drive unit Carefully remove the drive motor from the transmission.
Page 35 3. ELECTRICAL COMPONENTS Before removing each component, disconnect cables and earth lines attached to the component. REMOVAL B15T5RE001 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 846kg so the extreme care must be taken when handling them.
Page 36 Disconnect the battery connector. Pull with handle Disconnect B15T5RE18 Using a battery hanger, carefully raise the Hanger battery assembly. Be careful not to damage overhead guard or control system. Battery cover B207RE18 2-10...
Page 37 PUMP MOTOR Lower the forks to floor. B207RE24 Disconnect the battery connector. Pull with handle Disconnect B15T5RE18 Loosen the mounting bolts and remove Crane the counterweight from chassis. Tightening torque : 50kgf m (362lbf ft) Counterweight B15T5RE27 Disconnect the wiring of pump motor. Wiring harness Pump motor B15T5RE28...
Page 38 Disconnect the hose from pump. Hydraulic pump Low pressure hose Hose assy Pump motor B15T5RE29 Remove the tightening bolts of the motor mounting bracket. Hydraulic Tightening torque : pump Pump motor 2 ~ 3kgf m (14.5 ~ 21.7lbf ft) Mounting nuts B15T5RE32 Remove pump and pump motor from chassis.
Page 39 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) HBF15T-5 : 600kg(1323lb) HBF18T-5 : 785kg(1731lb) Battery conector Disconnect the battery connector. Pull with handle...
Page 40 Hose Disconnect the hoses from steering Steering Steering unit axle hydraulic motor. Hose B15T5RE37 Loosen bolts and remove steering Socket Steering hyd hydraulic motor assy from axle bracket. bolt motor B15T5RE38 Jacking up the chassis of truck. Steering wheel Loosen the hub nut and take off the tire assy steering wheel tire.
Page 41 Loosen steering axle bracket bolts and remove axle assy from chassis. B15T5RE42 2-15...
Page 42 INSTALLATION Installation is in the reverse order to removal, but be careful of the following points. When istalling the rear wheel, coat the Steering wheel hub bolt with molybdenum disulphide, and tire assy tighten the nut to 12.5~15.5kgf (90.4~112.1lbf ft) Hub nut B15T5RE39 Steering axle mounting torque.
Page 43 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4...
Page 44 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. DRIVE UNIT STRUCTURE B15T5PT01 Hexagon screw 12 Screw 23 Internal gear 35 Disk Parallel pin 13 Ball bearing 24 Fey ring 36 Friction disk Retaining ring 14 Planet gear 25 Housing 37 Housing cover Needle ring...
Page 45 2. SPECIFICATION Item Unit Specification Max drive output Max wheel load kg/lb 2500/5513 Acceleration at the wheel m/lbf ft 1320/974 Braking moment at the wheel kgf m/lbf ft 1700/1254 T/M ratio Weight without fluid kg/lb 28.5/62.8 Oil quantity(ATF) /U.S. qt 0.35/0.37...
Page 46 GROUP 2 TROUBLESHOOTING Problem robable cause Remedy 1. Noise 1) Knocking conditional on - Dismount electric motor. Gearing of helical gear steep has speed Check drive pinion and helical gear for been damaged when mounting damage. motor. 2) Singing noise - Check motor connection.
Page 47 It is explicitly pointed out to the fact that spare parts and accessories, which were not supplied by HYUNDAI are not checked and approved by us either. We do not accept any liability or admit any warranty for damages caused by the use of spare parts and accessoies which are no original parts fromHYUNDAI.
Page 48 2. AUXILIARY TOOLS Strap wrench "A" for holding the input pinion in place. B15T5DU01 Slotted nut wrench "B"(Ident-No 618846) for removal of the stop nut. B15T5DU02 Puller "C"(Ident-No.662244) to pull off the input pinion. B15T5DU03 Striker mandrel "J"(Ident-No.610390) to install the planet gear. B15T5DU04...
Page 49 Peening mandrel "K"(Ident-No.450971) to peen the planet gears. B15T5DU05 Puller "L"(Ident-No.4699 395 001) to pull off the planet gears from the planet carrier. B15T5DU06...
Page 50 3. DISASSEMBLY OF THE DRIVE UNIT Drain oil from transmission before disassembly of the drive unit. Loosen and remove the wheel nuts as well as take off the drive wheel. For further work on the transmission of the drive unit see chapter dissassembly.
Page 51 REMOVAL OF THE DRIVE MOTOR Drive motor and accessories mounted to Drive motor the drive motor have to be disconnected. Take off cautiously the drive motor from the drive unit. Do not damage the teeth of the motor pinion and the spur gear! Damages can cause louder running noises.
Page 52 HYUNDAI-units will be filled with oil after repair work. The following description of disassembly and reassembly serves to inform both the after-sales service centers of HYUNDAI and of the vehicle manufacturer, where adequate workshop facilities and trained specialists are present.
Page 53 5. DISASSEMBLY INTRODUCTION Prior to disassembly clean drive unit carefully. A great help is a bright, spacious working place, free of dirt and chips. The necessary working steps are descriped and illustrated in the correct sequence. Parts only available as assembly groups will not be stripped any further. DISASSEMBLY DRIVE UNIT Loosen and remove the two retaining rings(1).
Page 54 By means of the puller "L" pull off cautiously the three planet gears from the planet carrier. The planet gears are pulled off with the bearing completely. B15T5DU13 DISASSEMBLY HOUSING COVER Put the housing cover of the drive unit onto a level support. Loosen and remove the six hexagon screws M8 35(1).
Page 55 Press off the spur gear(with the bearing) from the bearing seat of the cover. Use the threads M8(6pcs.) on the spur gear for fastening of the inner disc carrier. B15T5DU17 By means of pliers remove the axial slide bearing from the bore seat of the cover. Do not damage the surface of the axial slide bearing.
Page 56 6. REASSEMBLY INTRODUCTION 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 57 DISC PACK ASSEMBLY OF DRIVE UNIT Two steps have to be observed for disc pack assembly: If for wearing reasons only the disc pack (1) is replaced, the previous pressure disc(2) can be reused. Place the clutch discs into the ring gear in the following sequence: - Pressure disc - Outer clutch disc / inner clutch disc /...
Page 58 Schritt If several parts of the drive unit(e.g. cover or pressure disc) are changed or replaced, the required thickness of the pressure disc has to be determined as follows. B15T5DU24 The following method is used to determine the thickness of the pressure disc. Dim.
Page 59 REASSEMBLY OF THE HOUSING COVER The housing cover will in principle be reassembled in reverse order of the disassembly. For reassembly it has to be observed as follows. Place the axial slide bearing into the bore seat of the cover. For assembly of the axial slide bearing the correct installation position has to B15T5DU25...
Page 60 The sealing face of the cover has to be sealed with LOCTITE 574. B15T5DU28 (10) Place the cover cautiously and install it until contact by beating slightly with a plastic hammer. By means of 8 cap screws M6 16(1) fasten the cover to the basic drive unit. Put one drop each of LOCTITE 234 onto the threads.
Page 61 The adjusting dimension has to be checked with a dial gauge. For this purpose position the feeler of the dial gauge on the brake lever in the specified measuring point range. Press the brake lever against the cover and read the deflection on the dial gauge.
Page 62 ASSEMBLY OF THE DRIVE UNIT The following sections are not dealt in detail, the illustrations, the description and the tightening torques are indicated in the manual "7. INSTALLATION AND MAINTENANCE". Assembly of the input pinion with the Drive motor See chapter "ASSEMBLY OF MOTOR WITH THE DRIVE UNIT" in the manual "7.
Page 63 Use only original HYUNDAI spare parts or spare parts approved by HYUNDAI. We expressly point out that spare parts and accessories that were not supplied by HYUNDAI were also not tested or approved by us. We will not accept any liability or guarantee for damage resulting from the use of spare parts or accessories that did not originate from HYUNDAI.
Page 64 TRANSMISSION SETUP The transmission is a helical and planetary gear drive unit with an integrated, hydraulically and mechanically actuated brake. The drive unit has been conceived as a double drive and is used predominantly with front-driven industrial trucks provided with single tires. The drive unit is driven by a horizontally mounted drive motor.
Page 65 Drive unit housing(1) with fluid filling and fluid draining plugs(according to mounting position,2) and breather filter(3). Wheel shaft with rim connection(4). Helical gear(5) with drive pinion(6), friction disk carrier(7). Three planetary gears(8), planetary carrier(9), internal gear(10). Brake lever(hydraulic and mechanical operation, 11), friction and steel disks(12). B15T5DU48 3-22...
Page 66 It is possible to mount motors up to a maximum motor diameter of 225mm. Motors which have not been supplied by HYUNDAI must be reworked according to below figure ; i.e.the A-bearing shield must be provided with two recesses. The reworked area should be coated with an anticorrosion agent.
Page 67 Mounting the motor to the drive unit Clean motor shaft(1) and taper bore of drive pinion(2) carefully(e.g.with LOCTITE No. 706). The taper connection must be free from grease and oil. Note faultless seat of the taper connection. Insert woodruff key(3) into motor shaft and push drive pinion.
Page 68 REPLENISHING WITH TRANSMISSION FLUID For reasons of safety, the drive units are Installation position deg. 45 shipped without fluid. Fill with drive unit fluid before commiss- ioning. Unscrew fluid filling plug(1) with sealing ring(2). Fill the drive unit with ATF drive unit fluid. Use the recommended ATF drive unit B15T5DU52 fluids only.
Page 69 FLUID CHANGE Place the vehicle on a level floor and secure to roll. Disconnect the current source of the motor or switch it off. Keep the area of the fluid filling and the fluid draining plugs clean. Place a suitably large vessel under the fluid draining plug(1).
Page 70 Remove oil overflow with an appropriate oil binder. Check the fluid level again after a short running time. Top up if necessary. CLEANING Do not bring cleaning agents, such as water stream or hot steam, into direct contact with the motor/ drive unit.
Page 71 SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6 Group 3 Test and adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8...
Page 72 SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE There are two brake systems, the service brake system and the parking brake system. In the service brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
Page 73 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 74 4. CONNECTING THE BRAKE We recommend to use a two-stage output cylinder for the service brake. Advantage compared to a single stage cylinder : the pedal stroke can be as small as possible. Three connections M10 1 are provided for connecting the hydraulic brake system and the brake cable.
Page 75 5. BRAKE VALVE STRUCTURE B15T5BS04 Body Spring seat Key wire Secondary cup Spring Boot Piston Check valve assembly Plate Spacer Union bolt Primary cup Gasket...
Page 76 DISASSEMBLY AND ASSEMBLY Remove the boot(12). Take out the key wire(11) and plate(13). Take out the piston(3), secondary cup(2), spacer(4), primary cup(5), spring sheet(6), 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 77 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS RAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. BRAKE LEVER Check sealing ring and wheel shaft for damages in the sealing area.
Page 78 . TROUBLESHOOTING Problem ause Remedy Brakes do not work Oil leakage in the system or oil to low Repair oil leakage. After bleeding fill low in tank. fill oil tank of master cylinder to speci- fied level with brake oil. Air trapped in the system.
Page 79 GROUP 3 TESTS AND ADJUSTMENTS 1. ADJUSTMENT OF BRAKE The adjusting dimension "A" has to be checked and set. The adjusting dimension "A" for the brake lever is between 0.4~1.0mm (0.02~0.04in). B15T5DU31 The adjusting dimension has to be checked with a dial gauge. For this purpose position the feeler of the dial gauge on the brake lever in the specified measuring point range.
Page 80 2 2 . BLEED THE BRAKE SYSTEM The brake system must be bleeded after replenishing with brake fluid. Please also refer to drive unit in section 3. Remove dust protector(1) from bleeder valve(2) and fit proper hose to collect escaping brake fluid in a vessel. Apply pressure by operating the brake pedal.
Page 81 SECTION 5 STEERING SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14...
Page 82 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1 Hydraulic gear pump 2 Steering unit 3 Steering motor 4 Steering wheel 5 Steering axle 6 Priority valve TO HYD TANK TO HYD TANK B15T5SS01 The steering system for this machine is composed of steering wheel assembly(4), steering unit(2), steering motor(3), steering axle(5) and pipings.
Page 83 2. HYDRAULIC CIRCUIT B15T5SS02 Hydraulic gear pump Hydraulic motor Priority valve Suction filter Steering unit 11 Hydraulic oil tank...
Page 84 NEUTRAL B15T5SS03 The steering wheel is not being operated so control spool(G) does not move. The oil from hydraulic tank(11) enters hydraulic gear pump(1) and pressurized so that the oil flows into the inlet port(P) of steering unit(4) and the spool of the priority valve(2) moves to the right. Most of pump oil flows to MCV through the EF port and partially flows into the hydraulic tank(11) through the spool of the priority valve(2).
Page 85 LEFT TURN B15T5SS04 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 86 RIGHT TURN B15T5SS05 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 from hydraulic gear pump(1) flows into the spool(G) of the steering unit(4) through the inlet port(P) and flows to gerotor(H).
Page 87 3. STEERING UNIT STRUCTURE B15T5SS06 Dust seal Cardan shaft 17 Special screw Housing 10 Spring set 18 Screw Ball 11 O-ring 19 Name plate Bushing 12 Distribution plate 20 Pilot relief valve O-ring 13 Gear wheel set 21 Ball Bearing race 14 O-ring 22 Suction valve pin Ring...
Page 88 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 89 4. STEERING AXLE STRUCTURE STEERING SENSOR STEERING HYD MOTOR 1-14 1-12 1-10 1-11 1-13 B15T5SS08 1-1 Steering axle 1-11 Split pin Bolt-w/washer 1-2 Bracket 1-12 Hub bolt 10 Lever 1-3 Taper roller bearing 1-13 Cap 11 Hexagon bolt 1-4 Taper roller bearing 1-14 Steering gear 2 12 Spring washer 1-5 Oil seal...
Page 90 TIGHTENING TORQUE AND SPECIFICATION 9 ~ 12 kgf m Right turn(90 ) (65 ~ 87 lbf ft) Default(43.5 ) 14 ~ 18 kgf m (101 ~ 130 lbf ft) 2 ~ 3 kgf m (15 ~ 22 lbf ft) Left turn(90 ) Default(3.5 ) SECTION A - A SECTION B - B...
Page 91 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 92 Problem ause Remedy Steering wheel turns unstea- Lockout loosening. Retighten. dily. Metal spring deteriorated. Replace. Steering system makes abn- Gear backlash out of adjustment. Adjust. ormal sound or vibration. Lockout loosening. Retighten. Air in oil circuit. Bleed air. Abnormal sound heard when Valve steering wheel is turned fully Faulty.
Page 93 TEERING AXLE Problem Cause Remedy Steering not stable Axle bracket bolts are loose. Retighten bolts. Side to side wander Hub bearings are worn out. Replace tapered roller bearings. Castle nut is loose. Retighten nut. Steering wheel hard to turn Inadequate lubrication of moving Apply lubrication.
Page 94 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 95 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE B15T5SS06 Dust seal Cardan shaft 17 Special screw Housing 10 Spring set 18 Screw Ball 11 O-ring 19 Name plate Bushing 12 Distribution plate 20 Pilot relief valve O-ring 13 Gear wheel set 21 Ball Bearing race 14 O-ring...
Page 96 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) 5-15...
Page 97 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1kgf (0~54.4lbf ft) 13mm socket spanner 6, 8mm and 12mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 5-70(2) TIGHTENING TORQUE L : Left port R : Right port T : Tank...
Page 98 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 99 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 5-18...
Page 100 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 101 (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 102 (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 5-21...
Page 103 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 104 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 105 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 106 (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 107 (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 108 (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 109 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20 5-82(2) (23) Place the distributor plate so that the channel holes match the holes in the...
Page 110 (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 111 (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 112 (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) 5-31...
Page 113 2. STEERING AXLE STRUCTURE Do not remove the stopper bolt unless necessary. STEERING SENSOR STEERING HYD MOTOR 1-14 1-12 1-10 1-11 1-13 B15T5SS08 1-1 Steering axle 1-11 Split pin Bolt-w/washer 1-2 Bracket 1-12 Hub bolt 10 Lever 1-3 Taper roller bearing 1-13 Cap 11 Hexagon bolt 1-4 Taper roller bearing...
Page 114 CHECK AND INSPECTION Fill 70% of the space in the bracket with lithium grease. Apply grease on the surface of seal lip when assembling. Fill 70% of the space in the bracket with lithium grease. Apply grease on the surface of seal lip when assembling.
Page 115 DISASSEMBLY Socket Steering motor bolt Steering Before dismounting steering motor hyd motor disconnect all hydraulic pipes from the steering motor. Losen socket bolts connecting motor with axle. Steering axle assembly B15T5SA01 Motor bracket Steering sensor Remove motor bracket with steering sensor.
Page 116 Axle bracket Take off the axle bracket together with the bearing. Be very careful because just Axle bracket before the axle bracket comes off, tapered roller bearing will fall out. Taper roller bearing After axle bracket is removed take off the inner race of bearing.
Page 117 ASSEMBLY In reassembling, have all parts washed, grease applied to lubricating parts, and all expendable items such as oil seal and spring washers replaced by new ones. Perform the disassembly in reverse order. Wheel hub Mount oil seal and inner race of tapered roller bearing on the axle beam.
Page 118 Steering gears Befor assembling, gears should be well greased. Spring pin Castle nut Install steering gear 1 and tighten Steering hexagon bolt. gear 2 Put the steering gear 2 on the axle beam Steering gear 1 and then assemble the castle nut with the pin.
Page 119 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-16 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20...
Page 120 SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT B15T5HS01 Hydraulic gear pump(W/Priority valve) Lift cylinder Priority valve Suction strainer Main control valve Down control valve Steering unit 10 Down safety valve Steering motor 11 Hydraulic oil tank Tilt cylinder...
Page 121 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION Return line Steering system B15T5HS02 When the lift control lever is pulled back, the spool in the first block is moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large chamber of lift cylinder(7) by pushing the load check valve of the spool.
Page 122 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION Return line Steering system B15T5HS03 When the lift control is pushed forward, the spool in 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 123 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION Return line Steering system B15T5HS04 When the tilt control lever is pushed forward, the spool in the second block is moved to tilt forward position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large chamber of tilt cylinder(6) by pushing the load check valve of the spool.
Page 124 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION Return line Steering system B15T5HS05 When the tilt control lever is pulled back, the spool in the second block is moved to tilt backward position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the small chamber of tilt cylinder(6) by pushing the load check valve of spool.
Page 125 2. HYDRAULIC GEAR PUMP STRUCTURE B15T5HS06 Front cover Bushing block 11 Dowel pin Rear cover Dry bearing 12 Shap ring Gear housing Channel seal 13 Socket head bolt Drive shaft 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 126 3. MAIN CONTROL VALVE STRUCTURE (3 Spool) Port name Size Inlet port 1-5/16-12UN Outlet port 1-5/16-12UN Gauge port PF1/4 Work port 1-1/16-12UN B153HS07 O-ring 12 Tilt lock plug 23 Bolt Dust seal 13 Nut 24 Main relief valve Seal plate 14 Nut 25 Outlet block Spring seat...
Page 127 LIFT SECTION OPERATION Lift position Load check valve(1) SECTION D353HS08 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 pump pushes up the load check valve(1) and flow into lift cylinder port(B1). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
Page 128 Lower position D353HS09 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 (B1) In lift lower position the fork drops due to its own weight.
Page 129 TILT SECTION OPERATION Tilt forward position D353HS10 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 pushes up the load check valve(1) and flow into tilt cylinder port(A2). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage.
Page 130 Tilt backward position D353HS11 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(B2).
Page 131 MAIN RELIEF VALVE Pressure setting A good pressure gauge must be installed in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit. Procedure Loosen lock nut.
Page 132 The loss of oil behind puppet C, effected by the opening of pilot puppet E, causes puppet C to move back and seat against pilot puppet E. This shuts off the oil flow to the area behind relief valve puppet D, and causes a low pressure area internally.
Page 133 4. STEERING HYDRAULIC MOTOR 15 18 B15T5HS51 Spigot flange Distributor plate 17 Output shaft Screw 10 End cover 18 Parallel key Dust seal 11 Washer 19 Cardan shaft Shaft seal 12 Drain plug 20 Screw O-ring 13 Washer 21 Gear wheel set Bearing race 14 Name plate 22 Plug...
Page 134 5. LIFT CYLINDER B153HS12 Tube assy Stop 12 Stopper Rod cover 13 Du-bushing Piston Dust wiper 14 Spacer U-packing 10 U-packing 15 O-ring Back up ring 11 O-ring Wear ring 6. TILT CYLINDER B153HS13 Tube assy O-ring 15 Du-bushing U-packing 16 Knuckle Cover 10 Piston...
Page 135 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 136 . 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 137 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 138 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 139 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 140 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 141 (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 142 (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 143 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 144 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 145 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 146 (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 147 (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 148 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 149 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 150 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 151 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 152 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 153 3. STEERING HYDRAULIC MOTOR DISASSEMBLY Seal plugs Put the motor in a holding tool, with the output shaft downward. For end port version, use 10mm(0.4in) hexagon socket spanner. Seal plug B15T5SM01 Drain plug & washer Drain plug A/flat, other version : 19mm(0.75in) Washer Not SAE washer.
Page 154 Cardan shaft, plate, O-ring. Remove orderly. Distributor plate O-ring Cardan shaft B15T5SM05 Output shaft Shaft and bearings should normally not be removed from housing. However, if necessary for inspecfion and cleaning, remove the shaft from the housing front Output shaft end.
Page 155 Dust seal, needle bearing Use a 4mm(0.16in) screw driver. Housing Needle bearing Dust seal B15T5SM09 6-36...
Page 156 ASSEMBLY Clean all parts carefully with low aromatic kerosine Check all parts carefully and replace if necessary Before assembly, lubricate all parts with hydraulic oil and grease rubber parts with vaseline. Needle bearing Place needle bearing onto the output shaft side.
Page 157 Bearing race, O-ring Grease the O-ring with vaseline and fit the bearing race and O-ring into the spigot Housing flange. Bearing race O-ring B15T5SM14 Spigot flange Turn so that the holes line up. Housing Spigot flange B15T5SM15 Screws(6 off) Tightening torque Slotted screw M6 Housing 0.5~0.8kgf m(3.6~5.8lbf ft)
Page 158 Output shaft(1 1/4inch splined shaft) The rear shaft end of 1 1/4inch splined shafts must be marked before fitted. Output shaft The mark must be positioned vertically above a communication slot leading up to the front annular channel. Grease the journals with hydraulic oil. B15T5SM17 O-ring, distributor plate Grease the O-ring and put it in the O-ring...
Page 159 (11) Gear wheel set Place the gearwheel set on the cardan Caution! Parts can fall Gear wheel set shaft so that the top of a tooth in the external teeth of the gearwheel are vertically above the key slot in the output shaft(cylindrical or tapered) or the top of a tooth on a 1 inch splined shaft.
Page 160 Washer, drain plug Drain plug Use a 19mm spanner socket. Washer Tightening torque : 3~6kgf m(21.7~43.4lbf ft) B15T5SM24 (15) Seal plugs(threaded plugs) Side port version. Screw plastic plugs. Seal plug B15T5SM25 6-41...
Page 161 4. LIFT CYLINDER STRUCTURE 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...
Page 162 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 163 5. TILT CYLINDER STRUCTURE B153HS15 Tube assy 10 Piston 18 Spring washer 11 Back up ring 19 Hexagon nut Gland 12 O-ring 20 O-ring Dust wiper 13 Lock nut 31 Spacer Bushing 14 Spring pin 32 O-ring Rod seal 15 Du bushing 33 O-ring Back up ring 16 Rod eye...
Page 164 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 165 SECTION 7 ELECTRICAL SYSTEM Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2 Group 3 Electric components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3...
Page 166 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION B15T5EL01 Combination switch DC-DC converter 15 CAN calibrator Start switch Battery assy 16 Beacon lamp Parking switch 10 Controller assy 17 Accelerator switch Flasher unit 11 Back buzzer 18 Monitor panel Relay 12 Steering sensor 19 Beacon switch(opt) High horn assy...
Page 167 SECTION 7 ELECTRICAL SYSTEM GROUP 2 ELECTRICAL CIRCUIT HBF15T-5(-#0027) HBF18T-5(-#0053) FUSE BOX ASSY SLAVE MASTER PUMP LOGIC "A" TRACTION TRACTION HEAD LOGIC "A" LOGIC "A" LAMP BRAKE SWITCH FLAS LAMP -HER SWITCH UNIT 032A LAMP LAMP SWITCH RELAY INPUT OUTPUT...
Page 168 HBF15T-5(#0028-) FUSE BOX ASSY HBF18T-5(#0054-) SLAVE MASTER PUMP LOGIC "A" TRACTION TRACTION HEAD LOGIC "A" LOGIC "A" LAMP BRAKE SWITCH FLAS LAMP -HER SWITCH UNIT 032A LAMP LAMP SWITCH RELAY INPUT OUTPUT (20A) (20A) DC-DC 032A CONVERTER (IN) (OUT) HORN CALIBRATOR LCD DISPLAY "A"...
Page 169 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 170 2. BATTERY STRUCTURE B15T5EL03 Cells Negative leading cable Steel box Positive leading cable Cell connector Connector Row connector Handle...
Page 171 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 172 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 173 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 174 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 175 (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 176 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 177 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 178 3. DRIVE MOTOR STRUCTURE B15T5EL07 Seal Frame and field assy 11 Bearing Drive endbell Brush 12 Wave washer Bearing Brush spring 13 Commutator endbell Retaining ring Brush box 14 Hole plug Armature 10 Brush lead assy kit 15 Headband assy 7-12...
Page 179 SPECIFICATION Item Unit Specification Model 203-19-4001 Type D.C. SEM, self ventilated Rated voltage 48(36) Rated output 5.5(4.5) Brush size Insulation Class H 7-13...
Page 180 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 7-14...
Page 181 SPECIFICATION Item Unit Specification Model KKDG 4006 Type D.C. series, self ventilated Rated voltage 48(36) Rated output 12.2(8.8) Brush size 14.5 25.3 38.0 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...
Page 182 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 183 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 7-17...
Page 184 Remove 4 bolts on the commutator side endbell. (below) B153EL091 Brush holder assembly B153EL092 Frame and field assembly. B153EL093 7-18...
Page 185 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 186 INSPECTION HIGH BAR HIGH MICA Armature inspection Check for roughened commutator, high mica, coil insulation, etc. If commutator surface is roughened correct with sand- paper(about No. 400) and throughly clean around the commutator with compressed air. If severely roughened, correct by B15T5EL51 machining on lathe.
Page 187 Clean field coils Field coils should always be cleaned with compressed air. If the dirt will not come off, lightly wipe off with piece of cotton soft wetted with gasoline, using care not to damage the coil insulation. Field coil open-circuit test Use a multi meter( -range) and check for B15T5EL53...
Page 188 5. CONTROLLER SYSTEM STRUCTURE B153EL28 Traction controller Pump controller Specifications Model Logic Application Type Power Actual value SEM low I/O Logic Traction 24-48V, 350A/50A 350A HBF15/18T-5 Pump I/O Logic Pump SERIES 24-48V, 450A 400A 7-22...
Page 189 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 190 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 191 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 192 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 193 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 194 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 195 (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 196 Storage temperature C to +70 C umidity 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) Powerpak has been highly accelerated life tested. Mechanical Unit size (all units) Length 142mm, width 142mm, height 140mm with logic fitted.
Page 197 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 198 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 199 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 200 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 201 1.1.34 Belly delay 0.5S 5.0S 0.1S 1.1.35 Speed limit 1.0KPH 51.0KPH 0.2KPH 5.0KPH 11.0KPH * Actual value 1 : For 350A(HBF15/18T-5), Actual value 2 : For 350A/420A(HBR14/15/18/20/25-7) 0.70V(HBF15T-5 : -#0027, HBF18T-5 : -#0053), 0.50V(HBF15T-5 : #0028-, HBF18T-5 : #0054-) 7-35...
Page 202 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 203 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 +225 C 1.2.5...
Page 204 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 205 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 206 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 207 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 9(15T : -#0027, 18T : -#0053), 10(15T : #0028-, 18T : #0054-) 1.6.3 Analogue IP 24V / On / Off...
Page 208 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 209 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. +225 C 2.2.6 Key switch hours count...
Page 210 (13) Pump setup menu enables / disables features 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 2.6.9...
Page 211 (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 212 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 213 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 214 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 215 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 216 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 217 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 218 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 219 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 220 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 221 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 222 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 223 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 224 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 225 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 226 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...
Page 227 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) LIFT CILINDER CARRIAGE B15T5MS01 Outer mast Anchor bolt 11 Nut Inner mast Roller 12 Shim(1.0T) Sheave Shim(0.5, 1.0T) 13 Mast support cap Back up ring Back up liner 14 Mast support metal Chain 10 Shim(0.5, 1.0T)
Page 228 2. 3 STAGE MAST(TF- MAST) CARRIAGE LIFT CILINDER FREE LIFT CYL B15T5MS02 Outer mast Shim(0.5, 1.0T) 13 Mast support cap Middle mast Sheave 14 Mast support metal Inner mast Back up ring 15 Nut Chain 10 Back up liner 16 Sheave bracket Anchor bolt 11 Shim(0.5, 1.0T) Roller...
Page 229 3. CARRIAGE, BACKREST AND FORK B15T5MS04 Backrest Shim(1.0T) Carriage Side roller Load roller Forks...
Page 230 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 64FD-11010 HBF15/18T-5 53(2.1) 48(1.9) B207FK01 Set forks in middle and measure out of...
Page 231 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 232 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 233 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 234 . 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 235 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 236 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 237 SIDE ROLLER Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws Side roller and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. Adjustment Once carriage is properly installed, loosen nuts and adjust screws, (if not...
Page 238 MAST LOAD ROLLER AND BACK UP LINER Sheave 2 stage mast(V mast) Chain Remove the carriage assembly and Anchor move them to one side. bolt Inner Loosen and remove hexagon bolts and mast washers securing lift cylinders to inner mast. Backup Loosen and remove hexagon bolts and liner...
Page 239 3 stage mast(TF mast) Remove the carriage assembly and move to one side. Loosen and remove hexagon bolt Chain securing bottom cylinder from outer mast. Inner Loosen and remove bolts and special mast washers securing lift cylinders to middle Sheave mast.
Page 240 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 241 CHAIN Chain sheave(V mast) Place a sling around carriage and attach Chain to an overhead hoist. Lift carriage high Inner mast enough so that the tension on the chain Outer over sheaves is relieved after the carriage mast is blocked. Position wooden blocks under the carriage and lower it.
Page 242 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 243 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 244 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 245 Adjustment Chain adjustments are important for the following reasons : Equal loading of chain. Proper sequencing of mast. Prevent over-stretching of chains. Prevent chains from jumping off sheaves if they are too loose. djustment procedure With mast in its fully collapsed and vertical position, lower the fork to the floor. Adjust the chain length by loosening or tightening nut on the chain anchor.

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