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Hyundai 15BT-9 Manual

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SECTION 1 GENERAL

SECTION 1 GENERAL

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

Group 2 Specifications --------------------------------------------------------------------------------------------------

Group 3 Periodic replacement --------------------------------------------------------------------------------------

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

Group 1 Major components -----------------------------------------------------------------------------------------

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

SECTION 3 POWER TRAIN SYSTEM

SECTION 3 POWER TRAIN SYSTEM

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

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

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

SECTION 4 BRAKE SYSTEM

SECTION 4 BRAKE SYSTEM

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

Group 2 Operational checks and troubleshooting ------------------------------------------------------

Group 3 Adjustments ----------------------------------------------------------------------------------------------------

SECTION 5 STEERING SYSTEM

SECTION 5 STEERING SYSTEM

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

Group 2 Operational checks and troubleshooting -----------------------------------------------------

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

SECTION 6 HYDRAULIC SYSTEM

SECTION 6 HYDRAULIC SYSTEM

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

Group 2 Operational checks and troubleshooting ------------------------------------------------------

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

SECTION 7 ELECTRICAL SYSTEM

SECTION 7 ELECTRICAL SYSTEM

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

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

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

SECTION 8 MAST

SECTION 8 MAST

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

Group 2 Operational checks and troubleshooting ------------------------------------------------------

Group 3 Adjustment ------------------------------------------------------------------------------------------------------

Group 4 Removal and installation --------------------------------------------------------------------------------

CONTENTS

CONTENTS

1-1

1-4

1-12

2-1

2-2

3-1

3-9

3-10

4-1

4-5

4-7

5-1

5-10

5-13

6-1

6-25

6-29

7-1

7-2

7-4

8-1

8-4

8-7

8-10

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Summary of Contents for Hyundai 15BT-9

Page 1 CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints ------------------------------------------------------------------------------------------------------ Group 2 Specifications -------------------------------------------------------------------------------------------------- Group 3 Periodic replacement -------------------------------------------------------------------------------------- 1-12 SECTION 2 REMOVAL AND INSTALLATION OF UNIT SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Major components ----------------------------------------------------------------------------------------- Group 2 Removal and Installation of Unit ------------------------------------------------------------------- SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM...
Page 2 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
Page 3 Revised edition mark(①②③…) Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
Page 4 3. CONVERSION TABLE 3. CONVERSION TABLE Method of using the 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 Example Method of using the Conversion Table to convert from millimeters to inches...
Page 5 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
Page 6 Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
Page 7 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 8 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
Page 9 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 10 SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints ------------------------------------------------------------------------------------------------------ 1-1 Group 2 Specifications --------------------------------------------------------------------------------------------------- 1-4 Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-12...
Page 11 GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
Page 12 Hand a caution sign in the operator's compartment (For example Do not start or Maintenance in progress). This will prevent anyone from starting or moving the machine by mistake. D50ASF07 When inspecting running parts or near such parts, always stop the machine first. Before checking or servicing accumulator or piping, depress brake pedal repeatedly to release pressure.
Page 13 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 14 GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS 15BT9OM113 Mast Dash board 11 Seat Lift cylinder Frame 12 Steering wheel Carriage and backrest Steering axle 13 Overhead guard Forks Counterweight Drive unit 10 Battery cover...
Page 15 2. SPECIFICATIONS 2. SPECIFICATIONS 15BT9SP01 Model Unit 15BT-9 18BT-9 20BT-9 Capacity kg (lb) 1500 (3000) 1800 (3500) 2000 (4000) ← ← Load center mm (ft-in) 500 (24") Weight kg (lb) 3125 (6890) 3365 (7420) 3500 (7715) ← Lifting height mm (ft-in) 3025 (9' 11")
Page 16 Type Rated voltage Output 14.0 Insulation Class F Class F BATTERY Item Unit 15BT-9 18/20BT-9 Rated voltage Dimension(W L H) 978 545 635 978 630 635 Min. Battery weight Max. Battery weight 1140 Connector(CE spec) SB 350 or SR350 (SBE 320)
Page 17 Gear ratio Weight without fluid kg/lb 35 kg (77 lb)/EA Oil quantity /U.S qt 0.6/0.63 8) 8) WHEELS WHEELS Item 15BT-9 18BT-9 20BT-9 Type (STD/OPT) SOLID Non-marking Quantity(front/rear) Front-drive 18 7-8 200 50-10 Rear-steering 15 4.5-8 15 4.5-8, 15 5.5-9 (wide tire) 9) 9) BRAKES &...
Page 18 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS kgf m lbf ft Items Size Hyd pump motor mounting bolt 1.25 2.5 0.5 18.1 3.6 Electric system Traction motor mounting bolt 1.25 2.5 0.5 18.1 3.6 Hydraulic pump mounting bolt 1.25 2.5 0.5 18.1 3.6 MCV mounting bolt, nut 1.25...
Page 19 5. TORQUE CHART 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT BOLT AND NUT 1) 1) Coarse thread Coarse thread (1) (1) Bolt size kgf m kgf m lbf ft lbf ft 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 1.25...
Page 20 2) 2) PIPE AND HOSE(FLARE TYPE) PIPE AND HOSE(FLARE TYPE) Thread size Width across flat mm kgf m lbf ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" PIPE AND HOSE(ORFS TYPE) PIPE AND HOSE(ORFS TYPE) Thread size kgf m lbf ft Width across flat mm 9/16-18...
Page 21 6. RECOMMENDED LUBRICANTS 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature °C (°F) Service Capacity ℓ (U.S. gal) Kind of fluid point (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) MOBIL FLUID 424 Axle Gear oil...
Page 22 GROUP 3 PERIODIC REPLACEMENT GROUP 3 PERIODIC REPLACEMENT For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time of periodic maintenance;...
Page 23 SECTION 2 REMOVAL AND INSTALLATION OF UNIT SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Major components ------------------------------------------------------------------------------------------ 2-1 Group 2 Removal and installation of unit --------------------------------------------------------------------- 2-2...
Page 24 SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 MAJOR COMPONENTS 9 10 11 12 13 1516 15BT9RE01 Lift cylinder Drive unit 17 Counterweight Mast 10 Drive motor 18 Traction controller Steering unit 11 Pump motor 19 Pump controller Backrest 12 Hydraulic pump 20 Seat Tilt cylinder...
Page 25 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Forks Knob Backrest Rolled pin Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Spring Turn knob up and slide one fork at a time toward the center of the carriage where a notch has been cut in the bottom plate for...
Page 26 While supporting lift chains, remove the Lift chain split pins and slide out chain anchor pins Outer mast from the chain anchors of stationary upright. Split pin 20B7RE05 Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain...
Page 27 Piping Loosen the bolts (2EA) of the weld- Inner mast connector (2) from low crossmember of the outer mast. Disconnect the connectors from the lift cylinders. Disassemble the velocity fuse valve (1), Lift cylinder hoses, and weld-connector (2). Outer mast Bolt 15BT9RE08 Lift cylinder...
Page 28 Inner mast Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Inner mast Be careful the mast not to swing or fall. Outer mast 15BT9RE12 Tilt cylinder pin Attach a crane to the stay at the top of the outer mast, and raise enough to sustain jacked up machine.
Page 29 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. Brone bushings Check the inside of the bronze bushings for wear which are the contact area with the mast mounting pins.
Page 30 2. POWER TRAIN ASSEMBLY REMOVAL Mast & Counterweight B153RE00 Mast and counterweight Refer to section on mast(Page 2-5) Crane After removing mast, remove the counterweight to prevent the truck from turning over. Mounting bolt 15BT9RE12A Brake piping Disconnect the brake piping from the drive Drive unit Brake master unit.
Page 31 Drive unit & motor assy Frame Drain the oil before disassembling the drive unit. Unscrew five wheel nuts and remove the Motor wiring wheel. Drive unit & motor assy Wheel nut 20B7RE15 Remove three hexagon bolts holding the Drive motor drive motor in place.
Page 32 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 weigh from around 710kg to 1140kg so the extreme care must be taken when handling them.
Page 33 Pump motor Lower the fork to floor. 15BT9RE21 Remove floor mat and rear floor plate. Floor mat Disconnect the wiring of pump motor. Floor plate Disconnect wiring 15BT9RE22 Remove elbow and connector and then Hydraulic hose disconnect the hydraulic hose from the Pump motor gear pump.
Page 34 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) 575kg (1270lb) 15BT-9 665kg (1470lb) 18BT-9 795kg (1750lb) 20BT-9 Tightening torque : 184~214 kgf m (1330~1550lbf ft) Battery connector Disconnect the battery connector.
Page 35 Hose Steering hyd Disconnect the hoses from steering motor hydraulic motor. Steering unit Hose 15BT9RE25 Loosen socket bolts and remove steering Socket hydraulic motor assy from steering axle bolt Steering hyd bracket. motor Steering axle 15BT9RE26 Jacking up the chassis of truck. Loosen the hub nut and take off the steering wheel tire assembly.
Page 36 Loosen bolts and remove steering axle assy from chassis. Bolt Steering axle assy 15BT9RE29 2-13...
Page 37 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation --------------------------------------------------------------------------------- 3-1 Group 2 Troubleshooting ---------------------------------------------------------------------------------------------- 3-9 Group 3 Disassembly and assembly --------------------------------------------------------------------------- 3-10...
Page 38 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION GROUP 1 STRUCTURE AND OPERATION 1. DRIVE UNIT 1. DRIVE UNIT 1) 1) STRUCTURE STRUCTURE (1) (1) Drive unit assembly Drive unit assembly 15BT9PT01 Dirve unit assembly (LH) 13 Snap ring (for shaft) Dirve unit assembly (RH) 14 Snap ring (for hole)
Page 39 (2) (2) Housing sub assembly Housing sub assembly 11 12 13 14 , , , 15BT9PT02 Housing sub assembly (LH) 15 Planetary carrier Housing sub assembly (RH) 16 Lock nut Housing carrier (LH) 17 Thrust washer Housing carrier (RH) 18 Needle bearing Oil seal 19 Planetary gear Gamma seal...
Page 40 (3) (3) Cover out sub assembly Cover out sub assembly 1, 2 15BT9PT03 Cover out assembly (LH) Ball bearing Cover out assembly (RH) Snap ring Cover out (LH) 10 Actuator Cover out (RH) 11 Return spring Parallel pin 12 Sun pinion Friction block 13 Socket bolt Ring gear (83T)
Page 41 (4) (4) Parking sub assembly Parking sub assembly 1, 2 3, 4 15BT9PT04 Parking sub assembly (LH) Quad ring Parking sub assembly (RH) Backup ring Parking cover (LH) 10 Shaft Parking cover (RH) 11 Lever Piston 12 Snap ring Quad ring 13 O-ring Backup ring...
Page 42 2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Max. output torque (wheel) N·m 2260 Max. axle load kg/lb 2700/5953 Max. input speed 5000 Gear ratio Weight without fluid kg/lb 35/77 ℓ/U.S.·qt Oil quantity(ATF) 0.67/0.71...
Page 43 3) 3) PRINCLPLE OF OPERATION PRINCLPLE OF OPERATION (1) (1) Outline of the power transmission system Outline of the power transmission system The drive units are composed of the drive unit (LH) and the drive unit (RH) which are connected with the motor as a power transmission system to assemble the drive wheel for the battery type fork lift.
Page 44 (2) (2) Principle of the operation Principle of the operation ① Structure of the drive unit Structure of the drive unit 15BT9PT06 Input pinion Housing (Ring gear) Ring gear Sun pinion Brake piston Planetary carrier Planetary gear Wheel hub Brake pack...
Page 45 ② The path of the power transmission The path of the power transmission Driving : Motor → Input pinion → Ring gear → Sun pinion → Planetary gear → Wheel hub Driving → Dirve wheel Braking Braking : Pressurization of hydraulic power through the brake port Forwarding of the brake piston →...
Page 46 GROUP 2 TROUBLESHOOTING Problem Cause Remedy 1. Consecutive noise in the Lack of oil Refill the oil housing Incorrect contact between planetary Disassemble, check and readjusting gear and driving gear Damage, wear planetary gear and Replace damaged or wear gear driving gear Loosened or worn wheel hub bearing Disassemble, check and readjusting...
Page 47 GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. Disassembly 1. Disassembly Drain oil from transmission before removal of the drive unit. Loosen and remove the wheel nuts as well as take off the drive wheel. For further work on the drive motor of the drive unit see chapter. 1) 1) REMOVAL OF THE DRIVE UNIT REMOVAL OF THE DRIVE UNIT...
Page 48 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. 3-11...
Page 49 3. DISASSEMBLY OF THE DRIVE UNIT 3. DISASSEMBLY OF THE DRIVE UNIT Disassembly of the drive unit assy. ※ Always keeps clean working area when disassebling the drive unit. 15BT9DU001 Drain out oil in the drive unit assy by removing the magnetic plug. Magnetic Plug 15BT9DU002...
Page 50 Loosen 6-socket bolts which are fixing for the parking sub assy. 15BT9DU004 Disassemble the parking sub assy. 15BT9DU005 Disassemble the piston sub assy after pushing away the lever of the parking sub assy. 15BT9DU006 Remove the quad ring and back up ring from the piston sub assy.
Page 51 Remove the O-ring from the parking sub assy. 15BT9DU008 Disassemble the snap rings, lever, and shaft from the parking sub assy. 15BT9DU009 Loosen the socket bolts (10EA) from the dirve unit assy. 15BT9DU010 Disassemble the cover out sub assy from the housing sub assy.
Page 52 Remove the snap ring from the housing sub assy. 15BT9DU012 Disassemble the input pinion assembly from the housing sub assembly. 15BT9DU013 DISASSEMBLY OF THE COVER OUT SUB ASSY DISASSEMBLY OF THE COVER OUT SUB ASSY Cover out sub assy. 15BT9DU014 Loosen the socket bolts (6EA) from the cover out sub assy.
Page 53 Disassemble the sun pinion and return Sun pinion springs (3EA) from the cover out sub assy. Return spring (3EA) 15BT9DU016 Disassemble the actuator from the cover out sub assy. 15BT9DU017 Remove the snap ring from the cover out sub assy. 15BT9DU018 Disassemble the ring gear from the cover out sub assy.
Page 54 Remove the bearing form the ring gear. 15BT9DU020 Remove the friction block and the parallel Friction block pin from the cover out sub assy. Parallel pin 15BT9DU021 DISASSEMBLY OF THE HOUSING SUB ASSY DISASSEMBLY OF THE HOUSING SUB ASSY Housing sub assy. 15BT9DU022 Loosen the special bolts (3EA) from the housing sub assy.
Page 55 Disassemble the friction disc 1 (2EA), Friction disc 2 friction disc 2 (1EA), plates (2EA), back plate (1EA). Plate Friction disc1 Back plate 15BT9DU024-1 15BT9DU024-2 Friction disc 1 Friction disc 2 15BT9DU024 Remove the snap rings (3EA) from the housing sub assy. 15BT9DU025 Remove the thrust washers (3EA) from the housing sub assy.
Page 56 Remove the thrust washers (3EA), the Needle bearing needle bearings (3EA) from the housing Thrust washer sub assy. 15BT9DU028 Remove the set screw from the housing sub assy. 15BT9DU029 Remove the lock nut from the housing sub assy. ※ When removing the lock nut from the housing sub assy, it should be used the special tool.
Page 57 Remove the bearing cap from the housing sub assy. 15BT9DU032 Remove the shims from the housing sub assy. ※ If the bearings are not replaced with new one, take care to safe keep the shims to the proper place. 15BT9DU033 Disassemble the wheel hub sub assy from the housing sub assy.
Page 58 Remove the bearing cup from the housing carrier. 15BT9DU036 Remove the oil seal from the housing carrier. 15BT9DU037 3-21...
Page 59 4. ASSEMBLY OF THE DRIVE UNIT 4. ASSEMBLY OF THE DRIVE UNIT 1) 1) ASSEMBLY OF THE HOUSING SUB ASSY ASSEMBLY OF THE HOUSING SUB ASSY Assembly of the parking sub assy. 15BT9DU038 Assemble the shaft to the parking cover. 15BT9DU039 Assemble the snap rings (3EA) to the shaft.
Page 60 Assemble the parking lever to the shaft and fix with snap ring. ※ Be sure that the marking on the parking lever gets into inline to the marking on the shaft (Refer to VIEW "A") 15BT9DU041 Assemble the O-ring to the parking cover. ※...
Page 61 Completion of assembly of the parking sub assy. 15BT9DU046 2) 2) ASSEMBLY OF THE COVER OUT SUB ASSY ASSEMBLY OF THE COVER OUT SUB ASSY Assemble the friction block after inserting Friction block the parallel pin. Parallel pin ※ When assembling the friction block, take care to the direction of assembling of it.
Page 62 Assemble the ring gear to the cover out assy. 15BT9DU050 Assemble the snap ring to the cover out assy. 15BT9DU051 Assemble the actuator to the cover out assy. 15BT9DU052 Assemble the sun pinion after assembling Sun pinion the return springs (3EA). Return spring (3EA) 15BT9DU053...
Page 63 Assemble the bolts (6EA) to the sun pinion. ·Tightening torque : 3.5~3.8 kgf·m ※ Apply the Loctite #277 on the thread of the bolts. When assembling the bolts, it should be fixed the ring gear using the filter wrench. 15BT9DU054 3) 3) ASSEMBLY OF THE HOUSING SUB ASSY ASSEMBLY OF THE HOUSING SUB ASSY...
Page 64 Assemble the bearing cup in the housing sub assy. ※ When assembling the bearing cup, it should be used the special tool. 15BT9DU058 Assemble the Gamma seal in the housing sub assy. ※ When assembling the Gamma seal in the housing sub assy, it should be used the special tool.
Page 65 15BT9DU062 Assemble the bearing cup in the housing carrier. ※ It should be used the special tool when assembling the bearing cup in the housing carrier. 15BT9DU063 Assemble the planetary carrier and bearing cone in the housing carrier. 15BT9DU064 Assemble the lock nut in the housing carrier.
Page 66 ※ After the locknut tightening, the preload value is measure in the DB torque wrench, it must be value below. (Seal resistance value +0.45 kgf·m) If it is not gotten the specified free load, rework repeatedly according as (5)~(8) procedure and it should be set with the specifed preload as an adding or removing the shims properly.
Page 67 (11) Assemble the snap rings (3EA) in the housing carrier. 15BT9DU071 (12) Assemble the components according as Friction disc 2 the following sequence. Back plate → (Friction disc 1 → plate)×2 Plate Friction disc1 → Friction disc 2 Back plate 15BT9DU024-1 15BT9DU024-2 Friction disc 1...
Page 68 (15) Assemble the socket bolts (10EA) to the housing carrier. ·Tightening torque : 3.5~3.8 kgf·m ※ Apply with Loctite #277 on the thread of the socket bolts. 15BT9DU075 (16) Assemble the input pinion in the housing carrier. 15BT9DU076 (17) Assemble the snap ring to the housing carrier.
Page 69 (19) Assemble the bolts (6EA) to the housing carrier. ·Tightening torque : 3.5~3.8 kgf·m ※ Apply with Loctite #277 on the thread of the bolts. 15BT9DU079 (20) Assemble the brake plug, O-ring, air breather, and cap to the housing carrier. ·Tightening torque : 1.5~2.0 kgf·m ※...
Page 70 (22) SETTING OF THE PISTON STROKE (1 mm) Hydraulic pressure or Air pressure 1mm plate ① Retain the space between the piston and the lever by pouring the hydraulic pressure or air pressure into the brake plug. ② Insert 1 mm thickness plate between lever and piston.
Page 71 SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------ 4-1 Group 2 Operational checks and troubleshooting ------------------------------------------------------ 4-5 Group 3 Adjustments ----------------------------------------------------------------------------------------------------- 4-7...
Page 72 SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 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 3. BRAKE PEDAL AND PIPING Drive line assembly(RH) Drive line assembly(LH) 15BT9BS01 Brake pedal & bracket assy Reservoir tank assy Parking lever assy Brake master cylinder...
Page 74 4. BRAKE MASTER CYLINDER 4. BRAKE MASTER CYLINDER STRUCTURE STRUCTURE 1) 1) 20B7BS03 Body Spring Plate Secondary cup Check valve assembly Piston Union bolt Gasket Spacer Union Primary cup Retaining ring Spring seat Boot...
Page 75 2) 2) DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY Remove the boot(12). Take out the retaining ring(11) and plate(13). Take out the piston(3), secondary cup(2), spacer(4), primary cup(5), spring seat(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 76 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. BRAKING FORCE Select a dry, flat, paved surface and, drive truck at maximum speed.
Page 77 2. TROUBLESHOOTING Problem Cause 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 78 GROUP 3 ADJUSTMENTS 1. ADJUSTMENT OF PEDAL BRAKE PEDAL Pedal height from floor plate adjust with stopper bolt. 140~145mm Pedal height : 140~145mm (5.5~5.7in) Play Adjust with rod of mast cylinder. Pedal play : 4~6mm (0.16~0.23in) Floor plate 15BT9BS09...
Page 79 SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------- 5-10 Group 2 Operational checks and troubleshooting ------------------------------------------------------- Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 5-13...
Page 80 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Steering motor Steering axle Steering unit Priority valve Hyd tank Hyd gear pump Hyd tank 15BT9SS01 The steering system for this truck is composed of steering wheel assembly, steering unit, steering motor, steering axle and pipings.
Page 81 2. HYDRAULIC CIRCUIT 15BT9SS26 Hydraulic gear pump Suction strainer Priority valve Return filter Steering unit 12 Hydraulic tank Hydraulic motor...
Page 82 NEUTRAL 15BT9SS04 The steering wheel is not being operated so control spool(G) does not move. The oil from hydraulic tank(12) enters hydraulic gear pump(1) and pressurized so that the oil flows into the inlet port(P) of steering unit(4). Oil flows out of T port to the hydraulic tank(12).
Page 83 LEFT TURN 15BT9SS06 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 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 84 RIGHT TURN 15BT9SS08 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. At 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 85 3. STEERING UNIT STRUCTURE 23-1 25-2 23-3 25-1 23-2 23-4 23-5 23-6 24-4 24-3 24-2 24-1 20B7SS09 14 Bore screw Dust seal 23-4 Spring Retaining ring 15 Drive shaft 23-5 Spool Cap seal 16 End cap 23-6 Bushing Thrust bearing 17 Bushing 24 P-port check valve Ball...
Page 86 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 87 4. STEERING AXLE STRUCTURE STEERING SENSOR 8 11 1-14 STEERING HYD MOTOR 1-15 1-12 1-10 1-11 1-13 20B7SS10 1-1 Steering axle 1-11 Split pin Bolt-w/washer 1-2 Bracket 1-12 Hub bolt Lever 1-3 Taper roller bearing 1-13 Hub cap Hexagon bolt 1-4 Taper roller bearing 1-14 Steering gear assy 10 Spring washer...
Page 88 TIGHTENING TORQUE AND SPECIFICATION SECTION B - B 9~12kgf m (65~87lbf ft) Apply loctite #277. 14~18kgf m (101~130lbf ft) Apply loctite #277. 2~3kgf m (15~22lbf ft) SECTION A - A 20B7SS11...
Page 89 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 90 Problem Cause 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 91 POWER STEERING UNIT Problem Cause 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 92 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 23-1 25-2 23-3 25-1 23-2 23-4 23-5 23-6 24-4 24-3 24-2 24-1 20B7SS09 Dust seal 14 Bore screw 23-4 Spring Retaining ring 15 Drive shaft 23-5 Spool Cap seal 16 End cap 23-6 Bushing Thrust bearing 17 Bushing...
Page 93 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 94 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 95 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 96 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. B20H7SS09 5-17...
Page 97 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 98 (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 (15) Screw out the plug using an 8mm hexagon socket spanner.
Page 99 (16) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (17) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (18) The pressure relief valve is now disassem- bled. D353SE13 5-20...
Page 100 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 101 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 102 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 103 (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 104 (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 105 (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 106 (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 107 (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 108 (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 109 (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 110 2. STEERING AXLE STRUCTURE STEERING SENSOR 8 11 1-14 STEERING HYD MOTOR 1-15 1-12 1-10 1-11 1-13 20B7SS10 1-1 Steering axle 1-11 Split pin Bolt-w/washer 1-2 Bracket 1-12 Hub bolt Lever 1-3 Taper roller bearing 1-13 Hub cap Hexagon bolt 1-4 Taper roller bearing 1-14 Steering gear assy 10 Spring washer...
Page 111 CHECK AND INSPECTION Apply grease on the surface of seal lip when assembling. Fill 70% of the space in the bracket with lithium grease. 20B7SS15 Check for any bend or twist. Slight bend or twist can be straightened by press, however, if not, replace the axle.
Page 112 DISASSEMBLY Socket bolt Steering motor Steering hyd motor Before dismounting steering motor disconnect all hydraulic pipes from the steering motor. Loosen socket bolts connecting motor with axle. Steering axle assembly 20B7SS16 Motor bracket Remove motor bracket with steering Steering sensor sensor.
Page 113 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 After axle bracket is removed take off the bearing inner race of bearing.
Page 114 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 115 Steering gears Before assembling, gears should be well Split pin greased. Castle nut Install pinion gear and tighten hexagon Steering gear bolt. Put the steering gear on the axle beam Pinion gear and then assemble the castle nut with the pin.
Page 116 3. 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 117 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, Output shaft remove the shaft from the housing front end.
Page 118 Dust seal, needle bearing Use a 4mm(0.16in) screw driver. Housing Needle bearing Dust seal B15T5SM09 5-39...
Page 119 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 120 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 121 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 122 (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 123 (14) 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 5-44...
Page 124 SECTION 6 HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function -------------------------------------------------------------------------------------- 6-25 Group 2 Operational checks and troubleshooting -------------------------------------------------------- 6-29 Group 3 Disassembly and assembly -----------------------------------------------------------------------------...
Page 125 SECTION 6 HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 1. HYDRAULIC CIRCUIT 15BT9HS01 Hydraulic gear pump Suction strainer Priority valve Return filter Main control valve 10 Down safety valve Steering unit 11 Down control valve Hydraulic motor...
Page 126 1) 1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION Steering system Return line Load check valve 15BT9HS02 When the lift control lever is pulled back, the spool on the first block is moves to lift position. The oil from hydraulic gear pump(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 127 2) 2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION Steering system Return line Load check valve 15BT9HS03 When the lift control lever is pushed forward, the spool on the first block is moved to lower position. The work port(1A) and the small chamber and the large chamber are connected to the return passage, so the forks will be lowered due to its own weight.
Page 128 3) 3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION Steering system Return line Load check valve 15BT9HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
Page 129 4) 4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION Steering system Return line Load check valve 15BT9HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
Page 130 2. HYDRAULIC GEAR PUMP STRUCTURE BRJ7HS19 Mounting flange Bearing block 11 Dowel pin End cover Backup ring 12 Start ring Gear housing Seal 13 Socket head bolt Drive gear O-ring 14 Spring washer Idler shaft 10 Shaft seal OPERATION This pump comprises of an rear cover, a body, bushings and a housing bolted together with bolts. The gear journals are supported in side plate within pressure balanced bushings to give high volumetric and mechanical efficiencies.
Page 131 3. MAIN CONTROL VALVE (without OPSS) STRUCTURE (3 Spool) INLET LIFT TILT AUX1 OUTLET 130K 190K 3A 3B 2A 2B VIEW A 15BT9HS07 Port name Size Port Inlet port 7/8-14UNF Outlet port 7/8-14UNF Work port 7/8-14UNF Work port 3/4-16UNF 2A, 2B, 3A, 3B Inlet block assy Main relief valve assy Lift block assy...
Page 132 STRUCTURE (4 Spool) INLET LIFT TILT AUX1 AUX2 OUTLET 130K 190K 3A 3B 4A 4B 2A 2B VIEW A Port name Size Port Inlet port 7/8-14UNF Outlet port 7/8-14UNF Work port 7/8-14UNF Work port 3/4-16UNF 2A, 2B, 3A, 3B, 4A, 4B 22B7HS07 Inlet block assy Outlet block assy...
Page 133 INLET SECTION Operation The inlet section contains the pump inlet connection and main relief valve. INLET 190bar 22B7HS09 Operation of relief valve at setting pressure When the pressure at inlet reaches to setting pressure, the pilot poppet which is in the main relief valve is opened by pressure.
Page 134 LIFT SECTION Operation The lift section has a single work port to direct flow to the lift cylinder. Only one work port is used, because the lift cylinder is single-acting(gravity returns the mast to the lowered position). The lift section also contains part of the components which comprise the safety features. There is a lift lock check valve.
Page 135 TILT SECTION Operation The tilt spool contains an internal plunger which acts to stop tilt forward actuation when the battery power is off. Tilt forward When the seated operator shifts the lever forward, pressure is applied to the head of the tilt cylinder, and the forks tilt forward.
Page 136 AUXILIARY SECTIONS Operation Many different functions can be controlled by the auxiliary spool sections. In general, one work port is pressurized by high pressure oil from the parallel passage, past the load check valve, past the metering notches, and to the cylinder. Simultaneously, oil from the other work port is directed across the spool metering notches to tank.
Page 137 OUTLET SECTION Operation The outlet section contains the tank port and the secondary relief valve(with built-in anti-cavitation feature). OUTLET 130bar 22B7HS17 Operation of relief valve at setting pressure When the pressure at outlet reaches to setting pressure, the pilot poppet which is in the main relief valve is opened by pressure.
Page 138 MAIN RELIEF VALVE This valve is a type of pilot piston to prevent hydraulic components and pipes from being broken by high pressure so, it keeps under pressure limited. Relief valve pressure varies by 130kgf/cm in accordance with 1 revolution of adjust bolt. 22B7HS20 Pilot seat Main spring...
Page 139 MAIN CONTROL VALVE (with OPSS) STRUCTURE (3 Spool) Needle valve (Emergency) INLET LIFT TILT AUX1 OUTLET 130K 190K 3A 3B 2A 2B VIEW A Port name Size Port Inlet port 7/8-14UNF Outlet port 7/8-14UNF 15BT9HS08 Work port 7/8-14UNF 2A, 2B, 3A, 3B Work port 3/4-16UNF Inlet block assy...
Page 140 STRUCTURE (4 Spool) Needle valve (Emergency) INLET LIFT TILT AUX1 AUX2 OUTLET 130K 190K 3A 3B 4A 4B 2A 2B VIEW A Port Port name Size Inlet port 7/8-14UNF Outlet port 7/8-14UNF 22B7HS08 Work port 7/8-14UNF Work port 3/4-16UNF 2A, 2B, 3A, 3B, 4A, 4B Inlet block assy Main relief valve assy Lift block assy...
Page 141 INLET SECTION Operation The inlet section contains the pump inlet connection and main relief valve. INLET 190bar 22B7HS09 Operation of relief valve at setting pressure When the pressure at inlet reaches to setting pressure, the pilot poppet which is in the main relief valve is opened by pressure.
Page 142 LIFT SECTION Operation The lift section has a single work port to direct flow to the lift cylinder. Only one work port is used, because the lift cylinder is single-acting(gravity returns the mast to the lowered position). The lift section also contains part of the components which comprise the safety features. There is a lift lock check valve.
Page 143 Secondary lowering method : A secondary lowering method is available in the event of the loss of battery power that is needed to energize the normally closed solenoid valve. Important note : Before opening the secondary needle valve, make sure personnel and equipment are safely positioned to avoid accidents.
Page 144 TILT SECTION Operation The tilt spool contains an internal plunger which acts to stop tilt forward actuation when the battery power is off. Tilt forward When the seated operator shifts the lever forward, pressure is applied to the head of the tilt cylinder, and the forks tilt forward.
Page 145 AUXILIARY SECTIONS Operation Many different functions can be controlled by the auxiliary spool sections. In general, one work port is pressurized by high pressure oil from the parallel passage, past the load check valve, past the metering notches, and to the cylinder. Simultaneously, oil from the other work port is directed across the spool metering notches to tank.
Page 146 OUTLET SECTION Operation The outlet section contains the tank port and the secondary relief valve(with built-in anti-cavitation feature). OUTLET 130bar 22B7HS17 Operation of relief valve at setting pressure When the pressure at outlet reaches to setting pressure, the pilot poppet which is in the main relief valve is opened by pressure.
Page 147 MAIN RELIEF VALVE This valve is a type of pilot piston to prevent hydraulic components and pipes from being broken by high pressure so, it keeps under pressure limited. Relief valve pressure varies by 130kgf/cm in accordance with 1 revolution of adjust bolt. 15BT9HS20 Pilot seat Main spring...
Page 148 4. LIFT CYLINDER D255HS18 Tube assembly Wear ring 11 O-ring Retaining ring 12 Guide Piston Gland 13 DU bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 5. TILT CYLINDER 24 18 19 20,21,22 8,7 3 11 12 6,5 10,9 4 1 2 16 14 15...
Page 149 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS CHECK ITEM CHECK ITEM 1) 1) Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1m from ground.
Page 150 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) SYSTEM SYSTEM Problem Problem Cause Cause Remedy 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 151 HYDRAULIC GEAR PUMP HYDRAULIC GEAR PUMP 2) 2) Problem Problem Cause Cause Remedy 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.
Page 152 LIFT CYLINDER LIFT CYLINDER 4) 4) Problem Problem Cause Cause Remedy 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.
Page 153 GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP 1. HYDRAULIC GEAR PUMP Tools required 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.
Page 154 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 155 (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 156 (17) Remove seals from both bearing blocks and discard. PUMP 11 2) 2) INSPECT PARTS FOR WEAR 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.
Page 157 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 158 3) 3) ASSEMBLY ASSEMBLY New seals should be installed upon New seals should be installed upon reassembly of pump. 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.
Page 159 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 160 (13) Gently slide the gear housing over the rear bearing block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place with hands, do not force or use any tool. Check to make sure the intake port in the housing in on the same side as the open end of the E-seal and that the marked lines on the mounting flange and gear...
Page 161 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. Tighten torque : 6~7kgf m (43.4~50.6lbf ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
Page 162 2. MAIN CONTROL VALVE 2. MAIN CONTROL VALVE (with OPSS) 1) 1) ASSEMBLY ASSEMBLY (1) (1) General General Ensure that the assembly area will be clean and free of contamination. Use a flat(within 0.2mm) work surface when bolting the valve sections together. Use calibrated torque wrenches and instrumentation.
Page 163 Lift lock check valve Solenoid v/v coil 4.5~5.0 kgf m 0.5~1.0 kgf m (32.5~36.2 lbf ft) (3.6~7.2 lbf ft) . Plug Spring 4.5~5.0 kgf m Solenoid valve Load check valve (32.5~36.2 lbf ft) cartidge 3.5~4.0 kgf m (Normally closed) (25.3~30 lbf ft) 3.5~4.0 kgf m (25.3~30 lbf ft) Needle valve...
Page 164 Lift lock check valve Solenoid v/v coil 4.5~5.0 kgf m 0.5~1.0 kgf m (32.5~36.2 lbf ft) (3.6~7.2 lbf ft) . Plug Spring 4.5~5.0 kgf m Solenoid valve Load check valve (32.5~36.2 lbf ft) cartidge 3.5~4.0 kgf m (Normally closed) (25.3~30 lbf ft) 3.5~4.0 kgf m (25.3~30 lbf ft) Needle valve...
Page 165 Lift lock check valve Solenoid v/v coil 4.5~5.0 kgf m 0.5~1.0 kgf m (32.5~36.2 lbf ft) (3.6~7.2 lbf ft) . Plug Spring 4.5~5.0 kgf m Solenoid valve Load check valve (32.5~36.2 lbf ft) cartidge 3.5~4.0 kgf m (Normally closed) (25.3~30 lbf ft) 3.5~4.0 kgf m (25.3~30 lbf ft) Needle valve...
Page 166 2) 2) DISASSEMBLY DISASSEMBLY (1) (1) General General Subassemblies (such as relief valves, check valves, and spools) may be removed without having to loosen the tie rods and disassembling the entire valve. Disassemble the valve sections on a flat working surface. Ensure that the disassembly area will be clean and free of contamination.
Page 167 3. MAIN CONTROL VALVE 3. MAIN CONTROL VALVE (FINGER TIP) Solenoid valve for lift Lift section block Solenoid valve for tilt Tilt section block Roll pin Reach & auxiliary section block Adapter End plate Roll pin Adapter 23Nm 15BT9HS34 1) 1) ASSEMBLY INSTRUCTION ASSEMBLY INSTRUCTION General...
Page 168 (3) (3) Lift block solenoid assembly Lift block solenoid assembly The solenoide is installed upper side and below side cavities in lift block. Torque to 4.1kgf cm (40Nm) Install the O-ring, coil, O-ring and washer to the assemblied cartridge. Insert the lock washer to the groove of the cartridge. (4) (4) Tilt &...
Page 169 4. LIFT CYLINDER 4. LIFT CYLINDER 1) 1) STRUCTURE STRUCTURE O.D Stroke (standard) 45 55 1645mm (1.8 2.2 65 in) Rod O.D : 35mm (1.4 in) 15BT9HS14 Tube assy Spacer 15 Dust wiper Retaining ring 16 Retaining ring Piston 10 Stop ring 17 Rod bush U-packing 11 Cushion seal...
Page 170 2) 2) DISASSEMBLY 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.
Page 171 5. TILT CYLINDER 5. TILT CYLINDER 1) 1) STRUCTURE STRUCTURE 20B7HS10 Tube assy 10 Back up ring 18 Rod eye 11 Lock washer 19 Spherical bearing Gland 12 O-ring 20 Hexagon bolt Bushing 13 Piston 21 Hexagon nut Rod seal 14 Piston seal 22 Spring washer Back up ring...
Page 172 2) 2) DISASSEMBLY 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 173 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component location --------------------------------------------------------------------------------------- 7-1 Group 2 Electrical circuit ----------------------------------------------------------------------------------------------- 7-2 Group 3 Electric components --------------------------------------------------------------------------------------- 7-4...
Page 174 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 15BT9EL02A Combination switch 12 Back buzzer 23 Accelerator assy Display 13 Steering sensor 24 Parking switch assy DC-DC converter 14 Controller-DUALAC2 25 Key switch assy Beacon lamp 15 Fuse box assy 26 Head lamp switch Pressure sensor 17 Relay 27 Rear working lamp switch...
Page 175 GROUP 2 ELECTRICAL CIRCUIT ·ELECTRICAL CIRCUIT (1/17, NON-UL, SEMIKRON, 15BT-9 : -#0002, 18BT-9 : -#0003, 20BT-9 : -#0007) FUSE BOX ASS'Y REVERSE RELAY RELAY WORK BEACON FLAS LAMP LAMP -HER 221A 120A HEAD UNIT LAMP BRAKE LAMP INPUT OUTPUT SWITCH...
Page 176 ·ELECTRICAL CIRCUIT (2/17, NON-UL, SEMIKRON, 15BT-9 : #0003-, 18BT-9 : #0004-, 20BT-9 : #0008-) FUSE BOX ASS'Y 221A RELAY WORK BEACON BRAKE FLAS LAMP LAMP LAMP -HER 120A HEAD SWITCH UNIT EMERGENCY LAMP SEAT BACK SWITCH HEATING BUZZER SWITCH SWITCH...
Page 177 ·ELECTRICAL CIRCUIT (3/17, UL, SEMIKRON, 15BT-9 : -#0002, 18BT-9 : -#0003, 20BT-9 : -#0007) PUMP INVERTER FUSE BOX ASS'Y FUSE BOX ASS'Y REVERSE REVERSE RELAY RELAY RELAY WORK WORK BEACON FLAS LAMP LAMP LAMP -HER 221A 120A HEAD UNIT LOAD...
Page 178 ·ELECTRICAL CIRCUIT (4/17, UL, SEMIKRON, 15BT-9 : #0003-, 18BT-9 : #0004-, 20BT-9 : #0008-) FUSE BOX ASS'Y 221A RELAY WORK BEACON BRAKE FLAS LAMP LAMP LAMP -HER 120A HEAD SWITCH UNIT LAMP LAMP INPUT OUTPUT SEAT DC-DC LIMIT S/W CONVERTER RELAY REV.
Page 179 ·ELECTRICAL CIRCUIT (5/17, NON-UL, ZAPI, 15BT-9 : #0003-0039, 18BT-9 : #0004-0058, 20BT-9 : #0008-0079) FUSE BOX ASS'Y RELAY WORK BEACON FLAS LAMP LAMP -HER HEAD BACK BRAKE UNIT LAMP BUZZER LAMP SWITCH SWITCH SEAT HEATING INPUT OUTPUT SWITCH DC-DC CONVERTER...
Page 180 ·ELECTRICAL CIRCUIT (6/17, NON-UL, ZAPI, 15BT-9 : #0040-0172, 18BT-9 : #0059-0228, 20BT-9 : #0080-0208) FUSE BOX ASS'Y TILT RELAY WORK BEACON FLAS RELAY LAMP LAMP -HER BRAKE BACK BACK HEAD UNIT EMERGENCY LAMP BUZZER BUZZER LAMP SWITCH SWITCH SWITCH S/W-...
Page 181 ·ELECTRICAL CIRCUIT (7/17, NON-UL, ZAPI, 15BT-9 : #0173-0370, 18BT-9 : #0229-0482, 20BT-9 : #0209-0477) FUSE BOX ASS'Y TILT RELAY FLAS WORK BEACON RELAY -HER LAMP LAMP BACK BACK BRAKE HEAD UNIT EMERGENCY BUZZER BUZZER LAMP LAMP SWITCH S/W- SWITCH SWITCH...
Page 182 ·ELECTRICAL CIRCUIT (8/17, NON-UL, ZAPI, 15BT-9 : #0371-, 18BT-9 : #0483-, 20BT-9 : #0478-) FUSE BOX ASS'Y TILT RELAY BEACON FLAS WORK BACK RELAY HORN LAMP -HER LAMP BUZZER BACK BRAKE HEAD SWITCH/ HORN UNIT S/W- EMERGENCY BUZZER LAMP LAMP...
Page 183 ·ELECTRICAL CIRCUIT (9/17, UL, ZAPI, 15BT-9 : -#0002, 18BT-9 : -#0003, 20BT-9 : -#0007) PUMP INVERTER FUSE BOX ASS'Y ( UL #1 ) BEACON WORK RELAY FLAS BRAKE LAMP LAMP -HER LAMP HEAD UNIT SWITCH LAMP BACK TILT BUZZER ANGLE...
Page 184 ·ELECTRICAL CIRCUIT (10/17, UL, ZAPI, 15BT-9 : #0003-0027, 18BT-9 : #0004-0031, 20BT-9 : #0008-0057) FUSE BOX ASS'Y ( UL #1 ) FLAS WORK BEACON BRAKE LAMP -HER LAMP LAMP HEAD UNIT SWITCH EMERGENCY LAMP BACK SWITCH BUZZER SEAT RELAY HEATING...
Page 185 ·ELECTRICAL CIRCUIT (11/17, UL, ZAPI, 15BT-9 : #0028-0038, 18BT-9 : #0032-0055, 20BT-9 : #0058-0070) FUSE BOX ASS'Y ( UL #1 ) FLAS WORK BEACON BRAKE LAMP -HER LAMP LAMP HEAD BACK UNIT SWITCH EMERGENCY LAMP BUZZER BACK SWITCH S/W- BUZZER...
Page 186 ·ELECTRICAL CIRCUIT (12/17, UL, ZAPI, 15BT-9 : #0039-0039, 18BT-9 : #0056-0058, 20BT-9 : #0071-0079) FUSE BOX ASS'Y ( UL #1 ) WORK BEACON FLAS BRAKE EMERGENCY -HER LAMP LAMP LAMP SWITCH HEAD BACK UNIT SWITCH LAMP BACK BUZZER BUZZER S/W-...
Page 187 ·ELECTRICAL CIRCUIT (13/17, UL, ZAPI, 15BT-9 : #0040-0370, 18BT-9 : #0059-0482, 20BT-9 : #0080-0477) FUSE BOX ASS'Y ( UL #1 ) TILT FLAS RELAY BEACON BRAKE EMERGENCY -HER LAMP LAMP SWITCH HEAD BACK UNIT SWITCH LAMP BUZZER BACK S/W- BUZZER...
Page 188 ·ELECTRICAL CIRCUIT (14/17, UL, ZAPI, 15BT-9 : #0371-, 18BT-9 : #0483-, 20BT-9 : #0478-) FUSE BOX ASS'Y ( UL #1 ) TILT RELAY WORK BEACON FLAS BRAKE EMERGENCY LAMP LAMP -HER LAMP HORN SWITCH HEAD BACK HORN UNIT SWITCH BUZZER...
Page 189 ·ELECTRICAL CIRCUIT (15/17, FINGERTIP, SEMIKRON) FINGERTIP CONTROLLER CAN EXPENSION UNIT FT LIFT 500A A8 -BATT A7 PAUX NPOT C20 1 GND LIFT UP 520A 2 POWER A8 KEY PPOT C1 324A A16 -BATT AI1_LOWER C3 3 VOUT A LOWERING AI2_LIFT C4 4 VOUT B FT TILT 500B...
Page 190 ·ELECTRICAL CIRCUIT (16/17, FINGERTIP, ZAPI, 15BT-9 : -#0002, 18BT-9 : -#0003, 20BT-9 : -#0007) CAN TILLER MHYRIO CB FT LIFT 500A B2 -BATT B2 PAUX NPOT C3 1 GND LIFT UP 520A A16 -BATT B1 KEY PPOT A9 2 POWER...
Page 191 ·ELECTRICAL CIRCUIT (17/17, FINGERTIP, ZAPI, 15BT-9 : #0003-, 18BT-9 : #0004-, 20BT-9 : #0008-) CAN TILLER MHYRIO CB FT LIFT 922/21 500A B2 -BATT 1 GND B2 PAUX NPOT C3 LIFT UP 321/21 520A A16 -BATT 2 POWER B1 KEY...
Page 192 For the monitoring system, there are many sensors such as current sensors, potentiometer sensors, and temperature sensors. The HYUNDAI Battery forklift trucks are equipped with the most advanced DRIVING CONTROL SYSTEM currently available world-widely.
Page 193 2. BATTERY 2. BATTERY 1) 1) STRUCTURE STRUCTURE 20BT9EL03A Cells Negative leading cable Steel box 10 Handle (red) Cell connector 11 Plug Row connector 12 Positive leading cable...
Page 194 GENERAL GENERAL As in the battery forklift, the battery is an energy source, the handling of the battery is very important. The life and performance 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 195 4) 4) SAFETY PRECAUTIONS SAFETY PRECAUTIONS (1) (1) When sulfuric acid contact with skin When 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 196 (2) (2) Performance and maintenance of batteries Performance and maintenance of batteries Initial charge Initial charge Wet-charged battery gradually decreases 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.
Page 197 Normal charge 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 198 Replenishment of distilled water Replenishment of distilled water Only the water content of electrolyte is decreased due to electrolysis of distilled water during charge and natural evaporation. If a battery used with the electrolyte decreased excessively, plates will deteriorate resulting in markedly shortening of battery life. Be sure to check the electrolyte level once every week.
Page 199 Cleaning Cleaning If electrolyte spills or the cells are polluted with dust or stains, it will cause generation of leak current. Wipe off dust and stains with moist cloth and clean in such a manner that the cells are kept in dry condition. In the case of plastic containers or covers, never use such organic solvents as paint thinner and gasoline.
Page 200 Summary of daily maintenance Summary of daily maintenance Avoid overcharge. After discharge, charge the batteries immediately. The standard frequency of equalizing charge is more than once every month. Be sure to check the electrolyte level once every week. If found decreased, replenish distilled water up to the specified level.
Page 201 7) 7) TROUBLESHOOTING TROUBLESHOOTING Nature of trouble Nature of trouble Symptoms Symptoms Causes Causes Corrective Action Corrective Action Deformation Deformation of container. Excessive temperature Replace Lid or one touch cap rising or external impact Breakage Electrolyte leakage acco- External impact, improper Replace or install a new rding to breakage of cont- handling, excessive vibrat-...
Page 202 3. DRIVE MOTOR 3. DRIVE MOTOR 1) 1) STRUCTURE STRUCTURE 20BT9EL07 Rotor assy Speed sensor kit 11 O-ring Stator assy Stud bolt 12 Flange nut Endbell De Protector-Terminal 13 Wave washer Endbell Bearing Block-Terminal A 10 Oil seal 7-13...
Page 203 2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Type AMDN4001 Rated voltage Rated output 4.7 2 Insulation Class F 3) 3) MAINTENANCE INSTRUCTION MAINTENANCE INSTRUCTION Before starting the maintenance please disconnect the power supply. (1) (1) Ball bearing Ball bearing Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of repair, they should be replaced.
Page 204 4. PUMP MOTOR 4. PUMP MOTOR STRUCTURE STRUCTURE 1) 1) 20BT9EL08 Rotor assy Block-Terminal A Protector-Terminal Stator assy Oil seal 10 Bearing Endbell De Speed sensor kit 11 Flange nut Endbell Stud bolt 12 Wave washer 7-15...
Page 205 2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Type ABDD4002 Rated voltage Rated output Insulation Class F 3) 3) INTERNAL INVOLUTE SPLINE DATA INTERNAL INVOLUTE SPLINE DATA Item Unit Specification Flat root side fit Class 7 No of teeth Spline pitch 16/32 Pressure angle Degree...
Page 206 5. CONTROLLER SYSTEM 5. CONTROLLER SYSTEM 1) 1) STRUCTURE STRUCTURE 20B7EL10 (1) (1) Specifications Specifications Model Model Application Type Power Current limit DUAL AC2 Traction MOSFET 36-48V, 330+330A 330A/3min 15/18/20BT-9 Pump MOSFET 36-48V, 450A 450A/3min 7-17...
Page 207 2) 2) OPERATIONAL FEATURES OPERATIONAL FEATURES (1) (1) Features Features Speed control. Optimum behavior an a slope due to the speed feedback: The motors speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set-point. The system can perform an electrical stop on a ramp (the machine is electrically hold on a slope) for a programmable time.
Page 208 3) 3) DESCRIPTION OF THE CONNECTORS DESCRIPTION OF THE CONNECTORS (1) (1) Traction controller Traction controller CONN C CONN B CONN A 20B7EL13 7-19...
Page 209 No. of Pin Function Description CAN_H High level CANBUS. CANT_H CAN_POS Low level CANBUS: to be used as repetition for CAN_L line or to CAN_L_OUT be connected to CANT_H to insert termination resistance. CANT_L CAN_L Low level CANBUS. High level CANBUS: to be used as repetition for CAN_ H line or CAN_H_OUT to be connected to CANT_L to insert termination resistance.
Page 210 No. of Pin Function Description NPOTB -BATT. NPOT Negative of accel pedal potentiometer. CPOT Accel pedal potentiometer wiper signal. PHA_L Left motor encoder phase A. PHB_L Left motor encoder phase B. NTHERM_R Negative of right traction motor temperature sensor. PTHERM_R Right traction motor temperature signal.
Page 211 (1) (1) Encoder installation Encoder installation Traction controller card is fit for different types of encoder. To control AC motor with Zapi inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90˚. The encoder power supply can be +12V.
Page 212 (2) (2) Pump controller Pump controller +BATT +BATT Before Fuse -BATT AC-2 INVERTER Voltage Label Registration Label 20B7EL14 No. of pin Function Description PCLRXD Positive serial reception. NCLRXD Negative serial reception. PCLTXD Positive serial transmission. NCLTXD Negative serial transmission. Negative console power supply. Positive console power supply.
Page 213 No. of pin Function Description D1÷D6 Incremental ENCODER connector. CPOT Accelerator potentiometer wiper. PPOT Potentiometer positive: 10V output; keep load > 1KW. NPOT Negative of accelerator unit, tested for wire disconnection diagnosis. Common of LIFT ENABLE / 1 SPEED / 2 SPEED / 3 SPEED / 4 SPEED / HYDRO / SR microswitches.
Page 214 4) 4) FUNCTION CONFIGURATION FUNCTION CONFIGURATION ■ TRACTION CONTROLLER-MASTER TRACTION CONTROLLER-MASTER Using the CONFIG MENU of the programming console, or using a display, the user can configure the following functions. (1) (1) Submenu Submenu "SET OPTIONS" "SET OPTIONS" ① Hour counter Hour counter - RUNNING : The counter registers travel time only.
Page 215 Set temperature Set temperature - DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to C25 (C35) input. - ANALOG : An analog motor thermal sensor is connected to C25 (C35) (the curve can be customized on a customer request). - NONE : No motor thermal sensor switch is connected.
Page 216 Throttle 0 zone Throttle 0 zone It establishes a deadband in the accelerator input curve (see also curve below). Throttle X point Throttle X point This parameter changes the characteristic of the accelerator input curve. Throttle Y point Throttle Y point This parameter changes the characteristic of the accelerator input curve.
Page 217 Speed factor Speed factor It adjusts the speed coefficient to have the correct speed indication on the display. This coefficient has to be regulated depending on truck mechanic characteristics. It results from the following formula : Speed factor = 88 * rr * p / where : rr = total gearbox ratio = traction wheel diameter (cm)
Page 218 (3) (3) Parameter change Parameter change Acceler. delay Acceler. delay It determines the acceleration ramp. Less value means better acceleration performance. Release braking elease braking It controls the deceleration ramp when the travel request is released. Less value means better braking performance. Invers.
Page 219 Frequency creep Frequency creep Minimum speed when the forward or reverse switch is closed, but the accelerator is on a minimum position. Maximum Maximum current current This changes the maximum current of the inverter. Acc. smooth Acc. smooth It gives a parabolic shape to the acceleration ramp. Inv.
Page 220 TRACTION CONTROLLER-SLAVE TRACTION CONTROLLER-SLAVE Using the config menu of the programming console, or using a display, the user can configure the following functions. Submenu Submenu "SET OPTIONS" "SET OPTIONS" (1) (1) Not available. (2) (2) Submenu Submenu "ADJUSTMENTS" "ADJUSTMENTS" Set battery type Set battery type It selects the nominal battery voltage.
Page 221 (2) (2) Submenu Submenu "ADJUSTMENTS" "ADJUSTMENTS" Set battery type Set battery type : Selects the nominal battery voltage. Adjust battery Adjust battery : Fine adjustment of the battery voltage measured by the controller. Please increase or decrease the value 1 by 1 and check the voltage. Throttle 0 zone Throttle 0 zone : Establishes a deadband in the accelerator input curve (see also curve below).
Page 222 (3) (3) Parameter change Parameter change Acceler delay Acceler delay It determines the acceleration ramp. More value means better deceleration performance. Deceler delay Deceler delay It determines the acceleration ramp. More value means better deceleration performance. Max speed up Max speed up Determines the maximum lifting speed with a potentiometer control.
Page 223 5) 5) PROGRAMMING & ADJUSTMENTS PROGRAMMING & ADJUSTMENTS There are two ways to adjust parameter via a console or buttons on a display. Adjustments via buttons on a display, please refer to the display section. (page 7-48) ADJUSTMENTS VIA CONSOLE ADJUSTMENTS VIA CONSOLE (Option) Adjustment of parameters and changes to the inverter's configuration are made using the digital console.
Page 224 (2) (2) Description of standard console menu Description of standard console menu Traction controller-Master Traction controller-Master 15BT9EL18 7-35...
Page 225 Traction controller-Slave Traction controller-Slave 24/36/48/72/80/9 22B9EL19 7-36...
Page 226 Pump controller Pump controller 15BT9EL20 7-37...
Page 227 (3) (3) Description of the console Description of the console SAVE SAVE function function The SAVE function allows the operator to transmit the parameter values and configuration data of the chopper into the console memory. It is possible to load 64 different programmers. The information saved in the console memory can then be reloaded into another chopper using the RESTORE function.
Page 228 (4) (4) Description of the console Description of the console RESTORE RESTORE function function The RESTORE PARAM function allows transfer of the console's stored data into the memory of the chopper. This is achieved in a fast and easy way using the method previously used with the SAVE PARAM.
Page 229 (5) (5) Description of alarms menu Description of alarms menu The microprocessor in the controller records the last five alarms that have occurred. Items remembered relative to each alarm are: the code of the alarm, the number of times the particular Alarm occurred, the hour meter count, and the inverter temperature.
Page 230 (6) (6) Description of console program vacc function Description of console program vacc function This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal. It enables compensation for non symmetry of the mechanical system between directions.
Page 231 (7) (7) DESCRIPTION OF CONSOLE USING DESCRIPTION OF CONSOLE USING Access to SET MODEL menu. Access to SET MODEL menu. The only parameter present in SET MODEL function is CONNECTED TO. By setting this parameter, operator can connect ZAPI console to every ZAPI product connected to CAN-BUS line.
Page 232 Flow chart showing how to make changes to option menu : Flow chart showing how to make changes to option menu : Opening Zapi menu. DA2H Press ROLL UP & SET UP Buttons to enter CONFIG MENU. The display will show: SET MODEL. Press ROLL UP or ROLL DOWN until SET OPTIONS appears.
Page 233 Flow chart showing how to use the tester function of the digital console: Flow chart showing how to use the tester function of the digital console: DA2H Opening Zapi menu. Press ENTER to go into the MAIN MENU. The display will show: PARAMETER CHANGE. Press ROLL UP or ROLL DOWN until TESTER menu appears on the display.
Page 234 6) 6) MORNITORING MENU MORNITORING MENU In Console, This menu appears as “TESTER” MENU (1) (1) Traction controller-Master Traction controller-Master Motor voltage Motor voltage This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage).
Page 235 Seat switch Seat switch The level of the seat microswitch digital input. - ON / +VB = Input active, switch closed. - OFF / GND = Input non active, switch open. Cutback switch Cutback switch The level of the speed reduction microswitch. - ON / GND = Input active, switch opened.
Page 236 Temperature Temperature The temperature measured on the aluminum heat sink holding the MOSFETdevices. Voltage booster Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage. Battery voltage Battery voltage Level of battery voltage measured at the input of the key switch.
Page 237 (3) (3) Pump controller Pump controller Motor voltage Motor voltage This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage). Frequency Frequency This is the frequency of the voltage and current supplied to the motor. Encoder Encoder This is the speed of the motor, expressed in the same unit of the frequency;...
Page 238 Voltage booster: Voltage booster: This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage. Battery voltage: Battery voltage: Level of battery voltage measured at the input to the key switch. Fork LVL.
Page 239 7) 7) GENERAL SUGGESTION FOR SAFETY GENERAL SUGGESTION FOR SAFETY For a proper installation take care of the following recommendations: After operation, even with the key switch open, the internal capacitors may remain charged for some time. For safe operation, we recommend that the battery is disconnected, and a short circuit is made between battery positive and battery negative power terminals of the inverter using a resister between 10 ohm and 100 ohm.
Page 240 6. INSTRUMENT PANEL : DISPLAY 6. INSTRUMENT PANEL : DISPLAY 1) 1) STRUCTURE STRUCTURE The DISPLAY has 6 red LEDs indicating the status information of the lift truck to the driver. Spare #1 Spare #2 Oil level Park brake Wrench Seat belt Thermometer Seat...
Page 241 2) 2) WARNING LAMP WARNING LAMP (1) (1) Brake oil level warning lamp Brake oil level warning lamp Blinks when the brake oil level in the reservoir is below the lower limit. 22BH9EFD01 (2) (2) Wrench warning lamp Wrench warning lamp This LED lights when an electric device (controller, motor, cable, etc.) is in alarm condition.
Page 242 3) 3) BUTTONS BUTTONS (1) (1) UP button UP button Press to select upward move 22BH9EFD07 (2) (2) DOWN button (DOWN/TURTLE button) DOWN button (DOWN/TURTLE button) Press to select downward move TURTLE MODE ON/OFF 22BH9EFD08 (3) (3) LEFT/MENU button LEFT/MENU button Press to select leftward move Go into the menu 22BH9EFD09...
Page 243 4) 4) LCD FUNCTION (MAIN SCREEN) LCD FUNCTION (MAIN SCREEN) MAIN SCREEN MAIN SCREEN 22BH9EFD13 Current time Hour meter Turtle mode Wheel position and running direction Truck speed pointer Power mode Speed level BDI (Battery Discharge Indicator) Truck speed 10 Load weight (option) (1) (1) Current time Current time...
Page 244 (3) (3) Truck speed pointer Truck speed pointer The speed of the truck is indicated with a pointer. (4) (4) Speed level Speed level It indicates the speed level by 2 km. (5) (5) Truck speed Truck speed The truck speed is shown in number. According to the DISPLAY setting km/h or mph unit is available.
Page 245 5) 5) HOW TO USE DISPLAY MENU HOW TO USE DISPLAY MENU 22BH9EFD14 7-56...
Page 246 22BH9EFD15 7-57...
Page 247 6) 6) DESCRIPTION OF THE TRUCK MENU DESCRIPTION OF THE TRUCK MENU Access to truck menu Access to truck menu (1) (1) If this button is pressed long, the PASSWORD dialog appears. Enter correct PASSWORD, then on MAIN SCREEN, Press button to access the controller “TRUCK MENU”...
Page 248 - Figure input 22B9EL31 Select a desired value with button, then save with button or press button to escape without saving. - Level Selection 22B9EL30 Select a desired value with button, then save with button or press button to escape without saving.
Page 249 7) 7) ALARM & ALARM HISTORY ALARM & ALARM HISTORY How to check alarms How to check alarms (1) (1) Normally, ALARM SCREEN pops up if any kind of a alarm happens, but service man can switch between a MAIN SCREEN and ALARM SCREEN with buttons as follows : (Press more than 1 sec) 22B9EL35...
Page 250 (2) (2) Detail description of ALARM SCREEN Detail description of ALARM SCREEN 22B9EL36 First yellow capital letter shows in which controller the alarm happens as below; M : Traction-Master S : Traction-Slave P : Pump V : Mhyrio CB Following two letters or digits show alarm code. Please refer to 7. ALARM CODE (Page 7-68). This shows a name of ALARM.
Page 251 Step 1 : Service man can check the alarm history on ALARM HISTORY menu Step 2 : When service man enter the ALARM HISTORY menu, display read entire alarm records of all controller. So it takes 9~15 seconds to read. Step 3 : When display finish to read alarm records, service man can choose each controller to read the alarm history.
Page 252 8) 8) VASS SETUP USING DISPLAY MENU VASS SETUP USING DISPLAY MENU This function searches and memorizes the minimum and maximum potentiometer wiper voltage of the accelerator pedal, lift lever, and steering sensor which use potentiometer sensors. The belows show how to use the VASS function of DISPLAY. (All figures in belows are just example.) While even a motor is running, VASS can not be configurated properly, so please be sure that all motors are not running before entering configuration process &...
Page 253 Now, you can see that voltage value of MAX REVERSE are changed. Please make sure that all motors are not running & direction lever is in NEUTRAL position. 22B9EL39-2 (2) (2) LIFT VASS setting method LIFT VASS setting method Please make sure that all motors are not running &...
Page 254 (3) (3) STEER ANGLE VASS setting method STEER ANGLE VASS setting method Please make sure that all motors are not running & direction lever is in NEUTRAL position. If “READY” appears beside STEER ANGLE, you are in configuration process. Now, operator can see that voltage value of STEER RIGHT is changed.
Page 255 9) 9) STRUCTURE OF TRUCK MENU STRUCTURE OF TRUCK MENU TRUCK MENU is in order to make configuration of truck easily, and consists of 3 major categorys : SETTING, MONITORING, ALARM HISTORY. [To know how to get in to TRUCK MENU, refer to 6-6)-(1) “ACCESS TO TRUCK MENU” page 7-58] (1) (1) Settings Settings...
Page 256 (2) (2) Monitoring Monitoring 22B9EL43 In MONITORING MENU, service man can check various stats of trucks. In MONITORING MENU, service man can check various stats of trucks. MASTER Refer to 5-6)-(1) “Traction controller-master” (page 7-45) SLAVE Refer to 5-6)-(2) “Traction controller-Slave” (page 7-46) PUMP Refer to 5-6)-(3) “Pump controller”...
Page 257 7. ALARM CODE 7. ALARM CODE 1) 1) TRACTION-MASTER & SLAVE CONTROLLER TRACTION-MASTER & SLAVE CONTROLLER Condition that has to occur to come out from Code Alarm name Description alarm status WATCHDOG Alarm: the Watchdog circuit has If the alarm is present in Init status, remove been triggered the alarm condition If the alarm has occurred in stby or running...
Page 258 Condition that has to occur to come out from Code Alarm name Description alarm status STBY I HIGH Alarm: wrong voltage in the If the alarm is present in Init status, remove current sensor feedback circuit the alarm condition If the alarm has occurred in stby or running mode, it is necessary to remove alarm condition and to activate a traction request CAPACITOR...
Page 259 Condition that has to occur to come out from Code Alarm name Description alarm status OVERLOAD Warning: Load weight sensor - To remove warning cause detects that loaded weight exceeds the weight limited i n O V E R L O A D W E I G H T programming.
Page 260 Condition that has to occur to come out from Code Alarm name Description alarm status NO CAN MSG.N Alarm: Master/Slave has lost To remove alarm cause Can communication with #X Check if any other alarm happens (Some alarms such as CHAT TIME or PEDAL WIRE KO, alarms related to CONTACTOR, DISPLAY ENABLE, alarms related to CANBUS can make this alarm sometimes.)
Page 261 2) 2) PUMP CONTROLLER PUMP CONTROLLER Condition that has to occur to come out from Code Alarm name Description alarm status WATCHDOG Alarm: the Watchdog circuit has If the alarm is present in Init status, remove been triggered the alarm condition If the alarm has occurred in stby or running mode, it is necessary to remove alarm condition and to activate a traction request...
Page 262 Condition that has to occur to come out from Code Alarm name Description alarm status MOTOR W a r n i n g : P u m p m o t o r ’ s To remove Warning cause TEMPERA-TURE temperature high Check the motor temp-sensor BATTERY LOW...
Page 263 Condition that has to occur to come out from Code Alarm name Description alarm status TILT FUNCT KO Fingertip tilt function is not working Check the MCV valve properly Re-conﬁ gurate lever Check the ﬁ ngertip controller LIFT FUNCT KO Fingertip lift function is not working Check the MCV valve properly...
Page 264 Condition that has to occur to come out from Code Alarm name Description alarm status BRAKE OIL Lack of Brake oil - Check the brake oil tank & sensor THERMIC SENSOR Warning: Controller temp. sensor - To remove Warning cause is out of range W A I T I N G F O R Warning: Controller signals that...
Page 265 8. BATTERY CHARGER 8. BATTERY CHARGER This explains basic information related to charger to help you easily understand and use it. This includes the contents from the way to install a charger to tips for emergency situations. This is focused on practices aiming to be usefully utilized in the field. 1) 1) BASIC INFORMATION BASIC INFORMATION...
Page 266 (3) (3) Names of each part (independent items) Names of each part (independent items) 22B9BAT30 Main PCB board Monitor PCB Resistance (RD) Main trans (Class H) Overload 10 Resistance (DR) Cooling fan MG S/W SCR module Assistant trans 7-77...
Page 267 Charger installation method location for charger installation ① dry and well ventilated place. ② no inflammable and B7 fire are near by. ③ safe place where no collision possibility with people or equipment is. Check points before installing charger ① enough capacity of aC input power source to operate charger.
Page 268 3) 3) HOW TO USE A CHARGER HOW TO USE A CHARGER (1) (1) General charging method (Floating General charging method (Floating charging) charging) Charging by this method supplies electric power to the charger as operating external AC power switch of the charger. Connect battery connecter and charger connecter.
Page 269 Tips for equalized charging Tips for equalized charging If once push the equalized charging button on the monitor in the beginning of charging, the equalized charging lamp becomes on and starts charging. When the green charging condition When the green charging condition lamp is on (over 85% charged), the lamp is on (over 85% charged), the equalized charging switch is locked...
Page 270 If charger's out voltage is under 60 V, it is abnormal. Please refer to the error sheet. When the charging voltage is indicated as n o r m a l c o n d i t i o n ( 6 4 V ) , c o nve r t automatic / manual switch to automatic and start charging.
Page 271 4) 4) CHECK POINTS BEFORE APPLYING A/S CHECK POINTS BEFORE APPLYING A/S AC input power source switch is input. Check if the battery connector of the order picker truck and charger's connector are connected. Check points when "Error" lamp is on in the front monitor of the charger.
Page 272 5) 5) ERROR DETECTION ERROR DETECTION Error list Error list Only floating charge lamp is on in the monitor but it is not charged. ON and OFF is repeated with a few minutes intervals even after starting charging. C h a r g e r T R I P i s o c c u r r e d a f t e r abnormality lamp is on.
Page 273 Troubleshooting Troubleshooting Only floating charge lamp is on after indicating "A.O", It's not charged. Only floating charge lamp is on after indicating "A.O", It's not charged. TB.4 (380V) TB.8(220V) 220/380V Model : Measure the voltage between input voltage change over tabs 2-4 2-6 4-6 70 / 220,380,410,440V Model : Measure the voltage in front of...
Page 274 ON and OFF is repeated with a few minutes intervals after starting charging. ON and OFF is repeated with a few minutes intervals after starting charging. Indicate "O.C" on the monitor. Indicate "O.C" on the monitor. - TH is operated (AC input over-current TRIP). - TH is operated (AC input over-current TRIP).
Page 275 Charger TRIP is occurred after abnormality lamp is on. Charger TRIP is occurred after abnormality lamp is on. In case error code is "O.V" In case error code is "O.V" Over-voltage output / Set at 66V (In case of BATT 48V) Over-voltage output / Set at 66V (In case of BATT 48V) 34V (In case of BATT 24V) 34V (In case of BATT 24V)
Page 276 Charger TRIP is occurred after abnormality lamp is on. Charger TRIP is occurred after abnormality lamp is on. After opening the cover which is located on the front bottom side of the charger. After opening the cover which is located on the front bottom side of the charger. In case error code is "O.C"...
Page 277 Charger TRIP is occurred after it started charging and charging completion lamp is on. Charger TRIP is occurred after it started charging and charging completion lamp is on. (In case input voltage is normal - Refer to the error detection No. 1) (In case input voltage is normal - Refer to the error detection No.
Page 278 Charger has no response even if the battery connector is connected. Charger has no response even if the battery connector is connected. - In case only floating LED is on, charger input power is cut off or doesn't connect. (In case - In case only floating LED is on, charger input power is cut off or doesn't connect.
Page 279 7) 7) HOW TO CHECK THE SCR MODULE HOW TO CHECK THE SCR MODULE Circuit Real diagram * Before checking SCR MODULE, be sure to disconnect bus bar and wire on the terminal. Measuring point Measure value SURGE PCB (Real diagram) (Measurement of digital tester) No.1 ~ No.3 Forward : Under 100 k ohm...
Page 280 8) 8) PCB MAJOR PARTS (NAME AND LOCATION) PCB MAJOR PARTS (NAME AND LOCATION) Lp lamp Auto Auto/manual Manual SHUNT switch TAP detect current Detect Auxiliary connector voltage power supply Correct Correct Correct output CPU voltage output voltage current Monitor display output SCR control Controlling micro unit #1...
Page 281 22B9BAT27 7-92...
Page 282 CHARGER INTERIOR PARTS CHARGER INTERIOR PARTS 22B9BAT28 Part name Remarks AC fan Over load Resister RD Trans-aux Magnet switch SCR module Monitor DC out cable Resister DR Main transformer AC input cable Main control board Filter Fuse 7-93...
Page 283 SECTION 8 MAST SECTION 8 MAST Group 1 Structure ------------------------------------------------------------------------------------------------------------- Group 2 Operational Checks and Troubleshooting ------------------------------------------------------ Group 3 Adjustment --------------------------------------------------------------------------------------------------------- Group 4 Removal and Installation ---------------------------------------------------------------------------------- 8-10...
Page 284 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) CARRIAGE LIFT CYLINDER TILT CYLINDER 15BT9MS01 Outer mast Bushing 10 Chain wheel bearing Shim (0.5, 1.0t) Inner mast 11 Roller Roller Lift chain 12 Back up liner Tilt cylinder pin Anchor bolt 13 Shim(0.5, 1.0t) Mast mounting pin...
Page 285 2. 3 STAGE MAST(TF MAST) LIFT CYLINDER TILT CYLINDER CARRIAGE FREE LIFT CYLINDER 15BT9MS02 Outer mast Lift chain 11 Mast mounting pin Middle mast Anchor bolt 12 Bushing Inner mast Sheave bracket 13 Pin Roller Sheave Shim(0.5, 1.0t) 10 Retaining ring...
Page 286 3. CARRIAGE, BACKREST AND FORK 15BT9MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...
Page 287 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 64FY-12030 15/18BT-9 35(1.4) 32(1.3) 64HM-11010 20BT-9 40(1.6)
Page 288 2. TROUBLESHOOTING MAST Problem Cause Remedy Forks fail to lower. Deformed mast or carriage. Disassemble, repair or replace. Fork fails to elevate Faulty hydraulic equipment. See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. Deformed mast assembly. Disassemble mast and replace damaged parts or replace complete mast assembly.
Page 289 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 290 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V MAST) INNER/OUTER MAST ROLLER CLEAR-ANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the roller side face and mast at the closest position on the opposite side to the...
Page 291 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 15L7MS06...
Page 292 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 293 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are Knob approximately 25mm(1inch) from the floor. Turn the knob up and slide forks, one by one, toward the center of the carriage Spring where a notch has been cut in the bottom plate for easy fork removal.
Page 294 SIDE ROLLER Side roller Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. Adjustment Once carriage is properly installed, loosen nuts and adjust screws, (if not...
Page 295 MAST LOAD ROLLER AND BACK UP LINER Chain 2 stage mast(V mast) Remove the carriage assembly and move them to one side. Inner Loosen and remove hexagon bolts and mast Stud washers securing lift cylinders to inner bolt mast. Loosen and remove hexagon bolts and Back up nuts securing lift cylinders to inner mast.
Page 296 3 stage mast(TF mast) Remove the carriage assembly and move it to one side. Loosen and remove hexagon bolt securing bottom cylinder from outer mast. Loosen and remove band and special washers securing lift cylinders to middle Chain mast. Remove the spring pin. Attach chains or sling to the inner and Inner middle mast section at top crossmember.
Page 297 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 298 CHAIN Chain sheave(V mast) Place a sling around carriage and attach Chain to an overhead hoist. Lift carriage high Anchor enough so that the tension on the chain bolt over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
Page 299 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 300 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 301 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 302 Adjustment Chain adjustments are important for the following reasons : Equal loading of chain. Proper sequencing of mast. Prevent over-stretching of chains. Prevent chains from jumping off sheaves if they are too loose. Adjustment procedure With mast in its fully collapsed and vertical position, lower the fork to the floor. Adjust the chain length by loosening or tightening nut on the chain anchor.

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18bt-9 20bt-9

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