Hyundai 18BRP-9 Manual
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Hyundai 18BRP-9 Manual

Hyundai 18BRP-9 Manual

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SECTION 1 GENERAL
Group 1 Safety hints ------------------------------------------------------------------------------------------------------ 1-1
Group 2 Specifications -------------------------------------------------------------------------------------------------- 1-5
Group 3 Periodic replacement -------------------------------------------------------------------------------------- 1-15
Group 1 Structure ---------------------------------------------------------------------------------------------------------- 2-1
Group 2 Removal and installation of unit -------------------------------------------------------------------- 2-2
Group 1 Structure and operation --------------------------------------------------------------------------------- 3-1
Group 2 Troubleshooting ---------------------------------------------------------------------------------------------- 3-3
Group 3 Disassembly and assembly -------------------------------------------------------------------------- 3-5
Group 1 Structure and function ------------------------------------------------------------------------------------ 4-1
Group 1 Structure and function ------------------------------------------------------------------------------------ 5-1
Group 1 Structure and function ------------------------------------------------------------------------------------ 6-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------ 6-17
Group 3 Disassembly and assembly --------------------------------------------------------------------------- 6-21
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 -------------------------------------------------------------------------------------------------- 1-5 Group 3 Periodic replacement -------------------------------------------------------------------------------------- 1-15 SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure ---------------------------------------------------------------------------------------------------------- 2-1 Group 2 Removal and installation of unit -------------------------------------------------------------------- 2-2 SECTION 3 POWER TRAIN SYSTEM 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 -- -- -- -- -- -- -- -- -- - - - - - - -- - - -- - - -- - -- - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - 1-5 Group 3 Periodic replacement -- -- - - - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- 1-15...

  • 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 machine by mistake. D50ASF07 When inspecting running parts or near such parts, always stop the machine first.
  • Page 13 · Unless you have special instructions to the contrary, maintenance should always be carried out with the machine stopped. If maintenance is carried out with the machine running, there must be two men present : one sitting in the operator's seat and the other one performing the maintenance.
  • Page 14 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 15: Group 2 Specifications

    GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS 15BRP9OM54 Mast Steering wheel Carriage and backrest Overhead guard Load tire and brake Reach Drive unit and tire...

  • Page 16: Specifications

    2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) 15BRP-9 15BRP-9 C' C 15BRP9SP01 Model Unit 15BRP-9 Capacity kg (lb) 1361 (3000) Load center mm (in) 610 (24) Weight (With battery) kg (lb) 3983 (8780) Lifting height mm (ft-in) 5335 (17' 6") Free lift (Without backrest) mm (ft-in) 1196 (3' 11") Fork...
  • Page 17 2) 2) 18/20BRP-9 18/20BRP-9 15BRP9SP02 Model Unit 18BRP-9 20BRP-9 Capacity kg (lb) 1588 (3500) 1814 (4000) ← Load center mm (in) 610 (24") Weight (With battery) kg (lb) 3360 (7410) 3505 (10' 10") ← Lifting height mm (ft-in) 5335 (17' 6") ←...
  • Page 18 3) 3) 23BRP-9 23BRP-9 15BRP9SP02 Model Unit 23BRP-9 Capacity kg (lb) 2041 (4500) Load center mm (in) 610 (24) Weight (With battery) kg (lb) 3901 (8600) Lifting height mm (ft-in) 5335 (17' 6") Free lift (Without backrest) mm (ft-in) 1196 (3' 11") Fork Lifting speed (Unload/load) mm/sec...

  • Page 19: Main Control Valve

    3. SPECIFICATION FOR MAJOR COMPONENTS 3. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) CONTROLLER CONTROLLER Item Unit Drive & Pump motor controller EPS motor controller Fingertip controller Model AC-2 EPS-AC0 Mhyrio CB ← ← Type MOSFET Dimension 200×250×147.5 180×144×64.8 197×82×73 Current limit 450A ←...
  • Page 20 38.4 20.5 31.0 1180 2601 * Standard : 15/23BRP - C type, 18BRP - A type, 20BRP - B type 9) 9) LOAD TIRE OPTION LOAD TIRE OPTION 15BRP-9 18BRP-9 20BRP-9 23BRP-9 Mast Ø5×4" Ø10.5×4" Ø5×4" Ø10.5×4" Ø5×4" Ø10.5×4" Ø5×4"...
  • Page 21 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Items Size kgf·m lbf·ft Hyd pump motor mounting bolt M10×1.5 6.9±1.4 50±10 Traction motor mounting bolt 7.0±1.0 50.6±7.2 M 8×1.25 Electric system EPS motor mounting bolt M10×1.5 3.05±0.5 22.1±3.6 Electric brake mounting bolt 4.0±0.8...

  • Page 22: 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 23 2) 2) PIPE AND HOSE(FLARE TYPE) PIPE AND HOSE(FLARE TYPE) Thread size Width across flat(mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" PIPE AND HOSE(ORFS TYPE) PIPE AND HOSE(ORFS TYPE) Thread size Width across flat(mm) kgf·m lbf·ft 9/16-18 28.9...

  • Page 24: 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) Service Capacity ℓ (U.S. gal) Kind of fluid point (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) Drive unit Gear oil SAE 80W-90...

  • Page 25: 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 26: 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 27 GROUP 1 MAJOR COMPONENTS GROUP 1 MAJOR COMPONENTS 15BRP9OM112 Mast Frame 13 Pump motor Lift cylinder EPS motor 14 Reach Carriage and backrest Traction motor 15 Camera (option) Forks 10 Drive wheel 16 Monitor (option) Drive unit 11 Load wheel 17 Electric service brake Dash board 12 Overhead guard...

  • Page 28: 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 Backrest & fork Carriage Piping Mast (1) (1) Backrest Backrest Backrest...
  • Page 29 ③ With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor. Make sure the carriage is level, this will prevent any binding when the mast is raised.
  • Page 30 ⑥ Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage to work area and lower the mast. Inner mast Make sure that carriage remains on Make sure that carriage remains on floor and does not bind while mast is floor and does not bind while mast is Middle mast being raised.
  • Page 31 (5) (5) Lift cylinder Lift cylinder ① Loosen hexagonal bolts and remove Shim washers securing the lift cylinders to Shim inner mast. ② Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no Inner slack or binding.
  • Page 32 (7) (7) Inner mast Inner mast ① Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. Be careful the mast not to swing or fall. ②...

  • Page 33: 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. Installation procedure for each of mast component is the reverse of the removal procedure. (1) (1) LIFT CYLINDER INSTALLATION AND ADJUSTMENT LIFT CYLINDER INSTALLATION AND ADJUSTMENT...
  • Page 34 2. POWER TRAIN ASSEMBLY 2. POWER TRAIN ASSEMBLY REMOVAL REMOVAL 1) 1) EPS motor and drive motor BRP9RE001 Disconnect the battery cable. Battery cable connector 15BRP9OM87 Remove side door. Side door BRP9RE13 Remove the pump and motor. Hydraulic pump To control valve mounting bolt ※...
  • Page 35 Remove the EPS motor. ※ For details, see page 2-14. Mounting bolt BRP9RE26 Remove the drive motor. ※ For details, see page 2-12. Drive motor BRP9RE23 Lift up the frame and support both side of frame on wood block. Jack up Wood block BRP9RE18 Loosen mounting bolts from frame and...
  • Page 36 Remove drive unit assembly from frame. ※ Be careful the drive unit does not hit the body. BRP9RE19 2) 2) INSTALLATION INSTALLATION Installation is in the reverse order to removal, but be careful of following points. Drive unit mounting bolts : 6EA Mounting bolt ·Tightening torque : 13.3~15.3 kgf·m...

  • Page 37: 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 BR7RE002 (1) (1) PUMP MOTOR PUMP MOTOR ① Disconnect the battery cable. Battery cable connector 15BRP9OM87 ② Remove side door.
  • Page 38 ③ Disconnect the hose, pipe and wiring Hydraulic pump To control valve mounting bolt from pump & motor assembly. Loosen mounting nuts from frame and Wiring then take out the assembly. Hydraulic ④ Remove 2 mounting bolts fastening the Pump motor pump assembly pump &...
  • Page 39 ④ Remove bolts connecting the motor and drive unit. Mounting bolt BRP9RE22 ⑤ Tie wire rope around the drive motor and lift up slowly. Drive motor BRP9RE23 ⑥ Put the motor on the clean work bench. BRP9RE24 2-13...
  • Page 40 (3) (3) EPS MOTOR EPS MOTOR ① Disconnect the battery cable. Battery cable connector 15BRP9OM87 ② Remove side door. Side door BRP9RE13 ③ Disconnect wirings. motor BRP9RE25 ④ Loosen bolts and remove EPS motor assembly. motor Mounting bolt BRP9RE26 2-14...

  • Page 41: Battery Removal

    (4) (4) BATTERY REMOVAL BATTERY REMOVAL ① Turn off the key. ② Release the lock screw of side support in frame. Battery cable connector ③ Disconnect the battery connector. ④ Pull out the battery and using a battery hanger, carefully raise the battery assembly.

  • Page 42: Pump Motor

    2) 2) INSTALLATION INSTALLATION Installation is in the reverse order to removal, but be careful of following points. (1) (1) PUMP MOTOR PUMP MOTOR Hydraulic pump To control valve mounting bolt ① Pump motor mounting nut. ·Tightening torque : 2.0~3.0 kgf·m Wiring (14.5~21.7 lbf·ft) Hydraulic...

  • Page 43: Battery Installation

    (4) (4) BATTERY INSTALLATION BATTERY INSTALLATION ① Using a battery hanger, carefully put the battery assembly compartment push the battery assembly to the frame. ② Adjust the lock screw of side support in frame. ③ Connect the battery connector. ④ Complete installation.
  • Page 44 4. TIRE & WHEEL ASSEMBLY 4. TIRE & WHEEL ASSEMBLY 1) 1) REMOVAL REMOVAL (1) (1) Drive tire & wheel assembly Drive tire & wheel assembly ① Lift up the frame ※ Lift up until the tire clear off the ground. Jack up Wood block BRP9RE18...
  • Page 45 2) 2) INSTALLATION INSTALLATION Installation is in the reverse order to removal, but be careful of the following points. (1) (1) Drive wheel nuts ·Tightening torque : 13.4~18.0 kgf·m (96.9~130 lbf·ft) Wheel nut BRP7RE34 When assembling bearings in the wheel Retaining ring box assembly, it should be cleaned on the...

  • Page 46: 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 ------------------------------------------------------------------------------------------------ 3-4 Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 3-6...

  • Page 47: 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 STRUCTURE BRJ7DU103 Turntable bearing 14 Retaining ring 27 Housing Hexagon screw 15 Taper roller bearing 28 Shim Steering gear...

  • Page 48: Specification

    2. SPECIFICATION 2. SPECIFICATION Item Unit Specification Gear ratio 20.2 ℓ Oil Quantity...

  • Page 49: Group 2 Troubleshooting

    GROUP 2 TROUBLESHOOTING GROUP 2 TROUBLESHOOTING Problem Problem Probable cause Probable cause Remedy Remedy 1. Noise 1. Noise · Gearing of helical gear stage 1) Loud, beating noise - Check tooth flanks of the drive pinion damaged, indentations. and the helical gear for damage. In case of damage always replace both components.
  • Page 50 Fault Fault Probable cause Probable cause Remedy Remedy · Dirt between sealing ring and housing. ·Cleaning required. Oil leakage on oil filler or oil Oil leakage on oil filler or oil ·Old sealing ring was used. drain plug drain plug ·Bolts not tightened according to the ·Use new sealing ring ·Tighten bolts with the specified...

  • Page 51: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. INSTRUCTION 1. INSTRUCTION Pay attention to cleanliness and expert like manner for all work to be carried out. Transmission removed from the vehicle has therefore to be cleaned prior to opening. Both utmost care and cleanliness are essential conditions for a correct disassembly and reassembly of the transmission as well as for the installation of each spare part.
  • Page 52 2. NECESSARY SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY 2. NECESSARY SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Reference number Description Is necessay for : 225296 Extracting fixture Removal of drive pinion 62513 Holding fixture Loosening of taper press fit 62507-1 Counter holder Determination of shim thickness 62523 Assembly fixture...

  • Page 53: Safety Instructions

    Modifications and changes without the proper permission are affecting the safety of the transmission and are not allowed. Only original spare parts from Hyundai are allowed to be used. It is explicitly pointed out to the fact that spare parts and accessories, which were not supplied by Hyundai are not checked and approved by us either.
  • Page 54 4. COMPLETE DISASSEMBLY 4. COMPLETE DISASSEMBLY 1) 1) GENERAL INSTRUCTIONS DISASSEMBLY GENERAL INSTRUCTIONS DISASSEMBLY Prior to dismantling the transmission is to be cleaned carefully. Parts which are only available as assemblies will not be dismantled further. It is recommendable to install a locating fixture as shown in Figure 44.
  • Page 55 3) 3) REMOVAL OF DRIVE PINION REMOVAL OF DRIVE PINION With a screwdriver press the radial sealing ring (item 2) upwards from the bore seat of the housing and remove it. Dispose of the radial sealing ring according to chapter 6. BRJ7DU045 Unsnap and remove the retaining ring (item 3) from the housing bore by means...
  • Page 56 Handle the extracting fixture "S" as shown on the right. Move the handle on the bar upwards strongly several times until the drive pinion is loosened from the bearing seat completely. Do not damage the gearing of the drive Do not damage the gearing of the drive pinion at the next work step! Damages pinion at the next work step! Damages might cause louder running noises and...
  • Page 57 4) 4) REMOVAL OF GEAR RING AND PIVOTED BOGIE BEARING REMOVAL OF GEAR RING AND PIVOTED BOGIE BEARING Loosen the 12 hexagon screws (item 1) on the pivoted bogie bearing (item 2), remove and dispose them of acc. to chapter 6. BRJ7DU053 With a dead-blow soft-face hammer slightly beat against the gear ring (item 3)
  • Page 58 5) 5) DISASSEMBLY OF TRANSMISSION HOUSING WITH TRANSMISSION COMPONENTS DISASSEMBLY OF TRANSMISSION HOUSING WITH TRANSMISSION COMPONENTS (1) (1) Removal of sealing cap Removal of sealing cap The surface (item 1) where the sealing The surface (item 1) where the sealing cap is located must not be damaged.
  • Page 59 ② Loosen the housing cover (item 2) by tapping against the outer edges and remove it. Use the two recesses in the housing. BRJ7DU059 ③ With a three-armed puller (item 4) pull the taper roller bearing inner ring (item 3) over the bearing seat of the wheel shaft and remove it.
  • Page 60 (4) (4) Loosening of taper press fit Loosening of taper press fit ※ For work at high oil pressures to loosen the taper press fit there is the danger of eye and skin injuries, if oil would come out under high pressure. Always wear goggles and safety gloves! Observe and follow the instructions of the pressure oil device manufacturer.
  • Page 61 ④ Connect the flexible high-pressure pipe (item 4) from the pressure oil device into the connecting bore provided in the wheel shaft (item 5). Fixedly tighten the connecting nipple with an openjaw spanner. Pay attention for pressing-off that there Pay attention for pressing-off that there is sufficient clearance in pressing-off is sufficient clearance in pressing-off direction avoiding that the wheel shaft...
  • Page 62 ⑧ Loosen the cap screws (item 10), take off and remove the holding fixture "S" from the housing. BRJ7DU069 ⑨ Pressing-off by means of 2nd hand pump Alternatively the wheel shaft can be pressed off with a second press-out cylinder, e.g. in the mobile area. It is to be proceeded as follows: Connect the dis- and assembly fixture with the press-out cylinder for the wheel...
  • Page 63 ⑫ T a k e t h e w h e e l s h a f t o u t o f t h e transmission. BRJ7DU073 ⑬ Unscrew the hydraulic hose from cylinder 1 of the wheel shaft. Wipe off excessive oil.
  • Page 64 Then remove the following parts from the housing (item 12): Shims, spacer ring and taper roller bearing BRJ7DU077 (5) (5) Removal of bevel pinion shaft Removal of bevel pinion shaft ① Put the gear lock "S" into the housing bearing bore of the drive pinion and block the helical gear with it.
  • Page 65 ⑤ Pull out, remove and keep the helical gear (item 3) from the cover opening of the housing. BRJ7DU081 ⑥ Take out and remove the taper roller bearing inner ring (item 4) upwards from the bearing bore: BRJ7DU082 ⑦ Pull off and remove the taper roller bearing inner ring (item 6) from the bevel pinion shaft.
  • Page 66 (6) (6) Removal of thread protective shield and Removal of thread protective shield and radial sealing ring radial sealing ring ① By means of a hammer remove the thread protective shield (item 1) from the glued joint on the housing. Do not damage the housing and Do not damage the housing and supporting face!
  • Page 67 Disassembly bearings bevel pinion shaft Disassembly bearings bevel pinion shaft ① Expel the outer rings of the taper roller bearings (item 2) on both sides from the housing seat cautiously. ② Shims which were damaged have to be replaced by new shims of the same size. BRJ7DU088 Disassembly bearings wheel shaft Disassembly bearings wheel shaft...
  • Page 68 5. COMPLETE REASSEMBLY 5. COMPLETE REASSEMBLY 1) 1) GENERAL INSTRUCTIONS FOR REASSEMBLY GENERAL INSTRUCTIONS FOR REASSEMBLY Clean components by means of cleaning agent if necessary and remove the loctite residues. Check all components for wear, damage and cracks, if necessary components have to be replaced.
  • Page 69 4) 4) USE OF REMOVED SHIMS AS BASIS FOR REASSEMBLY USE OF REMOVED SHIMS AS BASIS FOR REASSEMBLY The bevel gear set, consisting of bevel pinion shaft and crown gear, has fixed installation dimensions. However the transmission housing and the taper roller bearings have to be measured. If the removed shims are used as basis it is not necessary to measure the transmission housing.
  • Page 70 5) 5) DETERMINATION OF BEARING WIDTH DIFFERENCE OF A TAPER ROLLER BEARING DETERMINATION OF BEARING WIDTH DIFFERENCE OF A TAPER ROLLER BEARING (1) (1) Determination of bearing width general Determination of bearing width general ① Zeroize depth gauge (item 1) by means of gauge blocks (item 2).
  • Page 71 6) 6) DETERMINATION OF BASIC INSTALLATION DIMENSIONS DETERMINATION OF BASIC INSTALLATION DIMENSIONS (1) (1) Determination of the necessary shim thickness for the exact installation dimension setting of Determination of the necessary shim thickness for the exact installation dimension setting of the bevel pinion shaft the bevel pinion shaft The correct position of the bevel pinion shaft is required for an optimum service life of the...
  • Page 72 BRJ7DU095 BRJ7DU096 BRJ7DU097 At zero position of the dial gauge the following can be taken as basis: Dimension "1" = 117.00 mm Determine Dimension "2" in housing bearing bore L3 (see figure 94) and add it to the respective Dimension "1". Example : Dimension "1"...
  • Page 73 (2) (2) Determination of necessary shim thickness for optimum setting of torsional backlash of the Determination of necessary shim thickness for optimum setting of torsional backlash of the crown Gear crown Gear Correct setting of the crown gear is necessary to obtain an optimum torsional backlash of the bevel gearing.
  • Page 74 By means of the equation: Schematic sketch Schematic sketch X = G – E – B – H – K2 X = G – E – B – H – K2 the required thickness of the shim (Item 3) can be calculated, i.e. with Example : Dimension "G"...

  • Page 75: Bearing Preload

    7) 7) INSTALLATION OF BEARING FOR BEVEL PINION SHAFT AND EXACT SETTING OF THE INSTALLATION OF BEARING FOR BEVEL PINION SHAFT AND EXACT SETTING OF THE BEARING PRELOAD BEARING PRELOAD (1) (1) Preassembly of bevel pinion shaft with bearing Preassembly of bevel pinion shaft with bearing ①...
  • Page 76 (3) (3) Calculation of distance dimension Calculation of distance dimension between collar bevel pinion shaft and between collar bevel pinion shaft and housing housing ① Install the preassembled bevel pinion shaft (item 1) from the bottom into the housing. BRJ7DU105 ②...
  • Page 77 (4) (4) Determination of bearing slack of the Determination of bearing slack of the taper roller bearing taper roller bearing ① Arrow gap = Bearing slack H BRJ7DU110 Measure the bearing slack "H" with a measuring fixture and gauge blocks/ measuring ledge in the following steps : ①...
  • Page 78 (5) (5) Calculation of shims required for upper bevel pinion shaft bearing Calculation of shims required for upper bevel pinion shaft bearing By means of the equation X = D – H X = D – H the required thickness of the shim (Item 3 figure 108 or 109) can be calculated, i.e. with Dimension "D"...
  • Page 79 ③ Put the bearing inner ring (item 3) into the outer ring of the taper roller bearing. BRJ7DU116 (1) (1) Installation of grooved ball bearing for Installation of grooved ball bearing for drive pinion drive pinion ① Install the grooved ball bearing (item 1) with the striking mandrel "S"...
  • Page 80 ③ Install the bevel pinion shaft from the bottom into the housing and assemble is through the profiled seat of the helical gear bore. BRJ7DU123 ④ Preload the bevel pinion shaft (item 3) with the counter holder "S" hand-tight against the bearing outer rings in the housing.
  • Page 81 ⑧ Place the hexagon nut and M20×1.5 onto the bevel pinion shaft and tighten it with a torque spanner (item 4). Tightening torque : 150 Nm Do not yet peen the hexagon nut with Do not yet peen the hexagon nut with the bevel pinion shaft! The hexagon the bevel pinion shaft! The hexagon nut must only be peened after setting...
  • Page 82 9) 9) INSTALLATION OF CROWN GEAR AND WHEEL SHAFT INTO THE HOUSING INSTALLATION OF CROWN GEAR AND WHEEL SHAFT INTO THE HOUSING (1) (1) Installation of thread protective shield Installation of thread protective shield and radial sealing ring and radial sealing ring ①...
  • Page 83 (2) (2) Installation of taper roller bearing into Installation of taper roller bearing into the housing the housing ① By means of striking mandrel "S" drive the bearing outer ring into the bearing seat of the housing until contact is obtained.
  • Page 84 Pay attention not to damage the Pay attention not to damage the gearing, when the crown gear is gearing, when the crown gear is assembled. assembled. BRJ7DU135 ① Assemble the crown gear (item 4) into the housing carefully and insert it into the gearing of the bevel pinion shaft at the same time.
  • Page 85 (4) (4) Pressing-on wheel shaft Pressing-on wheel shaft Taper press fit must be grease- and oilfree. Pay attention to an impeccable surface of the Taper press fit must be grease- and oilfree. Pay attention to an impeccable surface of the press fit.
  • Page 86 (5) (5) Determination of seat Determination of seat The seat must be 10 to 15 The seat must be 10 to 15 mm ① Measure Dimension A from plane face/ wheel shaft to face/crown gear once again (see chapter 9) (3) at page 3-39 “Determination of control dimension for seat“).
  • Page 87 INSTALLATION OF BEARING FOR WHEEL SHAFT INSTALLATION OF BEARING FOR WHEEL SHAFT (1) (1) Determination of required shim thickness for exact bearing preload of the wheel shaft Determination of required shim thickness for exact bearing preload of the wheel shaft Thickness of the shim (item 4) to be added can be determined with the following method: BRJ7DU142 Measuring ledge...
  • Page 88 (2) (2) Calculation of shim required Calculation of shim required Thickness of shim can be calculated with the dimensions determined. Example for : Cover dimension : Dim. C measured on housing cover 0.85 mm Housing dimension : Dim. F measured on housing 23.01 mm Bearing dimension : Dim.
  • Page 89 ④ Place counter holder "N" into the assembly fixture and preload it hand-tight against the wheel shaft (cf. figure 124). (N) Counter holder 62507-1 ⑤ Mount the taper roller bearing inner ring (item 2) by means of striking mandrel "S" onto the bearing seat of the wheel shaft (item 3) until contact is obtained.
  • Page 90 (5) (5) Checking of bearing friction torque on Checking of bearing friction torque on wheel shaft wheel shaft Rolling Rolling For measuring of the bearing friction torque place tool "S" on the wheel shaft congruent with the wheel bolts and by means of the torque spanner turn the wheel shaft several times.
  • Page 91 (7) (7) Installation of side cover Installation of side cover Prior to the installation of the side cover clean the sealing surface on the housing and remove the oil residues. The sealing surface must not be damaged. Wear safety gloves for working with adhesives and observe the LOCTITE instructions. Wear safety gloves for working with adhesives and observe the LOCTITE instructions.
  • Page 92 Do not yet tighten the cap screws with the corresponding tightening torque. Do not yet tighten the cap screws with the corresponding tightening torque. Tighten the 10 cap screws evenly only in the tightening sequence shown in Figure 156. Sequence of tightening : Number 1 beginning ..
  • Page 93 (2) (2) Mounting of sealing cap Mounting of sealing cap For sealing of the bore in the drive pinion a sealing cap (item 5) must be mounted. This requires the following sealing application: ① LOCTITE 5910 : Product application as adhesive application onto the supporting face and around the bore in the drive pinion as sealing function by excessive...
  • Page 94 ③ Snap the retaining ring (item 2) by means of flat-head pliers into the groove of the housing bore and install it until contact is obtained. BRJ7DU162 ④ Wet the sealing lip of the radial sealing ring with grease (e.g. Shell Alvania R3) slightly.
  • Page 95 (5) (5) Attachment of pivoted connection Attachment of pivoted connection geared steering geared steering ① Place the gear ring (item 2) and turn it so that the bolt holes match the threaded holes of the connecting construction. ② Install the gear ring with a dead-blow soft face hammer until contact is obtained.
  • Page 96 6. DISPOSAL 6. DISPOSAL Disposal of the replaced components, materials and substances adequately, environmentally friendly and in accordance with the legal regulations for disposal for the respective material : Component Consisting of Disposal acc. to the regulations : Transmission oil Waste oil Side cover Sheet...

  • Page 97: Section 4 Brake System

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

  • Page 98: 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 14BRJ9SM128 Inductor Flange Friction disc Assembly screws Adjusting screws 2. SPECIFICATION 2. SPECIFICATION Item Specification Nominal torque (std versions) 120 Nm Nominal airgap 0.3 mm...
  • Page 99 3. PRECAUTIONS AND RESTRICTIONS ON USE 3. PRECAUTIONS AND RESTRICTIONS ON USE 1) 1) Restrictions on use Restrictions on use The equipment is designed for dry running. Friction faces must be kept completely clean of any oil, grease or abrasive dust. Exceeding the maximum rotation speeds stated in the catalogue invalidates the warranty.

  • Page 100: Maintenance

    5. MAINTENANCE 5. MAINTENANCE Airgap 1) 1) Adjusting the airgap Adjusting the airgap To adjust the airgap (right figure), undo the fitting screws then take off the brake. Undo the assembly screws (5) and adjust the Assembly screw screws (6) in order to get the necessary value (see specification).

  • Page 101: Troubleshooting And Fault Elimination

    7. TROUBLESHOOTING AND FAULT ELIMINATION 7. TROUBLESHOOTING AND FAULT ELIMINATION Fault Cause Remedy · · Brake does not Brake does not Power supply is too low Adjust power supply release release · · Power supply is interrupted Reconnect power supply ·...

  • Page 102: Section 5 Steering System

    SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------- 5-1...

  • Page 103: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. STRUCTURE 1. STRUCTURE Steering wheel Stepping motor Main harness Controller sub assy EPS motor Pinion & steering gear Traction motor Position sensor assy Drive unit 10 Drive tire 11 Steering panel...
  • Page 104 2. FUNCTION 2. FUNCTION Stepper motor (Encoder sensor) BRJ7SE13 1) 1) Steering wheel teering wheel It decides the direction of rotation of the truck. It transmits the handling of operator. 2) 2) Stepper motor Stepper motor It is sensing the operation of steering wheel. It is transmits the output signal to controller.

  • Page 105: 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 ------------------------------------------------------- 6-17 Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 6-21...

  • Page 106: 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 180 bar EMERGENCY (at 40 lpm) LOWERING 145 bar MOTOR BRP7HS01 Hydraulic pump Lift cylinder Return filter Main control valve Reach cylinder 10 Strainer...
  • Page 107 1) 1) WHEN THE JOYSTICK IS IN THE LIFT POSITION WHEN THE JOYSTICK IS IN THE LIFT POSITION 180 bar EMERGENCY (at 40 lpm) LOWERING 145 bar MOTOR BRP7HS02 When the joystick is pulled backward, the m1 valve in the lift block is moves to open position. The oil from hydraulic gear pump (1) flows into main control valve (2) and then goes to the large chamber of lift cylinder (5).
  • Page 108 2) 2) WHEN THE JOYSTICK IS IN THE LOWER POSITION WHEN THE JOYSTICK IS IN THE LOWER POSITION 180 bar EMERGENCY (at 40 lpm) LOWERING 145 bar MOTOR BRP7HS03 When the joystick is pushed forward, the m2 valve in the lift block is moved to open position. The work port (H) and the large chamber are connected to the return passage, so the lift will be lowered due to its own weight.
  • Page 109 3) 3) WHEN THE BUTTON ON THE JOYSTICK IS PUSHED FOR THE REACH OUT POSITION WHEN THE BUTTON ON THE JOYSTICK IS PUSHED FOR THE REACH OUT POSITION 180 bar EMERGENCY (at 40 lpm) LOWERING 145 bar MOTOR BRP7HS05 When the button on the joystick is pushed upward, the spool in the tilt block is moved to reach out position.
  • Page 110 4) 4) WHEN THE BUTTON ON THE JOYSTICK IS PUSHED FOR THE REACH IN POSITION WHEN THE BUTTON ON THE JOYSTICK IS PUSHED FOR THE REACH IN POSITION 180 bar EMERGENCY (at 40 lpm) LOWERING 145 bar MOTOR BRP7HS04 When the button on the joystick is pushed downward, the spool in the tilt block is moved to reach in position.
  • Page 111 5) 5) WHEN THE JOYSTICK IS IN THE BACKWARD TILT POSITION WHEN THE JOYSTICK IS IN THE BACKWARD TILT POSITION 180 bar EMERGENCY (at 40 lpm) LOWERING 145 bar MOTOR BRP7HS06 When the joystick is pulled during pressing the tilt button, the spool in the tilt block is moved to tilt backward position.
  • Page 112 6) 6) WHEN THE JOYSTICK IS IN THE FORWARD TILT POSITION WHEN THE JOYSTICK IS IN THE FORWARD TILT POSITION 180 bar EMERGENCY (at 40 lpm) LOWERING 145 bar MOTOR BRP7HS07 When the joystick is pushed forward during pressing the tilt button, the spool in the tilt block is moved to tilt forward position.
  • Page 113 7) 7) WHEN THE JOYSTICK IS IN THE RIGHT POSITION FOR THE SIDE SHIFT MOVEMENT WHEN THE JOYSTICK IS IN THE RIGHT POSITION FOR THE SIDE SHIFT MOVEMENT 180 bar EMERGENCY (at 40 lpm) LOWERING 145 bar MOTOR BRP7HS08 When the joystick is pulled backward during pressing the side shift button, the spool in the tilt block is moved to side shift right position.
  • Page 114 8) 8) WHEN THE JOYSTICK IS IN THE LEFT POSITION FOR THE SIDE SHIFT MOVEMENT WHEN THE JOYSTICK IS IN THE LEFT POSITION FOR THE SIDE SHIFT MOVEMENT 180 bar EMERGENCY (at 40 lpm) LOWERING 145 bar MOTOR BRP7HS09 When the joystick is pushed forward during pressing the side shift button, the spool in the tilt block is moved to side shift left position.

  • Page 115: Operation

    2. HYDRAULIC GEAR PUMP STRUCTURE 14BRJ9HS19 Housing Rear cover 11 E-backup ring Body oil seal 12 Pin Drive gear Snap ring 13 Washer Idle gear DU bush 14 Hex bolt Side plate 10 E-seal 15 O-ring 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 116 3. MAIN CONTROL VALVE STRUCTURE (2 Spool) Machine serial number 15BRP : -#0089, 18BRP : -#0055, 20BRP : -#0066, 23BRP :- #0049 Port name Size Port 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 BRP7HS12...
  • Page 117 Machine serial number 15BRP : #0090-, 18BRP : #0056-, 20BRP : #0067-, 23BRP : #0050- 3-1-1 3-1-2 31HR-02600 Main b lock 3-1-1 Ancillary block Socket head screw 1-1 Emergency drain 3-1-2 Socket head screw Socket head screw EPM 31 End plate 100 Section seal kit EDL 2 Washer...

  • Page 118: Emergency Lowering Valve

    EMERGENCY LOWERING Machine serial number In case of the mast cannot be lowered due 15BRP : -#0089, 18BRP : -#0055, to a problem in the controller, active the 20BRP : -#0066, 23BRP :- #0049 emergency lowering valve on the valve block with hexagonal wrench.

  • Page 119: Lift Cylinder

    4. LIFT CYLINDER BRP9HS21 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 19 O-ring Wear ring 13 Rod cover 20 Stop ring Check valve 14 U-packing...

  • Page 120: Free Lift Cylinder

    5. FREE LIFT CYLINDER BRP9HS23 Tube assy Check valve 11 Dust wiper Retaining ring 12 Retaining ring Piston Set screw 13 O-ring Piston seal Rod cover 14 Back up ring Wear ring 10 U-packing 6-14...

  • Page 121: Tilt Cylinder

    6. TILT CYLINDER BRP7HS25 Tube assy Dust wiper 11 Piston seal O-ring 12 O-ring Bushing Back up ring 13 Locking ring Rod cover Locking wire 14 O-ring U-packing 10 Piston 6-15...
  • Page 122 7. REACH CYLINDER BRP7HS27 Tube assy Back up ring 15 Wear ring Spherical bearing Dust wiper 16 O-ring Retaining ring 10 O-ring 17 Nylon nut 11 Back up ring 18 Hex nut Rod cover 12 O-ring 19 Eye Bushing 13 Piston 20 O-ring U-packing 14 Piston seal...

  • Page 123: 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. Load maximum load, 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).

  • Page 124: 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 ·Tilting backward : Check valve defective. ·Clean or replace.

  • Page 125: Hydraulic Gear Pump

    HYDRAULIC GEAR PUMP Problem Cause Remedy Pump does not develop ·System relief valve set too low or ·Check system relief valve for proper full pressure leaking. setting. ·Oil viscosity too low. ·Change to proper viscosity oil. ·Pump is worn out. ·Repair or replace pump.
  • Page 126 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 127: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP Tools required ※ ·Metric socket set ·Internal snap ring pliers ·Shaft seal sleeve ·Torque wrench It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
  • Page 128 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 129 Remove drive shaft from mounting flange. (12) 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 130: Inspect Parts For Wear

    (17) Remove seals from both bearing blocks and discard. PUMP 11 INSPECT PARTS FOR WEAR Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be replaced as new items. Check drive shaft spline for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway.
  • Page 131 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 132 ASSEMBLY New seals should be installed upon ※ reassembly of pump. Install new shaft seal in mounting flange with part number side facing outboard. Press the seal into the seal bore until the seal reaches the bottom of the bore. Uniform pressure must be used to prevent misalignment or damage to the seal.
  • Page 133 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 134 (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 135 (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 136: Assembly Instruction

    2. MAIN CONTROL VALVE Machine serial number 15BRP : -#0089, 18BRP : -#0055, 20BRP : -#0066, 23BRP :- #0049 Lock washer Washer O-ring Coil Lock washer O-ring Washer Cartridge O-ring Coil Solenoid valve for lift Cartridge Tightening torque : 4.0kgf m Tightening torque (40Nm) : 1.0kgf m...

  • Page 137: Disassembly Instruction

    Lift block solenoid assembly The solenoid is installed upper side and below side cavities in lift block. Torque to 4.1 kgf·cm ① (40 Nm) Install the O-ring, coil, O-ring and washer to the assembled cartridge. ② Insert the lock washer to the groove of the cartridge. ③...
  • Page 138 Machine serial number 15BRP : #0090-, 18BRP : #0056-, 20BRP : #0067-, 23BRP : #0050- Tightening torque : 2.3kgf m (23Nm) Tightening torque : 1.0kgf m (9.5Nm) Tightening torque : 0.6kgf m (6Nm) 15BRP9HS13 ASSEMBLY INSTRUCTION General Ensure that the assembly area will be clean and free of contamination. ①...
  • Page 139 3. LIFT CYLINDER STRUCTURE BRP9HS21 Tube assy Stop ring 13 Rod bush Cushion seal 14 Rod cover Piston Retaining ring 15 U-packing U-packing 10 Spacer 16 Dust wiper Back up ring 11 O-ring 17 O-ring Wear ring 12 Stopper 6-32...
  • Page 140 DISASSEMBLY Hold the cylinder tube in a vice, loosen Guide 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. Lever up the edge of the guide, then turn the guide in again and the guide can be removed.
  • Page 141 4. TILT CYLINDER STRUCTURE BRP7HS25 Tube assy Nylon nut 11 O-ring Gland 12 O-ring O-ring DU bushing 13 O-ring Piston Rod seal Piston seal 10 Dust wiper 6-34...
  • Page 142 CHECK AND INSPECTION mm (in) Check item Standard size Repair limit Remedy Clearance between 0.072~0.288 Replace bushing cylinder rod & bushing (0.003~0.011) (0.020) Clearance between rod 0.10~0.35 Replace bushing head bushing & pin (0.004~0.014) (0.024) 6-35...
  • Page 143 5. REACH CYLINDER STRUCTURE BRP7HS27 Tube assy Rod cover 13 Back up ring Spherical bearing Rod bush 14 O-ring Retaining ring U-packing 15 Piston Spherical bearing 10 Back up ring 16 Piston seal Retaining ring 11 Dust wiper 17 O-ring Rod assy 12 O-ring 18 Hex nut...
  • Page 144 CHECK AND INSPECTION mm (in) Check item Standard size Repair limit Remedy Clearance between 0.072~0.288 Replace bushing cylinder rod & bushing (0.003~0.011) (0.020) Clearance between rod 0.10~0.35 Replace bushing head bushing & pin (0.004~0.014) (0.024) 6-37...

  • Page 145: 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 146: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 15BRP9EL01 Traction motor 13 Display 26 Relay Pump motor 15 Dead man switch 27 Work lamp (LED) EPS motor 16 Pressure sensor 31 Fan assy Stepping &...

  • Page 147: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT FUSE BOX ASS'Y CONTROLLER MOTOR MHYRIO CB A5 SAFETY B2 PAUX LIFT UP A4 -BATT B1 KEY 324A A7 KEY THMOT B3 B3 -BATT BEACON REAR HEAD LOWERING LAMP LAMP LAMP A10 GND GND A13 C23 -BATT TEMP SENSOR...

  • Page 148: 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 149 2. BATTERY 2. BATTERY 1) 1) STRUCTURE STRUCTURE BRP9EL03 Cells Positive leading cable Steel box Negative leading cable Cell connector Plug Row connector Abrasion sleeve...
  • Page 150 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 151: 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 152 (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 153 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 154 (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 155 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 156 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 157 3. JOYSTICK STRUCTURE STRUCTURE 1) 1) Machine serial No. Machine serial No. 15BRP-9 : -#0249 15BRP-9 : #0250- 18BRP-9 : -#0228 18BRP-9 : #0229- 20BRP-9 : -#0212 20BRP-9 : #0213- 23BRP-9 : -#0155 23BRP-9 : #0156- 15BRP9JS01 Tilt button Reach button...
  • Page 158 2) 2) SPECIFICATION SPECIFICATION (Machine serial No. 15BRP-9 : -#0249, 18BRP-9 : -#0228, 20BRP-9 : -#0212, 23BRP-9 : -#0155) Description Unit Specification Supply voltage 9 to 36 Maximum survival Electrical Maximum current draw CAN bus baund rate 125 required ±20 Nominally...
  • Page 159 4. DRIVE MOTOR 4. DRIVE MOTOR 1) 1) STRUCTURE STRUCTURE 14BRJ9EL06 Rotor assy Speed Sensor Kit 11 Sunk key Stator assy Stud bolt 12 Flange nut Endbell De Terminal protector 13 Wave washer Endbell Bearing Terminal A block 10 Shaft holder 7-14...
  • Page 160 2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Model AMBL4002 Rated voltage Rated output Insulation Class F 3) 3) EXTERNAL INVOLUTE SPLINE DATA EXTERNAL INVOLUTE SPLINE DATA Item Unit Specification No of teeth Pressure angle Degree Pitch diameter 22.5 Shaft tip diameter 24.75 Shaft root diameter 22.25...
  • Page 161 3) 3) MAINTENANCE INSTRUCTION AINTENANCE INSTRUCTION (1) (1) Inspection Inspection ① Rotor assembly 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.
  • Page 162 (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 163 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 7-18...
  • Page 164 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 Perform assembly in the reverse order of disassembling.
  • Page 165 4. PUMP MOTOR 4. PUMP MOTOR 1) 1) STRUCTURE STRUCTURE BRP9EL07 Rotor assy Speed sensor kit Terminal protector Stator assy Bearing 10 Oil seal Endbell-De Stud bolt 11 Nut flange Endbell assy Terminal A block 12 Wave washer 7-20...
  • Page 166 2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Model AMBL4001 Rated voltage Rated output Insulation Class F 3) 3) INTERNAL INVOLUTE SPLINE DATA INTERNAL INVOLUTE SPLINE DATA Item Unit Specification Flat root side fit Class 7 No of teeth Spline pitch 16/32 Pressure angle Degree...
  • Page 167 4) 4) INSPECTION INSPECTION (1) (1) Rotor assembly inspection Rotor assembly inspection ① 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. Rotor out diameter : Ø123.1±0.05 Tool : Vernier calipers and standard tool 18BR9EL54...
  • Page 168 5) 5) 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 169 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 170 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 6) 6) Assembly and installation Assembly and installation Clockwise rotation...
  • Page 171 5. EPS MOTOR 5. EPS MOTOR 1) 1) STRUCTURE STRUCTURE BRJ7EL08 Rotor Screw 17 Screw Stator 10 Screw 18 Washer Flange 11 Thickness ring 19 Bakelite washer Flange 12 Flange nut 20 Sensor support Casing 13 Bakelite pipe 21 Magnet Super seal 14 Thermal 22 Screw...
  • Page 172 2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Model G104087A Rated voltage Rated output Insulation Class H 3) 3) MAINTENANCE INSTRUCTION AINTENANCE INSTRUCTION ※ Before starting the maintenance please disconnect the power supply. (1) (1) Ball bearing Ball bearing Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of repair, they should be replaced.
  • Page 173 6. CONTROLLER SYSTEM 6. CONTROLLER SYSTEM 1) 1) STRUCTURE STRUCTURE BRJ7EL11 (1) (1) Specifications Specifications Model Model Application Type Power Current limit Traction 36V, 450A 450A/3min 15/18/20/23BRP-9 Pump 36V, 550A 550A/3min 7-28...

  • Page 174: 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 175: Description Of The Connectors

    3) 3) DESCRIPTION OF THE CONNECTORS DESCRIPTION OF THE CONNECTORS (1) (1) Traction controller Traction controller BRJ7EL12 No. of pin Function Description PCLRXD Positive serial reception. NCLRXD Negative serial reception. PCLTXD Positive serial transmission. NCLTXD Negative serial transmission. Negative console power supply. Positive console power supply.
  • Page 176 No. of pin Function Description Floor brake request input. It must be connected to the floor foot brake switch, active high. NPO TB -BATT. Positive of main contactor coil. PBRAKE Positive of the electro brake coil. Floor foot S/W ; It must be connected to the floor foot microswitch ; It is PEDAL S/W active high.
  • Page 177 Encoder installation Encoder installation ① Traction controller card is fit for different types of encoder. To control AC motor with a inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90˚. The encoder power supply can be +12V. It can have different electronic output. D1 : +12V - Positive of encoder power supply.
  • Page 178 (2) (2) Pump controller Pump controller BRJ7EL12 No. of pin Function Description PCLRXD Positive serial reception. NCLRXD Negative serial reception. PCLTXD Positive serial transmission. NCLTXD Negative serial transmission. Negative console power supply. Positive console power supply. FLASH It must be connected to A8 for the flash memory programming. FLASH It must be connected to A7 for the flash memory programming.
  • Page 179 No. of pin Function Description ENC VCC Encoder (motor speed sensor) + supply (12V) ENC GND Encoder (motor speed sensor) negative supply ENC A Encoder (motor speed sensor) phase A input ENC B Encoder (motor speed sensor) phase B input CPOT Load sensor (optional) signal Input PPOT...

  • Page 180: Function Configuration

    4) 4) FUNCTION CONFIGURATION FUNCTION CONFIGURATION ■ TRACTION CONTROLLER TRACTION CONTROLLER Using the CONFIG MENU of the programming console or using a display, the service engineer can configure the following functions. (1) (1) Submenu "S Submenu "SET OPTIONS ET OPTIONS" ①...
  • Page 181 ⑧ Set temperature Set temperature - DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to F6 (F12) input. - ANALOG : An analog motor thermal sensor is connected to F6 (F12) (the curve can be customized on a customer request). - NONE : No motor thermal sensor switch is connected.
  • Page 182 ③ Throttle 0 zone Throttle 0 zone It establishes a deadband in the accelerator input curve (see also curve below). ④ Throttle X point Throttle X point This parameter changes the characteristic of the accelerator input curve. ⑤ Throttle Y poin Throttle Y point This parameter changes the characteristic of the accelerator input curve.
  • Page 183 ⑩ PWM on main contactor PWM on main contactor - OFF : The inverter applies the battery voltage to the coil on F8 (main contactor negative) output. - ON : The PWM reduces the voltage to the set value. ⑪ PWM on aux output PWM on aux output - OFF : The inverter applies the battery voltage to the coil on F9 (electrical parking brake) output.
  • Page 184 Model selection Model selection There are 3 options, 15/20/23. In case of BRP-9 truck, it has to be selected 15, 20 or 23 (15/18BRP-9 → 15, 18/20BRP-9 → 20, 23BRP-9 → 23). ※ Normally, model selection parameter in pump controller is supposed to be synchronized according to same parameter in traction controller.
  • Page 185 ④ Digital lift Digital lift - OFF : The lift sensor includes a lift switch and an analogue lift sensor. Lift speed can be controlled proportionally with lever position. - ON : The lift sensor includes a lift switch only. Lift speed cannot be controlled proportionally. ※...
  • Page 186 (2) (2) Submenu "ADJUSTMENTS" Submenu "ADJUSTMENTS" ① Set battery type Set battery type : Selects the nominal battery voltage. (nominal voltage of BRP-9 is 36V) ② Adjust battery Adjust battery : Fine adjustment of the battery voltage measured by the controller. Please increase or decrease the value 1 by 1 and check the voltage.
  • Page 187 ⑮ Load speed upd. : Load speed upd. : (This parameter used for load sensor function) To increase accuracy, load sensor only works when the traction motor speed is lower than as set in this parameter. Offset height : Offset height : (This parameter used for height indicator function) It sets the free lift height.

  • Page 188: 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 7-44) ADJUSTMENTS VIA CONSOLE ADJUSTMENTS VIA CONSOLE (Option) Adjustment of parameters and changes to the inverter's configuration are made using the digital console.
  • Page 189 (2) (2) Description of standard console menu Description of standard console menu ① Traction controller Traction controller HEADING MAIN MENU CONFIG MENU PARAMETER ACCELER. DELAY SET MODEL CONNECTED TO 2 CHANGE ACC.CUT BACK RELEASE BREAKING INVERS.BRAKING PEDAL BRAKING SPEED LIMIT BRK. HOUR COUNTER RUNNING/KEY ON BRAKE CUT BACK...
  • Page 190 ② Pump controller Pump controller HEADING MAIN MENU CONFIG MENU PARAMETER SET MODEL CONNECTED TO 5 ACCELER. DELAY CHANGE DECELER.DELAY MAX SPEED UP MIN SPEED UP CUTBACK SPEED REACH SPEED HOURCOUNTER RUNNING/KEY ON SHIFT SPEED SET OPTION SET TEMPERATURE ANALOG/DIGITAL TILT SPEED MODEL SELECTION 16/25/13/18/20...
  • Page 191 ruck menu → Alarm history) (3) (3) Description of Description of ALARMS ALARMS menu (in display, menu (in display, Truck menu larm history) 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 192 6) 6) TESTER MENU TESTER MENU (IN DISPLAY, MONITORING MENU) Traction controller raction controller The most important input or output signals can be measured in real time using the TESTER function of the console. (in display, Truck menu → Monitoring → Traction) ①...
  • Page 193 ⑭ Brake switch Brake switch The level of the pedal brake microswitch. - ON / +VB = Input active, switch closed. - OFF / GND = Input non active, switch open. ⑮ Brake pedal pot. Brake pedal pot. Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if the PEDAL BRAKING parameter is set ANALOG.
  • Page 194 ⑩ Joy Y Joy Y POS POS switch switch Status of the Joystick Y-axis positive input. - ON / +VB = Active entry of closed switch. - OFF / GND = Non active entry of open switch. ⑪ Joy Y NEG switch Joy Y NEG switch Status of the Joystick Y-axis negative input.
  • Page 195 Shift left switch Shift left switch Status of the shift left speed switch. - ON / +VB = Active entry of closed switch. - OFF / GND = Non active entry of open switch. Shift right switch Shift right switch Status of the shift right speed switch.
  • Page 196 7) 7) GENERAL SUGGESTION FOR SAFETY GENERAL SUGGESTION FOR SAFETY For a proper installation take care of the following recommendations: After operation, even with the key switch open, the internal capacitors may remain charged for some time. For safe operation, we recommend that the battery is disconnected, and a short circuit is made between battery positive and battery negative power terminals of the inverter using a resister between 10 ohm and 100 ohm.
  • Page 197 7. EPS CONTROLLER 7. EPS CONTROLLER 1) 1) STRUCTURE STRUCTURE BRJ7EL51 (1) (1) Specifications Specifications Model Model Application Type Power Current limit 15/18/20/23BRP-9 36-48V, 45A 45A/2min 7-52...
  • Page 198 2) 2) OPERATIONAL FEATURES OPERATIONAL FEATURES (1) (1) Features eatures A list of eps-ac0 operational features follows below: ① Static sensitivity boost in open loop (steering sensitivity increases for a slow moving steering wheel). ② Static numbness in closed loop (steering sensitivity decreases for handle steer close to the straight-ahead direction).

  • Page 199: Description Of Connectors

    3) 3) DESCRIPTION OF CONNECTORS DESCRIPTION OF CONNECTORS (1) (1) EPS controller EPS controller EPS-AC0 BRJ7EL52 No. of pin Function Description SW 2 2nd toggle switch (90 degrees). SW 1 1st toggle switch (0 degrees). -BATT. Safety switch lower voltage point. SAFETY Safety switch higher voltage point.
  • Page 200 No. of pin Function Description PCLRXD Positive serial reception. NCLRXD Negative serial reception. PCLTXD Positive serial transmission. NCLTXD Negative serial transmission. Negative console power supply. Positive console power supply. FLASH It must be connected to A8 for the flash memory programming. FLASH It must be connected to A7 for the flash memory programming.
  • Page 201 4) 4) FUNCTION CONFIGURATION FUNCTION CONFIGURATION Using the config menu of the programming console (or using a display), the service engineer can configure the following functions. (1) (1) Submenu "S Submenu "SET OPTIONS ET OPTIONS" ① MICRO CHECK MICRO CHECK (not to recommend to change) This option is useful to support debug and troubleshooting.
  • Page 202 (2) (2) Submenu " Submenu "ADJUSTMENTS" ADJUSTMENTS" ① SET BATTERY TYPE SET BATTERY TYPE Set this adjustment to the nominal battery voltage. Pay attention, never set SET BATTERY TYPE higher than 36 V for a 24/36 V controller. Never set SET BATTERY TYPE lower than 36V for a 36/48V controller.

  • Page 203: Speed Limit

    (3) (3) Submenu " Submenu "PARAMETER CHANGE" PARAMETER CHANGE" ① SPEED LIMIT SPEED LIMIT (not to recommend to change) Level 0 to 9. It determines the scaling factor between the speed of the steering wheel and the speed of the steering motor but only when the steering wheel is fast turning. By increasing the SPEED LIMIT value, the steering motor speed increases too.
  • Page 204 5) 5) PROGRAMMING & ADJUSTMENTS ROGRAMMING & ADJUSTMENTS There are two ways to adjust parameter via a console or a buttons on a display. ※ Adjustments via buttons on a display, please refer to the display section. Adjustments via buttons on a display, please refer to the display section. ADJUSTMENTS VIA CONSOLE (Option) Adjustment of Parameters and changes to the inverter's configuration are made using the Digital Console.
  • Page 205 (2) (2) Description of standard console menu Description of standard console menu BRJ7EL53 7-60...
  • Page 206 6) 6) TESTER MENU TESTER MENU (IN DISPLAY, MONITORING MENU) The most important input or output signals can be measured in real time using the TESTER function of the console. (in display, Truck menu → Monitoring → EPS) (1) (1) Stepper motor Stepper motor Voltage value with 2 decimal digit.
  • Page 207 (11) (11) Endstroke CW Endstroke CW Provides real time the active state (ON) or not of the CW toggle switch (connected to CNA#3). It is On when CNA#3 is low. (12) (12) Endstroke ACW Endstroke ACW Provides real time the active state (ON) or not of the CCW toggle switch (connected to CNA#2). It is On when CNA#2 is low.
  • Page 208 (21) (21) Slope peak Slope peak This reading is just for debugging the maximum slope of the potentiometers connected to the eps- ac0. Especially for not redundant sensor equipments (just a single command potentiometer or just a single feedback potentiometer without encoder) a concern regarding the safety raises: if a single potentiometer fails a sudden movement of the steered wheel may occur with danger.

  • Page 209: General Characteristic

    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 210 3) 3) STRUCTURE STRUCTURE BRJ7EL61 7-65...
  • Page 211 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 212 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 213 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 214 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 215 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 216: Tester Menu

    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 217 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 218 9. DISPLAY 9. DISPLAY 1) 1) STRUCTURE STRUCTURE The instrument panel (display) has six built-in red LED, which provide the operator with an easy information about the status of some truck devices. 22BH9OM65 Oil level warning lamp (not working) Down/turtle button Wrench warning lamp Left/menu button Thermometer warning lamp...

  • Page 219: Warning Lamp

    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. This lamp doesn't work in BRP-9 model, which doesn't have any hydraulic brake.
  • Page 220 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 221: Lcd Function

    4) 4) LCD FUNCTION LCD FUNCTION 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) Current time Current time The number shows the current time according to the setting, which can be changed by display setting at page 7-78.
  • Page 222 Hour meter Hour meter The number shows the hours worked. The letter present beside the hour meter number shows which hour meter is displayed. – hK : the Key Hour shows the truck Key ON time; – hT : the Traction Hour shows the Gate ON (driven) time of the traction motor. –...
  • Page 223 5) 5) HOW TO SET THE DISPLAY MENU HOW TO SET THE DISPLAY MENU 22BH9EFD14 7-78...
  • Page 224 22BH9EFD15 7-79...
  • Page 225 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 226 - Level Selection 22B9EL30 Select a desired value with button, then save with button or press button to escape without saving. 7-81...
  • Page 227 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 228 (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 12) DIAGNOSTIC FAULT CODES (Page 7-91).
  • Page 229 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 230 8) 8) 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 7-80] (1) (1) Settings...
  • Page 231 (2) (2) Monitoring Monitoring 20BC9EL43 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 6-6)-(1) “Traction controller” (page 7-47) ② PUMP Refer to 6-6)-(2) “Pump controller” (page 7-48) ③...
  • Page 232 LCD FUNCTION LCD FUNCTION (for height indicator, OPTION) (for height indicator, OPTION) (1) (1) Main Main 14BRJ9EFD01 7-87...
  • Page 233 (2) (2) User menu User menu 14BRJ9EFD02/03 7-88...
  • Page 234 (3) (3) Button Button Button Function 1. Number 1 input button 2. Go into the HEIGHT PRESELECTOR menu 1. Number 2 input button 2. Upward move button in menu 1. Number 3 input button 1. Number 4 input button 2. Leftward move button in menu 1.
  • Page 235 DESCRIPTION OF PROGRAMMABLE MENU DESCRIPTION OF PROGRAMMABLE MENU In truck menu → display, service engineer can adjust several parameters related to display as follows ; ① Password Password This parameter turns on the password function. - ON : Operater should enter the password which can be set in user menu, before operating truck. - OFF : Password function is deactivated.
  • Page 236 DIAGNOSTIC FAULT CODES IAGNOSTIC FAULT CODES Traction Pump Mhyrio Code Hex Alarm Description 6 SERIAL Main uC and Slave uC communicate via a local ERR#1 serial interface. This alarm occurs when the slave ○ uC does not receive the communication from the main uC through this serial interface.
  • Page 237 Traction Pump Mhyrio Code Hex Alarm Description 13 "LOGIC This alarm signals that an undervoltage / FAILURE #1" overvoltage protection operation has occurred. Two possible reasons: A real undervoltage / overvoltage situation happened. First, low charged level can cause a huge voltage drop during heavy duty, which leads to this error.
  • Page 238 Traction Pump Mhyrio Code Hex Alarm Description 30 1E VMN LOW The test is carried out during initial diagnosis and in standby. Possible causes: A) Problem with the motor connections or the motor power circuit; check if the 3 phases are correctly connected;...
  • Page 239 Traction Pump Mhyrio Code Hex Alarm Description This alarm occurs in the initial rest state after key on 25 CONTACTOR if the outputs of the motor voltage amplifiers are not CLOSED ○ in the window from 2.2 to 2.8 Vdc. It is necessary to replace the controller.
  • Page 240 Traction Pump Mhyrio Code Hex Alarm Description 3C CAPACITOR Follows the charging capacitor system: CHARGE power capacitor RES. INVERTER When the key is switched ON, the inverter tries to ○ ○ charge the capacitor through a power resistance, and check if the capacitor are charged within a timeout.
  • Page 241 Traction Pump Mhyrio Code Hex Alarm Description 47 POWER This alarm occurs when the current in the phase V FAILURE #3 of the motor is zero and the motor is commanded for moving. ○ Check the power fuse is OK. Check the battery positive arrives to the controller.
  • Page 242 Traction Pump Mhyrio Code Hex Alarm Description 4C COIL When the key is switched ON the uP checks the SHORTED MC driver FF SR. If it does not react in a correct way to the uP stimulus, the alarm is signalled. Replace the logic board.
  • Page 243 Traction Pump Mhyrio Code Hex Alarm Description 52 ENCODER Two consecutive readings of the encoder speed are ERROR too much different in between: because of the inertia of the system it is not possible the encoder changes its speed a lot in a short period. Probably an encoder failure has occurred (e.g.
  • Page 244 Traction Pump Mhyrio Code Hex Alarm Description 211 D3 WRONG This alarm means configurations of parameters aren't correct. CONFIG 1) Set "TRUCK TYPE" parameter in "Set Options" ○ again correctly (Option #5). 2) Recycle the key. 3) Turn on the "AutoTeaching" parameter. 4) Recycle the key.
  • Page 245 Traction Pump Mhyrio Code Hex Alarm Description 218 DA CLOCK PAL The main uC sends an analog signal towards the slave uC to reset the slave uC on demand. When NOT OK the slave uC detects this analog signal external to a ○...
  • Page 246 Traction Pump Mhyrio Code Hex Alarm Description 221 DD MICRO It occurs in one of the following conditions : If the SLAVE #4 slave uC detects the stator voltage phasor rotates in the opposite direction respect to the sign of the stepper motor speed, this alarm occurs.
  • Page 247 Traction Pump Mhyrio Code Hex Alarm Description 228 E4 POSITION This alarm occurs for an error in the redundant test ERROR of the feedback sensors. Here we have an encoder and two toggle switches. This alarm occurs whether the sector (toggle switches configuration) and the encoder counting are not matched.
  • Page 248 Traction Pump Mhyrio Code Hex Alarm Description 229 E5 EVPG2 DRIV One of the group 1 (Attach -A/B electrical SHORT proportional valves) valves drivers is shorted; 1) Check if wires & connectors attached to valves are fine Finger tip controller "MHYRIO" C4-C6 : ATTACH-A Valve ○...
  • Page 249 Traction Pump Mhyrio Code Hex Alarm Description 237 ED WAITING This warning occurs only if CAN BUS is PRESENT. DATA At key-on the eps-ac0 asks to the traction controller to send a list of parameters via CAN BUS. From the request until the parameters are correctly relieved, this warning occurs.
  • Page 250 Traction Pump Mhyrio Code Hex Alarm Description 238 EE SAFETY KO This alarm is present in combi systems (traction + pump). If a stopping alarm is detected on the pump, ○ the traction also stops. The failure must be looked for in the pump inverter.
  • Page 251 Traction Pump Mhyrio Code Hex Alarm Description 241 F1 DATA This alarm is signalled in the current gain ○ ○ ACQUISITION acquisition phase. Wait the end of the acquisition activity. CAN BUS KO There is a problem related to the CAN-BUS line. The error is signalled if the MHYRIO controller does not receive any message from the CAN-BUS line.
  • Page 252 Traction Pump Mhyrio Code Hex Alarm Description 242 F2 STEER DEAD EPS relay is open ○ ANGLE MOTOR Encoder locked unless controller receive any signal STALL from encoder (motor speed sensor) for more than 10sec, since after controller apply power on motor, controller recognize that motor is stuck.
  • Page 253 Traction Pump Mhyrio Code Hex Alarm Description 244 F4 ANGLE NOT Angle from EPS is not valid. ○ VALID JOYSTICK Joystick is in alarm. ○ ERROR 1) Check the joystick. 2) Check the wiring & connectors & fuse (F21). EVPG1 One of the group 1 valves drivers is open (it does DRIVER KO n o t c l o s e w h e n i t i s c o m m a n d e d b y t h e...

  • Page 254: Data Acquisition

    Traction Pump Mhyrio Code Hex Alarm Description 245 F5 WRONG SET When the key is turned ON, the controller check the BATT. battery voltage and verifies it is within a window around the nominal value. 1) Check each Controller's "SET BATTERY TYPE" parameter is correct (in BRP-9, 36V is default) * Please refer to "SET BATTERY TYPE"...
  • Page 255 Traction Pump Mhyrio Code Hex Alarm Description 246 F6 SAFETY This alarm is signalled when the "SAFETY" input is open. The "SAFETY" circuit gets active and opens ○ the drivers of LC and EB and stops the machine. Verify the "SAFETY" input connection. EVPG3 One of the group 3 valves drivers is open (it does DRIVER KO...
  • Page 256 Traction Pump Mhyrio Code Hex Alarm Description 247 F7 CAN BUS KO The diagnosis of the CAN-BUS line is present only if the inverter uses this link (depends on the software version). It is signalled if the inverter does not receive any message from the CAN-BUS line.
  • Page 257 Traction Pump Mhyrio Code Hex Alarm Description 248 F8 DISPLAY Communication with display ok but waiting for ○ ENABLE display message 1) Check the display UNDER This fault is signalled if an undervoltage condition is VOLTAGE detected in the MHYRIO power supply 1) Check the voltage value in monitoring menu &...
  • Page 258 Traction Pump Mhyrio Code Hex Alarm Description 250 FA MICRO It occurs two ways: SLAVE A) In steady state condition, when the main uC finds the safety contact controlled by the slave uC has been opened, but no alarm information has been communicated from the slave uC to justify the opening of the safety contact.
  • Page 259 Traction Pump Mhyrio Code Hex Alarm Description 252 FC CHAT MODE Don't be panic. Not a problem. Just no command (traction or pump) from operator ○ for CHAT TIME minutes (Please refer to "CHAT TIME" in "PARAMETER CHANGE" menu). FF VALVES Flip-flop circuit, that manages on/off valve drivers shortcircuit protection, does not reset in the correct ○...

  • Page 260: Battery Charger

    10. BATTERY CHARGER 10. 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 7-116...
  • Page 262 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 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 ( 4 8 V ) , c o n v e 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 50V (In case of BATT 36V) In case error code is "O.V" Over-voltage output / Set at 50V (In case of BATT 36V) After separating battery connector, Rotate charging voltage volume,...
  • 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 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 276 22B9BAT27 7-131...
  • 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 7-132...

  • Page 278: 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 ---------------------------------------------------------------------------------- 8-7...

  • Page 279: 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) Lift cylinder Reach support Free lift cylinder BRP9MS03 Outer mast Shim (0.5, 1.0t) Chain sheave Middle mast Retaining ring 10 Back up liner Inner mast...
  • Page 280 2. CARRIAGE, BACKREST AND FORK 2. CARRIAGE, BACKREST AND FORK BRP9MS05 Backrest Side roller Carriage Fork assy Load roller Extension fork...

  • Page 281: Group 2 Operational Checks And Troubleshooting

    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-11060 15/18BRP-9 40 (1.6) 36 (1.4) 64HN-21040 20/23BRP-9 45 (1.8) 40 (1.6) B153FK01 Set forks in middle and measure difference in height at tip of forks.
  • Page 282 3. TROUBLESHOOTING 3. 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 283 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 284: 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 285 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, lower rollers after loosen the adjust screws from the side rollers.

  • Page 286: 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 Anchor pin approximately 25 mm (1 inch) from the floor. Release fork anchor pins and slide forks, one by one, toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 287 3. CARRIAGE ASSEMBLY 3. CARRIAGE ASSEMBLY 1) 1) CARRIAGE CARRIAGE With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor.
  • Page 288 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 to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast.
  • Page 289 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 290 (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 291 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 292 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 293 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.
  • Page 294 APPENDIX : 15/18/20/23BRP-9 SETTING PROCEDURE APPENDIX : 15/18/20/23BRP-9 SETTING PROCEDURE 1. PURPOSE 1. PURPOSE This appendix is to set the reach type forklift 15/18/20/23BRP-9 after repair or change of the controllers if needed. 2. DESCRIPTION 2. DESCRIPTION BRP-9 setting procedure : Appendix #1 Display and access of the user/truck menu : Appendix #2 Description and setting for the Australia option : Appendix #3, #8 Load weight setting : Appendix #4, #7...

  • Page 295: Appendix #1 : Brp-9 Setting Procedure

    (12 key type, height indicator) EPS master Standard 1.86 over EPS slave Standard No needed CAN tiller Standard No needed CAN encoder Height indicator option No needed ※ If the controller program version is not satisfied, please consult the Hyundai or your Hyundai distributor.
  • Page 296 3. TRUCK TYPE SETTING 3. TRUCK TYPE SETTING Change the parameter of the model section as follows. Truck Menu -> Settings -> Traction -> Set Options -> Model Selection Truck Menu -> Settings -> Pump -> Set Options -> Model Selection 15BRP-9 : 15, 18/20BRP-9 : 20, 23BRP-9 : 23 ※...
  • Page 297 7. BACK BUZZER OUTPUT PARAMETER CHANGING 7. BACK BUZZER OUTPUT PARAMETER CHANGING Change the PWM output for the horn relay and back buzzer from 12V to 24V as follows. Truck Menu -> Settings -> Pump -> Adjustments -> MC/AUX PWM : 33% -> 66% 8.
  • Page 298 11. COOLING FAN CHECK 11. COOLING FAN CHECK Check the operation of the cooling fan as follows. Operate the cooling fan intentionally with changing the parameter for the check. Truck Menu -> Settings -> Pump -> Set Options -> FAN Control : Option #1 ※...

  • Page 299: Appendix #2 : Display And Access Of The User/Truck Menu

    APPENDIX #2 : DISPLAY AND ACCESS OF THE USER/TRUCK MENU APPENDIX #2 : DISPLAY AND ACCESS OF THE USER/TRUCK MENU There are two menu which are the USER MENU for the operator and TRUCK MENU for the maintenance in the display and you can access the MENU as follows. 1.
  • Page 300 3. ACCESS TRUCK MENU 3. ACCESS TRUCK MENU Step Display Description Initial screen is displayed as left when the start switch is turned ON. Press the ESC button more than 1 second in the initial screen. The display will show the password input screen. Enter the password using the buttons (LEFT, UP, DOWN, RIGHT) and then press the ENTER button.

  • Page 301: Appendix #3 : Descrition And Setting For The Australia Option

    APPENDIX #3 : DESCRITION AND SETTING FOR THE AUSTRALIA OPTION APPENDIX #3 : DESCRITION AND SETTING FOR THE AUSTRALIA OPTION 1. DESCRITION 1. DESCRITION This option limits the travel speed to 3 km/h when the mast is risen above the operation range of the free cylinder.

  • Page 302: Appendix #4 : Load Weight Setting

    APPENDIX #4 : LOAD WEIGHT SETTING APPENDIX #4 : LOAD WEIGHT SETTING 1. Display load weight menu by activating the load sensor parameter as below. Truck Menu -> Settings -> Pump -> Set Options -> Load Sensor : Option #1 2.
  • Page 303 Step Display Description The "ADJ REF" will turn ON in red and, start the "ADJ REF" setting. To set the load sensor input value of the lifting load for the "ADJ REF", shift the direction lever to forward and lift the load to about 50 cm from the working place.

  • Page 304: Appendix #5 : Height Indicator Operation

    APPENDIX #5 : HEIGHT INDICATOR OPERATION APPENDIX #5 : HEIGHT INDICATOR OPERATION 1. HEIGHT INDICATOR FUNCTION 1. HEIGHT INDICATOR FUNCTION This function displays the fork height when the fork is lifted above the free cylinder range. You can set the "Height Preset" maximum 50 kinds and call the set height using the display. In fork up and down operation, the fork will stop when the fork reaches the set height.
  • Page 305 Step Display Description 1. Now, display will show the number of the preset and the height value of stored in white and display the fork height at present in orange at below. Be note that the fork height display zero (0) in the free cylinder range because the height indicator function is not operated in the free cylinder range.
  • Page 306 3. HEIGHT PRESET OPERATION 3. HEIGHT PRESET OPERATION Preset operation is done as follows. Step Display Description 1. Press the H button using the key pad in the main display. The current time display is changed to the preset call display and the number 00 blinks in yellow. Input the the height preset number using the key pad and press the ENTER button.

  • Page 307: Appendix #6 : Height Offset For Each Mast

    2720 TF815 1455 2950 TF865 1570 3180 TF930 1710 3460 TF1010 1862 3764 TF500 1656 TF530 1810 TF610 1037 2114 18BRP-9 TF685 1190 2420 TF760 1340 2720 TF815 1455 2950 TF500 1661 TF530 1815 TF610 1037 2119 20BRP-9 TF685 1190...

  • Page 308: Appendix #7 : Overload Weight Table For Each Mast And Frame

    APPENDIX #7 : OVERLOAD WEIGHT TABLE FOR EACH MAST AND FRAME APPENDIX #7 : OVERLOAD WEIGHT TABLE FOR EACH MAST AND FRAME 1. 15BRP-9 A TYPE BATTERY 1. 15BRP-9 A TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight...
  • Page 309 2. 15BRP-9 B TYPE BATTERY 2. 15BRP-9 B TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 1361 1497 TF500 1361...
  • Page 310 3. 15BRP-9 C TYPE BATTERY 3. 15BRP-9 C TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 1361 1497 TF500 1361...
  • Page 311 4. 15BRP-9 D TYPE BATTERY 4. 15BRP-9 D TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 1361 1497 TF500 1361...
  • Page 312 5. 18BRP-9 A TYPE BATTERY 5. 18BRP-9 A TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 1588...
  • Page 313 6. 18BRP-9 B TYPE BATTERY 6. 18BRP-9 B TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 1588...
  • Page 314 7. 20BRP-9 B TYPE BATTERY 7. 20BRP-9 B TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 1814 1995 TF500 1814...
  • Page 315 8. 20BRP-9 C TYPE BATTERY 8. 20BRP-9 C TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 1814 1995 TF500 1814...
  • Page 316 9. 23BRP-9 B TYPE BATTERY 9. 23BRP-9 B TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 2041 2245 TF500 2041...
  • Page 317 10. 23BRP-9 C TYPE BATTERY 10. 23BRP-9 C TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 2041 2245 TF500 2041...
  • Page 318 11. 23BRP-9 D TYPE BATTERY 11. 23BRP-9 D TYPE BATTERY ·34 inch outrigger ·44 inch outrigger 34 inch outrigger 44 inch outrigger Load capacity Warning weight Load capacity Warning weight Mast Mast (kg) (kg, 110%) (kg) (kg, 110%) TF500 2041 2245 TF500 2041...

  • Page 319: Appendix #8 : Speed Limit Group Drawing

    APPENDIX #8 : SPEED LIMIT GROUP DRAWING APPENDIX #8 : SPEED LIMIT GROUP DRAWING ·15/23BRP-9 ·18/20BRP-9 15/23BRP-9 18/20BRP-9 TO MAIN HARNESS TO MAIN HARNESS TO LIMIT SWITCH TO LIMIT SWITCH 15BRP9024 15BRP9025 Speed limit 6 switch assy Speed limit 6 switch assy Limit switch (650) harness Limit switch (650) harness Switch bracket...

  • Page 320: Appendix # 9 : Alarm History Deleting

    APPENDIX # 9 : ALARM HISTORY DELETING APPENDIX # 9 : ALARM HISTORY DELETING Delete the alarm history that occured during the setting procedure using the display TRUCK MENU as follows. Step Display Description 1. Select the ALARM HISTORY MENU in the TRUCK MENU using the UP and DOWN button and press the ENTER button.
  • Page 321 Step Display Description The display will ask "ARE YOU SURE?". Delete the alarm history by pressing the ENTER button. Delete the alarm history of the pump controller through the above steps 3~5. Confi rm the deletion of the alarm history correctly through above steps 1 and 2.

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