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SECTION 1 GENERAL
Group 1 Safety hints
Group 2 Specifications
Group 3 Periodic replacement
SECTION 2 REMOVAL & INSTALLATION
Group 1 Structure
Group 2 Removal and Installation of Unit
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and operation
Group 2 Troubleshooting
Group 3 Disassembly and assembly
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function
Group 2 Operational checks and troubleshooting
Group 3 Test and adjustment
SECTION 5 STEERING SYSTEM
Group 1 Structure and function
Group 2 Operational checks and troubleshooting
Group 3 Disassembly and assembly
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function
Group 2 Operational checks and troubleshooting
Group 3 Disassembly and assembly
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component location
Group 2 Electrical circuit
Group 3 Electric components
CONTENTS
1-1
1-5
1-13
2-1
2-2
3-1
3-4
3-5
4-1
4-7
4-10
5-1
5-11
5-13
6-1
6-15
6-19
7-1
7-2
7-4

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Summary of Contents for Hyundai HBF 15III

  • Page 1 CONTENTS SECTION 1 GENERAL Group 1 Safety hints Group 2 Specifications Group 3 Periodic replacement 1-13 SECTION 2 REMOVAL & INSTALLATION Group 1 Structure Group 2 Removal and Installation of Unit SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation Group 2 Troubleshooting Group 3 Disassembly and assembly SECTION 4 BRAKE SYSTEM...
  • Page 2 SECTION 8 MAST Group 1 Structure Group 2 Operational checks and troubleshooting Group 3 Adjustment Group 4 Removal and installation 8-10...
  • 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 recorded on the bottom outside corner of the will 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 Group 1 Safety hints Group 2 Specifications Group 3 Periodic replacement 1-13...
  • 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 B153GEN01 Mast Dash board Seat Lift cylinder Frame 12 Steering wheel Backrest Steering axle 13 Overhead guard Forks Counterweight Drive axle 10 Battery...
  • Page 17 2. SPECIFICATIONS B153GEN02 Model Unit HBF 15III HBF 18III Capacity 1500 1750 ← Load center Weight 3106 3333 ← Lifting height 3300 ← Free lift Lifting speed(Unload/Load) 420/340 420/330 Fork mm/sec ← Lowering speed(Unload/Load) 450/500 mm/sec ← L×W×T L,W,T 900×100×40 ←...
  • Page 18 Model KRDB 4004 KNAQ 4003 DC Series, self ventilated Type Rated voltage Output Brush size 12.5×40×30 16×20×25 Insulation Class H BATTERY HBF 15III Item Unit HBF 18III Type VCD 450 VCDH 520 VCDH 520 Rated voltage Capacity 450/5 520/5 520/5...
  • Page 19 GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity 20.0 cc/rev Maximum operating pressure Rated speed(max/min) 3000/500 MAIN CONTROL VALVE Item Unit Specification Type 3 spool, 4 spool Operating method Mechanical Main relief valve pressure DRIVE AXLE Item Unit Specification Max input torque...
  • Page 20 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS kgf・m lbf・ft Items Size Hyd pump motor mounting bolt M10×1.5 6.9±1.4 50±10 Electric system Drive motor mounting bolt M10×1.5 6.9±1.4 50±10 Hydraulic pump mounting bolt M10×1.5 6.9±1.4 50±10 MCV mounting bolt, nut M 8×1.25 2.5±0.5 18.1±3.6 Steering unit mounting bolt...
  • Page 21 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT - Coarse thread Bolt size kgf・m lbf・ft kgf・m lbf・ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7 2.0 ~ 3.0...
  • Page 22 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 23 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature ° C(° F) Capacity ℓ (U.S. gal) Service Kind of point fluid 15/18III (-4) (14) (32) (50) (68) (86) (104) Axle Gear oil SAE 80W-90LSD/API GL-5 (1.6) ISO VG 32...
  • Page 24 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 25 SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
  • Page 26 SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 MAJOR COMPONENTS B153RE01 Lift cylinder Drive motor 15 Battery Mast Priority valve 16 Counterweight Backrest 10 Hydraulic pump 17 Overhead guard Tilt cylinder Pump motor 18 Seat Forks 12 Rear wheel 19 Main control valve Front wheel 13 Steering axle...
  • Page 27 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL FORKS ① Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. ② Release fork anchor pins and slide one fork at a time toward the center of the carriage where a notch has been cut in the bottom plate for easy removal.
  • Page 28 ② While supporting lift chains, remove the split pins and slide out chain anchor pins from the chain anchors of stationary upright. B153RE06 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. B153RE07 ④...
  • Page 29 PIPING ① Remove the return hoses and clamps attached to the cylinder. ② Remove the return hoses from the connector. ③ Remove hose assembly, connector, down safety valve from the lift cylinder. ④ Disconnect hose assembly from the flow regulator. B153RE09 LIFT CYLINDER ①...
  • Page 30 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. B153RE11 TILT CYLINDER PIN MAST SUPPORT CAP ① Attach a crane to the stay at the top of the outer mast, and raise enough to sustain jacked up machine.
  • Page 31 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 32 2. POWER TRAIN ASSEMBLY REMOVAL B153RE00 Mast Refer to section on mast(Page 2-2) Brake piping Disconnect the brake piping from the wheel cylinder end. B153RE13 Parking brake cable Disconnect parking brake cable from the wheel brake assembly. B153RE14 Drive axle ①...
  • Page 33 INSTALLATION Installation is the reverse order of removal, but be careful of the following points. Tightening torque of mounting bolt for drive axle. ・53.4~72.2kgf・m(386~522lbf・ft) B153RE16...
  • Page 34 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 750kg to 943kg so the extreme care must be taken when handling them.
  • Page 35 ② Using a battery hanger, carefully raise the battery assembly. ※ Be careful not to damage overhead guard or control system. Hanger Battery cover B153RE18 DRIVE MOTOR ① Drain out oil from differential case. B153RE19 ② Remove battery from chassis and remove driver’s compartment floor plate.
  • Page 36 ③ Disconnect drive motor wiring from terminal. B153RE21 ④ Pass wire rope under the drive motor, then remove the tightening bolts.(5 bolts) B153RE22 ⑤ Pull out drive motor about 100mm to right side. B153RE23 2-11...
  • Page 37 PUMP MOTOR ① Lower the fork to floor. B153RE24 ② Disconnect the battery connector and remove battery from chassis. ③ Remove the driver’s compartment floor plate. Hanger Battery cover B153RE18 ④ Remove the left hand side cover B153RE27 2-12...
  • Page 38 ⑤ Disconnect the wiring of pump motor and remove the gear pump from pump motor. B153RE28 B153RE29 ⑥ Remove the tightening bolts of the motor mounting bracket. B153RE30 ⑦ Remove the motor from mounting bracket. B153RE301 2-13...
  • Page 39 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. B153RE31 Drive shaft Pull out drive shaft carefully with lock washer, lock nut and oil seal.
  • Page 40 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) B153RE34 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 41 6. REAR AXLE REMOVAL Counter Rear wheel Mounting Hose weight (Left side) bolt D35ARE37 B153RE36 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) HBF15III : 680kg(1500lb) HBF18III : 870kg(1918lb) Hose...
  • Page 42 Mounting bolt Put a block under the rear axle, support Truck 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.
  • Page 43 7. OUTER PANELS B153RE40 2-18...
  • Page 44 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation Group 2 Troubleshooting Group 3 Disassembly and assembly...
  • Page 45 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 Bolt 19 Washer Case 12 Spring washer 20 Side gear Air breather 13 Dowel pin 21 Pinion gear shaft Plug 14 Magnetic plug...
  • Page 46 STRUCTURE 2 GEAR 4 DIFFERENTIAL CASE CASE 35 36 CASE DRIVE SHAFT 47,48 B153PT02 26 Ball bearing 35 Liner 44 Lock washer 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 47 2. SPECIFICATION Item Unit Specification Max input torque Kgf・m Max input rpm 3500 44 : 17(2.588 : 1) G2 : G1 49 : 22(2.227 : 1) G3 : G2 Gear ratio 50 : 13(3.846 : 1) G4 : G3 22.172 Total ℓ...
  • Page 48 GROUP 2 TROUBLESHOOTING Problem Probable cause Remedy 1. Continuous metallic groan ・Worn out gears. 1) During acceleration - Adjust back-lash or replace gears. ・Pinion and bevel gear meshed too deeply. ・Lack of gear oil. - Refill 2) During travelling at ・Worn out gears.
  • Page 49 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 50 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 51 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 52 (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 53 (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 54 (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 55 (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 56 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 57 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 58 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 59 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 60 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. B153DAA008 3-16...
  • Page 61 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 62 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 63 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 64 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 65 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. B153DAA028 3-21...
  • Page 66 (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 67 (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 68 (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 69 (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 (28)
  • Page 70 (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 71 (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 72 (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 73 (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 74 SECTION 4 BRAKE SYSTEM Group 1 Structure and function Group 2 Operational checks and troubleshooting Group 3 Test and adjustment 4-10...
  • Page 75 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 76 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 77 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the front axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force. By treading the pedal further, the brake are applied.
  • Page 78 5. 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. B153BS03 Back plate-LH/RH Spring 15 Adjuster guide...
  • Page 79 6. BRAKE VALVE STRUCTURE B153BS04 Body Spring seat Key wire Secondary cup Spring Boot Piston Check valve assembly Plate Spacer Union Primary cup Gasket...
  • Page 80 DISASSEMBLY AND ASSEMBLY Remove the boot(12) and push rod. Take out the snapring. 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 81 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 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. WHEEL BRAKE Compact wheel base chassis Measure lining at point with most wear, and check that lining thickness is at least 2.0mm(0.08in).
  • Page 82 2. TROUBLESHOOTING Problem cause Remedy ・Hydraulic system leaks oil. ・Repair and add oil. Insufficient braking force ・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 83 Problem cause Remedy ・Lining surface roughened. ・Repair by polishing or replace. Brake squeaks ・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 84 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 85 3. ADJUSTMENT OF PEDAL BRAKE PEDAL Pedal height from floor plate Parking brake Adjust with stopper bolt. lever ・Pedal height : 143~153mm(5.7~6.0in) Play Adjust with rod of master cylinder ・Play : 15~25mm(0.6 ~ 1in) B153BS05 4-11...
  • Page 86 SECTION 5 STEERING SYSTEM Group 1 Structure and function Group 2 Operational checks and troubleshooting 5-11 Group 3 Disassembly and assembly 5-13...
  • Page 87 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE B153SS01 The steering system for this machine is composed of steering wheel assembly(5), steering unit(3), steering cylinder(4), trail axle(6) and pipings. The steering force given to the steering wheel enters the steering unit through the steering column.
  • Page 88 2. HYDRAULIC CIRCUIT B153SS02 Hydraulic gear pump Steering cylinder Priority valve Suction filter Steering unit 12 Hydraulic tank...
  • Page 89 NEUTRAL B153SS03 The steering wheel is not being operated so control spool(G) does not move. The oil from hydraulic gear pump(1) enters port P of priority valve(2) and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(12). So, the pump flow is routed to the main control valve through the EF port.
  • Page 90 LEFT TURN B153SS04 When the steering wheel is turned to the left, the spool(G) within the steering unit(4) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) the steering unit through the spool(D) of priority valve and flows the gerotor(H).
  • Page 91 RIGHT TURN B153SS05 When the steering wheel is turned to the right, the spool(G) within the steering unit(4) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool(G) the steering unit through the spool(D) of priority valve and flows the gerotor(H).
  • Page 92 3. STEERING UNIT STRUCTURE B153SS06 Dust seal 11 Rolled screw 21 Spool 24-1 Guide 22 Sleeve 24-2 Shim Retaining ring 12 Gerotor set Cap seal 13 Bearing race 23 Relief valve 24-3 Spring Thrust bearing 14 Bore screw 23-1 Plug 24-4 Washer Ball 15 Drive shaft...
  • Page 93 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 94 4. PRIORITY VALVE STRUCTURE B153SS07 Body End plug End plug Spool Spring O-ring OPERATION The oil from the hydraulic gear pump flows to the priority valve. The priority valve supplies a flow of oil to the steering system and lift, tilt system. The steering flow is controlled by the steering unit to operate the steering cylinder.
  • Page 95 5. TRAIL AXLE STRUCTURE B153SS08 Trail axle 14 Thrust bearing 27 split pin Hexagonal bolt 15 Needle bearing 28 King pin washer Hexagonal nut 16 Oil seal 29 Grease nipple Knuckle-LH 17 Bearing thrust cap 30 Grease nipple Knuckle-RH 18 Wheel hub 32 Steering cylinder Taper roller bearing 19 Hub bolt...
  • Page 96 TIGHTENING TORQUE AND SPECIFICATION B153SS09 Center pin support Type Unit single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of degree 79.2 / 57.4 wheels(Inside/Outside) Tread mm(in) 1,120(44) 5-10...
  • Page 97 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 rin of steering wheel.
  • Page 98 Problem cause Remedy ・Lockout loosening. ・Retighten. Steering wheel turns unstea- ・Metal spring deteriorated. ・Replace. dily. ・Gear backlash out of adjustment. ・Adjust. Steering system makes abn- ・Lockout loosening. ・Retighten. ormal sound or vibration. ・Air in oil circuit. ・Bleed air. Abnormal sound heard when Valve ・Faulty.
  • Page 99 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE B153SS10 Dust seal 10 O-ring seal 19 Cap screw Retaining ring Rolled screw 20 Housing Cap seal 12 Gerotor set 21 Spool Thrust bearing 13 Bearing race 22 Sleeve Ball 14 Bore screw 23 Relief valve 15 Drive shaft 24 Check valve...
  • Page 100 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 101 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 102 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 103 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 104 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 105 (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 106 (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 107 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 108 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 109 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 110 (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 111 (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 112 (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 113 (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 114 (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 115 (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 ±...
  • Page 116 (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 117 2. PRIORITY VALVE STRUCTURE B153SS11 Body End plug End plug Spool Spring O-ring 5-31...
  • Page 118 DISASSEMBLY ※ Cleanliness is the primary means of assuring satisfactory the priority valve life. Select clean place. Before removing the piping, clean the surrounding area of valve ports. Fix the body(1) in a vise with copper or lead sheets. Do not over tighten jaws. Loosen plug(3) for LS port.
  • Page 119 Remove plug(5) and separate O-ring(6) and plug(3) individually. D353SE17 ASSEMBLY ※ Clean all metal parts in clean solvent and blow dry with air and correct any damage, burrs and rust. ※ Do not wipe dry with cloth or paper towel. ※...
  • Page 120 Install the O-ring(6) onto plug(3) and install the plug(3) into the body(1). ・Tighten torque : 4.5kfg・m(32.5lbf・ft) D353SE20 5-34...
  • Page 121 3. STEERING CYLINDER STRUCTURE ※ Specifications ・Cylinder bore : 60mm ・Outer diameter : 72mm ・Stroke : 180mm ・Rod diameter : 40mm D503SE21 Tube assembly U-packing Slipper seal Rod assembly O-ring 10 O-ring Rod cover Du-bushing Ring Dust wiper Piston 12 Retaining ring 5-35...
  • Page 122 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 123 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 124 3. TRAIL AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. D503SE24 Trail axle 14 Thrust bearing 27 Split pin Hexagonal bolt 15 Needle bearing 28 King pin washer Hexagonal nut 16 Oil seal 29 Grease nipple Knuckle-LH 17 Bearing thrust cap 30 Grease nipple Knuckle-RH...
  • Page 125 CHECK AND INSPECTION B153SS13 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 55(2.12) 54.5(2.1) Replace Damage, wear Rear axle, hub, knuckle, bearing Replace Seizure, abnormal noise, defective rotation 5-39...
  • Page 126 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 127 Loosen special bolt(11) and washer(41). Remove retaining ring(13), oil seal(16). (10) Push out the king pin(12) without damaging the knuckle arm (5). (11) Pull out the thrust bearing (14) and cap(17). If any defect is observed in needle bearing(25), pull it out by using extractor. (12) Remove spilt pin (27), plain washer(42) and then pull out clevis pin(24).
  • Page 128 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function Group 2 Operational checks and troubleshooting 6-15 Group 3 Disassembly and assembly 6-19...
  • Page 129 SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT B153HS01 Hydraulic gear pump Lift cylinder Priority valve Suction strainer Main control valve Down control valve Steering unit 10 Down safety valve Steering cylinder Lift cylinder Tilt cylinder 12 Hydraulic oil tank...
  • Page 130 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION B153HS02 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(4) and then goes to the large chamber of lift cylinder(9) by pushing the load check valve of the spool.
  • Page 131 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION B153HS03 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 132 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION B153HS04 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(3) and then goes to the large chamber of tilt cylinder(6) by pushing the load check valve of the spool.
  • Page 133 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION B153HS05 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(3) and then goes to the small chamber of tilt cylinder(6) by pushing the load check valve of spool.
  • Page 134 2. HYDRAULIC GEAR PUMP STRUCTURE D503HS06 Front cover Bushing block 10 Dowel pin Rear cover Dry bearing Lip seal Gear housing Channel seal 12 Snap ring Drive shaft gear Square seal 13 Socket bolt Driven gear OPERATION This pump comprises of an end cover, a body, bushings and a front cover bolted together with socket bolts.
  • Page 135 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 136 LIFT SECTION OPERATION Lift position Load check valve(1) SECTION A-A 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).
  • Page 137 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)→T. In lift lower position the fork drops due to its own weight.
  • Page 138 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).
  • Page 139 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 140 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.
  • Page 141 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 142 4. 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 O-ring Wear ring 5. TILT CYLINDER B153HS13 Tube assy O-ring 15 Du-bushing U-packing 16 Knuckle Cover 10 Piston 17 Hexagon bolt...
  • Page 143 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 144 2. TROUBLESHOOTING SYSTEM Problem cause Remedy ・Seal inside control valve defective. ・Replace spool or valve body. Large fork lowering speed ・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 145 HYDRAULIC GEAR PUMP Problem Cause Remedy Pump does not develop full ・System relief valve set too low or ・Check system relief valve for proper pressure leaking. setting. ・Oil viscosity too low. ・Change to proper viscosity oil. ・Pump is worn out. ・Repair or replace pump.
  • Page 146 LIFT CYLINDER Problem Cause Remedy Oil leaks out from rod cover ・Foreign matters on packing. ・Replace packing. ・Unallowable score on rod. ・Smooth rod surface with an oil stone. through rod ・Unusual distortion of dust seal. ・Replace dust seal. ・Chrome plating is striped. ・Replace rod.
  • Page 147 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP ※ ※ Tools required ・Metric socket set ・Internal snap ring pliers ・Shaft seal sleeve ・Torque wrench : 13.8 kgf・m (100lbf・ft) 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 148 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 149 (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 150 (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 151 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 152 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 153 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 154 (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 155 (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 156 2. MAIN CONTROL VALVE Lay out valve components on a clean, flat working surface. The inlet assembly will include an O-ring, and the spool section(s) include an O-ring, a load check puppet and a load check spring. Tools required for basic valve assembly include 3/4 and 11/16 open or box end wrenches and a torque wrench with thin wall sockets.
  • Page 157 Position valve assembly with the mounting pads of the end sections on a flat surface. To obtain proper alignment of end sections relative to the spool sections apply downward pressure to the end sections ; Snug tie rod nuts to about 10lbf・ft. Final torque the two 11/16 nuts to 48±lbf・ft Final torque one 3/4 nut to 74±8lbf・ft.
  • Page 158 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 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 6-30...
  • Page 159 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 160 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 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 161 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 162 SECTION 7 ELECTRICAL SYSTEM Group 1 Component location Group 2 Electrical circuit Group 3 Electric components...
  • Page 163 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION B153EL00 Key switch Seat switch 15 Main fuse Head lamp Rear combination lamp 16 Fuse plate Flasher lamp 10 Accelerator assy 17 Micro switch Horn Lift sensor 18 Flasher unit Micro switch 12 Magnetic connector 19 Monitor panel Back horn...
  • Page 164 GROUP 2 ELECTRICAL CIRCUIT 1. WIRE HARNESS PART M1 (+48V) DIODE 0.5W IN5408 FUSE 3 FUSE 2 M12(-) Main Contactor CONTROLLER CONNECTOR PIN SWITCH CONNECTOR "B" (DRIVE) PIN NO Key switch LIGHT SWITCH Forward switch HEAD LAMP Reverse switch FS1 switch HORN SWITCH HORN Seat switch...
  • Page 165 2. CABLE PART BATTERY(+) MAIN M1 (DC48V) 750A SHUNT SHUNT DRIVE MOTOR MOTOR PLUGGING DIODE FREEWHEEL FREEWHEEL DIODE DIODE BATTERY(-) DRIVE CONTROLLER HYD CONTROLLER B153EL021...
  • Page 166 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 B153EL03 Cells Negative leading cable Steel box Positive leading cable Cell connector Connector Row connector...
  • Page 168 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 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. Strict prohibition of fire and ventilation Since batteries generate explosive hydrogen gas, no fire should be drawn near.
  • Page 170 Performance and maintenance of batteries ① 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 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 Symptoms Causes Repair ・Deformation of container, ・Excessive temperature ris- ・Replace Deformation lid or one touch cap ing or external impact ・Electrolyte leakage acco- ・External impact, improper ・Replace or install a new Breakage rding to breakage of cont- handling, excessive vibrat- ainer, lid or one touch cap ・Termination of connector...
  • Page 175 3. DRIVE MOTOR STRUCTURE B153EL07 Armature assembly Spring Name plate Field assembly Fan cover 12 Spring washer Endbell de assembly Wave washer 13 Spring washer Endbell comm assembly Socket bolt 14 Setting pin Brush 10 Hexagon bolt 15 Oil seal 7-13...
  • Page 176 SPECIFICATION Item Unit Specification Model KRDB4004 Type D.C. series, self ventilated Rated voltage Rated output Brush size 12.5×40×40 Insulation Class H EXTERNAL INVOLUTE SPLINE DATA (Unit : mm) Involute spline shaft 30×22×1.25 Adendum modification +0.800 Number of teeth 22EA Ø27.50 Pitch circle dia Tooth (Unit : mm)
  • 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 7-17...
  • 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 Adjust to equal interval be adjusted equally at disassembly.
  • Page 181 TROUBLE SHOOTING Problem Probable cause Remedy 1. Motor fails to start. ・Brush contact faulty. ・Check brush to commutator contact. ・Wire breakage of faulty connection. ・Check connections. ・Field coil shorted or open. ・Replace winding. ・armature coil shorted or open. ・Check armature winding. ・Connection reversed.
  • 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 Commutator endbell Wave washer Field & frame assembly Bearing Armature assembly 10 Bearing Endbell C-ring Brush 12 Bolt Holder assembly 13 Bolt Cover 7-22...
  • Page 185 SPECIFICATION Item Unit Specification Model KNAQ 4003 Type D.C. series, self ventilated Rated voltage Rated output Brush size 16×20×25 Insulation Class H SERVICE STANDARDS (Unit : mm) Item Service standards Armature coil insulation resistance Ω Above 1M New part 90.5mm Commutator dia 83.5mm Repair limit...
  • 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 7-25...
  • Page 188 Remove 4 bolts on the commutator side endbell. (below) B153EL091 ① Brush holder assembly B153EL092 ② Frame and field assembly. B153EL093 7-26...
  • 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 Drive controller Pump controller 7-28...
  • Page 191 CONTROLLER SYSTEM VARIANTS Suffix B153EL028 1st digit 2nd digit 3rd digit Suffix 2 = Traction 2 = - Reserved - (24 - 36V) 3 = 300A L = Low I/O, Traction 3 = Pump 4 = 24 - 48V 4 = 450A M = Medium I/O, Traction 7 = - Reserved - (SEM) 8 = 72 - 80V...
  • Page 192 CONTROLLER FEATURES WITH THE DIFFERENT LOGIC VARIANTS 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 High frequency (silent operation)
  • Page 193 Logic Feature Pump Low I/O Logic Traction Med. I/O Logic Inching and timed burst inching facilities Economy pot input. OPTIONAL 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 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 TECHNICAL SPECIFICATIONS Electrical ① ① Voltage specifications Model Voltage Nominal Battery Absolute maximum operating voltage PP×4× 48V Units 24 - 48V 14.5 - 75V ② ② Current specifications Continuous current 1 hour rating. Unit Current limit Safe operating Model Power mounted on an aluminum base-plate (1 min) area (SOA)
  • Page 196 Mechanical ① ① Unit size (all units) Length 142mm, width 142mm, height 140mm with logic fitted. (Height is 86mm with logic unplugged) ② ② Enclosure Aluminium die cast base-plate with ABS plastic injection moulded power frame and logic covers. ③ ③ Power connections Aluminium vertical power bushes for M8 connection.
  • Page 197 Wiring connections The following section details the connectors on the minimum, medium and high logics. The minimum logic has 2 connectors, 1 for the vehicle/contactor connections and 1 for serial communications. The medium I/O logic has 3 connectors, 1 for the vehicle connections, 1 for the contactor connections and 1 for serial communications.
  • Page 198 CALIBRATOR AND ADJUSTMENTS A sophisticated, yet easy to use hand held adjustment unit, called the calibrator is used to make adjustments to the controller and select configurations. The calibrator is also used as a diagnostic tool displaying the status of all voltages, currents and temperatures within the controller together with the condition of all the controller’s switch and analogue inputs.
  • Page 199 Traction Controller Personalities(Controller Adjustments) 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 600A 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 2.5S...
  • 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 1.1.35 O.Temp pot full level Med i/o 5.0V 0.02V 1.1.36 Speed limit Med i/o 2kPH(0 disables) 60kPH...
  • Page 201 Traction Controller Status Information Cal. Parameter Logic Step Max display ref. displayed type display size info. 1.2.1 Battery voltage L, H, H 127V 0.1V 1.2.2 Traction motor voltage L, M, H 127V 0.5V 1.2.3 Traction motor current L, M, H 1200A 1.2.4 Traction controller temp...
  • Page 202 BDI Adjustments(it enabled in setup menu) Logic Min. Max. Actual Cal. Ref. Parameter adjusted/displayed Step size type setting setting value 1.4.1 xxx % Charge remaining L, M, H, P Display only 1.4.2 Battery volt xx V L, M, H, P Nominal V 2.00v/cell 2.50v/cell...
  • Page 203 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 204 Traction controller setup menu(enables/disables features) 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 205 Pump controller personalities(controller adjustments) Logic Min adjust Max adjust Max.adjust Step size Actual Cal. ref. Parameter adjusted type (all units) 450A unit 650A unit (all units) value 2.1.1 Current limit 50 A 500 A 650 A 10 A 400 A 2.1.2 Ramp up delay 0.1 S...
  • Page 206 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 207 (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 208 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 209 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 210 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 211 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 212 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 213 ・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 214 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 215 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. 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 216 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 217 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 218 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. ⑱...
  • Page 219 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 220 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 221 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 222 SECTION 8 MAST Group 1 Structure Group 2 Operational checks and troubleshooting Group 3 Adjustment Group 4 Disassembly and assembly 8-10...
  • Page 223 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) B153MS01 Outer mast Mast support metal 10 Chain wheel bearing Shim(0.5, 1.0t) Inner mast Roller Roller Lift chain 12 Back up liner Tilt cylinder pin Anchor bolt 13 Shim(0.5, 1.0t) Mast support cap...
  • Page 224 2. 3 STAGE MAST(TF MAST) B153MS02 Outer mast Chain Shim(0.5, 1.0t) Bushing 12 Sheave bracket Roller Middle mast 13 Inner mast Back up liner Sheave 14 Shim(0.5, 1.0t) Tilt cylinder pin 10 Anchor bolt 15 Mast up cylinder band...
  • Page 225 3. CARRIAGE, BACKREST AND FORK D503MS03 Backrest Side roller Carriage Fork assy Load roller Extension fork...
  • Page 226 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 64FD-11010 HBF15III 40(1.6) 38(1.5) B153FK01 Set forks in middle and measure out of parallel and difference in height at the top...
  • Page 227 2. TROUBLESHOOTING MAST Problem cause Remedy ・Deformed mast or carriage. ・Disassemble, repair or replace. Forks fail to lower. ・Faulty hydraulic equipment. ・See troubleshooting hydraulic pump Fork fails to elevate and cylinders in section 6, hydraulic system. ・Deformed mast assembly. ・Disassemble mast and replace damag-ed parts or replace complete mast assembly.
  • Page 228 FORKS Problem cause Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear wear and reduces the thickness of the limit, replace fork. fork. Inspection for thickness is needed. ・Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...
  • Page 229 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V MAST) INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the roller side face and mast at the closest position on the opposite side to the...
  • Page 230 2. MAST LOAD ROLLER(TF MAST) INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast and the middle mast, and adjust the clearance between the roller side face and mast at the closest position on the B153MS06...
  • Page 231 CARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, middle and lower rollers after loosen the adjust screws from the side rollers. Shift the carriage to one side to bring the roller into contact with the inner mast, and measure the clearance between the roller side face...
  • Page 232 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1inch) from the floor. Release fork anchor pins and slide forks, one at time toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 233 SIDE ROLLER Remove carriage as outlined in the carriage assembly 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 234 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) ① Remove the carriage assembly and move them to one side. ② Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast. ③ Loosen and remove hexagon bolts and nuts securing lift cylinders to inner mast.
  • Page 235 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 236 ELEVATING MAST Inner mast (V 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 237 CHAIN Chain sheave(V mast) ① Place a sling around carriage and attach 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 238 Sheave support(TF mast) ① Remove the carriage assembly and move to one side. ② After removing bolt to securing sheave support assembly to free lift cylinder. Attach a sling to the sheave support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 239 ② 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 240 ⑧ 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 241 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 ④ Adjustment procedure ・With mast in its fully collapsed and vertical position, lower the fork to the floor. ・Adjust the chain length by loosening or tightening nut on the chain anchor.

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Hbf 18iii