Hyundai 40B-9 Manual
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Hyundai 40B-9 Manual

Hyundai 40B-9 Manual

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Table of Contents

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Group 1 Safety hints ----------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-4
Group 3 Periodic replacement ------------------------------------------------------------------------------------- 1-12
Group 1 Major components ----------------------------------------------------------------------------------------- 2-1
Group 2 Removal and installation of unit -------------------------------------------------------------------- 2-2
Group 1 Structure and operation --------------------------------------------------------------------------------- 3-1
Group 2 Troubleshooting ---------------------------------------------------------------------------------------------- 3-4
Group 3 Disassembly and assembly --------------------------------------------------------------------------- 3-5
Group 1 Structure and function ------------------------------------------------------------------------------------ 4-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------ 4-5
Group 3 Tests and adjustments ----------------------------------------------------------------------------------- 4-7
Group 1 Structure and function ------------------------------------------------------------------------------------ 5-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------ 5-10
Group 3 Disassembly and assembly --------------------------------------------------------------------------- 5-13
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
CONTENTS
CONTENTS

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Summary of Contents for Hyundai 40B-9

  • Page 1: Table Of Contents

    CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints ----------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-4 Group 3 Periodic replacement ------------------------------------------------------------------------------------- 1-12 SECTION 2 REMOVAL & INSTALLATION SECTION 2 REMOVAL & INSTALLATION Group 1 Major components ----------------------------------------------------------------------------------------- 2-1 Group 2 Removal and installation of unit -------------------------------------------------------------------- 2-2 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM...
  • Page 2 SECTION 8 MAST SECTION 8 MAST Group 1 Structure --------------------------------------------------------------------------------------------------------- 8-1 Group 2 Operational Checks and Troubleshooting ---------------------------------------------------- 8-4 Group 3 Adjustment ------------------------------------------------------------------------------------------------------ 8-7 Group 4 Removal and Installation ------------------------------------------------------------------------------- 8-10...
  • Page 3 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 4 When a manual is revised, an edition mark is Any additions, amendments or other changes will recorded on the bottom outside corner of the be sent to HYUNDAI distributors. pages. Get the most up-to-date information before you start any work.

  • Page 5: 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 Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 7 Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
  • Page 8 m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 11: Section 1 General

    SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints ----------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-4 Group 3 Periodic replacement ------------------------------------------------------------------------------------- 1-12...

  • Page 12: 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 13 · Hand a caution sign in the operator's compartment (For example Do not start Do not start or Maintenance in progress Maintenance in progress). This will prevent anyone from starting or moving the machine by mistake. D50ASF07 When inspecting running parts or near such parts, always stop the machine first.
  • 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 40B9OM113 Mast Dash board 11 Seat Lift cylinder Frame 12 Steering wheel Carriage and backrest Steering axle 13 Overhead guard Forks Counterweight 14 Rear cover Drive unit 10 Battery cover...
  • Page 16 2. SPECIFICATIONS 2. SPECIFICATIONS 40B9SP01 Model Unit 40B-9 45B-9 50B-9 Capacity kg (lb) 4000 (9000) 4500 (10000) 4990 (11000) ← ← Load center mm (in) 500 (24") Weight kg (lb) 6855 (15110) 7345 (16190) 7805 (17210) ← Lifting height mm (ft -in) 3020 (9' 11")
  • Page 17 3. SPECIFICATION FOR MAJOR COMPONENTS 3. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) CONTROLLER CONTROLLER Item Unit Traction Pump ZAPI AC3 ×2 Model ZAPI AC3 ← Type ← Dimension 300×250×177 Current limit 600＋600 ← Communication 2) 2) MOTOR MOTOR Item Unit Traction Pump Type...
  • Page 18 5) 5) GEAR PUMP GEAR PUMP Item Unit Specification Type Fixed displacement gear pump Capacity cc/rev Maximum operating pressure Rated speed (max/min) 3000/500 6) 6) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Unit Specification Type 3 spool, 4 spool Operating method Mechanical Main relief valve pressure 2nd relief valve pressure...
  • Page 19 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Items Size kgf·m lbf·ft Hyd pump motor mounting nut M12×1.75 9.0±1.0 65.1±7.2 Electric system Traction motor mounting bolt M14×2.0 20±1.0 145±7.2 Hydraulic pump mounting bolt M12×1.75 12.8±3 92.5±21.5 MCV mounting bolt, nut M10×1.5 6.9±1.4...

  • Page 20: Torque Chart

    5. TORQUE CHART 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT BOLT AND NUT 1) 1) (1) (1) Coarse thread Coarse thread Bolt size kg·m lb·ft kg·m lb·ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25...
  • Page 21 2) 2) PIPE AND HOSE 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" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size Width across flat (mm) kgf·m lbf·ft 9/16-18...

  • Page 22: Recommended Lubricants

    6. RECOMMENDED LUBRICANTS 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature °C (°F) Service Kind of fluid Capacity ℓ (U.S. gal) point (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) MOBIL FLUID 424 Axle Gear oil...

  • Page 23: Group 3 Periodic Replacement

    GROUP 3 PERIODIC REPLACEMENT GROUP 3 PERIODIC REPLACEMENT For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time of periodic maintenance;...

  • Page 24: Section 2 Removal & Installation Of Unit

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

  • Page 25: Group 1 Major Components

    SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 MAJOR COMPONENTS GROUP 1 MAJOR COMPONENTS 17,18 13 14 40B9RE02 Lift cylinder Forks 15 Steering cylinder Mast Front wheel 16 Counterweight Backrest 10 Drive unit 17 Traction controller Steering unit 11 Pump motor...

  • Page 26: Group 2 Removal And Installation Of Unit

    GROUP 2 REMOVAL AND INSTALLATION OF UNIT GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST 1. MAST 1) 1) REMOVAL REMOVAL L15C3RE001 (1) (1) Forks Forks Backrest ① Lower the fork carriage until the forks are approximately 25 mm (1 in) from the floor.
  • Page 27 ② While supporting lift chains, remove the split pins and nuts from anchor pins of Lift chain stationary upright. Outer mast Split pin 22B7RE05 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain...
  • Page 28 (4) (4) Piping Piping ① Remove the return hoses and clamps attached to the cylinder. ② Remove the return hoses from the Band connector. clamp Hose ③ Remove hose assembly, tee, down clamp Return safety valve (1) from the lift cylinder. hose ④...
  • Page 29 (6) (6) Inner mast Inner mast ① Using an overhead hoist raise the inner mast straight and carefully draw out of Inner mast outer mast section. Be careful the mast not to swing or fall. Be careful the mast not to swing or fall. Outer mast 35B7RE10 Tilt cylinder pin...

  • Page 30: Installation

    2) 2) INSTALLATION INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. ※ Installation procedure for each of mast component is the reverse of the removal procedure. (1) (1) Mast mounting pin Mast mounting pin ①...

  • Page 31: Parking Brake Cable

    2. POWER TRAIN ASSEMBLY 2. POWER TRAIN ASSEMBLY 1) 1) REMOVAL REMOVAL B153RE00 (1) (1) Mast and counterweight Mast and counterweight Crane Refer to section on mast(Page 2-2) ※ After removing mast, remove the counterweight to prevent the truck from turning over.
  • Page 32 (4) (4) Drive unit & motor assy Drive unit & motor assy Frame ※ Drain the oil before disassembling the drive unit. ① Unscrew ten wheel nuts and remove the wheel. Motor wiring Drive unit & motor assy Wheel nut 40B9RE15 ②...

  • Page 33: 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 B15T5RE001 (1) (1) Battery Battery Before pulling out the battery plug, tilt the mast forward a little, and lower the fork to the Before pulling out the battery plug, tilt the mast forward a little, and lower the fork to the lowest position.
  • Page 34 ⑤ Using a battery hanger, carefully raise Hanger the battery assembly. Put down the battery with fork lift or Put down the battery with fork lift or chain block by hang up hook at 4 links chain block by hang up hook at 4 links which located in right and left of the which located in right and left of the battery.
  • Page 35 (2) (2) Pump motor Pump motor ① Lower the fork to floor. 40B9RE21 ② Remove the floor mat and the floor plate. Floor mat Floor plate Gear pump 40B9RE22 ③ Disconnect the wiring of pump motor and remove the gear pump from pump Gear pump Pump motor motor.
  • Page 36 Counterweight Install a lifting tool in the counterweight, and raise with a crane. Remove the mounting bolts, raise slightly and move to the rear. · Weight of counterweight (standard) 40B-9 1071 kg (2360 lb) 50B-9 1752 kg (3860 lb) 45B-9 1448 kg (3190 lb) ·Tightening torque : 85~115 kgf·m (615~832 lbf·ft)
  • Page 37 ③ Mounting bolt Mounting bolt Put a block under the steering axle, support on a truck, and raise the frame with a crane. Remove the mounting bolts installed to the frame, and pull out to the rear. There are shims between the support and rear axle to prevent play.

  • Page 38: 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 --------------------------------------------------------------------------- 3-5...

  • Page 39: 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 (1/2) 22 23 28 29 35B7PT01 Spacer 13 Screw plug 25 Retaining ring Wheel hub 14 Magnetic screw plug...
  • Page 40 STRUCTURE STRUCTURE (2/2) 47 48 49 50 61 62 63 35B7PT02 35 Helix pinion 45 Cap screw 55 Step seal 36 Ball bearing 46 Screw plug 56 Piston 37 Retaining ring 47 Washer 57 Disk pusher 38 Retaining ring 48 Connection 58 Friction disk 39 Locking pin 49 Bleeder nipple cap...
  • Page 41 2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Max wheel load kg/lb 6200/13670 Max input rpm 5000 Gear ratio 29.0 Weight without fluid(EA) kg/lb 125/276 ℓ/U.S.·qt Oil quantity 1.5/1.6...

  • Page 42: Group 2 Troubleshooting

    GROUP 2 TROUBLESHOOTING GROUP 2 TROUBLESHOOTING Problem Problem Cause Cause Remedy Remedy 1. Noise 1. Noise · Gearing of helical gear steep has 1) Knocking conditional on - Dismount electric motor. speed been damaged when mounting motor. Check drive pinion and helical gear for damage.

  • Page 43: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY ※ During maintenance, assembly and disassembly activities use caution and proper safety equipment, in observance of the rules provided by safety laws. 1. BRAKE DISASSEMBLY PROCEDURE 1. BRAKE DISASSEMBLY PROCEDURE 1) 1) GENERAL DESCRIPTION GENERAL DESCRIPTION...
  • Page 44 3) 3) REPLACING DISCS PUSHER REPLACING DISCS PUSHER The disc pusher device (57) is seated on the brake housing (51). Unscrew first the 3 screws (62) with their springs (61), then remove the discs pusher device (57). 35B7PT13 Place the spacer-seal (52) on the flange (34) contact surface.

  • Page 45: Gearbox Disassembly

    2. GEARBOX DISASSEMBLY 2. GEARBOX DISASSEMBLY ※ The gearbox is made with heavy parts, secure the parts and use proper lifting equipment. 1) 1) GENERAL DESCRIPTION GENERAL DESCRIPTION It's possible to open the gearbox without disassembling it from the truck. You have to drain the oil from both chambers, the reduction gearbox and the brake, removing the plugs from the bottom...
  • Page 46 To unscrew the lock nut (29) a special tool is required. To remove the wheel hub (2) place a special tool on the center of the M60 thread of the hub, and carefully press it out. At this point slip off the planet carrier (24) too.
  • Page 47 4) 4) DISASSEMBLY OF THE SUN PINION DISASSEMBLY OF THE SUN PINION To disassembly the sun pinion and the input shaft you have to remove the flange and the connected motor from the truck. Secure the motor, then unscrew the frame connecting screws (M24, 8EA).
  • Page 48 3. ASSEMBLY OF THE REDUCTION GEAR 3. ASSEMBLY OF THE REDUCTION GEAR ※ After the worn out parts have been replaced, to assemble the unit again follow the disassembling process steps in reverse order. 1) 1) ASSEMBLY OF THE SUN PINION ASSEMBLY OF THE SUN PINION Key the bearing (33) in its own slot on the flange (34), locking it with the retaining...
  • Page 49 Insert the ring gear carrier disc (19) into the ring gear (20) and fix it introducing the retaining ring (18) in its housing. 35B7PT24 Place the disc in the housing (12) centering it on the six studs (21). If the studs (21) need to be replaced, insert the 21,22,23 new ones into the housing (12) with high-...
  • Page 50 3) 3) ASSEMBLING THE HELIX PINION ASSEMBLING THE HELIX PINION Key the bearing (36) onto the helix pinion (35) and lock it with the retaining ring (37), then insert it into the housing in the flange and lock all with the retaining ring (38). 35B7PT28 4) 4) ASSEMBLY OF THE COVER...

  • Page 51: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------ 4-1 Group 2 Operational checks and troubleshooting ------------------------------------------------------ 4-5 Group 3 Tests and adjustments ----------------------------------------------------------------------------------- 4-7...

  • Page 52: Group 1 Structure And Function

    SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE There are two brake systems, the service brake system and the parking brake system. In the service brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
  • Page 53 3. BRAKE PEDAL AND PIPING 3. BRAKE PEDAL AND PIPING Drive unit(RH) Drive unit(LH) 40B9BS01 Brake pedal & bracket assy Reservoir tank assy Parking lever assy Brake master cylinder...

  • Page 54: Brake Installation

    4. BRAKE INSTALLATION 4. BRAKE INSTALLATION Service brake connection Parking brake Service brake bleeder nipple 35B7BS10 The brakes chamber shares the reduction gear oil and it is continuously feeded during the working processing. During the installation of the reduction gear, it is necessary to verify that the handbrake's draught cable is not under tension and that the gap between the brake disks is not reduced: this would compromise the correct working of the brake.
  • Page 55 5. BRAKE MASTER CYLINDER 5. BRAKE MASTER CYLINDER 1) 1) STRUCTURE STRUCTURE 35B7BS09 Body Head 11 Snap pin 16 Air bleeder Spring (Large) Head pin 12 Stop ring 17 Cap Check valve Boot nut 13 Boot 18 Cap Valve seat 14 Retainer 19 Cap 10 Washer...

  • Page 56: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS 1) 1) BRAKE PIPING BRAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed.

  • Page 57: Troubleshooting

    2. TROUBLESHOOTING 2. TROUBLESHOOTING Problem Problem Cause Cause Remedy Remedy · Oil leakage in the system or oil to low · Repair oil leakage. After bleeding fill Brakes do not work in tank. oil tank of master cylinder to specified level with brake oil.

  • Page 58: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS GROUP 3 TESTS AND ADJUSTMENTS 1. BLEED THE BRAKE SYSTEM 1. BLEED THE BRAKE SYSTEM The brake system must be bleeded after replenishing with brake fluid. Remove cap from bleeder nipple and fit proper hose to collect escaping brake fluid in a vessel.

  • Page 59: Section 5 Steering System

    SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------ 5-1 Group 2 Operational checks and troubleshooting ------------------------------------------------------ 5-10 Group 3 Disassembly and assembly --------------------------------------------------------------------------- 5-13...

  • Page 60: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE Steering wheel Steering cylinder Steering axle Steering unit Hydraulic tank Check coupling Priority valve Hydraulic pump 40B9SS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and pipings.

  • Page 61: Hydraulic Circuit

    2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT 120kgf/cm Return line MOTOR 35B7SS02 Hydraulic gear pump 10 Suction strainer Priority valve 11 Return filter Steering unit 12 Hydraulic oil tank Steering cylinder...
  • Page 62 1) 1) NEUTRAL NEUTRAL 120kgf/cm Return line MOTOR 35B7SS03 The steering wheel is not being operated so control spool (G) does not move. The oil from hydraulic tank (12) enters to hydraulic gear pump (1) and pressurized so that the oil flows into the inlet port (P) of steering unit (4) and the spool (K) moves to the left.
  • Page 63 2) 2) LEFT TURN LEFT TURN 120kgf/cm Return line MOTOR 35B7SS04 When the steering wheel is turned to the left, the spool (G) within the steering unit (4) connected with steering column turns in left hand direction. As this time, the oil discharged from hydraulic gear pump (1) flows into the spool (G) of the steering unit (4) through the inlet port (P) and flows to gerotor (H).

  • Page 64: Right Turn

    3) 3) RIGHT TURN RIGHT TURN 120kgf/cm Return line MOTOR 35B7SS05 When the steering wheel is turned to the right, the spool (G) within the steering unit (4) connected with steering column turn in right hand direction. As this time, the oil discharged from hydraulic gear pump (1) flows into the spool (G) of the steering unit (4) through the inlet port (P) and flows to gerotor (H).
  • Page 65 3. STEERING UNIT 3. STEERING UNIT 1) 1) STRUCTURE STRUCTURE 29-6 29-3 29-5 29-4 29-1 29-2 27-3 27-2 27-4 27-1 35B7SS08 Dust seal 13 Gerotor set 27 P-port check valve Retaining seal 14 Bearing race 27-1 Plug Cap seal 15 Bore screw 27-2 Poppet Thrust bearing 16 Drive...

  • Page 66: Operation

    2) 2) OPERATION OPERATION The steering unit is composed of the control valve (rotary valve) and the metering device. The control valve controls the flow of oil from the pump in the interior of the unit depending on the condition of the steering wheel.
  • Page 67 4. STEERING AXLE 4. STEERING AXLE 1) 1) STRUCTURE STRUCTURE 1-14 1-40 1-39 1-41 1-38 1-30 1-13 1-24 1-12 1-28 1-25 1-31 1-32 1-29 1-14 1-37 1-34 1-10 1-11 1-41 1-35 1-13 1-12 1-36 1-33 1-13 1-12 1-27 1-29 1-26 1-14 1-41 1-33...
  • Page 68 2) 2) TIGHTENING TORQUE AND SPECIFICATION TIGHTENING TORQUE AND SPECIFICATION Stroke 107mm Stroke 107mm Fill 70% of the space in the hub with lithium grease. 35B7SS07 Type Unit Center pin support single shaft Max steering angle of wheels (Inside/Outside) degree 82.8/61.6 40/45B-9 1141 (44.9)/1090 (42.9)

  • Page 69: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS Check item Checking procedure · Steering wheel Set rear wheels facing straight forward, then turn steering wheel to left and right. 30-60mm Measure range of steering wheel movement before rear wheel starts to move.
  • Page 70 Problem Cause Remedy ·Lockout loosening. ·Retighten. Steering wheel turns unstea- ·Metal spring deteriorated. ·Replace. dily. ·Gear backlash out of adjustment. ·Adjust. Steering system makes abn- ·Lockout loosening. ·Retighten. ormal sound or vibration. ·Air in oil circuit. ·Bleed air. Abnormal sound heard when Valve ·Faulty.

  • Page 71: Power Steering Unit

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

  • Page 72: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT 1. STEERING UNIT 1) 1) STRUCTURE STRUCTURE 29-6 29-3 29-5 29-4 29-1 29-2 27-3 27-2 27-4 27-1 35B7SS08 Dust seal 13 Gerotor set 27 P-port check valve Retaining seal 14 Bearing race 27-1 Plug...
  • Page 73 TOOLS TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-14...

  • Page 74: Tightening Torque

    Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1 kgf·m (0~54.4 lbf·ft) 13 mm socket spanner 6, 8 mm and 12 mm hexagon sockets 12 mm screwdriver 2 mm screwdriver 13 mm ring spanner 6, 8 and 12 mm hexagon socket spanners Plastic hammer Tweezers 5-70(2)
  • Page 75 4) 4) DISASSEMBLY DISASSEMBLY Disassemble steering column from steering unit and place the steering unit in the holding tool. Screw out the screws in the end cover(6- off plus one special screw). 5-72(1) Remove the end cover, sideways. 5-72(2) Lift the gearwheel set(With spacer if fitted) off the unit.
  • Page 76 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball. B20H7SS09 5-17...
  • Page 77 Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and thrust bearing will be pushed out of the housing together.
  • Page 78 (12) Carefully press the spool out of the sleeve. 5-74(4) (13) Press the neutral position springs out of their slots in the spool. 5-75(1) (14) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (15) Screw out the plug using an 8mm hexagon socket spanner.
  • Page 79 (16) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (17) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (18) T h e p r e s s u r e r e l i e f v a l v e i s n o w disassem-bled.
  • Page 80 5) 5) ASSEMBLY ASSEMBLY Assemble spool and sleeve. ※ When assembling spool and sleeve only one of two possible ways of positioning the spring slots is correct. There are three slots in the spool and three holes in the sleeve in the end of the spool / sleeve opposite to the end with spring slots.
  • Page 81 Press the springs together and push the neutral position springs into place in the sleeve. 5-77(2) Line up the springs and center them. 5-77(3) Guide the ring down over the sleeve. ※ The ring should be able to rotate free of the springs.
  • Page 82 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) ※ Assembly pattern for standard bearings 1 Outer bearing race 2 Thrust bearing 3 Inner bearing race 4 Spool 5 Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 83 (11) Grease O-ring with hydraulic oil and place them on the tool. 5-79(1) 5-79(2) (12) Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.
  • Page 84 (14) Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore. 5-80(1) Installation instructions for lip seal (15) Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 85 (17) Press and turn the lip seal into place in the housing. 5-81(1) (18) With a light turning movement, guide the spool and sleeve into the bore. ※ Fit the spool set holding the cross pin horizontal. 5-81(2) (19) The spool set will push out the assembly tool guide.
  • Page 86 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20˚C. 5-82(2) (23) Place the distributor plate so that the channel holes match the holes in the...
  • Page 87 (25) Place the cardan shaft as shown - so that it is held in position by the mounting fork. 5-83(1) (26) Grease the two O-rings with mineral oil approx. viscosity 500 cSt at 20˚C and place them in the two grooves in the gear rim.
  • Page 88 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ·Tightening torque : 4.0±0.5 kgf·m (28.9±3.6 lbf·ft) 5-84(3)
  • Page 89 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. ※ Do not use a hammer! 5-85(2) 5-30...
  • Page 90 2. STEERING CYLINDER 2. STEERING CYLINDER 1) 1) STRUCTURE STRUCTURE 35B7SS14 Tube assembly Rod seal 11 Back up ring Rod assembly Back up ring 12 O-ring Piston seal Dust wiper 13 Lock washer Gland Snap ring 14 Pin bushing Du bushing 10 O-ring 5-31...
  • Page 91 2) 2) DISASSEMBLY DISASSEMBLY ※ Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in a vice. Remove the gland by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube.
  • Page 92 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Set a special tool the cylinder, gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland assembly, and tighten it with torque 60±6 kgf·m (434±43.4 lbf·ft).
  • Page 93 3. STEERING AXLE 3. STEERING AXLE 1) 1) STRUCTURE STRUCTURE 1-14 1-40 1-39 1-41 1-38 1-30 1-13 1-24 1-12 1-28 1-25 1-31 1-32 1-29 1-14 1-37 1-34 1-10 1-11 1-41 1-35 1-13 1-12 1-36 1-33 1-13 1-12 1-27 1-29 1-26 1-14 1-41 1-33...
  • Page 94 2) 2) CHECK AND INSPECTION CHECK AND INSPECTION 35B7SS06 mm(in) Criteria Remedy Check item Standard size Repair limit Diameter of king pin 40 (1.57) 39.8 (1.56) Replace Diameter of center pin 55 (2.17) 54.5 (2.15) Replace ·Damage, wear Rear axle, hub, knuckle, bearing Replace ·Seizure, abnormal noise, defective rotation 5-35...
  • Page 95 3) 3) DISASSEMBLY DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the balance Hub nut weight part of the truck. Loosen the hub nut and take off the steering wheel.
  • Page 96 4) 4) ASSEMBLY ASSEMBLY Potentio- ※ In reassembling, have all parts washed, grease meter applied to lubricating parts, and all expendable items such as oil seal and spring washers RH SIDE replaced by new ones. Perform the disassembly in reverse order. Tighten the set screw (1-7) and hexagon nut (1-8) of king pin.

  • Page 97: 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 98: 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 (LEVEL TYPE) LIFT TILT AUX 1 AUX 2 35B7HS01 Hydraulic gear pump Tilt cylinder Priority valve Down safety valve Main control valve Down flow regulator...
  • Page 99 HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT (FINGERTIP TYPE) 40B9HS01 Hydraulic gear pump Down safety valve Priority valve Down flow regulator Main control valve 10 Suction strainer Steering unit 11 Return filter Steering cylinder 12 Auto tilt manifold Lift cylinder 13 Hydraulic oil tank Tilt cylinder...
  • Page 100 1) 1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION LIFT Return line Steering system 35B7HS02 When the lift control lever is pulled back, the spool on the first block is moves to lift position. The oil from hydraulic gear pump (1) flows into main control valve (3) and then goes to the large chamber of lift cylinder (6).
  • Page 101 2) 2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION Return line LOWER Steering system 35B7HS03 When the lift control lever is pushed forward, the spool on the first block is moved to lower position. The work port(1A) and the small chamber and the large chamber are connected to the return passage, so the forks will be lowered due to its own weight.
  • Page 102 3) 3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION Return line TILT Steering FORWARD system LIFT AUX 1 AUX 2 35B7HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
  • Page 103 4) 4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 4B 4A 150kgf/cm 210kgf/cm Return line Steering system LIFT TILT AUX 1 AUX 2 BACKWARD MOTOR 35B7HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
  • Page 104 2. HYDRAULIC GEAR PUMP 2. HYDRAULIC GEAR PUMP 1) 1) STRUCTURE STRUCTURE 35B7HS06 Flange Screw 14 Plate Body 15 Seal Drive gear 10 Lip seal 16 Seal Driven gear 11 Circlip 17 Seal Floating gear 12 Bushing 18 Name plate 13 Center plate 19 Screw Washer...
  • Page 105 3. MAIN CONTROL VALVE 3. MAIN CONTROL VALVE 1) 1) STRUCTURE STRUCTURE (4- Spool) Inlet port Gauge port Outlet port SECTION H - H 16 15 SECTION T - T SECTION E - E VIEW F - F VIEW G - G VIEW I - I Port name Size...
  • Page 106 INLET SECTION OPERATION INLET SECTION OPERATION (1) (1) Structure and description Structure and description (Relief valve piston) 9 10 Relief valve piston 20D7HS08 Hydrostat plug 14 Relief plug O-ring 16 Relief spring 10 Hydrostat spring 17 Pilot poppet 11 Hydrostat sleeve 28 O-ring 12 Relief piston 29 System relief seat...
  • Page 107 (2) (2) Operation Operation Secondary relief valve To neutral passage To aux block 15.0MPa System relief valve 21.0MPa To neutral passage To load check valve 35B7HS15 Oil flows from P (pump) port to reservoir (T) by pushing hydrostat spool (1). Before the center bypass line closed, hydrostat spool is keep opening, so pump port (P) and tank port (T) are always connected in operation to minimize heat generation.
  • Page 108 LIFT SECTION OPERATION LIFT SECTION OPERATION (1) (1) Lift position Lift position Load check valve 35B7HS09 When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flow into lift cylinder port (1A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 109 (2) (2) Lower position Lower position 35B7HS10 When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (1A) → T. In lift lower position the fork drops due to its own weight.
  • Page 110 TILT SECTION OPERATION TILT SECTION OPERATION (1) (1) Tilt forward position Tilt forward position Tilt lock spool Load check valve 35B7HS11 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed.
  • Page 111 (2) (2) Tilt backward position Tilt backward position Tilt lock spool Load check valve 35B7HS12 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flows into tilt cylinder port (2A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.

  • Page 112: Main Relief Valve

    MAIN RELIEF VALVE MAIN RELIEF VALVE (1) (1) Pressure setting Pressure setting Lock nut Relief plug Seat A good pressure gauge must be installed in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set Adjust bar pressure of the relief unit.

  • Page 113: Lift Cylinder

    4. LIFT CYLINDER 4. LIFT CYLINDER D255HS18 Tube assembly Wear ring 11 O-ring Retaining ring 12 Guide Piston Gland 13 DU bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 5. TILT CYLINDER 5. TILT CYLINDER 24 18 19,20 21,22,23 3 12 11 5,6 9,10...

  • Page 114: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS 1) 1) CHECK ITEM CHECK ITEM Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1 m from ground.

  • Page 115: Troubleshooting

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

  • Page 116: Hydraulic Gear Pump

    2) 2) HYDRAULIC GEAR PUMP HYDRAULIC GEAR PUMP Problem Cause Remedy ·System relief valve set too low or ·Check system relief valve for proper Pump does not develop full pressure leaking. setting. ·Oil viscosity too low. ·Change to proper viscosity oil. ·Pump is worn out.
  • Page 117 4) 4) LIFT CYLINDER LIFT CYLINDER Problem Cause Remedy ·Foreign matters on packing. ·Replace packing. Oil leaks out from rod cover ·Unallowable score on rod. ·Smooth rod surface with an oil stone. through rod ·Unusual distortion of dust seal. ·Replace dust seal. ·Chrome plating is striped.

  • Page 118: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP 1. HYDRAULIC GEAR PUMP 1) 1) DISASSEMBLY DISASSEMBLY Put the unit back side down to your work place. B207PMP01 Remove all fasteners, bolts and nuts. B207PMP02 Put all removed parts on a safe place.
  • Page 119 Remove the gear set and remove the balance plate from bottom of the body. B207PMP05 Remove the snap ring(located in front of the shaft seal ring). B207PMP06 Use proper and safe tools for this operation. B207PMP07 Push out the shaft seal. B207PMP08 6-22...
  • Page 120 Check balance plates, the mid plate and the sealing parts. B207PMP09 (10) Assemble new sealing parts, the rubber seal first, the plastic seal on top. B207PMP10 (11) Check all parts of the gear set including the key for the split gear. B207PMP11 (12) Remove the section seal from mounting...
  • Page 121 2) 2) ASSEMBLY ASSEMBLY Clean all mounting faces of the mounting flange from sealant and dirt. B207PMP13 Be careful, avoid mechanical surface damages. B207PMP14 Clean all mounting faces of the body from sealant and dirt. B207PMP15 Assemble the lower balance plate into the body, sealing parts can be fixed with grease.
  • Page 122 Assemble the basic gears into the body, journals and other contact faces should be oiled with clean hydraulic fluid. B207PMP17 Assemble the mid plate to the gear set. The mid plate is not rotation sensitive. B207PMP18 Fit the key to the drive shaft. The key should be fixed with grease.
  • Page 123 Put the upper balance plate on top of the gear set. Position is rotation sensitive. B207PMP21 (10) Prepare the shaft seal for assembly. Use a proper assembly fixture. B207PMP22 (11) The shaft seal should be packed with some grease. B207PMP23 (12) Press in the shaft seal to bottom of the shaft seal bore.
  • Page 124 (13) Assemble the snap ring. B207PMP25 (14) Check the section seal. Use of a new one is recommended in each case. B207PMP26 (15) Clean all assembly faces again. B207PMP27 (16) Put a rope of loctite sealant out side the interlock track on the body (it's for corrosion protection).
  • Page 125 (17) Fit an assembly fixture for shaft seal protection to the drive shaft. B207PMP29 (18) The assembly fixture should be oiled with clean hydraulic fluid to lubricate the shaft seal lip during assembly. B207PMP30 (19) Fit the mounting flange careful from top down to the body.
  • Page 126 (21) Fit fasteners, bolts or nuts with correct assembly torque, according to values shown on unit assembly drawing. B207PMP33 6-29...
  • Page 127 2. MAIN CONTROL VALVE 2. MAIN CONTROL VALVE Remove bolt (1) to separate the valve section. 20D7MCV01 Divide the valve body. Aux2 Aux1 Tilt Lift T-cover 20D7MCV02 Remove dust cap (3) and bolt (2) from the valve body. 20D7MCV03 Remove attachment spool (4) from the valve body.
  • Page 128 Remove O-ring seals (5) from the valve body. 20D7MCV05 Remove tilt spool (6) from the valve body. 20D7MCV06 Remove lift spool (7) from the valve body. Remove lock poppet (8) from the valve body. Remove normal close solenoid valve (9) from the valve body.
  • Page 129 Remove relief plugs (15), springs (14) and poppets (13). 20D7MCV09 Remove normal open solenoid valve (16) from the valve body. 20D7MCV10 6-32...

  • Page 130: Main Block

    2-1. MAIN CONTROL VALVE (FINGERTIP, OPT) STRUCTURE AUX 2 AUX 1 TILTING MAIN Main section Aux 2 section Tilt section Aux 1 section (lifting and lowering) 3-1-1 25L7AFT01 Tightening torque - Item (3-1-1, 4-2, 5-2,10) : 0.97 kgf·m (7.0 lbf.ft) - Item (9) : 2.35 kgf·m (16.9 lbf.ft) Main block...

  • Page 131: Main Section

    MAIN SECTION 25L7AFT02 Flow rate : 100 lpm Maximum pressure : 250 bar Lifting and lowering valve Main section EMP solenoid valve EMP 31V lifting valve AMP coil Cartridge 25L7AFT04 EMP 31V Tightening torque lowering valve 25L7AFT05 6.12 kgf·m (44.2 lbf·ft) 25L7AFT03 When it can’t control lifting &...
  • Page 132 3-way controller 9 bar spring 25L7AFT06 25L7AFT07 During unloading, supplied oil by the pump return to tank keeping 9 bar of system pressure. 6-32-3...

  • Page 133: Pressure Reducing Valve

    Pressure Reducing valve & G damping screw Pressure reducing valve Pressure reducing valve controls valve actuation by suppling internal control oil. Use flat screw driver. Tightening torque 0.71 kgf·m (5.2 lbf·ft) 25L7AFT08 G damping screw G damping increased throttling effect of load sensing line. Tightening torque 1.02 kgf·m (7.4 lbf·ft) 25L7AFT09A...

  • Page 134: Pressure Relief Valve

    Pressure relief valve 25L7AFT10 Use with a 12 mm spanner. Tightening torque (2) 1.43 kgf·m (10.3 lbf·ft) 25L7AFT11 Use with a 3 mm wrench. Tightening torque (1) 1.43 kgf·m (10.3 lbf·ft) = Pressure increases = Pressure decreases 25L7AFT12 Rotating clockwise to increase setting pressure with a wrench. 80 bar increase and decrease per 1 turn.

  • Page 135: Emergency Lowering Valve

    Emergency lowering valve and shuttle valve Emergency lowering valve 25B9UFT14 When need to force lowering, rotate counter clockwise increasingly with emergency lowering valve. Shuttle valve 25L7AFT15 Transfer bigger load pressure through shuttle valve. Use a flat screw driver. 6-32-6...
  • Page 136 TILT SECTION 25L7AFT16 Flow rate : 40 lpm Load holding pressure : 210 bar Proportional directional valve 25L7AFT17 Counter balance valve block Valve section block 6-32-7...
  • Page 137 Disassembly valve section Disassemble spool All block type, 40lpm Disassemble coil 25L7AFT18 AMP 4 pin coil Disassembling process Release spring cap. 25L7AFT19 Release spring cap completely. 25L7AFT20 Release lever block. 25L7AFT21 Pull out spool. 25L7AFT22 6-32-8...
  • Page 138 2 way controller and shuttle valve 2 way controller (6 bar) 6 bar spring 25L7AFT24 2 way controller make it keep 6 bar regardless of load change between in and out of spool. Shuttle valve 25L7AFT25 Transfer bigger load pressure through shuttle valve. Fix 4 mm bolt and pull out.
  • Page 139 Counter balance valve Counter balance valve needs during tilting out operation. 61-250 bar Tightening torque = Pressure increases 3.06 kgf·m (22.1 lbf·ft) = Pressure decreases 25L7AFT28A 6-32-10...

  • Page 140: Auxiliary Section

    AUXILIARY SECTION 25L7AFT29 Flow rate : 40 lpm Pressure limit aux section : 140 bar Proportional directional valve Valve section block 25L7AFT30 Ancillary block 6-32-11...
  • Page 141 2 way controller and shuttle valve 2 way controller (6 bar) 6 bar spring 25L7AFT24 2 way controller make it keep 6 bar regardless of load change between in and out of spool. Shuttle valve 25L7AFT25 Transfer bigger load pressure through shuttle valve. Fix 4 mm bolt and pull out.
  • Page 142 Second relief valve Controlling individual section pressure, rotating clockwise to increase setting pressure with wrench. 80 bar increase and decrease per 1 turn. Relief valve 25L7AFT26 25L7AFT27 Use with a 12 mm spanner. Use with a 3 mm wrench. Tightening torque (1) Tightening torque (2) 1.43 kgf·m (10.3 lbf·ft) 1.43 kgf·m (10.3 lbf·ft)
  • Page 143 ADD SECTION PART Disassembly Tightening torque 0.97 kgf·m (7.0 lbf·ft) Tightening torque 2.35 kgf·m (16.9 lbf·ft) 40B9HS02 When it needs to disassemble HMPL valve, it’s possible to release tension rod sets. 6-32-14...
  • Page 144 3. LIFT CYLINDER 3. LIFT CYLINDER 1) 1) STRUCTURE STRUCTURE 35B7HS23 Tube assy Retaining ring 12 Guide Gland 13 Du bushing Piston Dust wiper 14 O-ring Piston seal 10 Rod seal 15 Spacer Back up ring 11 O-ring 16 O-ring Wear ring 6-33...
  • Page 145 2) 2) DISASSEMBLY DISASSEMBLY Hold the cylinder tube in a vice, loosen the Guide cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn.
  • Page 146 4. TILT CYLINDER 4. TILT CYLINDER 1) 1) STRUCTURE STRUCTURE 35B7HS24 Tube assy 10 Back up ring 18 Rod eye 11 Lock washer 19 Spherical bearing Gland 12 Washer 20 Retaining ring Bushing 13 Piston 21 Hexagon bolt Rod seal 14 O-ring 22 Hexagon nut Back up ring...
  • Page 147 2) 2) DISASSEMBLY DISASSEMBLY Hold the parallel parts of the cylinder tube bottom in a vice and mark the rod head end to show how much it is screwed in, then remove the rod head. Next, hook a wrench into the notch at the cylinder head and remove the cylinder head from cylinder tube.

  • Page 148: 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 149: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION Option 40B-9 : #0231- 45B-9 : #0162- 50B-9 : #0853- 40B9EL02A Combination switch 10 Pump controller 19 Beacon lamp (opt) Parking micro switch 11 Traction controller...

  • Page 150: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT ·ELECTRICAL CIRCUIT (1/14, NON-UL, ZAPI, 50B-9 : #0001-#0004) ELECTRICAL CIRCUIT (1/14, NON-UL, ZAPI, 50B-9 : #0001-#0004) FUSE BOX ASS'Y ( UL #1 ) RELAY WORK BEACON FLAS BRAKE LAMP SEAT -HER LAMP LAMP HEATING HEAD...
  • Page 151 ·ELECTRICAL CIRCUIT (2/14, NON-UL, ZAPI, 40B-9 : #0001-#0009, 45B-9 : #0001-#0004, 50B-9 : #0005-#0011) ELECTRICAL CIRCUIT (2/14, NON-UL, ZAPI, 40B-9 : #0001-#0009, 45B-9 : #0001-#0004, 50B-9 : #0005-#0011) FUSE BOX ASS'Y ( UL #1 ) RELAY WORK BEACON FLAS BRAKE...
  • Page 152 ·ELECTRICAL CIRCUIT (3/14, NON-UL, ZAPI, 40B-9 : #0010-#0011) ELECTRICAL CIRCUIT (3/14, NON-UL, ZAPI, 40B-9 : #0010-#0011) FUSE BOX ASS'Y ( UL #1 ) FLAS 221B WORK BEACON RELAY BRAKE SEAT LAMP LAMP LAMP -HER HEATING HEAD SWITCH UNIT EMERGENCY SWITCH...
  • Page 153 ·ELECTRICAL CIRCUIT (4/14, NON-UL, ZAPI, 40B-9 : #0012-#0020, 45B-9 : #0005-#0007, 50B-9 : #0012-#0020) ELECTRICAL CIRCUIT (4/14, NON-UL, ZAPI, 40B-9 : #0012-#0020, 45B-9 : #0005-#0007, 50B-9 : #0012-#0020) FUSE BOX ASS'Y ( UL #1 ) RELAY FLAS 221B WORK BEACON...
  • Page 154 ·ELECTRICAL CIRCUIT (5/14, NON-UL, ZAPI, 40B-9 : #0021-#0040, 45B-9 : #0008-#0026, 50B-9 : #0021-#0064) ELECTRICAL CIRCUIT (5/14, NON-UL, ZAPI, 40B-9 : #0021-#0040, 45B-9 : #0008-#0026, 50B-9 : #0021-#0064) FUSE BOX ASS'Y ( UL #1 ) TILT RELAY WORK BEACON BRAKE...
  • Page 155 ·ELECTRICAL CIRCUIT (6/14, NON-UL, ZAPI, 40B-9 : #0041-#0065, 45B-9 : #0027-#0050, 50B-9 : #0065-#0152) ELECTRICAL CIRCUIT (6/14, NON-UL, ZAPI, 40B-9 : #0041-#0065, 45B-9 : #0027-#0050, 50B-9 : #0065-#0152) FUSE BOX ASS'Y ( UL #1 ) TILT WORK BEACON RELAY FLAS...
  • Page 156 ·ELECTRICAL CIRCUIT (7/14, NON-UL, ZAPI, 40B-9 : #0066-#0230, 45B-9 : #0051-#0161, 50B-9 : #0153-#0852) ELECTRICAL CIRCUIT (7/14, NON-UL, ZAPI, 40B-9 : #0066-#0230, 45B-9 : #0051-#0161, 50B-9 : #0153-#0852) FUSE BOX ASS'Y ( UL #1 ) TILT RELAY FLAS WORK BEACON...
  • Page 157 ·ELECTRICAL CIRCUIT (8/14, UL, ZAPI, 40B-9 : #0001-#0009, 45B-9 : #0001-#0004, 50B-9 : #0001-#0011) ELECTRICAL CIRCUIT (8/14, UL, ZAPI, 40B-9 : #0001-#0009, 45B-9 : #0001-#0004, 50B-9 : #0001-#0011) FUSE BOX ASS'Y ( UL #1 ) RELAY WORK BEACON FLAS BRAKE...
  • Page 158 ·ELECTRICAL CIRCUIT (9/14, UL, ZAPI, 40B-9 : #0010-#0013, 45B-9 : #0005, 50B-9 : #0012-#0014) ELECTRICAL CIRCUIT (9/14, UL, ZAPI, 40B-9 : #0010-#0013, 45B-9 : #0005, 50B-9 : #0012-#0014) FUSE BOX ASS'Y ( UL #1 ) RELAY FLAS WORK BEACON BRAKE...
  • Page 159 · ELECTRICAL CIRCUIT (10/14, UL, ZAPI, 40B-9 : #0014-#0020, 45B-9 : #0006-#0007, 50B-9 : #0015-#0020) ELECTRICAL CIRCUIT (10/14, UL, ZAPI, 40B-9 : #0014-#0020, 45B-9 : #0006-#0007, 50B-9 : #0015-#0020) FUSE BOX ASS'Y ( UL #1 ) WORK BEACON FLAS BRAKE...
  • Page 160 ·ELECTRICAL CIRCUIT (11/14, UL, ZAPI, 40B-9 : #0021-#0040, 45B-9 : #0008-#0026, 50B-9 : #0021-#0064) ELECTRICAL CIRCUIT (11/14, UL, ZAPI, 40B-9 : #0021-#0040, 45B-9 : #0008-#0026, 50B-9 : #0021-#0064) FUSE BOX ASS'Y ( UL #1 ) TILT WORK BEACON FLAS RELAY...
  • Page 161 ·ELECTRICAL CIRCUIT (12/14, UL, ZAPI, 40B-9 : #0041-#0065, 45B-9 : #0027-#0050, 50B-9 : #0065-#0152) ELECTRICAL CIRCUIT (12/14, UL, ZAPI, 40B-9 : #0041-#0065, 45B-9 : #0027-#0050, 50B-9 : #0065-#0152) FUSE BOX ASS'Y ( UL #1 ) TILT FLAS WORK BEACON RELAY...
  • Page 162 ·ELECTRICAL CIRCUIT (13/14, UL, ZAPI, 40B-9 : #0066-#0230, 45B-9 : #0051-#0161, 50B-9 : #0153-#0852) ELECTRICAL CIRCUIT (13/14, UL, ZAPI, 40B-9 : #0066-#0230, 45B-9 : #0051-#0161, 50B-9 : #0153-#0852) FUSE BOX ASS'Y ( UL #1 ) TILT FLAS WORK BEACON RELAY...
  • Page 163 ·ELECTRICAL CIRCUIT (14/14, FINGERTIP, 40B-9 : #0034-#0230, 45B-9 : #0016-#0161, 50B-9 : #0022-#0852) ELECTRICAL CIRCUIT (14/14, FINGERTIP, 40B-9 : #0034-#0230, 45B-9 : #0016-#0161, 50B-9 : #0022-#0852) MHYRIO CB CAN TILLER FT LIFT 21/922 500A B2 -BATT NPOT C3 B2 PAUX...
  • Page 164 GROUP 2 ELECTRICAL CIRCUIT (MACHINE NO. 40B-9 : #0231-, 45B-9 : #0162-, 50B-9 : #0853-) GROUP 2 ELECTRICAL CIRCUIT (MACHINE NO. 40B-9 : #0231-, 45B-9 : #0162-, 50B-9 : #0853-) ·ELECTRICAL CIRCUIT (1/9, NON-UL, NON-FUNCTIONAL SAFETY) ELECTRICAL CIRCUIT (1/9, NON-UL, NON-FUNCTIONAL SAFETY)
  • Page 165 ·ELECTRICAL CIRCUIT (2/9, UL, NON-FUNCTIONAL SAFETY) ELECTRICAL CIRCUIT (2/9, UL, NON-FUNCTIONAL SAFETY) SEAT OP TO HARNESS- TO HARNESS- STEERING COLUMN SWITCH TO HARNESS-REAR LH FRONT RH FRONT SEAT SW HEATING GEAR SELECTOR COMBI.SWITCH SWITCH SWITCH-EMERGENCY PARKING B IG BACKUP ALARM DIODE SEAT BELT INTERLOCK...
  • Page 166 ·ELECTRICAL CIRCUIT (3/9, FINGERTIP, NON-FUNCTIONAL SAFETY) ELECTRICAL CIRCUIT (3/9, FINGERTIP, NON-FUNCTIONAL SAFETY) HARNESS-ARMREST SWITCH-EMERGENCY 420 #20 RW 420 #20 RW 420 #20 RW 120 #20 P 120 #20 P 120 #20 P 20 #20 RL 20 #20 RL 20 #20 RL 32 #20 Y 32 #20 Y 32 #20 Y...
  • Page 167 ·ELECTRICAL CIRCUIT (4/9, OVER HEAD GUARD) ELECTRICAL CIRCUIT (4/9, OVER HEAD GUARD) *ELEC.DIAGRAM OF HARNESS-FRONT LH/RH(HALLOGEN LAMP) *ELEC.DIAGRAM OF HARNESS CABIN-OHG CL-30/31 CL-3/4 CN-106 REAR WIPER MOTOR TO:HARNESS-MAIN 44 #18 G 728 #18 Gr 44 #18 G TO:HARNESS CABIN-FRAME CN-703 HEAD LAMP SWITCH HEAD LAMP 02 #18 BW...
  • Page 168 ·ELECTRICAL CIRCUIT (5/9, OPTION) ELECTRICAL CIRCUIT (5/9, OPTION) *ELEC.DIAGRAM OF HARNESS-HEATER HEATER ASSY HEATER CONTACTOR DIODE DIODE DIODE *ELEC.DIAGRAM OF HARNESS-RMCU CN-D1 CN-T1 225 #20 RW RESISTOR 0.25W,120 226 #20 BW 226 #20 BW CAN_HIGH(500K) CN-T1 225 #20 RW 225 #20 RW CAN_LOW(500K) RESISTOR 0.25W,120...
  • Page 169 ·ELECTRICAL CIRCUIT (6/9, CABIN) ELECTRICAL CIRCUIT (6/9, CABIN) HEATER ASSY HEATER CONTACTOR DIODE DIODE DIODE CN-140 00 #14 B CS-701 BATTERY "-" 743 #18 Y CN-703 TO:HARNESS CABIN-OHG 723 #18 P 744 #18 W FRONT WIPER MOTOR 729 #18 W 726 #18 L ROOM LAMP 733 #18 Or...
  • Page 170 ·ELECTRICAL CIRCUIT (7/9, NON-UL, FUNCTIONAL SAFETY) ELECTRICAL CIRCUIT (7/9, NON-UL, FUNCTIONAL SAFETY) TO HARNESS- TO HARNESS- SEAT OP TO HARNESS-REAR STEERING COLUMN SWITCH LH FRONT RH FRONT SEAT SW HEATING GEAR SELECTOR COMBI.SWITCH SWITCH SWITCH-EMERGENCY PARKING B IG BACKUP SOCKET ALARM SEAT BELT INTERLOCK...
  • Page 171 ·ELECTRICAL CIRCUIT (8/9, UL, FUNCTIONAL SAFETY) ELECTRICAL CIRCUIT (8/9, UL, FUNCTIONAL SAFETY) 21B3-90920-00 7-2-21...
  • Page 172 ·ELECTRICAL CIRCUIT (9/9, FINGERTIP, FUNCTIONAL SAFETY) ELECTRICAL CIRCUIT (9/9, FINGERTIP, FUNCTIONAL SAFETY) HARNESS-ARMREST SWITCH-EMERGENCY 20 #20 RL 20 #20 L 20 #20 L 32 #20 Y 32 #20 Y 32 #20 Y CS-9 125 #20SH W 126 #20SH B 21 #18 Br 21 #18 Br 00 #18 B 00 #18 B...

  • Page 173: Group 3 Electric Components

    For the monitoring system, there are many sensors such as current sensors, potentiometer sensors, and temperature sensors. The HYUNDAI Battery forklift trucks are equipped with the most advanced DRIVING CONTROL SYSTEM currently available world-widely.
  • Page 174 2. BATTERY 2. BATTERY 1) 1) STRUCTURE STRUCTURE 40B9EL03 Cells Cable connector Steel box Negative leading cable Cell connector 10 Handle (red) Row connector 11 Plug Terminal connector 12 Positive leading cable...
  • Page 175 GENERAL GENERAL As in the battery forklift, the battery is an energy source, the handling of the battery is very important. The life and performance of the battery greatly depend on the ordinary handling and maintenance. Therefore, be sure to check and maintain the battery so that it may be kept best.

  • Page 176: Safety Precautions

    4) 4) SAFETY PRECAUTIONS SAFETY PRECAUTIONS (1) (1) When sulfuric acid contact with skin When sulfuric acid contact with skin For acid contact with skin, eye or clothing, flush with water immediately. If swallowed, drink a large amount of water or milk. Seek medical attention immediately. When handling acid, always wear eye goggles or a face shield and rubber gloves.
  • Page 177 (2) (2) Performance and maintenance of batteries Performance and maintenance of batteries ① Initial charge Initial charge Wet-charged battery gradually decreases its capacity during storage. In order to provide sufficient discharge capacity in the first discharge, the good initial charge is required. The conditions of initial charging are seen as below at room temperature.
  • Page 178 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 179 ⑥ Replenishment of distilled water Replenishment of distilled water Only the water content of electrolyte is decreased due to electrolysis of distilled water during charge and natural evaporation. If a battery used with the electrolyte decreased excessively, plates will deteriorate resulting in markedly shortening of battery life. Be sure to check the electrolyte level once every week.
  • Page 180 ⑦ Cleaning Cleaning If electrolyte spills or the cells are polluted with dust or stains, it will cause generation of leak current. Wipe off dust and stains with moist cloth and clean in such a manner that the cells are kept in dry condition.
  • Page 181 ⑩ Summary of daily maintenance Summary of daily maintenance Avoid overcharge. After discharge, charge the batteries immediately. The standard frequency of equalizing charge is more than once every month. Be sure to check the electrolyte level once every week. If found decreased, replenish distilled water up to the specified level.

  • Page 182: Troubleshooting

    7) 7) TROUBLESHOOTING TROUBLESHOOTING Nature of trouble Nature of trouble Symptoms Symptoms Causes Causes Corrective Action Corrective Action · · · Deformation Deformation of container. Excessive temperature Replace Lid or one touch cap rising or external impact · · · Breakage Electrolyte leakage acco- External impact, improper...
  • Page 183 3. DRIVE MOTOR 3. DRIVE MOTOR 1) 1) STRUCTURE STRUCTURE 40B9EL07 Rotor Block-Terminal A Bearing Stator Speed sensor kit 10 Bearing Endbell De Stud bolt 11 Oil seal Endbell Protector-Terminal 12 O-ring 7-13...

  • Page 184: Specification

    2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Type AQDU4001 Rated voltage Rated output 10.0 Insulation Class F 3) 3) MAINTENANCE INSTRUCTION MAINTENANCE INSTRUCTION ※ Before starting the maintenance please disconnect the power supply. (1) (1) Ball bearing Ball bearing Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of repair, they should be replaced.
  • Page 185 4. PUMP MOTOR 4. PUMP MOTOR 1) 1) STRUCTURE STRUCTURE 40B9EL08 Rotor Block-Terminal A Bearing Stator Speed sensor kit 10 Oil seal Endbell De Stud bolt Endbell Protector-Terminal 7-15...

  • Page 186: Ball Bearing

    2) 2) SPECIFICATION SPECIFICATION Item Unit Specification Type AQDV4001 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 187: Specifications

    5. CONTROLLER SYSTEM 5. CONTROLLER SYSTEM 1) 1) STRUCTURE STRUCTURE 35B7EL10 (1) (1) Specifications Specifications Model Model Application Type Power Current limit Traction MOSFET 80V, 600A 600A/3min 40/45/50B-9 Pump MOSFET 80V, 600A 600A/3min 7-17...

  • Page 188: 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 189: Description Of The Connectors

    3) 3) DESCRIPTION OF THE CONNECTORS DESCRIPTION OF THE CONNECTORS (1) (1) Traction controller Traction controller (Master) Rubber cap (No. of pin B1~B8) VIEW A 35B7EL14 7-19...
  • Page 190 No. of Pin Function Description +12V Positive of encoder power supply. +12V Negative of encoder power supply. PPOT Accelerator potentiometer positive : 10V output; keep load > 1kΩ. SEAT SEAT input; it must be connected to the SEAT microswitch; it is active high. FORWARD Forward direction request input.
  • Page 191 No. of Pin Function Description Connected to the power supply through a microswitch (CH) with a 10A fuse in series. -BATT -Batt. 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 192 Encoder installation Encoder installation ① Traction controller card is fit for different types of encoder. To control AC motor with Zapi inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90˚. The encoder power supply can be +12V. It can have different electronic output. C11/C1 : +12V : Positive of encoder power supply.
  • Page 193 (2) (2) Traction controller Traction controller (Slave) Rubber cap (No. of pin B1~B8) VIEW A 35B7EL14 7-23...
  • Page 194 No. of Pin Function Description +12V (+5V) Positive of encoder power supply. +12V (+5V) Negative of encoder power supply. SEAT SEAT input; it must be connected to the SEAT microswitch; it is active high. SAFETY OUT If not connected to -Batt (A34) MC coil power output will be disabled. It can also be used as a general purpose input.

  • Page 195: Encoder Installation

    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. C11/C1 : +12V : Positive of encoder power supply.

  • Page 196: Pump Controller

    (3) (3) Pump controller Pump controller 22B7EL14 No. of Pin Function Description +12V Positive of encoder power supply. ENC GND Negative of encoder power supply. PPOT Lift potentiometer positive: 10V output; keep load > 1kΩ. TILT LEVELING Tilt levelling switch input; it is active HIGH. LIFT ENABLE Input for potentiometer lifting enable input;...
  • Page 197 No. of Pin Function Description CAN H High level CAN-BUS voltage I/O. CAN L Low level CAN-BUS voltage I/O. NPOT-AUX (TILT ANGLE) Negative of tilt angle potentiometer. CPOT-AUX (TILT ANGLE) Tilt angle potentiometer wiper. ENC A* Phase A inverted of encoder (encoder with differential output). ENC B* Phase B inverted of encoder (encoder with differential output).

  • Page 198: Function Configuration

    4) 4) FUNCTION CONFIGURATION FUNCTION CONFIGURATION ■ TRACTION CONTROLLER-MASTER TRACTION CONTROLLER-MASTER Using the CONFIG MENU of the programming console, or using a display, the user can configure the following functions. (1) (1) Submenu Submenu "SET OPTIONS" "SET OPTIONS" ① Hour counter Hour counter - RUNNING : The counter registers travel time only.
  • Page 199 ⑪ Display Display If this option is set to on the communication with the graphic display is enabled. ⑫ S.R.O. S.R.O. If this option is set to on the static return to off is requested for starting the truck. The required sequence is : ·Seat-direction lever-accelerator pedal or : ·Seat-accelerator pedal-direction lever within the seq.
  • Page 200 ⑧ Throttle 0 zone Throttle 0 zone It establishes a deadband in the accelerator input curve (see also curve below). ⑨ Throttle X point Throttle X point This parameter changes the characteristic of the accelerator input curve. ⑩ Throttle Y point Throttle Y point This parameter changes the characteristic of the accelerator input curve.
  • Page 201 (3) (3) Parameter change Parameter change ① Acceler. delay Acceler. delay It determines the acceleration ramp. Less value means better acceleration performance. ② Release braking elease braking It controls the deceleration ramp when the travel request is released. Less value means better braking performance. ③...
  • Page 202 ⑫ Frequency creep Frequency creep Minimum speed when the forward or reverse switch is closed, but the accelerator is on a minimum position. ⑬ Maximum Maximum current current This changes the maximum current of the inverter. ⑭ Acc. smooth Acc. smooth It gives a parabolic shape to the acceleration ramp.
  • Page 203 ■ TRACTION CONTROLLER-SLAVE TRACTION CONTROLLER-SLAVE Using the config menu of the programming console, or using a display, the user can configure the following functions. (1) (1) Submenu Submenu "SET OPTIONS" "SET OPTIONS" ① Hour counter -RUNNING : The counter registers travel time only. -KEY ON : The counter registers when the "key"...
  • Page 204 ⑧ Overload type (option) Overload type (option) This option specifies how overload alarm works in overloaded situation. NONE : There would'n be any kind of alarms or limitations. If re-configuration of V.A.S.S LOAD is required, please set this parameter as NONE, then proceed re-configuration.
  • Page 205 (2) (2) Submenu Submenu "ADJUSTMENTS" "ADJUSTMENTS" Set battery type Set battery type : Selects the nominal battery voltage. ① Adjust battery Adjust battery : Fine adjustment of the battery voltage measured by the controller. Please ② increase or decrease the value 1 by 1 and check the voltage. Throttle 0 zone Throttle 0 zone : Establishes a deadband in the accelerator input curve (see also curve below).

  • Page 206: Maintenance

    (3) (3) Parameter change Parameter change ① Acceler delay Acceler delay It determines the acceleration ramp. More value means better deceleration performance. ② Deceler delay Deceler delay It determines the acceleration ramp. More value means better deceleration performance. ③ Max speed up Max speed up Determines the maximum lifting speed with a potentiometer control.

  • Page 207: 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 7-54) ADJUSTMENTS VIA CONSOLE ADJUSTMENTS VIA CONSOLE (Option) Adjustment of parameters and changes to the inverter's configuration are made using the digital console.
  • Page 208 (2) (2) Description of standard console menu Description of standard console menu ① Traction controller-Master Traction controller-Master 40B9EL18 7-38...
  • Page 209 ② Traction controller-Slave Traction controller-Slave 40B9EL19 7-39...
  • Page 210 ③ Pump controller Pump controller 40B9EL20 7-40...
  • Page 211 (3) (3) Description of the console Description of the console SAVE SAVE function function The SAVE function allows the operator to transmit the parameter values and configuration data of the chopper into the console memory. It is possible to load 64 different programmers. The information saved in the console memory can then be reloaded into another chopper using the RESTORE function.
  • Page 212 (4) (4) Description of the console Description of the console RESTORE RESTORE function function The RESTORE PARAM function allows transfer of the console's stored data into the memory of the chopper. This is achieved in a fast and easy way using the method previously used with the SAVE PARAM.
  • Page 213 (5) (5) Description of alarms menu Description of alarms menu The microprocessor in the controller records the last five alarms that have occurred. Items remembered relative to each alarm are: the code of the alarm, the number of times the particular Alarm occurred, the hour meter count, and the inverter temperature.
  • Page 214 (6) (6) Description of console program vacc function Description of console program vacc function This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal. It enables compensation for non symmetry of the mechanical system between directions.

  • Page 215: Config Menu

    (7) (7) DESCRIPTION OF CONSOLE USING DESCRIPTION OF CONSOLE USING ① Access to SET MODEL menu. Access to SET MODEL menu. The only parameter present in SET MODEL function is CONNECTED TO. By setting this parameter, operator can connect ZAPI console to every ZAPI product connected to CAN-BUS line.
  • Page 216 ② Flow chart showing how to make changes to option menu : Flow chart showing how to make changes to option menu : AC3M2BF 9HY1.00 Opening Zapi menu. 80V 600A 00000 Press ROLL UP & SET UP Buttons to enter CONFIG MENU.
  • Page 217 ③ Flow chart showing how to use the tester function of the digital console: Flow chart showing how to use the tester function of the digital console: AC3M2BF 9HY1.00 Opening Zapi menu. 80V 600A 00000 Press ENTER to go into the MAIN MENU. The display will show: PARAMETER CHANGE.
  • Page 218 6) 6) MORNITORING MENU MORNITORING MENU In Console, This menu appears as “TESTER” MENU (1) (1) Traction controller-Master Traction controller-Master ① Motor voltage Motor voltage This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage).
  • Page 219 Cutback switch Cutback switch The level of the speed reduction microswitch. - ON / GND = Input active, switch opened. - OFF / +VB = Input non active, switch closed. Brake switch Brake switch The level of the pedal brake microswitch. - ON / +VB = Input active, switch closed.
  • Page 220 ⑥ Temperature Temperature The temperature measured on the aluminum heat sink holding the MOSFETdevices. ⑦ Motor temperature Motor temperature This is the temperature of the left motor. ⑧ Voltage booster Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
  • Page 221 (3) (3) Pump controller Pump controller ① Motor voltage Motor voltage This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage). ② Frequency Frequency This is the frequency of the voltage and current supplied to the motor.

  • Page 222: Battery Voltage

    Aux pot: Aux pot: Level of the auxiliary analogue signal. The voltage is shown on the left hand side of the display and the value in percentage on the right hand side. 4th speed switch: 4th speed switch: Status of 4th speed switch. - ON / +VB = Active entry of closed switch.
  • Page 223 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 224 5. CONTROLLER SYSTEM (OPITON, 40B-9 : #0231-, 45B-9 : #0162-, 50B-9 : #0853-) 5. CONTROLLER SYSTEM (OPITON, 40B-9 : #0231-, 45B-9 : #0162-, 50B-9 : #0853-) 1) 1) STRUCTURE STRUCTURE Traction, Pump Controller Fingertip Controller 40B97EL25 (1) (1) Specifications Specifications...
  • Page 225 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 226 3) 3) DESCRIPTION OF THE CONNECTORS DESCRIPTION OF THE CONNECTORS (1) (1) Traction controller (RH) Traction controller (RH) No. of Pin Function Description Analog input 3. The default function is as load sensor reference (wiper EVP POT contact of the load potentiometer). Input of the key switch signal PPOT Positive supply for accelerator potentiometer (+5V, 200mA maximum).

  • Page 227: Brake Oil

    (2) (2) Traction controller (LH) Traction controller (LH) No. of Pin Function Description Input of the key switch signal. PPOT Positive supply for auto tilt potentiometer (+12V, 200mA maximum). Analog input 1. The default function is as auto tilt reference (wiper contact of AUTO TILT POT1 the auto tilt1 potentiometer).
  • Page 228 No. of Pin Function Description Digital input active when connected to +B. The default function is as aux1 AUX1 request. Channel A of the incremental encoder. Positive supply for the encoder or for other auxiliary devices like speed PENC transducers, potentiometers, sensors or others (+12V, 200mA maximum). Negative supply for the lift potentiometer.
  • Page 229 No. of Pin Function Description Common positive supply for EVP1 and EVP2 .This signal is the voltage PEVP 1/2 redirected from CNA-1 through a Smart Driver and a diode. (lift) Common positive supply for EVP3 and EVP4 .This signal is the voltage PEVP 3/4 redirected from CNA-1 through a diode.

  • Page 230: Hour Counter

    4) 4) FUNCTION CONFIGURATION FUNCTION CONFIGURATION (1) (1) Traction inverter (Master, RH) Traction inverter (Master, RH) ① Set option Set option Description TRUCK MODEL There are 2 options, 40/45B-9, 50B-9. This option specifies the hour counter mode. It can be set one of two: HOUR COUNTER RUNNING: The counter registers travel time only KEY ON: The counter registers when the "key"...
  • Page 231 Set option Description This parameter enables or disables the functionality that continues to give torque even if the traction (or lift) request has been released. ON = When the operator releases the traction request, the inverter keeps running the truck, as to oppose the friction that tends to stop it. Similarly, in pump applications, when the operator releases the lift request, the inverter keeps running the pump PULL IN BRAKING avoiding the unwanted descent of the forks.
  • Page 232 Set option Description This parameter decides the feature of the main potentiometer, connected to pin A5. Low to high / Direction Pot. type Eanble Switch En. deda band Hight to Low swtiches L to H L to H V-type H to L H to L L to H L to H...
  • Page 233 Set option Description This parameter defines which type of steering unit is connected to the controller. NONE = NO steering module is present on the truck, ACE2 NEW GENERATION does not wait for CAN message by the EPS and it does not apply EPS and braking steer cutback.

  • Page 234: High Dynamic

    Set option Description This parameter defines the voltage compensation for the MC and EB drivers in depen- dence of the battery voltage. 0 = None. COMP.VOLT.OUTPUT 1 = MC only. 2 = EB only. 3 = MC and EB. This parameter enables or disables the acceleration-modulation function. OFF = The acceleration rate is inversely proportional to the ACCELER.
  • Page 235 Set option Description This parameter sets the behavior of the Quick-Inversion input A11: ON = The Quick-Inversion switch is normally closed (function is active when the switch is INVERSION MODE open). OFF = The Quick-Inversion switch is normally open (function is active when the switch is closed).
  • Page 236 Set option Description This parameter defines whether the controller enables the delay in the forward and re- verse switch or not. F&R SWITCH - OFF = The controller disables the delay in the forward and reverse switch or not. - ON = The controller enables the delay in the forward and reverse switch or not. This parameter enables the function of the seat and seat belt sequence.
  • Page 237 Parameter Description This parameter defines the deceleration ramp performed upon a speed-reduction re- SPEED LIMIT BRK. quest, i.e. the time needed to decelerate the motor from 100 Hz down to 0 Hz. This parameter defines the deceleration ramp related to the steering angle, i.e. the time STEER BRAKING needed to decelerate the motor from 100 Hz down to 0 Hz.
  • Page 238 Parameter Description This parameter defines the frequency at which the smoothing effect of the acceleration STOP SMOOTH profile ends. This parameter defines the deceleration profile: 1 results in a linear ramp, higher values BRK SMOOTH result in smoother parabolic profiles. This parameter defines the frequency at which the smoothing effect of the deceleration STOP BRK SMOOTH profile ends.
  • Page 239 Adjustment Description Fine adjustment of the key voltage measured by the controller. Calibrated by Zapi pro- ADJUST KEY VOLT. duction department during the end of line test. Fine adjustment of the battery voltage measured by the controller. Calibrated by Zapi ADJUST BATTERY production department during the end of line test.
  • Page 240 Adjustment Description It adjusts the minimum variation of the battery discharge table to update the battery % at BDI RESET UP the start up. It is used to calibrate the discharge algorithm for the battery used. It affects when the new BDI is updated to a higher value than the old BDI. It adjusts the minimum variation of the battery discharge table to update the battery % at BDI RESET DOWN the start up.

  • Page 241: Speed Factor

    Adjustment Description This parameter defines the coefficient used for evaluating the truck speed (in km/h) from the motor frequency (in Hz), according to the following formula. frequency [Hz] Speed [km/h] = 10· Speed factor This parameter can be derived by the following formula too. SPEED FACTOR 88·rr·pp Speed factor =...
  • Page 242 (2) (2) Traction inverter (Master, LH) Traction inverter (Master, LH) ① Set option Set option Description This parameter enables or disables the functionality that continues to give torque even if the traction (or lift) request has been released. ON = When the operator releases the traction request, the inverter keeps running the truck, as to oppose the friction that tends to stop it.
  • Page 243 Set option Description This parameter enables or disables the NEB output A18, dedicated to the electrome- chanical brake. NONE = Diagnoses are masked and E.B. is not driven upon a traction request. BRAKE = E.B. is driven upon a traction request if all the related diagnoses pass. The AUX OUT FUNCTION behavior on a slope depends on the STOP ON RAMP setting.
  • Page 244 ③ Adjustment Adjustment Description This parameter must be set to the nominal battery voltage. The available options are: SET BATTERY 24V, 36V, 48V, 72V, 80V, 96V Fine adjustment of the key voltage measured by the controller. Calibrated by Zapi pro- ADJUST KEY VOLT.
  • Page 245 (3) (3) Pump inverter Pump inverter ① Set option Set option Description TRUCK MODEL There are 2 options, 40/45B-9, 50B-9. This option specifies the hour counter mode. It can be set one of two: HOUR COUNTER RUNNING: The counter registers travel time only KEY ON: The counter registers when the "key"...
  • Page 246 Set option Description This parameter decides the feature of the main potentiometer, connected to pin A5. Low to high / Direction Pot. type Eanble Switch En. deda band Hight to Low swtiches L to H L to H V-type H to L H to L L to H L to H...
  • Page 247 Set option Description This parameter defines the configuration of the NLC output A16, dedicated to the line contactor. OFF = Line contactor is not present. Diagnoses are masked and MC is not driven. ON = Line contactor is in standalone configuration. Diagnoses are performed and MC is closed after key-on only if they have passed.
  • Page 248 Set option Description This parameter defines the behavior of output EVP A19. NONE = Output A19 is not enabled. ANALOG = Output A19 manages a PWM-modulated current-controlled proportional EVP TYPE valve. DIGITAL = Output A19 manages an on/off valve. By default, it is activated by input LOW- ER A11.
  • Page 249 Set option Description This parameter enables the FINGERTIP function. ON : The truck model includes electro-hydraulic distributor and finger tips. Can FINGERTIP communication with VCM and Hydro CB zapi modules is enabled. OFF : The truck model includes mechanical lever distributor. (This parameter is used only if the FINGERTIP is ON.) ON : All combinations of hydraulic function are available.
  • Page 250 Parameter Description TILT SPEED N (N mode) This parameter defines the maximum speed of the pump motor during tilt. AUX1 SPEED N (N mode) This parameter defines the maximum speed of the pump motor during aux1. AUX2 SPEED N (N mode) This parameter defines the maximum speed of the pump motor during aux2. 5TH PUMP SPEED N NOT used in this truck.
  • Page 251 Parameter Description TILT SPEED P (H mode) This parameter defines the maximum speed of the pump motor during tilt. AUX1 SPEED P (H mode) This parameter defines the maximum speed of the pump motor during aux1. AUX2 SPEED P (H mode) This parameter defi nes the maximum speed of the pump motor during aux2. 5TH PUMP SPEED P NOT used in this truck.
  • Page 252 Adjustment Description This parameter defines the lift sensor input curve. - Lift sensor input curve THROTTLE Y3 MAP 13BOP97ES10 The speed remains at the FREQUENCY CREEP value as long as the voltage from the accelerator potentiometer is below THROTTLE 0 ZONE. Basically this defines a dead zone close to the neutral position.
  • Page 253 Adjustment Description This parameter defines the maximum motor temperature permitted, above which the STOP MOTOR TEMP. controller stops driving the motor. This parameter defines the motor thermal cutback. The control linearly reduces the mo- MOT.T. T.CUTBACK tor torque basing on the motor temperature. Reference limits of the linear reduction are MAX MOTOR TEMP and TEMP.
  • Page 254 (4) (4) Fingertip inverter Fingertip inverter ① Set option Set option Description This option specifies the hour counter mode. It can be set one of two: HOUR COUNTER RUNNING: The counter registers travel time only KEY ON: The counter registers when the "key" switch is closed. This parameter enables or disables the EVP1.
  • Page 255 Set option Description NMT CAN MESSAGE This parameter enables or disables the SAFETY MODE for CAN protocol. CAN SAFETY MODE If it is activated, the overall CAN protocol will be changed. SAFETY DEBUG This parameter enables or disables special debug messages about the SAFETY LAYER. This parameter enables or disables the SAFETY MODE for GR1.
  • Page 256 Parameter Description This parameter determines the maximum current applied to the EVP3 when the position I MAX EVP3_TILT IN of the control is at the maximum. I MIN EVP4_TILT This parameter determines the minimum current applied on the EVP4 when the position of the control is at the minimum.
  • Page 257 Parameter Description It determines the deceleration ramp on EVP4. The parameter sets the time needed to EVP4 CLOSE DELAY decrease the current from MAX EVP4 to MIN EVP4. It determines the acceleration ramp on EVP5. The parameter sets the time needed to EVP5 OPEN DELAY increase the current from MIN EVP5 to the MAX EVP5.
  • Page 258 Adjustement Description ANALOG 3 FILTER this parameter is used to set the filter for the analog input. ANALOG 4 FILTER this parameter is used to set the filter for the analog input. ANALOG 5 FILTER this parameter is used to set the filter for the analog input. ANALOG 6 FILTER this parameter is used to set the filter for the analog input.
  • Page 259 5) 5) PROGRAMMING AND ADJUSTMENTS PROGRAMMING AND ADJUSTMENTS There are two ways to adjust parameter via a smart console or buttons on a display. ※ Adjustments via buttons on a display, please refer to the display section. (page 7-64) ADJUSTMENTS VIA SMART CONSOLE (Option) ADJUSTMENTS VIA SMART CONSOLE (Option) Adjustment of parameters and changes to the inverter's configuration are made using the smart console.

  • Page 260: Parameter Change

    (1) (1) Connected Connected If connection is successful, the display will show a page similar to the next one. VMCM HY1.00 500H NO CAN MSG N.05 25B9UEL18 This menu shows basic information about the controller. · First line displays the controller firmware. ·...
  • Page 261 You can press ESC to exit the menu at any time. In case parameters have been modified, the console will prompt the request to confirm/discard changes. PARAMETER CHANGE ACCELER DELAY APPLY CHANGES? E. ACCELER DELAY YES=OK NO=ESC SPEED LIMIT BRK E.SPD.
  • Page 262 (4) (4) Tester Tester It shows four variables at once: use UP/DOWN keys to scroll the list. TESTER MOTOR VALTAGE FREQUENCY ENCODER BATTERY VOLTAGE 24.5V 25B9UEL24 (5) (5) Alarms Alarms It shows all controller alarms at once. ALARMS NO CAN MESSAGE INCORRECT START NONE NONE...
  • Page 263 6) 6) MORNITORING MENU MORNITORING MENU (1) (1) Traction controller (RH) Traction controller (RH) Monitoring Description KEY VOLTAGE KEY voltage A1 value measured in real time. BATTERY VOLTAGE Battery voltage measured in real time across the DC-bus. DC BUS CURRENT Estimation of the battery current based on the working point.
  • Page 264 Monitoring Description A13 POT#4 STEERING Voltage of the analog signal on A13(steer Signal) SET EVP Set-point of proportional electrovalve EVP. OUTPUT EV1 Status of the EV1 output A24. (No Use) OUTPUT EV2 Status of the EV2 output A25. (No Use) A34 EV3 FAN RELAY Status of the EV3 output A34.
  • Page 265 Monitoring Description CURRENT RMS Root-mean-square value of the line current supplied to the motor. Instantaneous values of the maximum current the inverter can apply to the motor to IMAX LIM. TRA satisfy respectively a traction or braking request. The value is evaluated basing on the IMAX LIM.

  • Page 266: Load Weight

    Monitoring Description Count of the warning events (error frames) occurred on the external CAN bus. It gets COUNT BUSWARN EX saved in the non-volatile memory. Count of the bus-off events occurred on the internal bus between the two microcon- COUNT BUSOFF IN trollers.
  • Page 267 Monitoring Description OVERLOAD VOLTAGE Calculated sensor volatge for Overload weight MAXLOAD VOLTAGE Calculated sensor volatge for Maxload weight A3 POT#1_LIFT 1 Voltage of the analog input 1 A3(Lift Signal 1) A10 POT#2_LIFT 2 Voltage of the analog input 2 A10(Lift Signal 2) B-2 POT#3 NOT used in this truck.
  • Page 268 Monitoring Description OUTPUT EVP5/6 % value. Percentage of the maximum current applied on the output EVP5 and EVP6 OUTPUT EVP7/8 % value. Percentage of the maximum current applied on the output EVP7 and EVP8 OUTPUT EVP9 % value. Percentage of the maximum current applied on the EVP9 OUTPUT EV1 % value.
  • Page 269 6. INSTRUMENT PANEL : DISPLAY 6. INSTRUMENT PANEL : DISPLAY 1) 1) STRUCTURE STRUCTURE The DISPLAY has 6 red LEDs indicating the status information of the lift truck to the driver. Spare #1 Spare #2 Oil level Park brake Wrench Seat belt Thermometer Seat...
  • Page 270 2) 2) WARNING LAMP WARNING LAMP (1) (1) Brake oil level warning lamp Brake oil level warning lamp Lights when the brake oil level in the reservoir is below the lower limit. 22BH9EFD01 (2) (2) Wrench warning lamp Wrench warning lamp This LED lights when an electric device (controller, motor, cable, etc.) is in alarm condition.
  • Page 271 3) 3) BUTTONS BUTTONS (1) (1) UP button UP button Press to select upward move 22BH9EFD07 (2) (2) DOWN button (DOWN/TURTLE button) DOWN button (DOWN/TURTLE button) Press to select downward move TURTLE MODE ON/OFF 22BH9EFD08 (3) (3) LEFT/MENU button LEFT/MENU button Press to select leftward move Go into the menu 22BH9EFD09...

  • Page 272: Main Screen

    4) 4) LCD FUNCTION (MAIN SCREEN) LCD FUNCTION (MAIN SCREEN) MAIN SCREEN MAIN SCREEN 22BH9EFD13 Current time Hour meter Turtle mode Wheel position and running direction Truck speed pointer Power mode Speed level BDI (Battery Discharge Indicator) Truck speed 10 Load weight (option) (1) (1) Current time Current time...
  • Page 273 (3) (3) Truck speed pointer Truck speed pointer The speed of the truck is indicated with a pointer. (4) (4) Speed level Speed level This indicator shows the truck speed same as the (3) Speed pointer. (5) (5) Truck speed Truck speed The truck speed is shown in number.
  • Page 274 5) 5) HOW TO USE DISPLAY MENU HOW TO USE DISPLAY MENU 22BH9EFD14 7-59...
  • Page 275 22BH9EFD15 7-60...
  • Page 276 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 277 - Figure input 22B9EL31 Select a desired value with button, then save with button or press button to escape without saving. - Level Selection 22B9EL30 Select a desired value with button, then save with button or press button to escape without saving.
  • Page 278 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) 22B9EL35...
  • Page 279 (2) (2) Detail description of ALARM SCREEN Detail description of ALARM SCREEN ① ③ ② 22B9EL36 ① First yellow capital letter shows in which controller the alarm happens as below; M : Traction-Master S : Traction-Slave P : Pump V : Mhyrio CB ②...
  • Page 280 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 281 8) 8) VASS SETUP USING DISPLAY MENU VASS SETUP USING DISPLAY MENU This function searches and memorizes the minimum and maximum potentiometer wiper voltage of the accelerator pedal, lift lever, and steering sensor which use potentiometer sensors. The belows show how to use the VASS function of DISPLAY. (All figures in belows are just example.) ※...
  • Page 282 Now, you can see that voltage value of MAX REVERSE are changed. Please make sure that all motors are not running & direction lever is in NEUTRAL position. 22B9EL39-2 (2) (2) LIFT VASS setting method LIFT VASS setting method Please make sure that all motors are not running &...
  • Page 283 (3) (3) STEER ANGLE VASS setting method STEER ANGLE VASS setting method Please make sure that all motors are not running & direction lever is in NEUTRAL position. If “READY” appears beside STEER ANGLE, you are in configuration process. Now, operator can see that voltage value of STEER RIGHT is changed.
  • Page 284 9) 9) STRUCTURE OF TRUCK MENU STRUCTURE OF TRUCK MENU TRUCK MENU is in order to make configuration of truck easily, and consists of 3 major categorys : SETTING, MONITORING, ALARM HISTORY. (1) (1) Setting Setting In setting, service man can choose a specific controller's submenu or V.A.S.S menu Truck Menu →...
  • Page 285 7. ALARM CODE 7. ALARM CODE 1) 1) TRACTION-MASTER CONTROLLER TRACTION-MASTER CONTROLLER Condition that has to occur to come out from Code Alarm name Description alarm status WATCHDOG Alarm: the Watchdog circuit has If the alarm is present in Init status, remove been triggered the alarm condition If the alarm has occurred in stby or running...
  • Page 286 Condition that has to occur to come out from Code Alarm name Description alarm status CAPACITOR Alarm: power capacitor voltage To remove alarm condition CHARGE does not increase when the key Check the contactor resistance (300, 10W) is turned ON; failure in the power Check the controller section, or in the Logic PCB, or in the driver PCB, or in the motor...
  • Page 287 Condition that has to occur to come out from Code Alarm name Description alarm status SEQUENCE Warning: an incorrect start - To remove Warning cause FAULT sequence has been detected on the seat, pedal and levers commands SAFETY Alarm : the controller detects To recycle the key malfunction on safety circuit Check if any other alarms happen on...
  • Page 288 Condition that has to occur to come out from Code Alarm name Description alarm status WAITING FOR Warning: Master Controller To remove Warning cause NODE signals that other controllers are C h e c k i f a n y o t h e r a l a r m h a p p e n s in alarm status (Some alarms such as CHAT TIME or PEDAL WIRE KO, alarms related to CONTACTOR,...
  • Page 289 2) 2) TRACTION-SLAVE CONTROLLER TRACTION-SLAVE CONTROLLER Condition that has to occur to come out from Code Alarm name Description alarm status WATCHDOG Alarm: the Watchdog circuit has If the alarm is present in Init status, remove been triggered the alarm condition If the alarm has occurred in stby or running mode, it is necessary to remove alarm condition and to activate a traction request...

  • Page 290: Motor Tempera-Ture

    Condition that has to occur to come out from Code Alarm name Description alarm status MOTOR Warning: Master or Slave or both To remove Warning cause TEMPERA-TURE motors temperature high Check the motor temp-sensor ENCODER Alarm: motor speed sensor To recycle the key ERROR ( e n c o d e r ) d o e s n o t w o r k Check the motor encoder...
  • Page 291 Condition that has to occur to come out from Code Alarm name Description alarm status THERMIC Warning: Master or slave temp. - To remove Warning cause SENSOR KO sensor is out of range WAITING FOR MC Warning: SLAVE Controller To remove Warning cause detects that Master Controller is C h e c k i f a n y o t h e r a l a r m h a p p e n s malfunctioning or ALARM occurs...
  • Page 292 3) 3) PUMP CONTROLLER PUMP CONTROLLER Condition that has to occur to come out from Code Alarm name Description alarm status WATCHDOG Alarm: the Watchdog circuit has If the alarm is present in Init status, remove been triggered the alarm condition If the alarm has occurred in stby or running mode, it is necessary to remove alarm condition and to activate a traction request...
  • Page 293 Condition that has to occur to come out from Code Alarm name Description alarm status - To remove warning cause HIGH Warning: controller temperature TEMPERATURE higher than 75°C MOTOR W a r n i n g : P u m p m o t o r ’ s To remove warning cause TEMPERA-TURE temperature high...
  • Page 294 Condition that has to occur to come out from Code Alarm name Description alarm status T I L T S E N S Value of tilt sensor (AUTO TILT Check the Tilt Sensor of AUTO TILT LOCKED LEVELING) is fixed even tilt LEVELING Option request is activated Re-configurate Tilt Sensor of AUTO TILT...
  • Page 295 Condition that has to occur to come out from Code Alarm name Description alarm status CAN BUS KO Alarm: controller doesn't receive Check the CAN wiring any message from CAN line Check if any other alarm happens (Some alarms such as CHAT TIME or PEDAL WIRE KO, alarms related to contactor, display enable, alarms related to CANBUS can make this alarm sometimes.)

  • Page 296: Troubleshooting

    7. ALARM CODE (OPTION, 16B-9 : #1192-, 18B-9 : #0403-, 20B-9 : #2316-) 7. ALARM CODE (OPTION, 16B-9 : #1192-, 18B-9 : #0403-, 20B-9 : #2316-) ERROR (RM, LM, PM, VM) ERROR (RM, LM, PM, VM) 1) 1) Code Alarm RM LM PM VM Description (DEC)
  • Page 297 Code Alarm RM LM PM VM Description (DEC) Cause 1: At start-up, the power bridge is found to be faulty in the sense that one of the three legs is not able to drive the motor phase high. Troubleshooting 1: Check the motor internal connections.
  • Page 298 Code Alarm RM LM PM VM Description (DEC) Cause 1: At start-up, the power bridge is found to be faulty in the sense that one of the three legs is not able to drive the motor phase high. Troubleshooting 1: Check the motor internal connections.
  • Page 299 Code Alarm RM LM PM VM Description (DEC) Cause Before driving the LC coil, the controller checks if the contactor is stuck. The controller drives the power bridge for several dozens of milliseconds, trying to discharge the capacitors bank. If the capaci- CON- tor voltage does not decrease by more than a certain percentage of ●...
  • Page 300 Code Alarm RM LM PM VM Description (DEC) It is related to the capacitor-charging system: Cause When the key is switched on, the inverter tries to charge the power capacitors through the series of a PTC and a power resistance, checking if the capacitors are charged within a certain timeout.
  • Page 301 Code Alarm RM LM PM VM Description (DEC) Cause: This warning occurs when the temperature sensor is open (if digital) or if it exceeds the threshold defined by MAX. MOTOR TEMP. (if analog). See paragraph 8.2.3. Troubleshooting: MOTOR ● ● ●...
  • Page 302 Code Alarm RM LM PM VM Description (DEC) Cause: The ACC POT input A5 (A3) is sensed above the minimum value acquired by the PROGRAM VACC procedure. VACC NOT OK Troubleshooting: ● ● ● Check the wirings. MISMATCH Check the mechanical calibraion and the functionality of the accel- erator potentiometer.
  • Page 303 Code Alarm RM LM PM VM Description (DEC) Cause This alarm is present only in traction controllers. PUMP MOT A safety-related blocking alarm is present on the pump controller. ● ALARM Troubleshooting Check the alarm on pump controller. Cause There is a mismatch between the setpoint and the feedback for one of the hydraulics outputs.
  • Page 304 Code Alarm RM LM PM VM Description (DEC) Cause: This alarm can occur only if the auxiliary potentiometer is of crossed-twin type, in combination with the main potentiometer (see parameter AUX.POT. TYPE under the SET OPTIONS list, para- graph 8.2.2). The sum of main and auxiliary potentiometers is not constant.
  • Page 305 Code Alarm RM LM PM VM Description (DEC) Cause: A wrong profi le has been set in the throttle profi le. FINGERTIP ● ● ● PROG Troubleshooting: Set properly the throttle-related parameters. Cause: The sum of the two tracese of the FORK LEVELING sensor are not constant.
  • Page 306 Code Alarm RM LM PM VM Description (DEC) Cause: Value of tilt sensor (AUTO TILT LEVELING) is fi xed even tilt request is activated. FORK SEN- ● ● ● SOR LOCK Troubleshooting: - Check the Tilt Sensor of AUTO TILT LEVELING Option. - Re-confi...
  • Page 307 Code Alarm RM LM PM VM Description (DEC) Cause: When MOTOR TYPE (under SPECIAL ADJUST.) is set to BL MOTOR, the maximumtraction speed is imposed by the motor speed constant; high back EMF values may damage the inverter. BACK EMF While motoring, if the traction speed exceeds the speed limit im- ●...
  • Page 308 Code Alarm RM LM PM VM Description (DEC) Cause One of the safety related modules has reported an eror during its initialization. The hexadecimal value "XX" facilitates Zapi technicians debugging the problem. SAFETY ● ● ● Troubleshooting INIT. XX The fault condition could be due to wrong adjustments of the safety related parameters.
  • Page 309 Code Alarm RM LM PM VM Description (DEC) Cause: The battery monitoring system is in FAULT status. It is received through CAN mgs. BMS FAULT ● ● ● Troubleshooting: Check the BMS(Battery Management System). Cause: This alarm occurs if the BMS FUNCTION is enabled and the con- troller does not receive any information about the battery state of BMS NOT charge;...
  • Page 310 Code Alarm RM LM PM VM Description (DEC) Cause: The current supplied on pin PENC A10 (A8) or PPOT A4 (A2) is outside the range MIN.CURR.SUPPLY1/2 through 200 mA. The SENSOR hexadecimal value "XX" defi nes the following cases: ● ●...
  • Page 311 Code Alarm RM LM PM VM Description (DEC) Cause: The voltage on terminal PEB A17(PM), downstream the internal smart diver and input PIN A24(RM, LM), is sensed higher than ex- pected with the smart driver driven OFF. POS. Troubleshooting: ● ●...
  • Page 312 Code Alarm RM LM PM VM Description (DEC) Cause One of the safety related modules has reported an error. The hexa- decimal value "XX" facilitates Zapi technicians debugging the prob- lem. SAFETY SW. ● Troubleshooting The fault condition could be due to wrong adjustments of the safety related parameters.
  • Page 313 Code Alarm RM LM PM VM Description (DEC) Cause: This alarm occurs if the absolute position sensor is used also for speed estimation. If signaled, it means that the controller measured that the motor was moving too quick. Troubleshooting: SPEED - Check that the sensor used is compatible with the software re- ●...
  • Page 314 Code Alarm RM LM PM VM Description (DEC) BLOCK ● NOT used in this truck. FROM CAN Cause: The motor speed has exceeded the maximum defi ned by param- eter TOP MAX SPEED (under HARDWARE SETTINGS) by more SPEED than a 100 Hz excess. ●...
  • Page 315 Code Alarm RM LM PM VM Description (DEC) Cause Mismatch between parameters ENCODER PULSES 1 and ENCODER PULSES 2. WRONG FB- ● ● ● SENS.SET Troubleshooting Set the two parameters with the same value, according to the ad- opted encoder. Cause: Input mismatch between H&S input (pin A6) and TILLER/SEAT in- put (pin A1): thetwo inputs are activated at the same time.
  • Page 316 Code Alarm RM LM PM VM Description (DEC) Cause: Man-presence switch is not enabled at pump request. Troubleshooting: PUMP INC ● ● ● - Check wirings. START - Check microswitches for failures. - Through the TESTER function, check the states of the inputs are coherent with microswitches states.
  • Page 317 Code Alarm RM LM PM VM Description (DEC) Cause: The voltage on PEB output (A17) is at high value even if it should not. The parameter POSITIVE E.B. has to be set in accordance with the hardware confi guration, because the software makes a proper diag- nosis depending on the parameter;...
  • Page 318 Code Alarm RM LM PM VM Description (DEC) Cause: There is a mismatch in the software versions of master and supervi- sor microcontrollers. WRONG ● ● ● SLAVE VER. Troubleshooting: Upload the software to the correct version or ask for assistance to a Zapi technician.
  • Page 319 Code Alarm RM LM PM VM Description (DEC) Cause This fault is displayed when the controller detects an overvoltage condition. Overvoltage threshold depends on the nominal voltage of the con- troller. Nominal Voltage 24 V 36 V, 48 V 80 V 96 V VDC LINK Under-Voltage Threshold...
  • Page 320 Code Alarm RM LM PM VM Description (DEC) Cause Before closing the main contactor and before driving power bridge, one or more motor phases voltage are sensed to be higher than expected. A short circuit or a low-impedance path to the positive rail is affecting the power section.
  • Page 321 Code Alarm RM LM PM VM Description (DEC) Cause: The controller has restored the default settings. If a CLEAR EE- PROM has been made before the last key re-cycle, this warning informs you that EEPROM was correctly cleared. PARAM RE- ●...
  • Page 322 Code Alarm RM LM PM VM Description (DEC) Cause: An open-load condition is detected on the proportional valve output NEVP (A19). EVP COIL ● ● ● OPEN Troubleshooting: Check the EVP coil. Check the wiring. If the problem is not solved, replace the logic board. Cause The EVP driver, on output NEVP (A19), is shorted to ground.
  • Page 323 Code Alarm RM LM PM VM Description (DEC) Cause: Terminal PIN A24 is not connected to the battery or the voltage is different from that defi ned by parameter SET POSITIVE PEB (see the ADJUSTMENTS list). This alarm can occur if one output among EVP, EV1, EV2 and EV3 is present or AUX OUT FUNCTION is ac- PEV NOT ●...
  • Page 324 Code Alarm RM LM PM VM Description (DEC) Cause This alarm can appear only in a traction-and-pump confi guration or in a multi-motor one. A mismatch is detected between the two TIL- LER/SEAT inputs A8 (A6) of the two controllers. SEAT MIS- ●...
  • Page 325 Code Alarm RM LM PM VM Description (DEC) Cause: The ACC POT input (A3) read by the microcontroller is not within the range MIN VACC through MAX VACC, programmed by the PROGRAMM VACC function. The minimum and maximum acquired values are inconsistent. VACC OUT ●...
  • Page 326 Code Alarm RM LM PM VM Description (DEC) Cause An open-load condition is detected on the proportional valve output NLC. LC COIL ● ● ● Troubleshooting OPEN Check the LC coil. Check the wiring. Check the LC positive terminal, possibly from the key line. If the problem is not solved, replace the logic board.
  • Page 327 Code Alarm RM LM PM VM Description (DEC) Cause: The current gain parameters are at the default values, which means that the maximum current adjustment procedure has not been car- CURRENT ried out yet. ● ● ● GAIN Troubleshooting: Ask for assistance to a Zapi technician in order to do the adjustment procedure of the current gain parameters.
  • Page 328 Code Alarm RM LM PM VM Description (DEC) Cause: This alarm occurs when there is an overload on any of the auxiliary voltage-controlled outputs: NEV1 A24, NEV2 A25,NEV3 A34 and NEV4 A35. COIL SHOR. ● ● ● Troubleshooting: EVAUX The typical root cause is in the wiring harness or in the load coil. heck the connections between the controller output and the load.
  • Page 329 Code Alarm RM LM PM VM Description (DEC) Cause: Warning on supervisor microcontroller. WARNING ● ● ● SLAVE Troubleshooting: Connect the Console to the supervisor microcontroller and check which alarm is present. Cause The error between the estimated q-axis current and the related set- point is out of range.
  • Page 330 Code Alarm RM LM PM VM Description (DEC) Cause: Timeout on the local CAN BUS NO CAN ● MSG. 05 Troubleshooting: Switch OFF and ON. If the alarm is still present replace the board. Cause: The output of the controller thermal sensor is out of range. THERMIC ●...
  • Page 331 2) 2) ERROR (RS, LS, PS, VS) ERROR (RS, LS, PS, VS) Code Alarm RM LM PM VM Description (DEC) Cause This is a safety related test. It is a self-diagnosis test that involves the logic between master and supervisor microcontrollers. WATCHDOG ●...
  • Page 332 Code Alarm RM LM PM VM Description (DEC) Cause There is a mismatch between the setpoint and the feedback for the valve outputs. SAFETY ● DIAG EVP2 Troubleshooting Check if there is a short circuit or a low impedance path between the negative terminal of the involved output and -B.
  • Page 333 Code Alarm RM LM PM VM Description (DEC) Cause There is a mismatch between the setpoint and the feedback for the valve outputs. SAFETY ● DIAG EVP7 Troubleshooting Check if there is a short circuit or a low impedance path between the negative terminal of the involved output and -B.
  • Page 334 Code Alarm RM LM PM VM Description (DEC) Cause There is a mismatch between the setpoint and the feedback for the valve outputs. SAFETY ● DIAG EV3 Troubleshooting Check if there is a short circuit or a low impedance path between the negative terminal of the involved output and -B.
  • Page 335 Code Alarm RM LM PM VM Description (DEC) Cause: The driver of the output NEVP1 is shorted. DRV. SHRT. Troubleshooting: ● EVP1 A) Check if there is a short or a low impedance pull-down between one of the outputs and –BATT. B) The driver circuit is damaged in the logic board, which has to be replaced.
  • Page 336 Code Alarm RM LM PM VM Description (DEC) Cause There is a mismatch between the two microcontrollers in the calcu- lation of the setpoint for one of the hydraulics outputs. The hexadeci- mal value "XX" identifi es the output. 01 – setpoint mismatch for DC pump 02 –...
  • Page 337 Code Alarm RM LM PM VM Description (DEC) Cause There is a mismatch in the calculation of the electronic differential between the two microcontrollers. The hexadecimal value "XX" rep- resents a bitmask, where the meaning of each bit is the following: BIT0 –...
  • Page 338 Code Alarm RM LM PM VM Description (DEC) Cause: The driver of the output NEVP8 is shorted. DRV. SHRT. Troubleshooting: ● EVP8 A) Check if there is a short or a low impedance pull-down between one of the outputs and –BATT. B) The driver circuit is damaged in the logic board, which has to be replaced.
  • Page 339 Code Alarm RM LM PM VM Description (DEC) Cause CAN bus communication with the display does not work properly. Upon this alarm, economy mode is activated by default. NO CAN ● ● ● Troubleshooting MSG DISP Verify the CAN bus network and the display connected to it. By a multimeter check the impedance between CANH and CANL;...
  • Page 340 Code Alarm RM LM PM VM Description (DEC) Cause: This alarm occurs when there is a short circuit of the EVP3 or EVP4 coil. After the overload condition has been removed, the alarm exits automatically by releasing and then enabling a travel demand. COIL SH.
  • Page 341 Code Alarm RM LM PM VM Description (DEC) Cause: This alarm occurs when there is a short circuit of the EVP7 or EVP8 coil. After the overload condition has been removed, the alarm exits au- tomatically by releasing and then enabling a travel demand. COIL SH.
  • Page 342 Code Alarm RM LM PM VM Description (DEC) Cause: This alarm occurs when there is a short circuit of the EV2 coil. After the overload condition has been removed, the alarm exits au- tomatically by releasing and then enabling a travel demand. COIL SH.
  • Page 343 Code Alarm RM LM PM VM Description (DEC) Cause: The algorithm implemented to check the main RAM registers fi nds wrong contents: the register is corrupted. This alarm inhibits the ma- WRONG chine operations. ● ● ● ● RAM MEM. Troubleshooting Try to switch the key off and then on again, if the alarm is still pres- ent replace the logic board.
  • Page 344 Code Alarm RM LM PM VM Description (DEC) Cause: Mismatch between uC Master and uC slave for output set point cal- VALVE culation. ● MISM. OUT Troubleshooting: The logic board has to be replaced. Cause: This is an alarm related to the hardware confi guration. OUT PORT ●...
  • Page 345 Code Alarm RM LM PM VM Description (DEC) Cause An issue with the speed or position feedback sensor is detected. The hexadecimal value "XY" helps to identify the nature of the prob- lem: the fi rst digit "X" encodes the type of feedback sensor, the sec- ond digit "Y"...
  • Page 346 Code Alarm RM LM PM VM Description (DEC) Cause: Timeout on the local CAN BUS NO CAN ● MESSAGE Troubleshooting: Switch OFF and ON. If the alarm is still present replace the board. Cause: Wrong customer ID code found in the protected area of memory CONTROL- where this parameter are stored ●...
  • Page 347 Code Alarm RM LM PM VM Description (DEC) Cause: VCM is not able to drive one of the fi rst eight outputs. ● DRV. OPEN Troubleshooting: This type of fault is not related to external components; replace the logic board. Cause: The driver of the output NEV1 is shorted.
  • Page 348 Code Alarm RM LM PM VM Description (DEC) Cause: The driver of the output NEV3 is shorted. DRV. SHRT. Troubleshooting: ● A) Check if there is a short or a low impedance pull-down between one of the outputs and –BATT. B) The driver circuit is damaged in the logic board, which has to be replaced.
  • Page 349 Code Alarm RM LM PM VM Description (DEC) Cause: This fault appears when no load is connected between the output NEVP9 and the positive terminal. COIL OPEN Troubleshooting: ● EVP9 A) It is suggested to check the harness, in order to verify if some coil is connected to the right connector pin and if it is not interrupted.
  • Page 350 Code Alarm RM LM PM VM Description (DEC) Cause: This fault appears when no load is connected between the output NEVP2 and the positive terminal. COIL OPEN Troubleshooting: ● EVP2 A) It is suggested to check the harness, in order to verify if some coil is connected to the right connector pin and if it is not interrupted.
  • Page 351 Code Alarm RM LM PM VM Description (DEC) Cause: This fault appears when no load is connected between the output NEVP5 and the positive terminal. COIL OPEN Troubleshooting: ● EVP5 A) It is suggested to check the harness, in order to verify if some coil is connected to the right connector pin and if it is not interrupted.

  • Page 352: Battery Charger

    8. BATTERY CHARGER 8. BATTERY CHARGER This explains basic information related to charger to help you easily understand and use it. This includes the contents from the way to install a charger to tips for emergency situations. This is focused on practices aiming to be usefully utilized in the field. 1) 1) BASIC INFORMATION BASIC INFORMATION...
  • Page 353 (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 7-83...
  • Page 354 Charger installation method location for charger installation dry and well ventilated place. ① no inflammable and B7 fire are near by. ② safe place where no collision possibility ③ with people or equipment is. Check points before installing charger enough capacity of aC input power ①...
  • Page 355 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 356 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 357 ⑥ If charger's out voltage is under 100 V, it is abnormal. Please refer to the error sheet. ⑦ When the charging voltage is indicated as normal condition (105 V), convert automatic / manual switch to automatic and start charging. ※...
  • Page 358 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 359: 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 360 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 361 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 362 ③ Charger TRIP is occurred after abnormality lamp is on. Charger TRIP is occurred after abnormality lamp is on. In case error code is "O.V" → Over-voltage output / Set at 66V (In case of BATT 48V) In case error code is "O.V" Over-voltage output / Set at 66V (In case of BATT 48V) 34V (In case of BATT 24V) 34V (In case of BATT 24V)
  • Page 363 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 364 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 365 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 366 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 367 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 368 22B9BAT27 7-98...
  • Page 369 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 7-99...
  • Page 370 SECTION 8 MAST SECTION 8 MAST Group 1 Structure --------------------------------------------------------------------------------------------------------- 8-1 Group 2 Operational Checks and Troubleshooting ---------------------------------------------------- 8-4 Group 3 Adjustment ------------------------------------------------------------------------------------------------------ 8-7 Group 4 Removal and Installation ------------------------------------------------------------------------------- 8-10...

  • Page 371: Group 1 Structure

    SECTION 8 MAST SECTION 8 MAST GROUP 1 STRUCTURE GROUP 1 STRUCTURE 1. 2 STAGE MAST 1. 2 STAGE MAST (V MAST) TILT CYLINDER CARRIAGE LIFT CYLINDER 35B7MS01 Outer mast Mast mounting block Anchor bolt Shim (0.5, 1.0t) Bushing 10 Chain sheave Roller Inner mast 11 Back up liner...
  • Page 372 2. 3 STAGE MAST 2. 3 STAGE MAST (TF MAST) TILT CYLINDER CARRIAGE FREE LIFT CYLINDER 35B7MS02 Outer mast Lift chain 10 Chain sheave Middle mast Anchor bolt 11 Retaining ring Inner mast Sheave bracket 12 Mast mounting block Roller Chain guard 13 Tilt cylinder pin Shim (0.5, 1.0t)
  • Page 373 3. CARRIAGE, BACKREST AND FORK 3. CARRIAGE, BACKREST AND FORK 35B7MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...

  • Page 374: Group 2 Operational Checks And Troubleshooting

    Measure thickness of root of forks and check that it is more than specified value. EX : ℓ=1070 mm (42.1 in) mm (in) STD Fork assy Applicable model Standard Limit S173896-02 40B-9 50 (2.0) 45 (1.8) F13710010 45B-9 50 (2.0) 45 (1.8) B153FK01...
  • Page 375 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) MAST MAST Problem Cause Remedy ·Deformed mast or carriage. ·Disassemble, repair or replace. Forks fail to lower. ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump Fork fails to elevate and cylinders in section 6, hydraulic system.
  • Page 376 2) 2) FORKS FORKS Problem Cause Remedy Abrasion Long-time operations causes the fork If the measured value is below the to wear and reduces the thickness of wear limit, replace fork. the fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...

  • Page 377: Group 3 Adjustment

    GROUP 3 ADJUSTMENT GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER 1. MAST LOAD ROLLER (V MAST) 1) 1) INNER/OUTER MAST ROLLER CLEAR- INNER/OUTER MAST ROLLER CLEAR- ANCE ADJUSTMENT ANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480 mm. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the...
  • Page 378 2. MAST LOAD ROLLER 2. 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. Shift the inner mast to one side to bring the roller into contact with the outer mast and the middle mast, and adjust the clearance between the roller side face...
  • Page 379 3) 3) CARRIAGE LOAD ROLLER CARRIAGE LOAD ROLLER Outer mast Adjust Bring into screw contact Measure the clearance when the center of the carriage upper roller is 100 mm from the top of the inner mast. Measure the clearance at upper, middle Side roller Carriage...
  • Page 380 GROUP 4 REMOVAL AND INSTALLATION GROUP 4 REMOVAL AND INSTALLATION 1. FORKS 1. FORKS Lower the fork carriage until the forks are approximately 25 mm (1 inch) from the floor. Knob Turn the knob up and slide forks, one by Spring one, toward the center of the carriage where a notch has been cut in the bottom...
  • Page 381 2) 2) SIDE ROLLER SIDE ROLLER Side roller Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly.
  • Page 382 4) 4) MAST LOAD ROLLER AND BACK UP MAST LOAD ROLLER AND BACK UP LINER LINER 2 stage mast 2 stage mast (V mast) (1) (1) ① Chain Remove the carriage assembly and move them to one side. Bolt ② Loosen and remove hexagon bolts and Special special washers securing lift cylinders to...
  • Page 383 (2) (2) 3 stage mast 3 stage mast (TF mast) ① Remove the carriage assembly and move it to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. ③ Loosen and remove band and special washers securing lift cylinders to middle mast.
  • Page 384 5) 5) ELEVATING MAST ELEVATING MAST Inner mast Inner mast (V mast) (1) (1) ① After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. ②...
  • Page 385 6) 6) CHAIN Outer mast Chain sheave Chain sheave (V mast) (1) (1) ① Chain Place a sling around carriage and attach to an overhead hoist. Lift carriage high Sheave enough so that the tension on the chain over sheaves is relieved after the carriage is blocked.
  • Page 386 (3) (3) Chain wheel bearing support 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 387 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 388 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 389: Adjustment Procedure

    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 390: 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 approximately 25 mm (1 inch) from the floor. Knob Turn the knob up and slide forks, one by Spring one, toward the center of the carriage where a notch has been cut in the bottom...
  • Page 391 2) 2) SIDE ROLLER SIDE ROLLER Side roller Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly.
  • Page 392 4) 4) MAST LOAD ROLLER AND BACK UP MAST LOAD ROLLER AND BACK UP LINER LINER 2 stage mast 2 stage mast (V mast) (1) (1) ① Chain Remove the carriage assembly and move them to one side. Bolt ② Loosen and remove hexagon bolts and Special special washers securing lift cylinders to...
  • Page 393 (2) (2) 3 stage mast 3 stage mast (TF mast) ① Remove the carriage assembly and move it to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. ③ Loosen and remove band and special washers securing lift cylinders to middle mast.
  • Page 394 5) 5) ELEVATING MAST ELEVATING MAST Inner mast Inner mast (V mast) (1) (1) ① After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. ②...
  • Page 395 6) 6) CHAIN Outer mast Chain sheave Chain sheave (V mast) (1) (1) ① Chain Place a sling around carriage and attach to an overhead hoist. Lift carriage high Sheave enough so that the tension on the chain over sheaves is relieved after the carriage is blocked.
  • Page 396 (3) (3) Chain wheel bearing support 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 397 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 398 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 399 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.

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45b-950b-9

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