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

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4

Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12

SECTION 2 REMOVAL & INSTALLATION OF UNIT

Group 1 Major components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

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

SECTION 3 POWER TRAIN SYSTEM

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

Group 2 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8

SECTION 4 BRAKE SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5

Group 3 Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7

SECTION 5 STEERING SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15

SECTION 6 HYDRAULIC SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-25

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-29

SECTION 7 ELECTRICAL SYSTEM

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

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

Group 3 Electric components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4

SECTION 8 MAST

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4

Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7

Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10

CONTENTS

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Troubleshooting

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Summary of Contents for Hyundai 10BTR-9

Page 1: Table Of Contents
CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12 SECTION 2 REMOVAL &...
Page 2 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
Page 3 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: Conversion Table
3. CONVERSION TABLE 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example 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 SECTION 1 GENERAL Group 1 Safety hints ----------------------------------------------------------------------------------------------------- Group 2 Specifications ------------------------------------------------------------------------------------------------- Group 3 Periodic replacement ------------------------------------------------------------------------------------- 1-12...
Page 11: Group 1 Safety Hints
GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
Page 12 Hand a caution sign in the operator's compartment (For example Do not start or Maintenance in progress). This will prevent anyone from starting or moving the machine by mistake. D50ASF07 When inspecting running parts or near such parts, always stop the machine first. Before checking or servicing accumulator or piping, depress brake pedal repeatedly to release pressure.
Page 13 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 10BTR9OM113 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: Specifications
2. SPECIFICATIONS 10BTR9SP01 Model Unit 10BTR-9 13BTR-9 15BTR-9 Capacity kg (lb) 1000 (2000) 1300 (2500) 1500 (3000) Load center ← mm (ft-in) 500 (24") ← Weight kg (lb) 2390 (5270) 2610 (5750) 2850 (6280) Lifting height ← ← mm (ft-in) 3025 (9' 11")
Page 16 Unit Traction Pump Model AMDH6001 AMDA4001 Type Rated voltage Output Insulation Class F Class F BATTERY Item Unit 10BTR-9 13BTR-9 15BTR-9 Rated voltage ← ← Dimension(W×L×H) 827×324×627 827×432×627 827×486×627 Min. Battery weight Max. Battery weight SRE 320A BLACK Connector CHARGER...
Page 17: Drive Unit
GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity 16.5 cc/rev Maximum operating pressure Rated speed (max/min) 3000/500 MAIN CONTROL VALVE Item Unit Specification Type 3 spool, 4 spool Operating method Mechanical Main relief valve pressure 2nd relief valve pressure DRIVE UNIT Item Unit...
Page 18 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS kgf m lbf ft Items Size Hyd pump motor mounting bolt 3.4 ± 0.7 24.6 ± 5.1 1.25 Electric system Traction motor mounting bolt 2.5 ± 0.5 18.1 ± 3.6 1.25 Hydraulic pump mounting bolt 6.9 ±...
Page 19: Torque Chart
5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT Coarse thread Bolt size kgf m lbf ft kgf m lbf ft 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8 1.25...
Page 20 PIPE AND HOSE(FLARE TYPE) Thread size Width across flat 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) Thread size Width across flat kgf m lbf ft 9/16-18 28.9 11/16-16 36.2 13/16-16 68.7 1-3/16-12 1-7/16-12...
Page 21: Recommended Lubricants
6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature C( F) Service Kind of Capacity (U.S. gal point fluid (-58) (22) (-4) (14) (32) (50) (68) (86) (104) Drive unit Gear oil SAE 80W-90 (1.6) Front axle...
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 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
SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 MAJOR COMPONENTS 18 19 12 11 15 16 10BTR9RE01 Lift cylinder Front axle 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
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 10BTR9RE12 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
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. Bronze 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 10BTR9RE12A Brake piping Disconnect the brake piping from the front Brake master axles.
Page 31 Front axle assy Frame Drain the oil before disassembling the front axles. Unscrew five wheel nuts and remove the wheel. Front axle Wheel nut 10BTR9RE15 Loosen seven mounting bolts on the truck frame and carefully take out the front axles. Frame Mounting bolt Front axle...
Page 32: Electrical Components
3. ELECTRICAL COMPONENTS Before removing each component, disconnect cables and earth lines attached to the component. REMOVAL Floor plate 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 450kg to 690kg so the extreme care must be taken when handling them.
Page 33 Pump motor Lower the fork to floor. 10BTR9RE21 Remove floor mat and front floor plate. Floor mat Disconnect the wiring of pump motor. Floor plate Disconnect wiring 10BTR9RE22 Remove elbow and connector and then Pump motor disconnect the hydraulic hose from the gear pump.
Page 34: Steering Axle
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) 525kg (1160lb) 10BTR-9 590kg (1300lb) 13BTR-9 695kg (1530lb) 15BTR-9 Tightening torque : 184~214 kgf m (1330~1550lbf ft) Battery connector Disconnect the battery connector.
Page 35 Hose Steering Disconnect the hoses from steering unit hydraulic motor. Hose Steering hyd motor 10BTR9RE25 Loosen socket bolts and remove steering hydraulic motor assy from drive unit assy. Traction Socket bolt motor Steering hyd unit Drive unit assy 10BTR9RE26 Jacking up the chassis of truck. Loosen the hub nut and take off the steering wheel tire assembly.
Page 36 Loosen bolts and remove drive unit assy from chassis. Bolt Drive unit assy 10BTR9RE29 2-13...
Page 37: Section 3 Power Train System
SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation --------------------------------------------------------------------------------- 3-1 Group 2 Disassembly and assembly --------------------------------------------------------------------------- 3-8...
Page 38: Group 1 Structure And Operation
SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. FRONT AXLE ASSY STRUCTURE Front axle, LH 22 12 15 13 10BTR9PT01 Wheel bolt 17 Parking lever (LH) 33 Fitting Dirve shaft 18 Plain washer 34 Bleeder screw Oil seal 19 Bushing 35 O-ring Taper roller bearing...
Page 39 Front axle, RH 33, 43 34, 35 9 7 45,46,47 29 13 15 10BTR9PT02 Wheel bolt 17 Parking lever (RH) 33 Fitting Dirve shaft 18 Plain washer 34 Bleeder screw Oil seal 19 Bushing 35 O-ring Taper roller bearing 20 Cam shaft 36 Fitting brake line Housing (RH) 21 Cover (RH)
Page 40: Specification
SPECIFICATION Item Unit Specification Max axle load (1 axle) kg/lb 2100/4630 Max input speed 5000 Gear ratio 20.0 Brake type Wet disc brake Max brake torque kgf m 250 (at 60 bar) Mobilfluid 424 Front axle Oil type Hydraulic oil SAE 10W(AZOLLA ZS32) Brake liter 0.6 2EA...
Page 41: System Operation
SYSTEM OPERATION General specification 10BTR9PT05 Drive shaft assy Housing assy Brake cover assy Outline of the power transmission system The front axle assy is composed of the drive shaft assy (1), housing assy (2), and brake cover assy (3). The traction power is transmitted from the drive unit assy and the drive shaft of the front assy is transmitted only traction torque and braking torque.
Page 42 Basic components Housing assy 10BTR9PT06 Housing Oil seal Taper roller bearing Drive shaft...
Page 43 Brake cover assy 10BTR9PT07 Brake cover Parking lever Actuator Piston Cam shaft...
Page 44 Tightening torque Housing assy 10BTR9PT08 Drive shaft 0.25±0.05kgf m Housing bolt 3.6±0.1kgf m Lock nut 21±1.0kgf m Bolt 0.95±0.15kgf m Brake bolt 1.5±0.10kgf m...
Page 45: Group 2 Disassembly And Assembly
GROUP 2 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF THE FRONT AXLE ASSY DISASSEMBLY OF THE HOUSING Remove the drain plug of the housing using the wrench (1) and O-ring, and then, drain out the oil. 15BTR9FA01 Loosen the socket bolts (2, 8EA), and remove the brake cover assy (3).
Page 46 Remove plate (5, 5pcs), discs (6, 4EA), collar spline (7, 1pcs) and pin (8, 3EA). 15BTR9FA04 15BTR9FA05 Disassemble the drive shaft (10) and the bearing (9) using the special tool and the plastic mallet. 15BTR9FA06 It should be removed the bearing cup which is assembled on the opposite side of the housing prior to dissassemble the drive shaft (10) and the bearing (9).
Page 47 Take out the bearing (11) and the oil seal (12) from the drive shaft (10). 15BTR9FA08 Remove the wheel bolts (13, 5EA). 15BTR9FA09 3-10...
Page 48 DISASSEMBLY THE BRAKE COVER ASSY Disassemble the actuator (14, 1EA) from the brake cover (3). 15BTR9FA10 Remove the square ring 1 (16) and the square ring 2 (17) after disassembling the piston (15) using the special tool. 15BTR9FA11 15BTR9FA12 3-11...
Page 49 Remove the snap ring (18), washer (19) and the roller (20). 15BTR9FA13 Disassemble the cam shaft (22) after removing the snap ring (21). 15BTR9FA14 3-12...
Page 50 2. ASSEMBLY THE FRONT AXLE ASSY ASSEMBLY THE HOUSING ASSY Apply the bond (#1102) on the outside of the needle bearing (1) and the Loctite (#609) on the outside of the bush (2), and then assemble to the brake cover (3). 15BTR9FA15 15BTR9FA16 Fit the snap ring (6) after assembling the...
Page 51 Assemble the square ring 1 (10) and square ring 2 (11) on the piston (12). 15BTR9FA19 It should be used the special tool for the piston and apply the Mobil #424 on the moving surface of the piston, and assemble it. 15BTR9FA20 Apply the Loctite #271 on the brake bolt (14) and assemble the brake bolt (14) with spring...
Page 52 Assemble the bearing cup (16, 2EA) to the housing (15) using the special tool and the plastic mallet. 15BTR9FA22 After heating to 100 C for the bearing cones (16, 2EA), and assemble the bearing cones to the housing (15) using the special tool and the plastic mallet with applying Mobil #424.
Page 53 Assemble the drive shaft assy (18) to the housing (15). 15BTR9FA26 (10) Assemble the collor spline (19, 1EA) and pin (20, 3EA) to the housing. 15BTR9FA27 (11) Assemble the plate (21, 5pcs) and the disc (22, 4pcs) to the housing. 15BTR9FA28 After applying the Loctite #242 on the bolts (3EA), assemble the bolts to the collor spline (19) with tightening torque (0.8~1.1kg...
Page 54 (12) Apply the Loctite to the socket bolt (23) and tighten it with tightening torque (5.0~7.0kgf 15BTR9FA29 3-17...
Page 55: Section 4 Brake System
SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------ Group 2 Operational checks and troubleshooting ------------------------------------------------------ Group 3 Adjustments ----------------------------------------------------------------------------------------------------...
Page 56: Group 1 Structure And Function
SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE There are two brake systems, the service brake system and the parking brake system. In the service brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
Page 57 3. BRAKE PEDAL AND PIPING 10BTR9BS01 Brake pedal & bracket assy Reservoir tank assy Parking lever assy Brake master cylinder...
Page 58 4. BRAKE MASTER CYLINDER STRUCTURE 20B7BS03 Body Spring Plate Secondary cup Check valve assembly Piston Union bolt Gasket Spacer Union Primary cup Retaining ring Spring seat Boot...
Page 59: 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 60: Group 2 Operational Checks And Troubleshooting
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 61: Troubleshooting
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 62: Group 3 Adjustments
GROUP 3 ADJUSTMENTS 1. ADJUSTMENT OF PEDAL BRAKE PEDAL Pedal height from floor plate adjust with stopper bolt. 128~133mm Pedal height : 128~133mm (5.1~5.2in) Play Adjust with rod of mast cylinder. Floor plate Pedal play : 4~6mm (0.16~0.23in) 10BTR9BS09...
Page 63: Section 5 Steering System
SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------- 5-1 Group 2 Operational checks and troubleshooting ------------------------------------------------------- 5-11 Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 5-15...
Page 64: Group 1 Structure And Function
SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Steering motor Steering unit Drive unit assy Priority valve Hyd tank Hyd gear pump Hyd tank 10BTR9SS01 The steering system for this truck is composed of steering wheel assembly, steering unit, steering motor, drive unit assy and pipings.
Page 65: Hydraulic Circuit
2. HYDRAULIC CIRCUIT 10BTR9SS26 Hydraulic gear pump Suction strainer Priority valve Return filter Steering unit 12 Hydraulic tank Hydraulic motor...
Page 66 NEUTRAL 10BTR9SS04 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 67 LEFT TURN 10BTR9SS06 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 68: Right Turn
RIGHT TURN 10BTR9SS08 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 69 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 70: Operation
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 71 4. DRIVE UNIT STRUCTURE Traction motor Steering hyd motor Item Unit Spcification 20.5 Gear ratio Oil quality 10BTR9SS10 Drive unit assy Ball bearing 16 Bracket Steering gear 10 Pinion 17 Bolt w/washer-hex Socket bolt 11 Retaining ring (C) 18 Bracket Drive unit bracket 12 Spring washer 19 Socket bolt...
Page 72 Drive unit (1/4) 4 3 8 9 10BTR9DU01 Housing Ring-seal Circlip Plug Cover Plug-w/magnet O-ring Drive unit (2/4) 1-12 1-11 1-10 10BTR9DU02 1-1 Pinion shaft 1-6 Shim ring 1-11 Shim 1-2 Bevel gear 1-7 Taper roller bearing 1-12 Hexagon nut 1-3 Hexagon nut 1-8 Taper roller bearing Wheel shaft...
Page 73 Drive unit (3/4) 10BTR9DU03 1-7 Sealing ring-shaft 1-1 Spur gear 1-4 Ball bearing 1-2 Input pinion 1-5 Ball bearing 1-3 Plug 1-6 Retaining ring Drive unit (4/4) 10BTR9DU04 Housing upper part O-ring Torx screw Taper roller bearing Connecting plate 10 Valve-breather Cylindrical pin Bush Shim set...
Page 74: Group 2 Operational Checks And Troubleshooting
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS Check item Checking procedure Steering wheel Set rear wheels facing straight forward, then turn steering wheel to left and right. Measure range of steering wheel movement before rear wheel starts to move. 30-60mm (1.2-2.4 in) Range should be 30~60mm at rim of steering wheel.
Page 75 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 76: Power Steering Unit
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 77 DRIVE UNIT Noises Problem Cause Remedy High-pitch, striking noise Gearing of spur gear stage damaged. Replacement of the gearing parts. Contamination or dirt on gearing Change oil or replace relevant parts. gearing part if necessary. High-pitch, continuous noise Motor/transmission connection Check motor fitting or replace input defective.
Page 78: Group 3 Disassembly And Assembly
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 79 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) 5-16...
Page 80: Tightening Torque
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 81 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 82 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 5-19...
Page 83 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 84 (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 85 (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 5-22...
Page 86 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 87 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 88 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 89 (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 90 (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 91 (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 92 (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 93 (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 94 (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 95 (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) 5-32...
Page 96 2. DRIVE UNIT STRUCTURE Traction motor Steering hyd motor 10BTR9SS10 Drive unit assy Ball bearing 16 Bracket Steering gear 10 Pinion 17 Bolt w/washer-hex Socket bolt 11 Retaining ring (C) 18 Bracket Drive unit bracket 12 Spring washer 19 Socket bolt Steering pinion 13 Socket bolt 20 Plain washer...
Page 97 Drive unit (1/4) 4 3 8 9 10BTR9DU01 Housing Ring-seal Circlip Plug Cover Plug-w/magnet O-ring Drive unit (2/4) 1-12 1-11 1-10 10BTR9DU02 1-1 Pinion shaft 1-6 Shim ring 1-11 Shim 1-2 Bevel gear 1-7 Taper roller bearing 1-12 Hexagon nut 1-3 Hexagon nut 1-8 Taper roller bearing Wheel shaft...
Page 98 Drive unit (3/4) 10BTR9DU03 1-7 Sealing ring-shaft 1-1 Spur gear 1-4 Ball bearing 1-2 Input pinion 1-5 Ball bearing 1-3 Plug 1-6 Retaining ring Drive unit (4/4) 10BTR9DU04 Housing upper part O-ring Torx screw Taper roller bearing Connecting plate 10 Valve-breather Cylindrical pin Bush Shim set...
Page 99 CHECK AND INSPECTION When repairing the drive unit, ensure utmost cleanliness and excellent workmanship. Dismantle the drive unit only if any damaged parts must be replaced. After removing screws or nuts, loosen covers and housing parts which were installed with seals by slight blows with a plastic hammer.
Page 100 5870 350 000 (S) Clamping device AA00 852 804 The following figures show a different clamping device. Hyundai offers only the device shown in fig. 001. 10BTR9DU001 Loosen all screw plugs and drain the oil. Waste oil to be disposed of ecologically and according to the legal provisions.
Page 101 Loosen the cylindrical screws. Loosen the frame plate by means of slight hits with a plastic hammer and remove it. 10BTR9DU005 If necessary, remove the cylindrical screws (steering stop). 10BTR9DU006 Loosen countersunk screws (arrows 1) and lift off the steering stop (arrow 2). 10BTR9DU007 5-38...
Page 102 Input and output Use lever to remove protective cap from the gear shaft. 10BTR9DU028 Install locking device (S) on the gear shaft (see arrow) thus blocking the gear shaft against rotation. Loosen both hexagon nuts on the bevel gear shaft one after the other.
Page 103 Lift off the cover on the cast brackets. 10BTR9DU032 Remove O-ring (see arrow). 10BTR9DU033 Install locking device (S) on the gear shaft (see arrow) thus blocking the gear shaft against rotation. Loosen both hexagon nuts on the gear shaft one after the other. Remove disk.
Page 104 Press off the bearing inner ring from the gear shaft. (S) Cut-off device 5870 300 028 10BTR9DU036 Remove the crown wheel from the housing. 10BTR9DU037 Remove the bearing inner ring out of the housing. 10BTR9DU038 Carefully remove the bevel gear shaft out of the spur gear using a plastic hammer (bearing inner ring below) and take out from the bottom.
Page 105 Support the bearing inner ring with a suitable sleeve and press it off the bevel gear shaft. 10BTR9DU040 Remove spur gear from the housing. 10BTR9DU041 Remove bearing inner ring from the housing. 10BTR9DU042 Force bearing outer ring out of the housing and remove the adjusting washer behind.
Page 106 Force out the opposite bearing outer ring. 10BTR9DU044 Lift-off shaft seal. If the shaft seal is stuck, you can force it out from the opposite side. 10BTR9DU045 Force bearing outer ring out of the housing and remove the adjusting washer behind. Pay attention so that the releasing adjusting washer does not drop.
Page 107 REASSEMBLY Input and output If either crown wheel or bevel gear shaft is damaged, both parts must be jointly replaced. Legend : 1 = Bevel gear shaft 2 = Crown wheel 3 = Adjusting washer of contact pattern 4 = Adjusting washer of backlash (circumferent.
Page 108 Fit bearing outer ring into the bearing hole on the housing until contact is obtained. (S) Driver tool AA00 658 635 10BTR9DU051 Press-on the bearing inner ring until contact with the bevel gear shaft is obtained. 10BTR9DU052 Insert bearing inner ring into the bearing outer ring.
Page 109 Place the spur gear on top of the housing. Observe the installation position. Convex side of spur gear to face upwards. Mount the preassembled bevel gear shaft to the spur gear from below. 10BTR9DU055 Press against the bevel gear shaft from below.
Page 110 Check rolling torque of the bevel gear shaft bearing 0.7~1.3 Nm. Try to achieve the lower value. If rolling torque is incorrect, loosen both hexagon nuts and repeat the work steps shown in fig. 057~059. Use the lower hexagon nut for correction. 10BTR9DU059 Drive in the bearing outer ring until contact is obtained.
Page 111 Insert adjusting washer into the bearing hole and force in bearing outer ring until contact is obtained. (S) Driver tool AA00 658 776 When installing the old taper roller bearing (fig. 048 item 6), use the adjusting washer removed during disassembly. 10BTR9DU063 Insert the bearing inner ring into the bearing outer ring.
Page 112 Press on the bearing inner ring until contact with the gear shaft is obtained. 10BTR9DU067 Install the gear shaft on the crown wheel from below. Secure with hexagon nut. 10BTR9DU068 Support unit on the gear shaft. Use a press to bring crown wheel and suitable sleeve to contact position.
Page 113 Fix and support the locking device (S) on the gear shaft. Position the counter support (S) and adjust contact position. Tighten the second hexagon nut. ·Tightening torque : M = 550 Nm (S) Locking device 5870 240 002 (S) Counter support AA00 857 163 10BTR9DU071 Check rolling torque of the gear shaft...
Page 114 Grease the O-ring and install it into the annular groove on the cover (see arrow). 10BTR9DU074 Mount the preassembled cover into the housing until contact is obtained. Observe installation position. Bring recess for taper roller bearing into the correct position. See arrow. 10BTR9DU075 Insert snap ring into the annular groove on the housing and fix the cover.
Page 115 Upper housing part and components If removed, or in case of a new part, flush- mount the protection cap with the open side facing inwards. 10BTR9DU077 Press ball bearing onto the input pinion until contact is obtained. Apply assembly force only on the bearing inner ring.
Page 116 Fix ball bearing on the input pinion by means of a retaining ring. 10BTR9DU081 Press bearing inner ring onto the bushing as illustrated. 10BTR9DU082 Insert both bearing outer rings onto the upper housing part until contact is obtained. 10BTR9DU083 Place upper housing part on the preassembled bushing, as illustrated.
Page 117 Adjust rolling torque of the connection plate bearing (fig. 085~097). Support the preassembled upper housing part on the bushing. Determine dimension I from front side of bearing inner ring to front side of bushing. Dimension I e.g....9.90 mm 10BTR9DU085 Determine dimension II on connection plate.
Page 118 Use a plastic hammer to bring the upper housing part carefully into contact position with the housing. 10BTR9DU089 Fix the upper housing part by means of cylindrical screws. ·Tightening torque (M8/10.9) : M = 30 Nm 10BTR9DU090 If removed, or in case of a new part, install breather (S) on upper housing part by means of a driver tool.
Page 119 Flush-mount the shaft-seal into the connection plate. Apply grease (Shell Alvania RL3) to the inner side of the shaft seal. Observe installation position. Also refer to fig. 087. If removed, or in case of a new part, insert the cylindrical pin (see arrow) into the hole near the M12-threads, until contact is 10BTR9DU093 obtained.
Page 120 Check rolling torque of connection plate bearing 18~25Nm. (S) Assembly fixture AA00 630 183 10BTR9DU097 Geared steering version Mount steering stop as illustrated. Force in grooved pins in alignment with the steering stop. Fix steering stop by means of countersunk screws. ·Tightening torque (M6/10.9) : M = 14Nm Secure countersunk screws with Loctite 243.
Page 121 Wet inner gearing at the input pinion evenly with grease. 10BTR9DU101 Apply grease evenly on the shaft at the electric motor. 10BTR9DU102 Place electric motor onto the connection plate and fix it by means of cylindrical screws. ·Tightening torque (M8/8.8) : M = 23Nm Observe installation position.
Page 122 CONTACT PATTERN EXAMPLES OF GLEASON TOOTH SYSTEM Ideal contact pattern: Concave flank convex flank GEAR1 Contact pattern setting: The contact patterns are viewed on the crown wheel flanks. The contact pattern must be tangent to the center of tooth flank (middle of tooth), otherwise it is too far on the tooth top or on the tooth root.
Page 123: Section 6 Hydraulic System
SECTION 6 HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------- Group 2 Operational checks and troubleshooting ------------------------------------------------------- 6-25 Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 6-29...
Page 124: Group 1 Structure And Function
SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 10BTR9HS01 Hydraulic gear pump Lift cylinder Priority valve Suction strainer Main control valve Return filter Steering unit 10 Down safety valve Hydraulic motor 11 Down control valve Tilt cylinder 12 Hydraulic oil tank ※...
Page 125 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 10BTR9HS02 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 126 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 10BTR9HS03 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 127 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 10BTR9HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position. The oil from hydraulic gear pump(1) flows into main control valve (3) and then goes to the large chamber of tilt cylinder(6) by pushing the load check valve of the spool.
Page 128 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 10BTR9HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the small chamber of tilt cylinder(6) by pushing the load check valve of spool.
Page 129 2. HYDRAULIC GEAR PUMP STRUCTURE 10BTR9HS19 Housing assy Rear cover 11 E-back up ring Body Oil seal 12 Pin-S Drive gear Snap ring 13 Wahser Idler gear Bushing 14 Bolt Side plate assy 10 E-seal 15 Square 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 130 3. MAIN CONTROL VALVE (without OPSS) STRUCTURE (3 Spool) INLET LIFT TILT AUX1 OUTLET 130k 150k 3A 3B 2A 2B VIEW A 10BTR9HS07A 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 131 STRUCTURE (4 Spool) INLET LIFT TILT AUX1 AUX2 OUTLET 130K 150K 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 10BTR9HS07B Inlet block assy Outlet block assy...
Page 132: Inlet Section
INLET SECTION Operation The inlet section contains the pump inlet connection and main relief valve. INLET 150bar 10BTR9HS09 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 133 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 134: Tilt Section
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 135 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 136 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 137: Main Relief Valve
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. 10BTR9HS20 Pilot seat Main spring...
Page 138 MAIN CONTROL VALVE (with OPSS) STRUCTURE (3 Spool) Needle valve (Emergency) INLET LIFT TILT AUX1 OUTLET 130k 150k 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 139 STRUCTURE (4 Spool) Needle valve (Emergency) INLET LIFT TILT AUX1 AUX2 OUTLET 130K 150K 3A 3B 4A 4B 2A 2B VIEW A Port Port name Size Inlet port 7/8-14UNF Outlet port 7/8-14UNF 10BTR9HS08A 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 140 INLET SECTION Operation The inlet section contains the pump inlet connection and main relief valve. INLET 150bar 10BTR9HS09 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 141 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 142 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 143 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 144 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 145 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 146 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. 10BTR9HS20 Pilot seat Main spring...
Page 147: Lift Cylinder
4. LIFT CYLINDER 15 ,16 14 17 18 19 20 10 7 8,9 4,5 3 6 11, 12 10BTR9HS18 Tube assembly Spacer 15 Dust wiper Retaining ring 16 Retaining ring Piston 10 Stop ring 17 Rod bush U-packing 11 Cushion seal 18 Spacer Back up ring 12 Retaining ring...
Page 148: Group 2 Operational Checks And Troubleshooting
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1m from ground. Wait for 10 minutes and measure hydraulic drift(amount forks move down and amount mast tilts forward). Check condition 10BTR9HS08 - Hydraulic oil : Normal operating temp...
Page 149: Troubleshooting
2. TROUBLESHOOTING SYSTEM Problem Cause Remedy Large fork lowering speed Seal inside control valve defective. Replace spool or valve body. Oil leaks from joint or hose. Replace. Seal inside cylinder defective. Replace packing. Large spontaneous tilt of mast Tilting backward : Check valve defec- Clean or replace.
Page 150: Hydraulic Gear Pump
HYDRAULIC GEAR PUMP Problem Cause Remedy Pump does not develop full System relief valve set too low or Check system relief valve for proper pressure leaking. setting. Oil viscosity too low. Change to proper viscosity oil. Pump is worn out. Repair or replace pump.
Page 151 LIFT CYLINDER Problem Cause Remedy Oil leaks out from rod cover Foreign matters on packing. Replace packing. through rod Unallowable score on rod. Smooth rod surface with an oil stone. Unusual distortion of dust seal. Replace dust seal. Chrome plating is striped. Replace rod.
Page 152: Group 3 Disassembly And Assembly
GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP DISASSEMBLY Throughly clean the outside of the pump so that it can not remain the foreign material on the pump. 10BTRPUMP01 Loosen and remove the bolts (4EA) from the pump cover. 10BTRPUMP02 Remove the sharp edge of the drive shaft and smear a clean grease on the shaft...
Page 153 Take off the snap ring using the proper tool. (If should be carried out above work when it is necessary for replacing the oil seal) 10BTRPUMP05 Remove the oil seal from the cover to pay keen attention to do not damaging the surface of the shaft hole.
Page 154 Disassemble the rear cover and side plate of the lower side from the pump housing. 10BTRPUMP09 6-31...
Page 155 ASSEMBLY Throughly clean the components of the pump so that it can not remain the foreign material on the components. 10BTRPUMP09 Insert the oil seal carefully and fix it inside of the mounting flange using the proper tool. 10BTRPUMP10 Fit the snap ring in pre-arranged position using the proper tool.
Page 156 Insert the pin in pre-arranged position of the rear cover after fitting the pin in the bottom side of the body. 10BTRPUMP12 Insert the E-seal in the right position of the side plate. After that, fit the back up ring in the groove of the E-seal.
Page 157 Insert the side plate in the body to take care of direction of the side plate. 10BTRPUMP07 (10) Assemble the cover on the pump housing. 10BTRPUMP04 (11) Tighten alternately the bolts one after another in a diagonal direction order with 45~48Nm torque value after inserting the washer.
Page 158 2. MAIN CONTROL VALVE (with OPSS) ASSEMBLY 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. Additional auxiliary valve sections may be added to the main control valve in a similar manner as indicated below.
Page 159 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 160 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 161 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 162 DISASSEMBLY 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. Keep the disassembly area neat to avoid loss or damage of parts.
Page 163: Main Control Valve
3. MAIN CONTROL VALVE 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 ASSEMBLY INSTRUCTION General Ensure that the assembly area will be clean and free of contamination. Use a flat(within 0.5mm) work surface when bolting the valve sections together.
Page 164: Disassembly Instruction
Lift block solenoid assembly The solenoide is installed upper side and below side cavities in lift block. Torque to 4.1kgf (40Nm) Install the O-ring, coil, O-ring and washer to the assemblied cartridge. Insert the lock washer to the groove of the cartridge. Tilt &...
Page 165 4. LIFT CYLINDER STRUCTURE O.D Stroke (standard) 45 55 1495mm (1.8 2.2 58.9 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 18 Spacer Back up ring...
Page 166 DISASSEMBLY Hold the cylinder tube in a vice, loosen the Guide cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn. Lever up the edge of the guide, then turn the guide in again and the guide can be removed.
Page 167 5. TILT CYLINDER STRUCTURE 10BTR9HS10 Tube assy Bushing 17 Spherical bearing 10 Rod seal 18 Grease nipple Piston 11 Back up ring 19 Hexagon bolt Piston seal 12 Dust wiper 20 Spring washer Wear ring 13 O-ring 21 Hexagon nut O-ring 14 Back up ring 22 Dust cap...
Page 168 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 169: Section 7 Electrical System
SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component location --------------------------------------------------------------------------------------- 7-1 Group 2 Electrical circuit ----------------------------------------------------------------------------------------------- 7-2 Group 3 Electric components --------------------------------------------------------------------------------------- 7-4...
Page 170: Group 1 Component Location
SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 10BTR9EL02 Combination switch 11 Fuse box 22 Horn high Display 12 Back buzzer 23 Accelerator assy Converter 13 Angle sensor 24 Parking switch assy Beacon lamp 14 Pump controller 25 Key switch assy Pressure sensor 15 Fuse &...
Page 171: Group 2 Electrical Circuit
GROUP 2 ELECTRICAL CIRCUIT ·ELECTRICAL CIRCUIT (1/12, NON-UL, 10BTR-9 : -#0039, 13BTR-9 : -#0062, 15BTR-9 : -#0205) FUSE BOX ASS'Y BRAKE FLAS LAMP -HER EMERGENCY SWITCH SWITCH UNIT HEAD BACK HORN LAMP BUZZER S/W- SEAT BACK S/W- BUZZER KNOB HEATING...
Page 172 · ELECTRICAL CIRCUIT (2/12, NON-UL, 10BTR-9 : #0040-0047, 13BTR-9 : #0063-0066, 15BTR-9 : #0206-0255) FUSE BOX ASS'Y BRAKE FLAS LAMP -HER EMERGENCY SWITCH UNIT HEAD SWITCH BACK HORN LAMP BUZZER BACK S/W- SEAT S/W- BUZZER KNOB HEATING KNOB SWITCH SWITCH...
Page 173 ·ELECTRICAL CIRCUIT (3/12, NON-UL, 10BTR-9 : #0048-0053, 13BTR-9 : #0067-0079, 15BTR-9 : #0256-0374) FUSE BOX ASS'Y BRAKE FLAS LAMP -HER EMERGENCY SWITCH SWITCH HEAD UNIT BACK LAMP HORN BACK BUZZER S/W- SEAT BUZZER S/W- KNOB HEATING SWITCH KNOB SWITCH BACK...
Page 174 ·ELECTRICAL CIRCUIT (4/12, NON-UL, AUSTRALIA OPTION, 10BTR-9 : #0048-0053, 13BTR-9 : #0067-0079, 15BTR-9 : #0256-0374) FUSE BOX ASS'Y BRAKE FLAS LAMP EMERGENCY -HER SWITCH HEAD SWITCH UNIT HORN LAMP BACK BACK S/W- SEAT BUZZER BUZZER KNOB/ HEATING S/W- HORN SWITCH...
Page 175 ·ELECTRICAL CIRCUIT (5/12, NON-UL, 10BTR-9 : #0054-, 13BTR-9 : #0080-, 15BTR-9 : #0375-) FUSE BOX ASS'Y BRAKE FLAS LAMP -HER EMERGENCY SWITCH UNIT SWITCH HEAD LAMP HORN SEAT BACK BACK S/W- HEATING BUZZER BUZZER KNOB/ HORN SWITCH S/W- SWITCH F-TIP...
Page 176 ·ELECTRICAL CIRCUIT (6/12, UL, 10BTR-9: -#0001, 13BTR-9: -#0001, 15BTR-9: -#0006) FUSE BOX ASS'Y(UL#1) BRAKE FLAS LAMP EMERGENCY -HER SWITCH SWITCH UNIT HEAD BACK LAMP HORN BACK BUZZER SEAT SEAT SEAT S/W- S/W- BUZZER KNOB HEATING HEATING HEATING KNOB SWITCH SWITCH...
Page 177 ·ELECTRICAL CIRCUIT (7/12, UL, 10BTR-9: #0002-0039, 13BTR-9: #0002-0062, 15BTR-9: #0007-0205) FUSE BOX ASS'Y(UL#1) BRAKE FLAS LAMP EMERGENCY -HER HEAD SWITCH SWITCH UNIT LAMP HORN BACK S/W- SEAT SEAT BUZZER KNOB HEATING HEATING SWITCH SWITCH SWITCH EMERGENCY CONTACTOR HORN HORN RELAY...
Page 178 ·ELECTRICAL CIRCUIT (8/12, UL, 10BTR-9: #0040-0048, 13BTR-9: #0063-0067, 15BTR-9: #0206-0255) FUSE BOX ASS'Y(UL#1) BRAKE FLAS EMERGENCY LAMP -HER SWITCH HEAD HEAD SWITCH UNIT LAMP LAMP BACK HORN BACK BUZZER S/W- SEAT BUZZER S/W- KNOB HEATING SWITCH KNOB SWITCH BACK HORN...
Page 179 ·ELECTRICAL CIRCUIT (9/12, UL, 10BTR-9: #0048-0053, 13BTR-9: #0067-0079, 15BTR-9: #0256-0374) FUSE BOX ASS'Y(UL#1) BRAKE FLAS EMERGENCY LAMP -HER SWITCH HEAD SWITCH UNIT LAMP BACK HORN BACK BUZZER S/W- SEAT SEAT SEAT BUZZER S/W- KNOB HEATING HEATING HEATING SWITCH KNOB SWITCH...
Page 180 ·ELECTRICAL CIRCUIT (10/12, UL, AUSTRALIA OPTION, 10BTR-9: #0048-0053, 13BTR-9: #0067-0079, 15BTR-9: #0256-0374) FUSE BOX ASS'Y(UL#1) BRAKE FLAS EMERGENCY LAMP -HER SWITCH HEAD SWITCH UNIT LAMP BACK HORN BACK BUZZER SEAT S/W- BUZZER S/W- HEATING KNOB SWITCH KNOB SWITCH HORN BACK...
Page 181 ·ELECTRICAL CIRCUIT (11/12, UL, 10BTR-9 : #0054-, 13BTR-9 : #0080-, 15BTR-9 : #0375-) FUSE BOX ASS'Y(UL#1) BRAKE FLAS EMERGENCY LAMP -HER SWITCH HEAD SWITCH UNIT LAMP BACK HORN BACK HORN SEAT BUZZER BUZZER S/W- SWITCH/ HEATING SWITCH S/W- REAR KNOB/...
Page 182 ·ELECTRICAL CIRCUIT (12/12, FINGERTIP) CAN TILLER MHYRIO CB FT LIFT 21/421 500A B2 -BATT B2 PAUX NPOT C3 1 GND LIFT UP 520A 21/321 A16 -BATT 2 POWER B1 KEY PPOT A9 324A 3 VOUT A B3 -BATT SIG A C2 LOWERING FT AUX 501A...
Page 183: Group 3 Electric Components
For the monitoring system, there are many sensors such as current sensors, hydraulic pressure sensors, and temperature sensors. The HYUNDAI Battery forklift trucks are equipped with the most advanced DRIVING CONTROL SYSTEM currently available world-widely. The operator friendliness features enable him to set the truck conditions properly according to each working circumstance easily on his seat, and the SELF- DIAGNOSTIC function displays current status of truck in working.
Page 184 2. BATTERY STRUCTURE Protective tube 7,10,11,12,13 10BTR9EL03 Cells Wrench bolt Steel box Spacer Cell connector 10 Handle Row connector 11 Screw Positive leading cable 12 Nut Negative leading cable 13 Spring washer Plug...
Page 185 Therefore, be sure to check and maintain the battery so that it may be kept best. 10BTR9EL04 SPECIFICATION AND SERVICE DATA Item Unit 10BTR-9 13BTR-9 15BTR-9 Type 5PzS625 6PzS750 Rated voltage Capacity...
Page 186: Safety Precautions
SAFETY PRECAUTIONS When a sulfuric acid contact with skin For acid contact with skin, eye or clothing, flush with water immediately. If swallowed, drink a large amount of water or milk. Seek medical attention immediately. When handling acid, always wear eye goggles or a face shield and rubber gloves.
Page 187 Performance and maintenance of batteries ① Initial charge Wet-charged battery gradually decrease its capacity during storage. In order to provide sufficient discharge capacity in the first discharge, the good initial charge is required. The conditions of initial charging are seen as below at room temperature. By modified constant voltage charger Connect the battery to the charger and turn on the equalizing charge “ON”.
Page 188 ④ Normal charge Charge the discharged batteries as quickly as possible. The temperature of electrolyte before starting the charging operation shall preferably be below 45。 C, and the temperature during the charge should be maintained at no higher than 55。 C. (Under any unavoidable situations, it should never be above 55。...
Page 189 (for the purpose of uniform stirring of electrolyte by charging). If the electrolyte level is improper after completion of charging, you may topping up the electrolyte level to the maximum level . Determination of replenishment time and methods(cell with ONE TOUCH CAP) Confirm the electrolyte level by looking at the float in the ONE TOUCH CAP.
Page 190 You must make sure to clear of explosive hydrogen gas in the cells before repairs. Be careful not to drill to far into the cell and damage the unit. During drilling operation make sure lead curls produced do not contact opposite cell poles and cause a spark.
Page 191: Troubleshooting
TROUBLESHOOTING Nature of trouble Symptoms Causes Repair Deformation ·Deformation of container, ·Excessive temperature ris- ·Replace lid or one touch cap ing or external impact Breakage ·Electrolyte leakage acco- ·External impact, improper ·Replace or install a new rding to breakage of cont- handling, excessive vibrat- ainer, lid or one touch cap ·Termination of connector...
Page 192 3. DRIVE MOTOR STRUCTURE 10BTR9EL07 Rotor assy Terminal block(A) Bearing Startor assy Speed sensor kit 10 Flange nut Endbell De Stud bolt 11 Wave washer Endbell Terminal protector 7-13...
Page 193 SPECIFICATION Item Unit Specification Type AMDH6001 Rated voltage Rated output Insulation Class F 7-14...
Page 194 INSPECTION Rotor assembly inspection Rotor should always be cleaned with compressed air. If the dirt will not come off lightly wipe off with piece of cotton or soft cloth wetted with gasoline. Ø123.1±0.05 Rotor out diameter : Tool : Vernier calipers and standard tool 10BTR9DM01 Stator assembly inspection ①...
Page 195 DISASSEMBLY FOR AC MOTOR Before disassembling motor, remove terminal protector from the motor and separate thermistor and speed sensor connectors from hanger. 10BTR9DM04 10BTR9DM05 Remove 3-nuts from terminal block of the motor to disassemble terminal block from the motor. 10BTR9DM06 Remove 4 screw fixing speed sensor on the enbell side and then disassemble speed sensor, fixed nut and toothed wheel...
Page 196 Remove 4 flange nuts with available general tool on the endbell drive side. 10BTR9DM08 Remove endbell de and wave washer. 10BTR9DM09 Remove stator assembly by hand or suitable tool. Removing stator Removing endbell 10BTR9DM11 10BTR9DM10 Remove endbell from rotor assembly by hand-puller as a above picture. 7-17...
Page 197: Assembly And Installation
The motor are composed of 5-parts (Rotor assembly, stator assembly, enbell de, endbell, ETC) 10BTR9DM12 ASSEMBLY AND INSTALLATION Perform assembly in the reverse order of disassembling After assembling, check for speed sensor. Normal signal is as below. Clockwise rotation Counter clockwise rotation 10BTR9DM13 7-18...
Page 198 4. PUMP MOTOR STRUCTURE 10BTR9EL16 Rotor assy Terminal block(A) Bearing Startor assy Speed sensor kit 10 Flange nut Front endbell Stud bolt 11 Wave washer Rear endbell Terminal, protector 7-19...
Page 199 SPECIFICATION Item Unit Specification Type AMDA4001 Rated voltage Rated output Insulation Class F 7-20...
Page 200 INSPECTION Rotor assembly inspection Rotor should always be cleaned with compressed air. If the dirt will not come off lightly wipe off with piece of cotton or soft cloth wetted with gasoline. Ø123.1±0.05 Rotor out diameter : Tool : Vernier calipers and standard tool 10BTR9PM01 Stator assembly inspection ①...
Page 201 DISASSEMBLY FOR AC MOTOR Before disassembling motor, remove terminal protector from the motor and separate thermistor and speed sensor connectors from hanger. 10BTR9PM04 10BTR9PM05 Remove 3-nuts from terminal block of the motor to disassemble terminal block from the motor. 10BTR9PM06 Remove 4 screws fixing speed sensor on the enbell side and then disassemble speed sensor, fixed nut and toothed wheel...
Page 202 Remove 6 flange nuts with available general tool on the endbell drive side. 10BTR9PM08 Remove endbell de and wave washer. 10BTR9PM09 7-23...
Page 203 Remove stator assembly by hand or suitable tool. Removing stator Removing endbell 10BTR9PM11 10BTR9PM10 Remove endbell from rotor assembly by hand-puller as a above picture. 7-24...
Page 204 The motor are composed of 5-parts (Rotor assembly, stator assembly, enbell de, endbell, ETC) 10BTR9PM12 ASSEMBLY AND INSTALLATION Perform Assembly in the reverse order of disassembling. After Assembling, check for speed sensor. Normal signal is as below. Clockwise rotation Counter clockwise rotation 10BTR9PM13 7-25...
Page 205 5. CONTROLLER SYSTEM STRUCTURE (Traction controller/Pump controller) Traction controller Pump controller 10BTR9EL10 Specifications Model Model Normal battery voltage Continuous output current Current limit 10/13/15BTR-9 ACE2 24V 500Arms 250Arms 500Arms / 3min 7-26...
Page 206 PIN MAP DESCRIPTION TRACTION INVERTER (ACE2) No. of Pin Function Description Input of the key switch signal. PPOT Potentiometer positive. CPOT Accelerator potentiometer wiper signal. FORW Forward direction request input. Backward direction request input. SEAT&SBR SEAT and SBR(Side Battery Removal) input. ENC A Traction motor encoder phase A.
Page 207 PUMP INVERTER (ACE2) No. of Pin Function Description Input of the key switch signal. PPOT Positive of steering Potentiometer & lift potentiometer. CPOT Lift potentiometer wiper signal. LIFT ENABLE Input for lifting enable input. TILT Input for tilt up and tilt down digital input. SEAT&SBR SEAT and SBR(Side Battery Removal) input.
Page 208 MENU DESCRIPTION TRACTION INVERTER PARAMETER CHANGE ACCELERATION 0 It specifies the motor acceleration at 0 Hz. At level 0 the acceleration is maximum. Increasing the parameter's level the acceleration decreases. INV. ACCEL 0 It specifies the motor acceleration at 0 Hz after an inversion of direction. At level 0 the acceleration is maximum.
Page 209 PARAMETER CHANGE SPEED LIMIT BRK Seconds. It controls the deceleration ramp when a speed reduction has been activated. The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz. CURVE BRAKING Seconds. It controls the deceleration ramp when a curve speed reduction has been activated.
Page 210: Battery Check
SET OPTION HOUR COUNTER This option specifies the hour counter mode. It can be set one of two: - RUNNING: The counter registers travel time only. - KEY ON: The counter registers when the "key" switch is closed. BATTERY CHECK This option specifies the handling of the low battery charge detection.
Page 211 SET OPTION PEDAL TYPE - OPTION #1 : The pedal position is sent to the display for graphic indication. - OPTION #2 : The speed set-point is sent to the display for graphic indication. PEDAL BRK.STOP If set to on the truck is stopped when the pedal brake is pressed. If set to off the traction current is reduced to the half of the maximum current.
Page 212 ADJUSTMENTS MAX STEER RIGHT This is the function to record in the controller EEPROM the steering poti output voltage when the wheels are fully turned right (maximum of the steering poti range). MAX STEER LEFT This is the function to record in the controller EEPROM the steering poti output voltage when the wheels are fully turned left (minimum of the steering poti range).
Page 213 ADJUSTMENTS CHECK UP TIME Hours. It specifies the time of the CHECK UP NEEDED warning. MAIN CONT VOLT It specifies the percentage of battery voltage supplied to MC coil to close the contactor. AUX OUTPUT VOLT It specifies the percentage of battery voltage supplied to AUX coil to close the AUXILIARY electro valve.
Page 214 PUMP INVERTER PARAMETER CHANGE ACCELERATION 0 It specifies the motor acceleration at 0 Hz. At level 0 the acceleration is maximum. Increasing the parameter's level the acceleration decreases. ACCELERATION 1 It specifies the motor acceleration at ACC PROF. FREQ 1 [Hz]. At level 0 the acceleration is maximum.
Page 215: Aux Function
SET OPTION This option specifies the hour counter mode. It can be set one of two: HOUR COUNTER - RUNNING: The counter registers travel time only. - KEY ON: The counter registers when the "key" switch is closed. BATTERY CHECK This option specifies the handling of the low battery charge detection.
Page 216 ADJUSTMENTS LOAD SENSOR ON : Load Sensing Function is activated OFF : Load Sensing Function is disactivated. OVERLOAD TYPE This option specifies how overload alarm works in overloaded situation. NONE : There would'n be any kind of alarms or limitations . OPTION #1 : If the weight of load filed on forks exceeds the overload weight set in overload parameter, OVER LOAD alarm will be displayed and followed by traction &...
Page 217 ADJUSTMENTS THROTTLE Y POINT This parameter, together with the THROTTLE X POINT, changes the characteristic of the lift potentiometer input curve : when the potentiometer is de-pressed to X point per cent, the corresponding pump speed is Y point per cent of the Maximum pump speed. The relationship between the potentiometer position and the pump speed is linear between the THROTTLE 0 ZONE and the X point and also between the X point and the maximum accelerator position but with two different slope.
Page 218: Tester Menu
TESTER MENU TRACTION INVERTER HOUR METER TRUCK This parameter displays the working hour of traction controller. BATTERY VOLTAGE Voltage value with 1 decimal digit. Battery voltage value measured at the key on. MOTOR VOLTAGE Percentage value. It is the voltage generated by the inverter expressed in percent of the actual battery voltage.
Page 219 PUMP INVERTER HOUR METER TRUCK This parameter displays the working hour of pump controller. BATTERY VOLTAGE Voltage value with 1 decimal digit. Battery voltage value measured at the key on. MOTOR VOLTAGE Percentage value. It is the voltage generated by the inverter expressed in percent of the actual battery voltage.
Page 220: General Characteristic
6. FINGERTIP CONTROLLER INTRODUCTION OF FINGER TIP The general forklift performs lifting and tilting using the mechanical lever mounted on MCV (Main Control Valve) by an operator. A new system is designed in order to improve operator's convenience and match up with marketing trend.
Page 221 STRUCTURE BRJ7EL61 7-41...
Page 222 Description of connectors No. of Pin Function Description PCLRXD Serial communication interface NCLRXD Serial communication interface PCLTXD Serial communication interface NCLTXD Serial communication interface Negative supply. +12V supply. Mhyrio CB positive power supply +KEY Input of valves positive power supply PAUX Mhyrio CB negative supply -BATT...
Page 223 Type Function Description SET BATTERY 12/24/36 This parameter sets the battery nominal voltage, that is the key input voltage TYPE /48/72/80 (MHYRIO supply) V valves coil This parameter sets the ON/OFF valves coil nominal voltage. 12/24/36 /48/72/80 Valves supply 12/24/36 This parameter sets the voltage of the valve's coil positive supply.
Page 224 ADJUSTMENTS & FUNCTION There are two ways to adjust parameter via a console or buttons on a display. Adjustments via console or buttons on a display Adjustment of Parameters and changes to the controller's configuration are made using the Digital Console or buttons on a display.
Page 225 Description of parameters that may be programmed (parameter change) In addition to the configuration, parameter settings can be factory set (default parameters), or the customer can make changes according to the application, using a digital console or a display. During the setting up procedure on the machine, the console can remain connected to the controller during travel.
Page 226 Max EVP6 This parameter adjusts the maximum current of valve 6, if it is set as proportional (see "set option menu"). Min EVP7 This parameter adjusts the minimum current of valve 7, if it is set as proportional (see "set option menu").
Page 227 EVP5 Open delay EVP5 proportional valve current ramping up time: this parameter sets the EVP5 valve current ramp, to change from 0 A to operating current. EVP5 Close delay EVP5 proportional valve current ramping down time: this parameter sets the EVP5 valve closing ramp, to change the coil current from operating current to 0 A.
Page 228: Change Menu
(3-1) Description to change parameters by a console The flow chart shows how to change parameters by a console. Opening finger tip controller menu (MHY CB) Press ENTER to go into the GENERAL MENU. The display will show: PARAMETER CHANGE. Press ENTER to go into the PARAMETER CHANGE menu.
Page 229 (3-2) Description to change parameters by a display The flow chart shows how to change parameters by buttons on a display. Press to enter password for 2~3 seconds. The display will show: ENTER PASSWORD. Enter the password using After finishing entering it, press for 2~3 sec The display will show: TRUCK MENU.
Page 230 When the desired parameter appears, the display will show a level number that will be between 0 and 9. Press either to change the level value The display will show the new level. When you are satisfied with the results of the changes you have made, press The display asks : "ARE YOU SURE?"...
Page 231 Input 2 Level of digital input 2 : - ON / +VB : input active, switch closed - OFF / COND : input not active, switch open. Analog input 1 Voltage of the analog input. (4-1) Description to check data by a console The flow chart shows how to use the TESTER function of the digital console.
Page 232 (4-2) Description to check data by a display The flow chart shows how to use the TESTER function of buttons on a display. Press to enter password for 2~3 seconds. The Display will show: ENTER PASSWORD. Enter the password using After finishing entering it, press for 2~3 sec The display will show: TRUCK MENU.
Page 233 The first variable to be tested is shown on the display Press either Next variable for measurement appears. When you have finished, press The display shows : TESTER Press again and return to MHY CB HY. BRJ7EL68 ANALYSIS OF ALARMS EEPROM KO Fault in the area of memory where the adjustment parameters are stored.
Page 234 EV driver short One of the on/off valves driver is shorted; check the external connection, if it is ok the driver is probably damaged. EVP driver short The single proportional valve driver is shorted; check the external connection, if it is ok the driver is probably damaged.
Page 235 7. DISPLAY STRUCTURE The instrument panel has six built-in red LED, which provide the operator with an easy information about the status of some truck devices. H Y U N D A I 15B7OM65 Oil level warning lamp (option) Key 2 button Wrench warning lamp Key 3 button Thermometer warning lamp...
Page 236 WARNING LAMP When the key switch is OFF, the display makes a general test lighting and switching OFF all the LED in sequence. Oil level warning lamp (Option) This LED lights when the measured oil level of the hydraulic circuit is under the minimum acceptable mark. To connect the oil sensor output to the Analogue Input #1.
Page 237 TESTER MENU Status of keyboard buttons can be monitored in real time in the TESTER menu. Key 1 button Status of keyboard button: ON = Input active, button pushed OFF = Input not active, button released 16B7OM67 Key 2 button Status of TURTLE keyboard button: ON = Input active, button pushed...
Page 238: Lcd Function
LCD FUNCTION 15B7OM77 Battery's state of charge The battery's state of charge indication is displayed on the left side of the unit (1); it is shown by ten notches. Each notch represents the 10% of the battery charge. As the battery becomes discharged, the notches turn off progressively, one after the other, in proportion to the value of the residual battery charge.
Page 239 Turtle The turtle symbol (3) is normally off; when it appears (fixed) it shows activation of the "soft" mode of the truck, in which maximum speed and acceleration are reduced. The "soft" mode can be activated pressing button Hour meter The number displayed on the bottom right side of the unit (4) shows the Hours Worked.
Page 240 DESCRIPTION OF PROGRAMMABLE FUNCTIONS Menu set model Connect to Using CANBUS link, every module connected to can net can act as the "access node" to the canbus net for the external world. For example the ZAPI hand console (or the PC-Win console) can be physically connected to one module and, by the canbus, virtually connected to any other module of the net.
Page 241 Maintenance The options are : PRESENT : A maintenance hour-counter is incremented with key ON. When the hours elapsed reach the programmed value with the display the warning SERVICE REQUIRED is shown. ABSENT : No SERVICE REQUIRED warning Maintenance done It can be ON/OFF.
Page 242: Config Menu
DESCRIPTION OF CONSOLE USING 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. This functionality allows completely control of every ZAPI product without changing the position of the console connector.
Page 243 Flow chart showing how to make changes to option menu: Opening Zapi menu. 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. SET OPTIONS menu appears.
Page 244 Flow chart showing how to use the TESTER function of the digital console: 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. The display will show: TESTER.
Page 245 DESCRIPTION OF ALARM 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 and the hour meter count. This function permits deeper diagnosis of problems as the recent history can now be accessed.
Page 246: Maintenance
Graphic Smart Display menu structure by the six operator buttons integrated in a membrane keyboard. At turn on the display shows the HYUNDAI logo for some seconds, then asks the starting password to have access to the main page (if "USER PASSWORD" option is ON), otherwise it shows directly the main page (if "USER PASSWORD"...
Page 247: Track Menu
ENTER PASSWORD ENTER USER PASSWORD SERVICE / ENGINEERING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 PERFORMANCE ROLLING D 247 :...
Page 248 ZAPI CONSOLE TRUCK MENU The display will act like a Zapi console. MAINTENANCE HOURS MAINTENANCE 00000 CHANGE PASSWORD ENTER OLD PASSWORD - - - - 1 2 3 4 5 6 7 8 9 ENTER OLD PASSWORD ENTER NEW PASSWORD - - - - 1 2 3 4 5 6 7 8 9 PASSWORD HAS...
Page 249 Performance rolling From MAIN PAGE using membrane keyboard numbers, it is possible to select the performance mode which must be used in traction and pump controllers. Performance can be chosen with button 4, and it is displayed in the top right side of the unit. When one performance is selected, the related information will be sent via canbus to traction and pump controllers that will manage this data.
Page 250 ANALYSIS OF GRAPHIC SMART DISPLAY RELATED ALARMS Graphic Smart Display alarms WATCHDOG Cause: At start-up the watch dog signal is already active before the software has generated it. At standby or running condition the watch dog signal is not active (in alarm status). Troubleshooting: The WD hardware circuit or microcontroller output port are damaged.
Page 251 CAN BUS KO Cause: Graphic Smart Display doesn't receive messages from canbus line or the hour meter synchronization at key-on fails. Troubleshooting: A) If this fault code is displayed together with other alarm messages, the fault is probably to be looked for in the Graphic Smart Display can interface, since the display seems to be unable to receive any can message.
Page 252: Diagnostic Fault Codes
10 10) DIAGNOSTIC FAULT CODES DIAGNOSTIC FAULT CODES (1) (1) Traction controller raction controller Condition that has to occur to come out from Code Alarm name Description alarm status EEPROM KO Warning: Eeprom fault, - To remove Warning cause controller will use default parameters LOGIC FAILURE #3 Alarm: failure in over-load To remove alarm condition + activation of...
Page 253 Condition that has to occur to come out from Code Alarm name Description alarm status CAPACITOR Alarm: power capacitor To remove alarm condition Check the contactor resistance (300 Ω, 10W) CHARGE voltage does not increase when the key is turned Check the controller ON;...
Page 254 Condition that has to occur to come out Code Alarm name Description from alarm status AUX COIL SHORT Alarm: shortcircuit on EB/AUX - To remove alarm cause coil VACC OUT RANGE Waring: The accelerator input - Try to perform a program VACC is out of the range Vacc_min ÷...
Page 255: Motor Stall
Condition that has to occur to come out Code Alarm name Description from alarm status MOTOR STALL Warning: the encoder signal To recycle the key is constantly zero when the Check the motor and encoder maximum torque is applied to the motor Warning: an incorrect start - To remove Warning cause...
Page 256 (2) (2) Pump controller ump controller Condition that has to occur to come out from Code Alarm name Description alarm status EEPROM KO Warning: Eeprom fault, - To remove Warning cause controller will use default parameters LOGIC FAILURE #3 Alarm: failure in over-load To remove alarm condition + activation of protection hw circuit pump request...
Page 257 Condition that has to occur to come out from Code Alarm name Description alarm status CAPACITOR Alarm: power capacitor To remove alarm condition Check the contactor resistance (300 Ω, 10W) CHARGE voltage does not increase when the key is turned Check the controller"...
Page 258 Condition that has to occur to come out Code Alarm name Description from alarm status ACQUIRE FT3 Warning: FT3 acquisition is - Make a new acquisition wrong (shift) ACQUIRE FT2 Warning: FT2 acquisition is - Make a new acquisition wrong (tilt) ACQUIRE FT1 Warning: FT1 acquisition is - Make a new acquisition...
Page 259: Analog Input
Condition that has to occur to come out Code Alarm name Description from alarm status HANDBRAKE W a r n i n g : h a n d b r a k e - To remove Warning cause microswitch is open and a travel request is active CURRENT GAIN Wa r n i n g : T h e M a x i mu m...
Page 260: Battery Charger
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 261 (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 7-81...
Page 262 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 263 3) 3) HOW TO USE A CHARGER HOW TO USE A CHARGER (1) (1) General charging method (Floating General charging method (Floating charging) charging) ① Charging by this method supplies electric power to the charger as operating external AC power switch of the charger. ②...
Page 264 ② 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 265 ⑥ If charger's out voltage is under 60 V, it is abnormal. Please refer to the error sheet. ⑦ 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 266 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 267: Error Detection
5) 5) ERROR DETECTION ERROR DETECTION Error list Error list ① Only floating charge lamp is on in the monitor but it is not charged. ② ON and OFF is repeated with a few minutes intervals even after starting charging. ③...
Page 268 Troubleshooting Troubleshooting ① 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 70Ω/ ·...
Page 269 ② 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 270 ③ 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" → Over-voltage output / Set at 66V (In case of BATT 48V) In case error code is "O.V" Over-voltage output / Set at 66V (In case of BATT 48V) 34V (In case of BATT 24V) 34V (In case of BATT 24V)
Page 271 ④ 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 272 ⑤ 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 273 ⑥ 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 274 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 275 8) 8) PCB MAJOR PARTS (NAME AND LOCATION) PCB MAJOR PARTS (NAME AND LOCATION) ②Lp lamp Auto ⑬Auto/manual ④SHUNT Manual switch TAP detect current ⑫Auxiliary ③Detect connector power supply voltage ⑥Correct ⑦Correct ⑤Correct output CPU voltage output voltage current ⑧Monitor display output ⑩SCR control ①Controlling micro unit #1...
Page 276 22B9BAT27 7-96...
Page 277 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 7-97...
Page 278: Section 8 Mast
SECTION 8 MAST SECTION 8 MAST Group 1 Structure ------------------------------------------------------------------------------------------------------------ Group 2 Operational Checks and Troubleshooting ------------------------------------------------------ Group 3 Adjustment -------------------------------------------------------------------------------------------------------- 8-10 Group 4 Removal and Installation ---------------------------------------------------------------------------------...
Page 279: Group 1 Structure
SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) CARRIAGE TILT CYLINDER LIFT CYLINDER 10BTR9MS01 Outer mast Bronze bushing Chain wheel bearing Shim (0.5, 1.0t) Inner mast 10 Roller Roller Lift chain 11 Back up liner Tilt cylinder pin Anchor bolt 12 Shim(0.5, 1.0t)
Page 280 2. 3 STAGE MAST(TF MAST) CARRIAGE TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER 10BTR9MS02 Outer mast Shim(0.5, 1.0t) Sheave Middle mast Lift chain 10 Retaining ring Inner mast Anchor bolt 11 Bushing Roller Sheave bracket 12 Tilt cylinder pin...
Page 281 3. CARRIAGE, BACKREST AND FORK 10BTR9MS03 Backrest Load roller Extension fork Carriage Fork assembly...
Page 282: Group 2 Operational Checks And Troubleshooting
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. EX : =900mm(35.4in) mm(in) STD Fork assy Applicable model Standard Limit 64HT-12030 10/13/15BTR-9 35(1.4) 32(1.3) B153FK01 Set forks in middle and measure difference in height at top of forks.
Page 283 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 284 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 285: Group 3 Adjustment
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 286 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 287 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 288: Group 4 Removal And Installation
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 289 CARRIAGE LOAD ROLLER Remove carriage as outlined in the Carriage load roller carriage assembly removal paragraph. Loosen and remove flat head bolts and plain washers from top load roller bracket. Using a pryer, remove load rollers from load roller bracket. Reverse the above procedure to assemble.
Page 290 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 mast. Remove the spring pin. Chain Attach chains or sling to the inner and middle mast section at top crossmember.
Page 291 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 292 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 293 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 294 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 295 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 296 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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13btr-9 15btr-9

Hyundai 10BTR-9 Manual

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