Hyundai 15BCS-9 Manual
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Hyundai 15BCS-9 Manual

Hyundai 15BCS-9 Manual

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SECTION 1 GENERAL
Group 1 Safety hints ------------------------------------------------------------------------------------------------------ 1-1
Group 2 Specifications -------------------------------------------------------------------------------------------------- 1-4
Group 3 Periodic replacement -------------------------------------------------------------------------------------- 1-13
Group 1 Major components ----------------------------------------------------------------------------------------- 2-1
Group 2 Removal and installation of unit -------------------------------------------------------------------- 2-2
Group 1 Structure and operation --------------------------------------------------------------------------------- 3-1
Group 2 Troubleshooting ---------------------------------------------------------------------------------------------- 3-4
Group 3 Disassembly and assembly -------------------------------------------------------------------------- 3-6
Group 1 Structure and function ------------------------------------------------------------------------------------ 4-1
Group 1 Structure and function ------------------------------------------------------------------------------------ 5-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------ 5-12
Group 3 Disassembly and assembly --------------------------------------------------------------------------- 5-15
Group 1 Structure and function ------------------------------------------------------------------------------------ 6-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------ 6-13
Group 3 Disassembly and assembly --------------------------------------------------------------------------- 6-17
Group 1 Component location --------------------------------------------------------------------------------------- 7-1
Group 2 Electrical circuit ----------------------------------------------------------------------------------------------- 7-2
Group 3 Electric components --------------------------------------------------------------------------------------- 7-3
Group 1 Structure ---------------------------------------------------------------------------------------------------------- 8-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------ 8-3
Group 3 Adjustment ------------------------------------------------------------------------------------------------------ 8-6
Group 4 Removal and installation -------------------------------------------------------------------------------- 8-8
CONTENTS
CONTENTS

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  • Page 1: Table Of Contents

    CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints ------------------------------------------------------------------------------------------------------ 1-1 Group 2 Specifications -------------------------------------------------------------------------------------------------- 1-4 Group 3 Periodic replacement -------------------------------------------------------------------------------------- 1-13 SECTION 2 REMOVAL & INSTALLATION OF UNIT 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 SECTION 3 POWER TRAIN SYSTEM...
  • Page 2 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
  • Page 3 Revised edition mark (①②③…) Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.

  • Page 4: 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 Millimeters to inches 1 mm = 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...
  • Page 6 Liter to U.S. Gallon Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
  • Page 7 kgf·m to to lbf lbf·ft ft 1 kgf·m = 7.233 lbf·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...
  • Page 8 kgf/cm kgf/cm to to lbf/in lbf/in 1 kgf / cm = 14.2233 lbf / 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...
  • Page 9 TEMPERATURE 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 - -- -- -- -- -- -- -- -- -- -- - - - - -- - - -- - - -- - -- - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- 1-1 Group 2 Specifications -- -- -- -- -- -- -- -- -- - - - - - - -- - - -- - - -- - -- - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - 1-4 Group 3 Periodic replacement -- -- - - - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- 1-13...

  • Page 11: Group 1 Safety Hints

    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 Do not start or Maintenance in progress in progress). This will prevent anyone from starting or moving the truck by mistake. D50ASF07 When inspecting running parts or near such parts, always stop the machine first.
  • 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 GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS VIEW : A 18BCS9OM113 Mast Dashboard 11 Brake switch Lift cylinder Frame 12 Dead man switch Carriage and backrest Drive motor 13 Overhead guard Forks Drive wheel 14 Electric service brake Drive unit 10 Steering wheel...
  • Page 15 2. SPECIFICATIONS 2. SPECIFICATIONS C C' 18BCS9SP01 Model Unit 15BCS-9 18BCS-9 20BCS-9 Capacity kg (lb) 1361 (3000) 1588 (3500) 1814 (4000) ← ← Load center distance mm (in) 610 (24") Weight (Unloaded, with battery) kg (lb) 3862 (8514) 4074 (8981) 4211 (9283) ←...
  • Page 16 3. SPECIFICATION FOR MAJOR COMPONENTS 3. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) MOTOR MOTOR Item Unit Drive motor Hydraulic pump motor Model AMDD4004 ABDD4002 ← Type ← Rated voltage 30V 3Ø Output ← Insulation Class F 2) 2) BATTERY BATTERY Item Unit 15/18BCS-9...
  • Page 17 4) 4) GEAR PUMP GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity cc/rev 16.5 Maximum operating pressure Rated speed (max/min) 3000/500 5) 5) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Unit Specification Type 3 spool, 4 spool Operating method Electric Main relief valve pressure...
  • Page 18 9) 9) WHEELS WHEELS Item 15/18/20BCS-9 Type (Front/rear) Rubber / Urethane Quantity (Front/rear) 2 / 2 Ø308×178 Front wheel Ø254×127 Rear wheel 10 10) BRAKES BRAKES Item Specification Brakes (Service) Regen brake Brakes (Parking) Electric brake (2EA)
  • Page 19 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Items Size kgf·m lbf·ft Hyd pump motor mounting bolt M 8×1.25 2.5±0.5 18.1±3.6 Electric Drive motor mounting bolt M 8×1.25 1.5±0.2 10.8±1.4 system Steering motor mounting bolt M12×1.75 10.5±1.5 75.9±10.8 Hydraulic pump mounting bolt...

  • Page 20: Torque Chart

    5. TORQUE CHART 5. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread Bolt size kgf·m lbf·ft kgf·m lbf·ft M 6 × 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8 ×...
  • Page 21 2) 2) PIPE AND HOSE (FLARE TYPE) PIPE AND HOSE (FLARE TYPE) Width across flat (mm) Thread size kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" PIPE AND HOSE (ORFS TYPE) PIPE AND HOSE (ORFS TYPE) Width across flat (mm) Thread size kgf·m lbf·ft...

  • Page 22: Recommended Lubricants

    6. RECOMMENDED LUBRICANTS 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature °C (°F) Capacity ℓ (U.S. gal) Service Kind of fluid point 15/18/20BCS-9 (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) 0.45 ×...

  • Page 23: Group 3 Periodic Replacement

    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 24: Section 2 Removal & Installation Of Unit

    SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Major components -------------------------------------------------------------------------------------------- 2-1 Group 2 Removal and installation of unit ----------------------------------------------------------------------- 2-2...

  • Page 25: Group 1 Major Components

    SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 MAJOR COMPONENTS GROUP 1 MAJOR COMPONENTS 13 17 18BCS9RE01 Mast Tilt cylinder 17 Hydraulic pump Lift cylinder 10 Drive wheel 18 Overhead guard Main control valve 11 Pump controller 19 Rear work lamp (opt) Free lift cylinder...

  • Page 26: Group 2 Removal And Installation Of Unit

    GROUP 2 REMOVAL AND INSTALLATION OF UNIT GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST 1. MAST 1) 1) REMOVAL REMOVAL 18BCS9RE000 (1) (1) Forks Forks Knob Backrest Rolled pin ①...
  • Page 27 ② While supporting lift chains, remove the split pins and nuts from the anchor bolts and slide out chain anchor bolts from the chain anchors of stationary upright. Outer mast Split pin 18BCS9RE05 Inner mast Free lift chain Split pin Free lift cylinder 18BCS9RE05-1...
  • Page 28 ④ Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage to work area and lower the Inner mast mast. Make sure that carriage remains on Make sure that carriage remains on Free lift chain floor and does not bind while mast is floor and does not bind while mast is being raised.
  • Page 29 (4) (4) Piping Piping ① Disconnect the return hoses attached to the lift cylinder. ② Remove the return hoses from the pipe Inner (2). mast ③ Remove the velocity fuse valve (1) from the lift cylinder. Bolt ④ Disconnect and remove the free lift hose. ⑤...
  • Page 30 (5) (5) Free lift cylinder Free lift cylinder ① Bind the free lift cylinder with overhead Inner mast hoist rope and pull up so that the rope has no slack or binding. Middle mast ② Loosen the bolts and remove clamp, shims securing the free lift cylinder to inner mast.
  • Page 31 (7) (7) Inner mast Inner mast ① Using an overhead hoist raise the inner mast straight and carefully draw out of Inner mast middle mast section. Be careful the mast not to swing or fall. Be careful the mast not to swing or fall. Middle mast Outer mast 18BCS9RE12...

  • Page 32: Installation

    2) 2) 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. (1) (1) Brone bushings Brone bushings ① Check the inside of the bronze bushings for wear which are the contact area with the mast mounting pins.

  • Page 33: Power Train Assembly

    2. POWER TRAIN ASSEMBLY 2. POWER TRAIN ASSEMBLY 1) 1) REMOVAL REMOVAL 18BCS9RE001 (1) (1) Mast Mast Refer to section on mast (page 2-2). Disconnect the battery cable. Disconnect 18BCS9OM120 Front cover. Knob ① Loosen bolt and remove the lock bracket. ·Tightening torque : 0.85~1.25 kgf ·...
  • Page 34 ② Disconnect the cables and harness to the drive motor assembly. Wiring 18BCS9RE16 Jack up the frame and support both side of frame on wood block. 18BCS9JB09A Loosen hub bolt and remove the tire. Hub bolt 18BCS9RE17 (7) (7) Drive motor assembly Drive motor assembly Loosen the mounting socket bolt and remove the drive motor with the electric...
  • Page 35 (8) (8) Drive unit assembly Drive unit assembly Loosen the mounting socket bolts and remove the drive unit carefully. Socket bolt 18BCS9RE20 2) 2) INSTALLATION INSTALLATION Installation is in the reverse order to removal, but be careful of following points. Drive unit mounting bolts (M14×2.0) ·Tightening torque : 14~18 kgf·m (101~130 lbf·ft)

  • Page 36: Electrical Components

    3. ELECTRICAL COMPONENTS 3. ELECTRICAL COMPONENTS Before removing each component, disconnect cables and earth lines attached to the component. 1) 1) REMOVAL REMOVAL 18BCS9RE002 (1) (1) PUMP MOTOR PUMP MOTOR ※ Drain the oil before disassembling the pump motor. ① Disconnect the battery cable.
  • Page 37 ③ Disconnect the cables and wirings from Pump & motor assembly pump & motor assembly. ④ Disconnect the suction hose and the hose assembly. Priority valve Wiring Hyd tank Hose 18BCS9RE15 ⑤ Loosen mounting nuts from the bracket. Mounting nut 18BCS9RE15-1 ⑥...

  • Page 38: Drive Motor

    (2) (2) DRIVE MOTOR DRIVE MOTOR ① Disconnect the battery cable. Disconnect 18BCS9OM120 ② Remove the front cover. Knob Front cover 18BCS9RE41 ③ Disconnect the harness to the electric brake assembly. Disconnect 18BCS9RE13A ④ Disconnect the cables and harness to the drive motor assembly.
  • Page 39 ⑤ Tie wire rope around the drive motor not to drop. 18BCS9RE23 ⑥ Remove socket bolts connecting the motor and drive unit and lift up slowly. Socket bolt 18BCS9RE22A ⑦ Put the motor on the clean work bench. 18BCS9RE24 2-15 2-15...
  • Page 40 (3) (3) BATTERY BATTERY ① Disconnect the battery connector. Disconnect 18BCS9OM120 ② Pull the side plate out. Side plate 18BCS9OM121A ③ Adjust the height of the roller of the stand to that of the roller of the truck and pull the battery out carefully.
  • Page 41 2) 2) INSTALLATION INSTALLATION Installation is in the reverse order to removal, but be careful of following points. (1) (1) PUMP MOTOR PUMP MOTOR Pump & motor assembly ① Pump motor mounting nut. (M8×1.25) ·Tightening torque : 2.0~3.0 kgf·m Hex bolt (14.5~21.7 lbf·ft) ②...
  • Page 42 ③ Connect the battery connector. Connect 18BCS9OM120A 2-18 2-18...
  • Page 43 4. STEERING AXLE ASSEMBLY 4. STEERING AXLE ASSEMBLY 18BCS9RE003 1) 1) REMOVAL REMOVAL Disconnect the battery cable. Disconnect 18BCS9OM120 Loosen the bolt and remove the inner cover. Inner cover Bolt 18BCS9RE28 Disconnect the harness from the steering sensor. Hose Disconnect Disconnect the hoses from the steering Steering motor hydraulic motor.
  • Page 44 Loosen the nut and remove the steering sensor and lever. Steering sensor Lever 18BCS9RE50 Loosen the socket bolt and remove the Socket bolt bracket. Pull the spring pin out. Spring pin Bracket 18BCS9RE51 Loosen the bolt and spring washer. Hydraulic motor Remove the steering hydraulic motor with steering pinion carefully.
  • Page 45 (11) Loosen the wheel nut and remove the tire and rim assembly. Tire & rim assembly Bearing Bolt Washer Wheel nut Cover 18BCS9RE54 (12) Pull the spring pin out. Castle nut (13) Loosen the castle nut and remove the steering gear assembly. Steering gear Spring pin 18BCS9RE55...
  • Page 46 2) 2) INSTALLATION INSTALLATION Bolt (1) Installation is in the reverse order to Hydraulic motor removal, but be careful of the following points. Steering axle assembly mounting bolt (1). ·Tightening torque : 14~18 kgf·m (101~130 lbf·ft) Sepcial washer ※ Apply loctite #277 on the thread of the bolt Bolt (2) before tightening.
  • Page 47 (5) (5) Steering sensor assembling Steering sensor assembling Steering sensor ① Fit the steering sensor into the bracket. Bracket 18BCS9RE61 ② Turn the shaft of the steering sensor clockwise to the maximum. Maximum 18BCS9RE62 ③ Align the groove of the steering sensor shaft with the lever in a straight line and fit them with the bolt and nut.

  • Page 48: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation ------------------------------------------------------------------------------------ 3-1 Group 2 Troubleshooting ------------------------------------------------------------------------------------------------- 3-5 Group 3 Disassembly and assembly ------------------------------------------------------------------------------ 3-6...

  • Page 49: Group 1 Structure And Operation

    SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION GROUP 1 STRUCTURE AND OPERATION 1. DRIVE UNIT 1. DRIVE UNIT 1) 1) STRUCTURE - LH STRUCTURE - LH 18BCS9DU001 Elastic ring 13 Planetary carrier 25 O-ring 37 Magnetic plug Wheel hub bolt...
  • Page 50 STRUCTURE - RH STRUCTURE - RH 18BCS9DU002 Elastic ring 13 Planetary carrier 25 O-ring 37 Magnetic plug Wheel hub bolt 14 Planet gear 26 Roller bearing 38 Screw Gearbox cover - RH 15 Gearbox housing 27 Ball bearing 39 Screw Planetary ring gear 16 Spacer 28 Ball bearing...

  • Page 51: Specification

    2. SPECIFICATION 2. SPECIFICATION Item Unit Specification Gear ratio 27.1 ℓ Oil quantity 0.45 × 2EA...

  • Page 52: Operation

    3. OPERATION 3. OPERATION The drive units are composed of the drive unit (LH) and the drive unit (RH) which are connected with the motor as a power transmission system to assemble the drive wheel for the battery type fork lift. 18BCS9DU003 Drive unit (LH) Drive unit (RH)

  • Page 53: Group 2 Troubleshooting

    GROUP 2 TROUBLESHOOTING GROUP 2 TROUBLESHOOTING Problem Problem Cause Cause Remedy Remedy ·Refill the oil ·Lack of oil 1. Consecutive noise in the 1. Consecutive noise in the ·Incorrect contact between planetary ·Disassemble, check and readjusting housing housing gear and driving gear ·Damage, wear planetary gear and ·Replace damaged or wear gear driving gear...

  • Page 54: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY 1. DISASSEMBLY ※ During assembly and disassembly activities use caution and proper safety equipment, in observance of the rules provided by safety laws. 1) 1) GEARBOX DISASSEMBLY GEARBOX DISASSEMBLY Remove the oil from gearbox.
  • Page 55 Insert 2 grub screws in the threaded hole extraction of the cover. Threaded hole axtraction Screw 18BCS9DU103 Insert 2 screws in the threaded hole extraction of the cover. Screw ※ Pay attention not to damage components. ※ Compulsory requirement. 18BCS9DU104 Tighten the screws and so remove the gearbox cover.
  • Page 56 Remove the grub screws from the housing. ※ Pay attention not to damage components. ※ Compulsory requirement. Screw 18BCS9DU106 Using the appropriate pliers remove the Snap ring snap rings of the planetary carrier. ※ Pay attention not to damage components. 18BCS9DU107 U s i n g t h e e x t r a c t o r r e m o v e t h e assembled planet gears.
  • Page 57 Using the appropriate wrench remove the locknut. ※ The crushing must be cut out before to removing the locknut. ※ Pay attention not to damage components. ※ Compulsory requirement. Locknut Locknut crushing 18BCS9DU109 (10) Place the gearbox on 3 pins and using the press push the hub and so remove it.
  • Page 58 (11) Using the appropriate wrench remove the screws of the planetary ring gear. Screw 18BCS9DU111 (12) Then remove the planetary ring gear. Planetary ring gear 18BCS9DU112 3-10...

  • Page 59: Cover Disassembly

    2) 2) COVER DISASSEMBLY COVER DISASSEMBLY Remove the input shaft seal. Seal 18BCS9DU113 Using the appropriate pliers remove the snap ring. Snap ring 18BCS9DU114 Remove the input shaft assy. Use the press if necessary. Crush hazard : keep hands clear. Crush hazard : keep hands clear.
  • Page 60 Insert 3 M8 screws in the threaded holes of the sun gear. ※ Pay attention not to damage components. ※ Compulsory requirement. Screw 18BCS9DU117 For remove the sun gear tighten the screws. ※ Pay attention not to damage components. Sun gear 18BCS9DU118 3-12...
  • Page 61 2. DISASSEMBLY 2. DISASSEMBLY 1) 1) COVER DISASSEMBLY COVER DISASSEMBLY Place the spur gear on the tool and place on it the snap ring. Snap ring 18BCS9DU119 Place the bearing on the sun gear and Press piston using the press insert it. Crush hazard : keep hands clear.
  • Page 62 Using the appropriate pliers insert the snap ring and so block the sun gear. Snap ring 18BCS9DU123 Place the input shaft assy on the gearbox cover and insert it using the press. Press piston ※ Use the tool for this operation. Crush hazard : keep hands clear.

  • Page 63: Gearbox Assembly

    2) 2) GEARBOX ASSEMBLY GEARBOX ASSEMBLY Planetary ring gear Insert the planetary ring gear in the gearbox housing. ※ Pay attention not to damage components. ※ Compulsory requirement. 18BCS9DU127 Spread with medium threadlocker the screws and place them in the appropriate seat.
  • Page 64 Place the bearing in the hub and using the press insert it. Bearing ※ The bearing must be heated for this operation (about 80 ˚C). ※ Use an appropriate tool to push the bearing. ※ Pay attention not to damage components. ※...
  • Page 65 Place a planet gear assy on a planetary Planetary gear gear pin and, using the press, insert it. Repeat the operation for all planet gears assy. Press piston 18BCS9DU133 Using the appropriate pliers insert the snap rings on the planet gears. Snap ring 18BCS9DU134 Spread with liquid gasketing the housing.
  • Page 66 (11) Insert the screws and tighten them using the following torque : M8 : 3.6 kgf · m (26.0 lbf · ft) M10 : 7.1 kgf · m (51.4 lbf · ft) M14 : 24.0 kgf · m (174 lbf · ft) ※...

  • Page 67: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and function --------------------------------------------------------------------------------------- 4-1...

  • Page 68: Group 1 Structure And Function

    SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. STRUCTURE 1. STRUCTURE 10BOP7EB01 Inductor Flange Friction disc Screw Adjusting spacer 2. SPECIFICATION 2. SPECIFICATION Item Unit Specification Nominal torque (Standard version) Nominal airgap (S+0.1/-0.5) 0.35 Ø...

  • Page 69: Pre-Installation Checks

    Hyundai, in the same way than any use out of the contractual specifications accepted by Hyundai, will result in the warranty being invalidated and Hyundai will no longer be liable in Hyundai, will result in the warranty being invalidated and Hyundai will no longer be liable in any way with regard to conformity.

  • Page 70: Reassembly And Installation

    5. REASSEMBLY AND INSTALLATION 5. REASSEMBLY AND INSTALLATION PK brakes are delivered completely assembled. Put the key into the shaft then slide the hub (3) onto the shaft and secure it axially by suitable means. Slide the brake onto the hub (3), taking care not to damage the splines of the disc (2).

  • Page 71: Maintenance

    Put the new friction disc into position, fit the flange (4) and the assembly screw (5) secured with loctite 221 or similar. Assembly screws BRP7EB04 7. ELECTRICAL CONNECTION 7. ELECTRICAL CONNECTION 1) 1) IMPORTANT RECOMMENDATIONS IMPORTANT RECOMMENDATIONS All works on the electrical connections have to be made with power off. All works on the electrical connections have to be made with power off.

  • Page 72: 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 -------------------------------------------------------- 5-12 Group 3 Disassembly and Assembly ----------------------------------------------------------------------------- 5-15...

  • Page 73: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE Steering handle Steering column Steering unit Steering hydraulic Hyd tank motor Steering sensor Steering axle Priority valve Steering wheel Hydraulic gear pump 18BCS9SS01...

  • Page 74: Hydraulic Circuit

    2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT 18BCS9SS26 Hydraulic gear pump Suction strainer Priority valve 10 Return filter Steering unit 11 Hydraulic tank Steering hydraulic motor...
  • Page 75 (1) (1) NEUTRAL NEUTRAL 18BCS9SS04 The steering wheel is not being operated so control spool (G) does not move. The oil from the hydraulic gear pump (1) enters P port of the steering unit (4) through the priority valve (4) and standby for steering system. Almost all of pump flow goes to the attachment system (main control valve) through the EF port and partly flows into the hydraulic tank (11) through the control spool (G).
  • Page 76 (2) (2) LEFT TURN LEFT TURN 18BCS9SS06 When the steering handle 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 77: Right Turn

    (3) (3) RIGHT TURN RIGHT TURN 18BCS9SS08 When the steering handle 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 78 3. STEERING UNIT 3. STEERING UNIT 1) 1) STRUCTURE STRUCTURE Hydraulic circuit 25-1 25-2 25-4 25-3 SECTION B-B 24-2 24-1 24-3 24-4 24-6 24-5 SECTION A - A 18BCS9SE32 Dust seal 10 O-ring 19 Cap screw 24-4 Spring seat Retaining ring 11 Rolled screw 20 Housing 24-5 Plug...
  • Page 79 2) 2) 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.
  • Page 80 4. STEERING HYDRAULIC MOTOR 4. STEERING HYDRAULIC MOTOR 1) 1) STRUCTURE STRUCTURE 15 18 18BCS9SE33 Spigot flange Distributor plate 17 Output shaft Screw 10 End cover 18 Parallel key Dust seal 11 Washer 19 Cardan shaft Shaft seal 12 Drain plug 20 Screw O-ring 13 Washer...
  • Page 81 5. PRIORITY VALVE 5. PRIORITY VALVE 1) 1) STRUCTURE STRUCTURE HYDRAULIC CIRCUIT 18BCS9SE06 Plug Spool Plug Seal Housing Orifice Spring 2) 2) OPERATION OPERATION The oil from the hydraulic gear pump flows to the priority valve. The priority valve supplies a flow of oil to the steering system and lift, tilt system. The steering flow is controlled by the steering unit to operate the steering hydraulic motor.
  • Page 82 6. STEERING AXLE AND WHEEL 6. STEERING AXLE AND WHEEL 1) 1) STRUCTURE STRUCTURE STEERING SENSOR STEERING HYDRAULIC MOTOR FRAME 18BCS9SE24-1 Steering axle assy 1-7 Bearing Lever 15 Spring washer 1-1 Steering axle wa Bolt Hexagon bolt 16 Ball beating 1-2 Bracket Spring washer 10 Spring washer...
  • Page 83 2) 2) TIGHTENING TORQUE AND SPECIFICATION TIGHTENING TORQUE AND SPECIFICATION SECTION A-A Socket bolt 9-12 kgf m (65.1~86.8 lbf ft) Axle mounting bolt 14~18 kgf m (101~130 lbf ft) Socket bolt 2-3 kgf m (14.5~21.7 lbf ft) Apply loctite #277 on the thread of the bolt before tightening. 18BCS9SE25 Item Unit...

  • Page 84: Group 2 Operational Checks And Troubleshooting

    Ask assistant to drive machine at minimum turning radius. · Fit bar and a piece of chalk at outside edge of counterweight to mark line of turning radius. · Min turning radius (Outside) 15BCS-9 1397 mm (4' 7")) 18BCS-9 1397 mm (4' 7")) 20BCS-9 1467 mm (4' 10") Hydraulic pressure of power Remove plug from outlet port of flow divider and install oil pressure gauge.
  • Page 85 Problem Problem C Cause ause Remedy Remedy ·Lockout loosening. ·Retighten. Steering wheel turns unstea- ·Metal spring deteriorated. ·Replace. dily. ·Gear backlash out of adjustment. ·Adjust. Steering system makes abn- ·Lockout loosening. ·Retighten. ormal sound or vibration. ·Air in oil circuit. ·Bleed air.

  • Page 86: Power Steering Unit

    POWER STEERING UNIT POWER STEERING UNIT Problem Problem Cause Cause Remedy Remedy ·Fittings loose, worn, or damaged. ·Check and replace the damaged Oil leakage parts. ·Deteriorated seals by excessive heat. ·Replace the seals. ·Loose screw or its deteriorated ·Replace the sealing and tighten sealing.

  • Page 87: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT 1. STEERING UNIT 1) 1) STRUCTURE STRUCTURE 24-5 24-6 24-4 24-3 24-1 24-2 25-3 25-2 25-4 25-1 18BCS9SE05 Dust seal 10 O-ring 19 Cap screw 24-4 Spring seat Retaining ring 11 Rolled screw 20 Housing...
  • Page 88 TOOLS 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 5-16...

  • Page 89: Tightening Torque

    Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1 kgf·m (0~54.4 lbf·ft) 13 mm socket spanner 6, 8 mm and 12 mm hexagon sockets 12 mm screwdriver 2 mm screwdriver 13 mm ring spanner 6, 8 and 12 mm hexagon socket spanners Plastic hammer Tweezers 5-70(2)
  • Page 90 4) 4) DISASSEMBLY 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 off the unit. Take out the two O-rings.
  • Page 91 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball and suction valve pins and balls. D353SE09 5-19 5-19...
  • Page 92 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 93 (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 Disassembling the pressure relief valve (15) Screw out the plug using an 8mm hexagon socket spanner.
  • Page 94 (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) T h e p r e s s u r e r e l i e f v a l v e i s n o w disassembled.
  • Page 95 5) 5) ASSEMBLY 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 96 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 97 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) ※ Assembly pattern for standard bearings Assembly pattern for standard bearings Outer bearing race Thrust bearing Inner bearing race Spool Sleeve 5-78(3) Installation instruction for O-ring Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 98 (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 99 (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 Installation instructions for lip seal (15) Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 100 (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 101 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20 °C . 5-82(2) (23) Place the distributor plate so that the...
  • Page 102 (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 103 (29) Fit the special screw with washer and place it in the hole shown. 5-84(2) (30) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ·Tightening torque : 4.0±0.5 kgf·m (28.9±3.6 lbf·ft) 5-84(3) (31) Place the dust seal ring in the housing.
  • Page 104 (33) Press the plastic plugs into the connection ports. ※ Do not use a hammer! 5-85(2) 5-32...
  • Page 105 2. HYDRAULIC MOTOR 2. HYDRAULIC MOTOR 1) 1) DISASSEMBLY DISASSEMBLY (1) (1) Seal plugs Seal plugs Put the motor in a holding tool, with the output shaft downward. For end port version, use 10 mm (0.4 in) hexagon socket spanner. Seal plug B15T5SM01 (2) (2)
  • Page 106 Cardan shaft, plate, O-ring. Remove orderly. Distributor plate O-ring Cardan shaft B15T5SM05 (6) (6) Output shaft Output shaft Shaft and bearings should normally not be removed from housing. However, if necessary for inspecfion and cleaning, Output shaft remove the shaft from the housing front end.
  • Page 107 (9) (9) Dust seal, needle bearing Dust seal, needle bearing Use a 4 mm (0.16 in) screw driver. Housing Needle bearing Dust seal B15T5SM09 5-35 5-35...
  • Page 108 2) 2) ASSEMBLY ASSEMBLY · Clean all parts carefully with low aromatic kerosine · Check all parts carefully and replace if necessary · Before assembly, lubricate all parts with hydraulic oil and grease rubber parts with vaseline. (1) (1) Needle bearing Needle bearing Place needle bearing onto the output shaft side.
  • Page 109 (4) (4) Bearing race, O-ring Bearing race, O-ring Grease the O-ring with vaseline and fit the bearing race and O-ring into the spigot Housing flange. Bearing race O-ring B15T5SM14 (5) (5) Spigot flange Spigot flange Turn so that the holes line up. Housing Spigot flange B15T5SM15...
  • Page 110 (7) (7) Output shaft (1 1/4 inch splined shaft) Output shaft (1 1/4 inch splined shaft) The rear shaft end of 1 1/4 inch splined Output shaft shafts must be marked before fitted. The mark must be positioned vertically above a communication slot leading up to the front annular channel.
  • Page 111 (11) (11) Gear wheel set Gear wheel set Caution! Place the gearwheel set on the cardan Parts can fall Gear wheel set shaft so that the top of a tooth in the external teeth of the gearwheel are vertically above the key slot in the output shaft (cylindrical or tapered) or the top of a tooth on a 1 inch splined shaft.
  • Page 112 (14) (14) Washer, drain plug Washer, drain plug Drain plug Use a 19 mm spanner socket. Washer ·Tightening torque : 3~6 kgf·m (21.7~43.4 lbf·ft) B15T5SM24 (15) (15) Seal plugs (threaded plugs) Seal plugs (threaded plugs) Side port version. Screw plastic plugs. Seal plug B15T5SM25 5-40...
  • Page 113 3. PRIORITY VALVE 3. PRIORITY VALVE 1) 1) STRUCTURE STRUCTURE 18BCS9SE08 Plug Spool Plug Seal Housing Orifice Spring 5-41 5-41...
  • Page 114 DISASSEMBLY DISASSEMBLY ※ Cleanliness is the primary means of assuring satisfactory the priority valve life. Select clean place. Before removing the piping, clean the surrounding area of valve ports. Fix the housing (5) in a vise with copper or lead sheets. Do not over tighten jaws.
  • Page 115 Remove plug (1) and separate seal (2) and plug (1, 7) individually. 18BCS9SE17 3) 3) ASSEMBLY ASSEMBLY ※ Clean all metal parts in clean solvent and blow dry with air and correct any damage, burrs and rust. ※ Do not wipe dry with cloth or paper towel. ※...
  • Page 116 Install the seal (2) onto plug (1, 7) and install the plug (1, 7) into the housing (5). ·Tighten torque : 4.5 kgf · m (32.5 lbf · ft) 18BCS9SE14 5-44 5-44...
  • Page 117 4. STEERING AXLE AND WHEEL 4. STEERING AXLE AND WHEEL 1) 1) STRUCTURE STRUCTURE STEERING SENSOR STEERING HYDRAULIC MOTOR FRAME 18BCS9SE24-1 Steering axle assy 1-7 Bearing Lever 15 Spring washer 1-1 Steering axle wa Bolt Hexagon bolt 16 Ball beating 1-2 Bracket Spring washer 10 Spring washer...
  • Page 118 2) 2) CHECK AND INSPECTION CHECK AND INSPECTION Fill the Shell retinax grease up to base line of upper taper roller bearing (if disassembled) Taper roller bearing Apply grease on the surface of seal lip 18BCS9SS15 Check for any bend or twist. Slight bend or twist can be straightened by press, however, if not, replace the axle.

  • Page 119: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function -------------------------------------------------------------------------------------- 6-1 Group 2 Operational checks and troubleshooting -------------------------------------------------------- 6-13 Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 6-17...

  • Page 120: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 1. HYDRAULIC CIRCUIT 18BCS9HS01 Hydraulic gear pump Lift cylinder Priority valve Suction strainer Main control valve Down safety valve Steering unit 10 Return filter Steering hydraulic motor...
  • Page 121 1) 1) WHEN THE JOYSTICK IS IN THE LIFT POSITION WHEN THE JOYSTICK IS IN THE LIFT POSITION Steering system Return line 18BCS9HS02 When the joystick is pulled back, the solenoid valve (M1) on the main block is energized and then the spool moves to lift position.
  • Page 122 2) 2) WHEN THE JOYSTICK IS IN THE LOWER POSITION WHEN THE JOYSTICK IS IN THE LOWER POSITION Steering system Return line 18BCS9HS03 When the joystick is pushed forward, the solenoid valve (M2) on the main block is energized and then the spool moves to lower position.
  • Page 123 3) 3) WHEN THE JOYSTICK IS IN THE FORWARD POSITION WHEN THE JOYSTICK IS IN THE FORWARD POSITION Steering system Return line 18BCS9HS04 When the tilt button of the joystick is pushed forward position, the solenoid valve (M3) on the tilt block is energized and then the spool moves to tilt forward position.
  • Page 124 4) 4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION Steering system Return line 18BCS9HS05 When tilt button of the joystick is pushed the backward position, the solenoid valve (M4) on the tilt block is energized and then the spool moves to tilt backward position.
  • Page 125 2. HYDRAULIC GEAR PUMP 2. HYDRAULIC GEAR PUMP 1) 1) STRUCTURE STRUCTURE 14BRJ9HS19 Housing Rear cover 11 E-back up ring Body Oil seal 12 Pin Drive gear Snap ring 13 Washer Idle gear DU bushing 14 Hex bolt Side plate 10 E-seal 15 O-ring 2) 2)
  • Page 126 3. MAIN CONTROL VALVE 3. MAIN CONTROL VALVE STRUCTURE STRUCTURE (3 Spool) 1) 1) Port name Size Port 18BCS9HS12A Inlet port 1 1/16-12UN Outlet port 1 1/16-12UN Work port 1 1/16-12UN Work port 9/16-18 UNF A, B Main block 4-2 Disc 11 Hex socket screw Solenoid valve (Lift) 4-3 Circlip...
  • Page 127 2) 2) STRUCTURE STRUCTURE (4 Spool, Option) Port name Size Port Inlet port 1 1/16-12UN Outlet port 1 1/16-12UN Work port 1 1/16-12UN 18BCS9HS12 Work port 9/16-18 UNF A, B Main block 4-2 Disc 11 Adapter Solenoid valve (Lift) 4-3 Circlip 12 Hex socket screw 2-1 EVI coil 4-4 Black plug...

  • Page 128: Emergency Lowering

    3) 3) EMERGENCY LOWERING EMERGENCY LOWERING In case of the mast cannot be lowered due to a problem in the controller, active the emergency lowering valve on the valve block with hexagonal wrench. Turn off the electric emergency switch. Open the lowering valve using the 5mm hexagonal wrench.
  • Page 129 4. LIFT CYLINDER 4. LIFT CYLINDER (TF-MAST) 15, 16 17 18 20 10 8, 9 4, 5 11, 12 18BCS9HS33 Tube assy Spacer 15 Dust wiper Retaining ring 16 Retaining ring Piston 10 Stop ring 17 Rod bushing U-packing 11 Cushion seal 18 Spacer Back up ring 12 Retaining ring...
  • Page 130 5. FREE LIFT CYLINDER 5. FREE LIFT CYLINDER (TF-MAST) 11, 12 10 13, 14 18BCS9HS35 Tube assy Check valve 11 Dust wiper Retaining ring 12 Retaining ring Piston Set screw 13 O-ring Piston seal Grand cover 14 Back up ring Wear ring 10 U-packing 15 Pipe...

  • Page 131: Tilt Cylinder

    6. TILT CYLINDER 6. TILT CYLINDER 18 16 17 19,20,21 12 15 9 10,11 13,14 8 18BCS9HS19 Tube assembly Rod bushing 17 Spherical bushing 10 U-packing 18 Grease nipple Piston 11 Back up ring 19 Hexagon bolt Piston seal 12 Dust wiper 20 Spring washer Wear ring 13 O-ring...

  • Page 132: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS CHECK ITEM CHECK ITEM 1) 1) Check visually for deformation, cracks or damage of rod. Load maximum load, set mast vertical and raise 1m from ground. Wait for 2 minutes and measure hydraulic drift (amount forks move down and amount mast tilts forward).

  • Page 133: Troubleshooting

    2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) SYSTEM SYSTEM Problem Problem Cause Cause Remedy Remedy ·Seal inside control valve defective. ·Replace spool or valve body. Large fork lowering speed ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. ·Tilting backward : Check valve ·Clean or replace.

  • Page 134: Hydraulic Gear Pump

    2) 2) HYDRAULIC GEAR PUMP HYDRAULIC GEAR PUMP Problem Problem Cause Cause Remedy Remedy ·System relief valve set too low or ·Check system relief valve for proper Pump does not develop full pressure leaking. setting. ·Oil viscosity too low. ·Change to proper viscosity oil. ·Pump is worn out.

  • Page 135: Lift Cylinder

    4) 4) LIFT CYLINDER LIFT CYLINDER Problem Problem Cause Cause Remedy Remedy ·Foreign matters on packing. ·Replace packing. Oil leaks out from rod cover ·Unallowable score on rod. ·Smooth rod surface with an oil stone. through rod ·Unusual distortion of dust seal. ·Replace dust seal.

  • Page 136: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP 1. HYDRAULIC GEAR PUMP ※ Tools required Tools required ·Metric socket set ·Internal snap ring pliers ·Shaft seal sleeve ·Torque wrench It is very important to work in a clean work area when repairing hydraulic products.
  • Page 137 Lift and remove end cover. PUMP 03 Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts. PUMP 04 (10) Remove rear bearing block from drive and idler shafts. PUMP 05 (11) Remove idler shaft from bearing block.
  • Page 138 (12) Remove drive shaft from mounting flange. There is no need to protect the shaft seal as it will be replaced as a new item. PUMP 07 (13) Remove the front bearing block. PUMP 08 (14) Turn mounting flange over, with shaft seal up, and remove the retaining ring with proper snap ring pliers.
  • Page 139 (17) Remove seals from both bearing blocks and discard. PUMP 11 INSPECT PARTS FOR WEAR INSPECT PARTS FOR WEAR Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be replaced as new items.
  • Page 140 Inspect bearing blocks for excessive wear or scoring on the surfaces which are in contact with the gears. Also inspect the bearings for excessive wear or scoring. Inspect the area inside the gear housing. It is normal for the surface inside the gear housing to show a clean "wipe"...
  • Page 141 ASSEMBLY ASSEMBLY ※ New seals should be installed upon New seals should be installed upon reassembly of pump. reassembly of pump. Install new shaft seal in mounting flange with part number side facing outboard. Press the seal into the seal bore until the seal reaches the bottom of the bore.
  • Page 142 Insert the drive end of the drive shaft through the bearing block with the seal side down, and the open side of the E-seal pointing to the intake side of the pump. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal.
  • Page 143 (13) Gently slide the gear housing over the rear bearing block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place with hands, do not force or use any tool. Check to make sure the intake port in the housing in on the same side as the open end of the E-seal and that the marked lines on the mounting flange and gear...
  • Page 144 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. ·Tighten torque : 6~7 kgf·m (43.4~50.6 lbf·ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.

  • Page 145: Main Control Valve

    2. MAIN CONTROL VALVE 2. MAIN CONTROL VALVE Solenoid valve for lift Lift section block O-ring Solenoid valve for tilt Tilt section block Roll pin Auxiliary section block Adapter End plate Roll pin Adapter Hex nut 18BCS9HS34 1) 1) ASSEMBLY INSTRUCTION ASSEMBLY INSTRUCTION (1) (1) General...

  • Page 146: Disassembly Instruction

    (3) (3) Lift block solenoid assembly Lift block solenoid assembly ① The solenoide is installed upper side and below side cavities in lift block. Torque to 4.1 kgf·m (29.7 lbf · ft) ② Install the O-ring, coil, O-ring and washer to the assemblied cartridge. ③...
  • Page 147 3. LIFT CYLINDER (TF-MAST) 3. LIFT CYLINDER (TF-MAST) 1) 1) STRUCTURE STRUCTURE · I.D ×O.D×Stroke (standard, TF470) 45×55×1510 mm (1.8×2.2×59.4 in) · Rod O.D : 35 mm (1.4 in) 18BR9HS33 Tube assy 8 Spacer 15 Dust wiper Retaining ring 16 Retaining ring Piston 10 Stop ring 17 Rod bushing...
  • Page 148 2) 2) DISASSEMBLY DISASSEMBLY Hold the cylinder tube in a vice, loosen the cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn.
  • Page 149 4. FREE LIFT CYLINDER (TF-MAST) 4. FREE LIFT CYLINDER (TF-MAST) STRUCTURE STRUCTURE 1) 1) · I.D ×O.D×Stroke (standard, TF470) 65×76×840 mm (2.6×3.0×33.1 in) · Rod O.D : 45 mm (1.8 in) 18BCS9HS33A Tube assy Check valve 11 Dust wiper Retaining ring 12 Retaining ring Piston Set screw...
  • Page 150 2) 2) DISASSEMBLY DISASSEMBLY Hold the cylinder tube in a vice, loosen the cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn.
  • Page 151 5. TILT CYLINDER . TILT CYLINDER 1) 1) STRUCTURE STRUCTURE · I.D ×O.D×Stroke : 80×70×86 mm (3.1×2.8×3.4 in) · Rod O.D : 30 mm (1.2 in) 18BCS9HS15 Tube assembly Rod bushing 17 Spherical bushing 10 U-packing 18 Grease nipple Piston 11 Back up ring 19 Hexagon bolt Piston seal...
  • Page 152 2) 2) DISASSEMBLY DISASSEMBLY Hold the parallel parts of the cylinder tube bottom in a vice and mark the rod head end to show how much it is screwed in, then remove the rod head. Next, hook a wrench into the notch at the cylinder head and remove the cylinder head from cylinder tube.

  • Page 153: Section 7 Electrical System

    SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component location ----------------------------------------------------------------------------------------- 7-1 Group 2 Electrical circuit ------------------------------------------------------------------------------------------------- 7-2 Group 3 Electric components ----------------------------------------------------------------------------------------- 7-3...

  • Page 154: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION DETAIL A 18BCS9EL01 Start switch 13 Room lamp 25 Relay Switch board 14 Beacon lamp 26 Pump motor Cluster 15 Pressure sensor 27 Static strap Joystick 16 Pump controller 28 Fan...

  • Page 155: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT FUSE BOX ASS'Y ( UL #1 ) HORN BACK RELAY BUZZER RELAY BEACON RELAY 133A LAMP 133A REAR EMERGENCY BLUE ROOM HEAD WORK SWITCH SPOT LAMP LAMP LAMP SOCKET INPUT OUTPUT FAN- FAN- FAN- FAN-...

  • Page 156: 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 157 2. BATTERY 2. BATTERY 1) 1) STRUCTURE STRUCTURE 15/18BCS-9 20BCS-9 18BCS9EL03 Cells Round head screw Battery connector Weld nut Handle Spring washer...
  • Page 158 2) 2) GENERAL GENERAL As in the battery forklift, the battery is an energy source, the handling of the battery is very important. The life and performan- ce of the battery greatly depend on the ordinary handling and maintenance. Therefore, be sure to check and maintain the battery so that it may be kept best.

  • Page 159: Safety Precautions

    4) 4) SAFETY PRECAUTIONS SAFETY PRECAUTIONS (1) (1) When a sulfuric acid contact with skin 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 160 (2) (2) Performance and maintenance of batteries Performance and maintenance of batteries ① Initial charge 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.
  • Page 161 ④ Normal charge Normal charge Charge the discharged batteries as quickly as possible. The temperature of electrolyte before starting the charging operation shall preferably be below 45°C, and the temperature during the charge should be maintained at no higher than 55°C. (Under any unavoidable situations, it should never be above 55°C).
  • Page 162 (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 . a. a. Determination of replenishment time and methods (cell with ONE TOUCH CAP) 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 163 You must make sure to clear of explosive hydrogen gas in the cells before repairs. Be 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 careful not to drill to far into the cell and damage the unit.

  • Page 164: Troubleshooting

    7) 7) TROUBLESHOOTING TROUBLESHOOTING Nature of trouble Nature of trouble Symptoms Symptoms Causes Causes Corrective Action Corrective Action · · · Deformation Deformation of container. Excessive temperature Replace Lid or one touch cap rising or external impact · · · Breakage Electrolyte leakage acco- External impact, improper...
  • Page 165 3. DRIVE MOTOR 3. DRIVE MOTOR 1) 1) STRUCTURE STRUCTURE UL-EE 18BCS9EL06A Rotor assembly Speed sensor kit 11 Snap ring Stator assembly Stud bolt 12 Flange nut Endbell de Protector-terminal 13 Wave washer Endbell Bearing Block-terminal A 10 Sunk key 7-12...
  • Page 166 2) 2) SPECIFICATION SPECIFICATION Item Unit 15/18/20BCS-9 Type AMDU6001 Rated voltage Rated output Insulation Class F Speed 1750 Frequency 3) 3) MAINTENANCE INSTRUCTION AINTENANCE INSTRUCTION (1) (1) Inspection Inspection ① Rotor assembly Rotor assembly Rotor should always be cleaned with compressed air.
  • Page 167 (2) (2) Disassembly for AC motor Disassembly for AC motor ① Before disassembling motor, remove terminal protector from the motor and separate thermistor and speed sensor connectors from hanger. 18BR9EL44 18BR9EL45 ② Remove 3-nuts from terminal block of the motor to disassemble terminal block from the motor.
  • Page 168 ④ Remove 4 flange nuts with available general tool on the endbell drive side. 18BR9EL48 ⑤ Remove endbell de and wave washer. 18BR9EL49 ⑥ Remove stator assembly by hand or suitable tool. 18BR9EL50 7-15...
  • Page 169 ⑦ Remove endbell from rotor assembly by hand-puller as a right picture. 18BR9EL51 ⑧ The motor are composed of 5-parts (rotor assembly, stator assembly, enbell de, endbell, etc). 18BR9EL52 (3) (3) Assembly and installation Assembly and installation Clockwise rotation ① Perform assembly in the reverse order of disassembling.
  • Page 170 4. PUMP MOTOR 4. PUMP MOTOR STRUCTURE STRUCTURE 1) 1) 18BCS9EL16 Rotor assembly Block-terminal A Bearing Stator assembly Speed sensor kit 10 Oil seal Endbell De Stud bolt 11 Flange nut Endbell Protector-terminal 12 Wave washer 7-17...
  • Page 171 2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Type AMBP4001 Rated voltage Rated output 14.0 Insulation Class F Speed 2180 Freq. P.F. Duty S3-15 Voltage Current 3) 3) INSPECTION INSPECTION (1) (1) Rotor assembly Rotor assembly ① Rotor should always be cleaned with compressed air.
  • Page 172 Insulation test Use insulation tester (1000 Vac, Min. 10 Ω ) and measure as a picture. If the insulation is defective, replace with new parts. 18BR9EL43 4) 4) Disassembly for AC motor Disassembly for AC motor ① Before disassembling motor, remove terminal protector from the motor and separate thermistor and speed sensor connectors from hanger.
  • Page 173 ③ Remove 4 screw fixing speed sensor on the endbell side and then disassemble speed sensor, fixed nut and toothed wheel of the motor. 18BR9EL55 ④ Remove 4 flange nuts with available general tool on the endbell drive side. 18BR9EL56 ⑤...
  • Page 174 ⑥ Remove stator assembly by hand or suitable tool. 18BR9EL58 ⑦ Remove endbell from rotor assembly by hand-puller as a right picture. 18BR9EL51 ⑧ The motor are composed of 5-parts (rotor assembly, stator assembly, enbell de, endbell, etc). 18BR9EL59 5) 5) Assembly and installation Assembly and installation Clockwise rotation...

  • Page 175: Specifications

    5. CONTROLLER SYSTEM 5. CONTROLLER SYSTEM 1) 1) STRUCTURE STRUCTURE Traction controller Pump controller 18BCS9EL11 (1) (1) Specifications Specifications Model Model Application Type Power Current limit ACE2 Traction 48V, 350A×2 350A/3min 15/18/20BCS-9 ACE2 Pump 48V, 500A 500A/3min 7-22...

  • Page 176: Operational Features

    2) 2) OPERATIONAL FEATURES OPERATIONAL FEATURES (1) (1) Features Features ① Speed control. ② Optimum behavior an a slope due to the speed feedback: ·The motors speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set-point. ·The system can perform an electrical stop on a ramp (the machine is electrically hold on a slope) for a programmable time.

  • Page 177: Description Of The Connectors

    3) 3) DESCRIPTION OF THE CONNECTORS DESCRIPTION OF THE CONNECTORS (1) (1) Traction controller Traction controller 18BCS9EL11 ① Master Master No. of pin Function Description Input of the key switch signal. PPOT Potentiometer positive for steering sensor. BRAKE Input for brake digital input. ENABLE Input for foot switch digital input.
  • Page 178 No. of pin Function Description PLC/PEB Positive of main contactor coil / Electrical brake (RH). Electrical brake (RH) coil driver (drives to -Batt). If not connected to slave A11 (safety in), the MC coil power output will be SAFETY OUT disabled.
  • Page 179 ② Slave Slave No. of pin Function Description Input of the key switch signal. TRAVEL SR Input for travel speed reduction digital input. Input for SBR (Side Battery Removal) digital input. ENABLE FOOT Input for foot switch digital input. ENC A Left motor encoder phase A.
  • Page 180 (2) (2) Pump controller Pump controller 18BCS9EL11 No. of pin Function Description Input of the key switch signal. PPOT Potentiometer positive for tilt angle sensor and load sensor. CPOT Load sensor wiper signal. LIFT CUTBACK Input for lift cutback digital input. ENC A Pump motor encoder phase A.
  • Page 181 No. of pin Function Description CAN L Low level CAN-BUS voltage I/O. CAN H High level CAN-BUS voltage I/O. PTHERM Input for pump motor temperature sensor. NTHERM Negative of pump motor temperature sensor. 7-28...

  • Page 182: Function Configuration

    4) 4) FUNCTION CONFIGURATION FUNCTION CONFIGURATION ■ TRACTION CONTROLLER - MASTER TRACTION CONTROLLER - MASTER Using the CONFIG MENU of the programming console, the user can configure the following functions. (1) (1) Submenu Submenu "SET OPTIONS" "SET OPTIONS" ① Display Display - OFF: when display is not connected to the CAN bus.
  • Page 183 ⑩ Steer table Steer table OPTION#1 is a steer table of 20BCS-9 Truck. ⑪ Set mot. temperature Set mot. temperature It can be set : - ANALOG : An analogue sensor for the control of the motor temperature is connected to CNA#22.
  • Page 184 ⑫ Throttle Y2 map Throttle Y2 map This parameter changes the characteristic of the accelerator input curve. - Range = 0 - 100%, Resolution = 1% ⑬ Throttle X3 map Throttle X3 map This parameter changes the characteristic of the accelerator input curve. - Range = 0 - 100%, Resolution = 1% ⑭...
  • Page 185 M. pre warn time M. pre warn time Time to set the maintenance pre waring time before the maintenance time. Maintenance time Maintenance time Time setting for the maintenance time. Main cont. volt Main cont. volt It specifies the percentage of battery voltage supplied to MC coil to close the contactor. Aux output volt Aux output volt It specifies the percentage of battery voltage supplied to EB coil to apply the electro mechanic...
  • Page 186 (3) (3) Submenu " Submenu "PARAMETER CHANGE PARAMETER CHANGE" ① Acceleration 0 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. ② INV. accel 0 INV.
  • Page 187 ⑪ Decel braking Decel braking Seconds. It controls the deceleration ramp when the accelerator has turned down but not completely released. The parameter sets the time needed to decelerate the traction motor from 100 Hz to 0 Hz. ⑫ Pedal braking Pedal braking Seconds.
  • Page 188 FREQUENXY Frequency (Hz) (Hz) Max speed MAX SPEED FORW (BACK) Forw (back) Mid. curve ctb. MID. CURVE CTB. Curve ctb. CURVE CUTBACK MIDDLE SPEED DEAD MIDDLE STEER ANGLE Middle Speed dead Middle Speed angle ANGLE ANGLE ANGLE (Degree) angle angle angle (degree) 18BR9EL60...
  • Page 189 ■ TRACTION CONTROLLER - SLAVE TRACTION CONTROLLER - SLAVE Using the CONFIG MENU of the programming console, the user can configure the following functions. (1) (1) Submenu Submenu "SET OPTIONS" "SET OPTIONS" ① Hour counter Hour counter This option specifies the hour counter mode. It can be set one of two : - RUNNING : The counter registers travel time only.
  • Page 190 (2) (2) Submenu " Submenu "ADJUSTMENTS ADJUSTMENTS" ① Set battery type Set battery type It selectes the nominal battery voltage. ② Adjustments battery Adjustments battery Fine adjustment of the battery voltage measured by the controller. ③ Load HM from mdi Load HM from mdi Not used ④...
  • Page 191 ■ PUMP CONTROLLER PUMP CONTROLLER Using the config menu of the programming console, the user can configure the following functions. (1) (1) Submenu "SET OPTIONS" Submenu "SET OPTIONS" ① Seat switch Seat switch - HANDLE : CNA #6 is managed as tiller input (no delay when released). - SEAT : CNA #6 is managed as seat input (with a delay when released - debouncing function).
  • Page 192 (2) (2) Submenu "ADJUSTMENTS" Submenu "ADJUSTMENTS" ① Set battery type Set battery type It selectes the nominal battery voltage. ② Adjust battery Adjust battery Fine adjustment of the battery voltage measured by the controller. ③ Throttle 0 zone Throttle 0 zone It establishes a dead band in the lift potentiometer input curve.
  • Page 193 ⑭ Ref. load weight Ref. load weight This parameter is used to show and configurate the reference load weight. ⑮ Rated load w. Rated load w. This parameter is used to show and configurate the rated load weight. Max load weight Max load weight This parameter is used to show and configurate the trigger condition for LOAD SENSOR alarm.
  • Page 194 (3) (3) Submenu " Submenu "PARAMETER CHANGE PARAMETER CHANGE" ① Acceleration 0 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. ② Acceleration 1 Acceleration 1 It specifies the motor acceleration at ACC PROF.
  • Page 195 ⑫ Lift cutb. speed Lift cutb. speed It determines the lifting maximum speed when the lift cutback switch is open ⑬ 1st speed coarse 1st speed coarse It determines the pump maximum speed when speed1 switch is closed. ⑭ Auto fork speed Auto fork speed It determines the pump speed when the automatic fork leveling function is performed.
  • Page 196 Auxiliary time Auxiliary time Time units value (seconds). It is the time delay before close the EM brake when motor speed reach 0 rpm. Rollback speed Rollback speed Not used. Mot. sta max curr Mot. sta max curr It determines the maximum current when the motor is stalled. 7-43...

  • Page 197: Programming & Adjustments

    5) 5) PROGRAMMING & ADJUSTMENTS PROGRAMMING & ADJUSTMENTS There are two ways to adjust parameter via a console or buttons on a display. ※ Adjustments via buttons on a display, please refer to the display section. (page 7-64) ADJUSTMENTS VIA CONSOLE ADJUSTMENTS VIA CONSOLE (Option) Adjustment of parameters and changes to the inverter's configuration are made using the digital console.
  • Page 198 (2) (2) Description of standard console menu Description of standard console menu ① Traction controller - master Traction controller - master HEADING MAIN MENU ACCELERATION 0 PARAMETER SET MODEL CONNECTED TO 2 CHANGE INV. ACCEL 0 ACCELERATION 1 ACCELERATION 2 ACCELERATION 3 DISPLAY ON/OFF...
  • Page 199 ② Traction controller - slave Traction controller - slave HEADING MAIN MENU MAXIMUM CURRENT PARAMETER SET MODEL CONNECTED TO 2 CHANGE ROLLBACK SPEED FAN WORKING TEMP °C HOUR COUNTER RUNNING/KEY ON SET OPTIONS FAN RELAY COIL PRESENT / ABSENT BATTERY VOLTAGE TESTER COOLING FAN OPTION #1 / #2 / #3...
  • Page 200 ③ Pump controller Pump controller HEADING MAIN MENU ACCELERATION 0 PARAMETER SET MODEL CONNECTED TO 2 ACCELERATION 1 CHANGE ACCELERATION 2 ACCELERATION 3 ACC PROF.FREQ 1 SEAT SWITCH HANDLE / SEAT ACC PROF.FREQ 2 SET OPTIONS HOUR COUNTER RUNNING / KEYON ACC PROF.FREQ 3 STOP ON RAMP ON/OFF...

  • Page 201: Alarms Menu

    (3) (3) Description of Description of ALARMS ALARMS menu menu The microprocessor in the controller records the last five alarms that have occurred. Items remembered relative to each alarm are: the code of the alarm, the number of times the particular Alarm occurred, the hour meter count, and the inverter temperature.
  • Page 202 6) 6) TESTER MENU (IN DISPLAY, MONITORING MENU) TESTER MENU (IN DISPLAY, MONITORING MENU) (1) (1) Traction controller - master raction controller - master The most important input or output signals can be measured in real time using the TESTER function of the console.
  • Page 203 ⑮ Accelerator Accelerator From 0.0V to 5.0V. ACCELERATOR reading is in the range 0.0 to 5.0Vdc. Handle / seat SW. Handle / seat SW. ON/OFF. This is the status of handle/seat switch. Forward switch Forward switch ON/OFF. This is the status of forward signal. Backward switch Backward switch ON/OFF.
  • Page 204 (2) (2) Traction controller - slave raction controller - slave The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to read voltage, current and temperature.
  • Page 205 (3) (3) Pump controller Pump controller The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to read voltage, current and temperature. In the following chapter a list of relative measurements for different configurations. ①...
  • Page 206 Fork level but Fork level but ON/OFF. This is the status of horn switch on joystick. Tilt pot Tilt pot Level of the tilt analogue signal. The voltage is shown on the left hand side of the display and the value in percentage on the right hand side. 2nd hourmeters 2nd hourmeters This parameter displays the working hour of pump controller.
  • Page 207 X axis joystick X axis joystick This is the amount of joystick Y axis operation. Mode select Mode select Perfomance sent from the display to Zapi controller. Truck model sel. Truck model sel. Type of the truck selected: 20 or 23. 7-54...
  • Page 208 8. FINGERTIP JOYSTICK CONTROLLER 8. FINGERTIP JOYSTICK CONTROLLER 1) 1) INTRODUCTION OF FINGER TIP INTRODUCTION OF FINGER TIP ( (JOYSTICK JOYSTICK) 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 209 3) 3) STRUCTURE STRUCTURE (Connector console) Fingertip controller 18BCS9EL61 7-56...
  • Page 210 4) 4) Description of connectors 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. +KEY Mhyrio CB positive power supply PAUX Input of valves positive power supply -BATT Mhyrio CB negative supply...
  • Page 211 5) 5) ADJUSTMENTS & FUNCTION ADJUSTMENTS & FUNCTION There are two ways to adjust parameter via a console or buttons on a display. (1) (1) Adjustments via 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 212 6) 6) DESCRIPTION OF PARAMETERS THAT MAY BE PROGRAMMED 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 213 ⑬ Min EVP6 Min EVP6 (not being used) This parameter adjusts the minimum current of valve 6, if it is set as proportional (see "set option menu"). ⑭ Max EVP6 Max EVP6 (not being used) This parameter adjusts the maximum current of valve 6, if it is set as proportional (see "set option menu").
  • Page 214 EVP4 Close delay EVP4 Close delay (attach-A) EVP4 proportional valve current ramping down time: this parameter sets the EVP4 valve closing ramp, to change the coil current from maximum EVP4 to minimum EVP4. EVP5 Open delay EVP5 Open delay (not being used) EVP5 proportional valve current ramping up time: this parameter sets the EVP5 valve current ramp, to change the coil current from minimum EVP5 to maximum EVP5.
  • Page 215 7) 7) TESTER MENU TESTER MENU (IN DISPLAY, MONITORING MENU) Following parameters can be measured in real time in the TESTER menu: ① Battery voltage Level of battery voltage measured at the input of the key switch. ② Valves supply Level of voltage at the positive valve supply input (B2).
  • Page 216 8) 8) GENERAL SUGGESTION FOR SAFETY GENERAL SUGGESTION FOR SAFETY For a proper installation take care of the following recommendations: After operation, even with the key switch open, the internal capacitors may remain charged for some time. For safe operation, we recommend that the battery is disconnected, and a short circuit is made between battery positive and battery negative power terminals of the inverter using a resister between 10 ohm and 100 ohm.
  • Page 217 6. INSTRUMENT PANEL : DISPLAY 6. INSTRUMENT PANEL : DISPLAY 1) 1) STRUCTURE STRUCTURE The DISPLAY has 6 red LEDs indicating the status information of the lift truck to the driver. Spare #1 Spare #2 Brake oil level Park brake Wrench Seat belt Thermometer...
  • Page 218 2) 2) WARNING LAMP WARNING LAMP (1) (1) Brake oil level warning lamp rake oil level warning lamp This LED lights when measured level of brake oil stored in reservoir tank is below the minimum acceptable mark. ※ BCS-9 truck does not have any mechanical brake which BCS-9 truck does not have any mechanical brake which requires brake oil, so that re-fill of brake oil is not required.
  • Page 219 3) 3) BUTTON BUTTON These buttons are used to select or change the menu and input value of the LCD function and display menu. (1) (1) Up button Up button Press to select upward move. 22BH9EFD07 (2) (2) DOWN/TURTLE DOWN/TURTLE button button Press to select downward move.

  • Page 220: Main Screen

    4) 4) LCD FUNCTION (MAIN SCREEN) LCD FUNCTION (MAIN SCREEN) MAIN SCREEN MAIN SCREEN 22BH9EFD13 Current time Hour meter Turtle mode Wheel position and running direction Truck speed pointer Power mode Speed level BDI (Battery Discharge Indicator) Truck speed 10 Load weight (option) (1) (1) Current time Current time...
  • Page 221 (3) (3) Truck speed pointer Truck speed pointer The speed of the truck is indicated with a pointer. (4) (4) Speed level Speed level This indicator shows the truck speed same as the (3) Speed pointer. (5) (5) Truck speed Truck speed The truck speed is shown in number.
  • Page 222 5) 5) HOW TO USE DISPLAY MENU HOW TO USE DISPLAY MENU 22BH9EFD14 7-69...
  • Page 223 20BC9EFD15 7-70...
  • Page 224 6) 6) DESCRIPTION OF THE TRUCK MENU DESCRIPTION OF THE TRUCK MENU (1) (1) Access to truck menu Access to truck menu If this button is pressed long, the PASSWORD dialog appears. Enter correct PASSWORD, then on MAIN SCREEN, Press button to access the controller “TRUCK MENU”...
  • Page 225 - Level Selection 22B9EL30 Select a desired value with button, then save with button or press button to escape without saving. 7-72...
  • Page 226 7) 7) ALARM & ALARM HISTORY ALARM & ALARM HISTORY (1) (1) How to check alarms How to check alarms Normally, ALARM SCREEN pops up if any kind of a alarm happens, but service man can switch between a MAIN SCREEN and ALARM SCREEN with buttons as follows : (Press more than 1 sec) 18BR9EL35...
  • Page 227 (2) (2) Detail description of ALARM SCREEN Detail description of ALARM SCREEN ① ③ ② 18BR9EL36 ① First yellow capital letter shows in which controller the alarm happens as below; T : Traction P : Pump ② Following two letters or digits show alarm code. Please refer to 7. ALARM CODE (Page 7-81). ③...
  • Page 228 ① Step 1 : Service man can check the alarm history on ALARM HISTORY menu ② Step 2 : When service man enter the ALARM HISTORY menu, display read entire alarm records of all controller. So it takes 9~15 seconds to read. ③...
  • Page 229 8) 8) VASS SETUP USING DISPLAY MENU VASS SETUP USING DISPLAY MENU This function searches and memorizes the minimum and maximum potentiometer wiper voltage of the accelerator pedal, lift lever, and steering sensor which use potentiometer sensors. The belows show how to use the VASS function of DISPLAY. (All figures in belows are just example.) ※...
  • Page 230 Now, you can see that voltage value of MAX REVERSE are changed. Please make sure that all motors are not running & direction lever is in NEUTRAL position. 22B9EL39-2 7-77...
  • Page 231 (2) (2) STEER ANGLE VASS setting method STEER ANGLE VASS setting method Please make sure that all motors are not running & direction lever is in NEUTRAL position. If “READY” appears beside STEER ANGLE, you are in configuration process. Now, operator can see that voltage value of STEER RIGHT is changed.
  • Page 232 9) 9) STRUCTURE OF TRUCK MENU STRUCTURE OF TRUCK MENU TRUCK MENU is in order to make configuration of truck easily, and consists of 3 major categorys : SETTING, MONITORING, ALARM HISTORY. [To know how to get in to TRUCK MENU, refer to 6-6)-(1) “ACCESS TO TRUCK MENU” page 7-71] (1) (1) Settings Settings...
  • Page 233 (2) (2) Monitoring Monitoring 22B9EL43 In MONITORING MENU, service man can check various stats of trucks. In MONITORING MENU, service man can check various stats of trucks. ① TRACTION Refer to 5-6)-(1) “Traction controller” (page 7-49, 7-51) ② PUMP Refer to 5-6)-(3) “Pump controller” (page 7-52) (3) (3) Alarm history Alarm history...
  • Page 234 7. ALARM CODE 7. ALARM CODE TRACTION CONTROLLER TRACTION CONTROLLER 1) 1) Description No Code Alarm name Master Slave Cause Troubleshooting ○ ○ EEPROM KO Warning : EEPROM fault, - To remove warning cause. controller will use default parameters. ○ ○...
  • Page 235 Description No Code Alarm name Master Slave Cause Troubleshooting ○ ○ Capacitor Alarm : power capacitor To remove alarm condition. Check the contactor resistance (300 , 10 Charge voltage does not increase when the key is turned ON; failure in the power section, Check the controller.
  • Page 236 Description No Code Alarm name Master Slave Cause Troubleshooting ○ ○ Maint pre Warning : this alarm occurs - Set to ON " MAINTEN. RESET " parameter. Warn when the controller works a f t e r " M . P R E W A R N TIME"...
  • Page 237 Description No Code Alarm name Master Slave Cause Troubleshooting ○ ○ Safety Input A-11 voltage is not correct. - Check wiring between A-19 and A-11 of the left and right controller. ○ ○ VACC Out Waring : the lift input is - - Try to perform a program VACC.
  • Page 238 Description No Code Alarm name Master Slave Cause Troubleshooting ○ ○ Flash Alarm : the program verify Try to program the controller again. Checksum is not OK. Check the controller logic board. ○ Right ENC Encoder speed from the - Check the connection between the right Locked right motor is zero.

  • Page 239: Pump Controller

    2) 2) PUMP CONTROLLER PUMP CONTROLLER Description No Code Alarm name Pump Cause Troubleshooting ○ EEPROM KO Warning : EEPROM fault, - To remove warning cause. controller will use default parameters. ○ Logic Alarm : failure in over-load To remove alarm condition + activation of Failure#3 protection hw circuit.
  • Page 240 Description No Code Alarm name Pump Cause Troubleshooting ○ Capacitor Alarm : power capacitor To remove alarm condition. Check the contactor resistance (300 , 10 Charge voltage does not increase when the key is turned ON; failure in the power section, Check the controller.
  • Page 241 Description No Code Alarm name Pump Cause Troubleshooting ○ Aux2 Out Of Warning : voltage value Re-confi gurate the AUX2 lever. Rng. of AUX2 sensor is out of Check the AUX2 lever. range. ○ AUX1 Out Of Warning : voltage value Re-confi...
  • Page 242 Description No Code Alarm name Pump Cause Troubleshooting ○ Waiting For Warning : pump controller To recycle the key. NODE signals that other controllers Check if any other alarm happens (Some are in alarm status. alarms such as CHAT TIME or PEDAL WIRE KO, alarms related to CONTACTOR, DISPALY ENABLE, alarms reated to CANBUS can make this alarm sometimes.)
  • Page 243 Description No Code Alarm name Pump Cause Troubleshooting ○ Wrong 0 Alarm : the motor phases - To remove alarm cause. Voltage voltage feedback are out of permitted range. ○ Safety Output Alarm : the safety-out driver - To remove alarm cause. is damaged (shorted or open).
  • Page 244 Description No Code Alarm name Pump Cause Troubleshooting ○ Wrong Set Alarm : the battery voltage - To remove alarm cause. BAT. does not correspond to SET BATTERY programming. ○ Foc Lost Field current doesn't follow - Change the controller. the set point.
  • Page 245 DiAGNOSTiC fAULT CODES Of MHYRiO No Code Alarm name Description The test is made in both running and standby. it is a self-diagnosing test within the WATCHDOG logic. if an alarm should occur, replace the logic. fault in the area of memory in which the adjustment parameters are stored; this alarm inhibits machine operation.
  • Page 246 No Code Alarm name Description "EVPG4 One of the Group 4 valves drivers is open (it does not close when it is commanded by DRiVER KO" the microcontroller). UNDER This fault is signalled if an undervoltage condition is detected in the MHYRiO power VOLTAGE supply "EVP...

  • Page 247: 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 248 (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 7-93...
  • Page 249 2) 2) CHARGER INSTALLATION METHOD CHARGER INSTALLATION METHOD (1) (1) Location for charger installation 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.
  • Page 250 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 251 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 252 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 n v e r t automatic / manual switch to automatic and start charging.
  • Page 253 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 254: 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 255 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 256 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 257 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 258 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 259 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 260 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 261 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 262 8) 8) PCB MAJOR PARTS (NAME AND LOCATION) PCB MAJOR PARTS (NAME AND LOCATION) ②Lp lamp Auto ⑬Auto/manual Manual ④SHUNT 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 263 22B9BAT27 7-108...
  • Page 264 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 7-109...

  • Page 265: Section 8 Mast

    SECTION 8 MAST SECTION 8 MAST Group 1 Structure ------------------------------------------------------------------------------------------------------------ 8-1 Group 2 Operational Checks and Troubleshooting ------------------------------------------------------ 8-3 Group 3 Adjustment -------------------------------------------------------------------------------------------------------- 8-6 Group 4 Removal and Installation ---------------------------------------------------------------------------------- 8-8...

  • Page 266: Group 1 Structure

    SECTION 8 MAST SECTION 8 MAST GROUP 1 STRUCTURE GROUP 1 STRUCTURE 1. 3 STAGE MAST (TF MAST) 1. 3 STAGE MAST (TF MAST) CARRIAGE LIFT Tilt cylinder CYLINDER FREE LIFT CYLINDER 18BCS9MS03 Outer mast Lift chain 11 Back up liner Middle mast Anchor bolt 12 Bushing...
  • Page 267 2. CARRIAGE, BACKREST AND FORK 2. CARRIAGE, BACKREST AND FORK 18BCS9MS05 1-1 Carriage Shim (1.0t) 10 Flat head bolt 1-2 Backrest Bushing 11 Retaining washer 1-3 Hardened washer Back plate 12 Fork assy 1-4 Hexagon bolt Socket bolt 13 Extention fork Road roller Hexagon nut Shim (0.5t)

  • Page 268: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS FORKS FORKS 1) 1) Measure thickness of root of forks and check that it is more than specified value. EX : ℓ=1050 mm (41.3 in) mm (in) STD Fork assy Applicable model Standard Limit 64HM-11040...
  • Page 269 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) MAST MAST Problem Problem Cause Cause Remedy Remedy ·Deformed mast or carriage. ·Disassemble, repair or replace. Forks fail to lower. ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump Fork fails to elevate and cylinders in section 6, hydraulic system.
  • Page 270 2) 2) FORKS FORKS Problem Problem Cause Cause Remedy Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear and reduces the thickness of the wear limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion...

  • Page 271: Group 3 Adjustment

    GROUP 3 ADJUSTMENT GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER (TF MAST) 1. MAST LOAD ROLLER (TF MAST) 1) 1) INNER AND MIDDLE MAST ROLLER INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480 mm.
  • Page 272 3) 3) CARRIAGE LOAD ROLLER CARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100 mm 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.

  • Page 273: Group 4 Removal And Installation

    GROUP 4 REMOVAL AND INSTALLATION GROUP 4 REMOVAL AND INSTALLATION 1. FORKS 1. FORKS Lower the fork carriage until the forks are Knob approximately 25 mm (1 inch) 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...
  • Page 274 2) 2) CARRIAGE LOAD ROLLER CARRIAGE LOAD ROLLER Carriage Remove carriage as outlined in the 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.
  • Page 275 3) 3) MAST LOAD ROLLER AND BACK UP MAST LOAD ROLLER AND BACK UP LINER LINER (1) (1) 3 stage mast (TF mast) 3 stage mast (TF mast) ① Remove the carriage assembly and move it to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast.
  • Page 276 4) 4) ELEVATING MAST ELEVATING MAST (1) (1) Inner and middle mast (TF mast) Inner and middle mast (TF mast) ① After completing all necessary steps for load rollers and back up liner removal. Remove rear chains and sheave support if not already done. ②...
  • Page 277 5) 5) CHAIN CHAIN (1) (1) Rear chain sheave (TF mast) Rear chain sheave (TF mast) Inner mast Free lift Lift ① chain Raise and securely block carriage and chain inner mast section. ② Remove the split pin securing the chain anchor pins and discard.
  • Page 278 (2) (2) Chain wheel bearing support(TF mast) Chain wheel bearing support(TF mast) ① Remove the carriage assembly and move to one side. ② After removing bolt to securing chain wheel bearing support assembly to free lift cylinder. After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 279 ② ② Rust and corrosion 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 280 ⑧ ⑧ Chain wear scale 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 281 ③ Adjustment Adjustment Chain adjustments are important for the following reasons : ·Equal loading of chain. ·Proper sequencing of mast. ·Prevent over-stretching of chains. ·Prevent chains from jumping off sheaves if they are too loose. ④ Adjustment procedure Adjustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor.

This manual is also suitable for:

18bcs-920bcs-9

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