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Hyundai 20BC-7, Service Manual

The Hyundai 20BC-7 Service Manual is now available for free download on manualshive.com. This comprehensive manual offers insightful instructions and detailed troubleshooting guidelines to ensure seamless operation of your Hyundai 20BC-7. Download the manual today and optimize your experience with this remarkable product.

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7-76

PCB MAJOR PARTS NAME AND LOCATION

BR7BAT24

1

Micro control unit #1

2

Micro control unit #2

3

CN6 voltage detect

4

SH current detect

5

Adjust charging current

6

Adjust charging voltage

7

Over voltage

8

Monitor level yellow

9

Monitor level green

10

Under current

11

Over current

12

Set input over voltage

13

Set input over current

14

Auto/manual switch

15

SCR control connector

16

CN4 RY contact point

1

2

7

8

5

6

9

10

3

4

15

14

13

12

11

16

8)

Summary of Contents for 20BC-7

Page 1: ...ECTION 3 POWER TRAIN SYSTEM This section explains the structure of the transmission as well as control valve and drive axle SECTION 4 BRAKE SYSTEM This section explains the brake piping each component and operation SECTION 5 STEERING SYSTEM This section explains the structure of the steering unit priority valve trail axle as well as steering circuit and operation SECTION 6 HYDRAULIC SYSTEM This se...

Page 2: ...ation before you start any work Filing method See the page number on the bottom of the page File the pages in correct order Following examples shows how to read the page number Example 1 2 3 Item number 2 Structure and Function Consecutive page number for each item Additional pages Additional pages are indicated by a hyphen and number after the page number File as in the example 1 2 3 Symbol Item ...

Page 3: ...oint one place to the left to convert it to 55mm Carry out the same procedure as above to convert 55mm to 2 165 inches The original value 550mm was divided by 10 so multiply 2 165 inches by 10 Move the decimal point one place to the right to return to the original value This gives 550mm 21 65 inches 1 2 1 2 3 1 2 3 Millimeters to inches 1mm 0 03937 in ͽ 0 1 2 3 4 5 6 7 8 9 0 0 039 0 079 0 118 0 15...

Page 4: ...3 425 3 465 3 504 90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound 1kg 2 2046lb 0 1 2 3 4 5 6 7 8 9 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89 20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 5 61 73 63 93 30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 9...

Page 5: ...2 455 22 719 22 983 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon 1 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139 8 ...

Page 6: ...0 629 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 10005 4 140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2...

Page 7: ...280 1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 233...

Page 8: ... 131 0 32 2 90 194 0 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8 17 6 ...

Page 9: ...onal checks and troubleshooting 4 5 Group 3 Tests and adjustments 4 8 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 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function 6 1 Group 2 Operational checks and troubleshooting 6 16 Group 3 Disassembly and assembly 6 20 SECTION 7 ELECTRICAL SYSTEM...

Page 10: ...SECTION 1 GENERAL Group 1 Safety hints 1 1 Group 2 Specifications 1 4 Group 3 Periodic replacement 1 12 ...

Page 11: ...ting equipment   Wear well fitting helmet safety shoes and working clothes When drilling grinding or hammering always wear protective goggles Always do up safety clothes properly so that they do not catch on protruding parts of machines Do not wear oily clothes When checking always release battery plug  Flames should never be used instead of lamps Never use a naked flame to check leaks or the l...

Page 12: ...ke pedal repeatedly to release pressure Park the machine on firm flat ground Lower the fork to the ground and stop the engine Return each lever to NEUTRAL and apply the brake lock  D50ASF07 D50ASF08 Immediately remove any oil or grease on the floor of the operator s compartment or on the handrail It is very dangerous if someone slips while on the machine  OIL When working with others choose a gr...

Page 13: ...er replacing oil filter element or strainer bleed the air from circuit When the strainer is located in the oil filler the strainer must not be removed while adding oil When changing the oil filter check the drained oil and filter for any signs of excessive metal particles or other foreign materials When removing parts containing O ring gaskets or seals clean the mounting surface and replace with n...

Page 14: ...AL LOCATIONS 1 Mast 2 Lift cylinder 3 Carriage and backrest 4 Forks 5 Drive unit 6 Dash board 7 Frame 8 Steering axle 9 Counterweight 10 Battery cover 11 Seat 12 Steering wheel 13 Overhead guard 5 8 9 10 11 12 13 2 3 4 6 7 1 20BC7OM113 ...

Page 15: ...d Unload Load LÝWÝT Tilt angle forward backward Max height Min height Travel speed Unload Load Gradeability Load Min turning radius Outside 2000 500 4027 3300 115 610 420 450 500 1050Ý100Ý45 6 8 4485 2135 18 17 14 5 13 20 1885 2500 ą 4362 ą ą 610 410 ą ą ą ą ą ą 17 1910 Fork Mast Body H I C C G R L K D A E J T B M W F M lb G H I J K M ETC Max hydraulic pressure Hydraulic oil tank 190 24 ą ą kgf cm...

Page 16: ...t C CHARGER 4 48 1007Ý766Ý597 1130 1400 SB 350 Item Type Battery capacity for charge V AH 48V 845 850 Unit 30 32BC 7 48V 660 740 20 25BC 7 Triple phase 410 Single phase 220 Triple phase 220 380 Triple phase 440 Constant current constant voltage ą ą ą ą ą ą ą 62Ü1 8Ü2 SB 350 AC input V DC output Charge time Connector V hr Item Model Type Dimension Current limit Communication mm A Unit Pump Traction...

Page 17: ...ification D DRIVE AXLE 7 Item Max input torque Max input rpm Gear ratio Weight without fluid Oil quantity kgfÂm rpm kg lb U SÂqt 24 3500 15 348 252 555 6 5 3 5 6 Unit Specification W WHEELS 8 Item Type front rear Quantity front rear Front drive Rear steering Cushion OPT Non marking 2 2 BRAKES STEERING 9 Item Brakes Front wheel hydraulic drum brake Mechanical Full hydraulic power steering Specifica...

Page 18: ...draulic oil tank mounting bolt Drive axle mounting bolt nut Steering axle mounting bolt nut Front wheel mounting nut Counterweight mounting bolt Seat mounting bolt Head guard mounting bolt M10Ý1 5 M10Ý1 5 M10Ý1 5 M 8Ý1 25 M 8Ý1 25 M 8Ý1 25 M 8Ý1 25 M20Ý2 0 M20Ý2 5 M18Ý1 5 M24Ý3 0 M 8Ý1 25 M16Ý2 0 6 9Ü1 4 6 9Ü1 4 5Ü1 2 5Ü0 5 2 5Ü0 5 2 5Ü0 5 2 5Ü0 5 50 5Ü2 5 58Ü3 23 5Ü1 5 100Ü15 2 5Ü0 5 12 8Ü3 0 50Ü...

Page 19: ... 0 115 169 229 250 310 kgfÂm 8 2 12 6 19 7 29 8 39 8 60 71 114 121 167 182 247 254 343 356 482 476 709 615 832 1223 1655 1808 2242 lbfÂft 8T 10T F Fine thread 2 Bolt size M 8 Ý 1 0 M10 Ý 1 25 M12 Ý 1 25 M14 Ý 1 5 M16 Ý 1 5 M18 Ý 1 5 M20 Ý 1 5 M22 Ý 1 5 M24 Ý 2 0 M30 Ý 2 0 M36 Ý 3 0 kgfÂm 2 17 3 37 4 46 6 66 7 78 11 58 13 3 18 1 19 9 26 9 28 6 43 6 40 0 54 0 52 7 71 3 67 9 91 9 137 185 192 260 lbfÂ...

Page 20: ...130 152 253 P PIPE AND HOSE ORFS TYPE Thread size 9 16 18 11 16 16 13 16 16 1 3 16 12 1 7 16 12 1 11 16 12 Width across flat mm 19 22 27 36 41 50 kgfÂm 4 5 9 5 18 21 35 lbfÂft 28 9 36 2 68 7 130 152 253 3 3 4 FITTING Thread size 1 4 3 8 1 2 3 4 1 1 1 4 Width across flat mm 19 22 27 36 41 50 kgfÂm 4 5 9 5 18 21 35 lbfÂft 28 9 36 2 68 7 130 152 253 5 5 ...

Page 21: ...dardization ÂNLGI National Lubricating Grease Institute Service point Kind of fluid Ambient temperature Á C Á F SAE 80W 90 ISO VG 46 ISO VG 68 DOT 3 DOT4 SAE J1703 Hydraulic oil tank 10 14 0 32 10 50 20 68 30 86 ISO VG 22 Hydraulic oil Brake system Brake oil Grease Fitting Grease nipple Axle Gear oil 5 3 1 4 20 4 Capacity U S gal 40 104 20 25 30 32BC 7 24 6 3 0 5 0 1 NLGI No 1 NLGI No 2 0 1 0 03 S...

Page 22: ...ibed period of replacement Or earlier if trouble is found Note that periodic replacement has nothing to do with guarantee service Replacement of consumable service parts is not covered under warranty Description Period of replacement Hydraulic oil Brake fluid Differential oil Gear oil Wheel bearing grease Power steering hose Rubber parts of the power steering inside Cups and dust seals etc of cyli...

Page 23: ...SECTION 2 REMOVAL INSTALLATION OF UNIT Group 1 Major components 2 1 Group 2 Removal and installation of unit 2 2 ...

Page 24: ...eering unit 4 Backrest 5 Tilt cylinder 6 Main control valve 7 Forks 8 Front wheel 9 Drive unit 10 Drive motor 11 Hyd gear pump 12 Pump motor 13 Battery 14 Rear wheel 15 Steering axle 16 Steering cylinder 17 Counterweight 18 Traction controller 19 Pump controller 20 Seat 21 Overhead guard 22 Steering wheel ...

Page 25: ...g units as explained in the flow chart Backrest Carriage Fork Knob Center notch Pin Spring Backrest If necessary Remove bolts securing backrest to fork carriage Lift backrest straight up and remove it from carriage 2 Backrest Bolt Carriage 22BHA7RE04 22BHA7RE03 Η Θ Ι ö Η C Carriage With the mast vertical raise the carriage high enough to place blocks under the load forks This is done to create sla...

Page 26: ...eaves and drape them over the front of the carriage Ι Block Lift chain Carriage Mast 22B7RE06 Slowly raise inner mast upright until mast clears top of fork carriage Move carriage to work area and lower the mast Make sure that carriage remains on floor and does not bind while mast is being raised Inspect all parts for wear or damage Replace all worn or damaged parts Κ Λ 20BC7RE07 ...

Page 27: ...bolts and remove spacers securing the lift cylinders to outer mast Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no slack or binding Make sure that the lift cylinder be tightened firmly for safety Loosen and remove hexagon bolts and clamp securing cylinder Using an overhead hoist slowly raise the inner mast high enough to clear lift cylinder Using an overhead hoi...

Page 28: ...Attach a crane to the stay at the top of the outer mast and raise enough to sustain jacked up machine This operation is carried out from under the machine so use a pit or if there is no pit jack up the machine and loosen with on impact wrench Remove the mounting bolts from the cap Then slowly raise the outer mast 7 8 Outer mast Tilt cylinder Pin Mounting bolt Pin Bushing Mast support cap 20BC7RE11...

Page 29: ...Η Θ ö ö 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 Mast support cap Check the mast support cap and spring pin for wear Jack up the machine so that the front is raised and then using an overhead hoist assemble outer mast to drive axle...

Page 30: ...2 POWER TRAIN ASSEMBLY REMOVAL 1 B153RE00 Brake piping Disconnect the brake piping from the wheel brake assembly 2 Brake pipe Wheel brake LH Drive axle Wheel brake RH Brake master cylinder Parking brake cable Disconnect parking brake cable from the wheel brake assembly 3 Drive axle Parking brake lever Parking brake cable 20BC7RE13 B207RE14 20BC7RE17 ...

Page 31: ...chine enough for truck to slide under drive axle transmission drive motor assembly Put the block between the truck and drive axle assembly Disconnect the harness from the drive motor terminal Remove drive axle mounting bolts from the frame and then slowly pull out the truck with drive axle forward the front 4 Η Θ Ι Κ Axle mounting bolt Drive axle motor assy Crane 20BC7RE15 Remove five socket bolts...

Page 32: ...to the lowest position The batteries weigh from around 1130kg to 1600kg so the extreme care must be taken when handling them 1 Battery cover Latch Connector 1 22B7RE29 22B7RE19 Disconnect the battery connector Release the battery cover latch and open the battery cover Η Battery cover Hanger 22B7RE20 Using a battery hanger carefully raise the battery assembly Be careful not to damage overhead guard...

Page 33: ...e cover Θ Side cover LH 22B7RE22 Disconnect the wiring of pump motor and remove the gear pump from pump motor Ι Pump motor Gear pump 22B7RE23 Remove the tightening bolts of the pump motor mounting bracket Remove the motor from mounting bracket Κ Bracket Bolt Pump motor 22B7RE24 ...

Page 34: ... lock washer lock nut and oil seal Remove lock nut with a hub nut wrench 2 Block Fork down Hub bolt B207RE32 Brake drum assembly The oil seal inside the nub acts as a seal for the axle shaft end Therefore when removing or installing the brake and drum assembly remove or install in a straight line to prevent twisting the seal up and down or to the right and left When the brake and drum assembly is ...

Page 35: ...p on outside and knock into place 2 Measuring starting torque Spring balance B207RE35 Wipe the inside of the brake drum clean coat the lip of the seal with grease and assemble the brake and drum assembly Adjust the starting torque with the nut Attach a spring balance to the hub bolt and adjust the nut to give a starting force of 12 to 20kgf 27 44lbf 3 Hub nut Block Fork down Hub bolt Drive shaft B...

Page 36: ...he counterweight and raise with a crane Remove the mounting bolts raise slightly and move to the rear  Weight of counterweight standard ÂTightening torque 70 90 kgfÂm 506 651lbfÂft Apply loctite 277 Η 22B7RE25 D35ARE37 H Hose Θ L R B207RE37 Counterweight 20BC 7 25BC 7 590kg 1300lb 925kg 2040lb Rear wheel 30BC 7 32BC 7 1080kg 2380lb 1250kg 2760lb ...

Page 37: ...acing the bushing at the support install so that the hole in the bushing faces down 2 1 Bushing Support Support Bushing B207RE39 B207RE41 Install the support so that the clearance is under 0 5mm when the support is pushed fully to the rear Tightening torque of mounting bolt for support Â55 61kgfÂm 398 441lbfÂft 2 When installing the rear wheel coat the hub bolt with molybdenum disulphide and tight...

Page 38: ...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: ...1 1 Case 2 Case 3 Case 4 Air breather 5 Plug 6 Plug 7 Drive support 8 O ring 9 Bolt 10 Spring washer 11 Bolt 12 Spring washer 13 Dowel pin 14 Magnetic plug 15 Bolt 16 Differential case 17 Gear 4 18 Drive shaft 19 Washer 20 Side gear 21 Pinion gear shaft 22 Pinion gear 23 Pin spring 24 Bolt 25 Ball bearing ...

Page 40: ...RUCTURE 2 2 26 Ball bearing 27 Gear 1 28 Ball bearing 29 Gear 3 30 T roller bearing 31 Ball bearing 32 Gear 2 33 T roller bearing 34 Distance piece 35 Liner 36 Lock nut 37 Drum brake 38 Oil seal 39 Retainer 40 Bearing 41 Hub wheel 42 Hub bolt 43 Lock nut 44 Lock washer 45 Oil seal 46 Hub bolt 47 Wheel brake LH 48 Wheel brake RH 49 Bolt 50 Washer 51 Bolt ...

Page 41: ...3 3 2 SPECIFICATION Item Max input torque Max input rpm Gear ratio Quantity of oil G2 G1 G3 G2 G4 G3 Total kgfÂm rpm 24 3500 43 24 1 792 1 49 22 2 227 1 50 13 3 846 1 15 348 5 3 Unit Specification ...

Page 42: ...ontinuous knocking sound 1 During travelling at uniform speed ÂChipped gear teeth ÂForeign matter in axle case ÂWorn out spline of drive shaft Lower oil level Replace Retighten Replace Replace Replace Replace Repair or replace Replace Replace 3 3 Oil leakage 1 Differential housing housing leaks 2 Axle case leaks 3 Hub leaks 4 Power is not transmitted 1 Drive shaft gear ÂOil level too high ÂBroken ...

Page 43: ... DRIVE AXLE Remove the drive tires from wheel hub 3 5 GROUP 3 DISASSEMBLY AND ASSEMBLY 1 Remove the drain plug and drain gear oil 2 Pull out the drive shaft with universal puller 3 1 B153DAD001 B153DAD002 B153DAD003 ...

Page 44: ...not use improper method to loosen this nut 4 B153DAD004 B153DAD005 B153DAD006 Remove the inner nut by straightening the locking part of the inner nut When loosening the nut use special tool and do not use improper method to loosen this nut 5 Separate the brake hub assembly 6 B153DAD007 Pull out the tapered roller bearing 7 ...

Page 45: ...7 B153DAD008 Remove the brake bolts 8 B153DAD009 Separate the brake from drive axle 9 B153DAD010 Separate the drive support righthand from drive axle 10 B153DAD011 Separate the T M case from drive axle 11 ...

Page 46: ...3 8 B153DAD012 Pull out the differential case assembly 12 B153DAD013 Remove T M case bolts 13 B153DAD014 Separate the T M case 14 B153DAD015 Pull out the gear 15 ...

Page 47: ...3 9 B153DAD016 Pull out the gear 16 B153DAD017 Pull out the bearing with universal puller 17 B153DAD018 Remove the locking nut 18 B153DAD019 Pull out the distance piece 19 ...

Page 48: ...10 B153DAD020 Separate the gear from differential case with rubber mallet 20 B153DAD021 Pull out the gear 21 B153DAD022 Remove the tapered roller bearing if needed 22 B153DAD023 Remove the bearing cup 23 ...

Page 49: ...3 11 B153DAD024 Remove the opposite bearing cup 24 HUB DRUM Remove the bolts 1 2 B153DAD025 Separate drum and wheel hub 2 B153DAD026 Replace a worn wheel bolts 3 B153DAD027 ...

Page 50: ...ogether with brake drum Tapered roller bearing will come out with the hub Replace oil seal O ring and retainer 4 B153DAD028 Separate tapered roller bearing and retainer 5 B153DAD029 Remove the opposite bearing cup 6 B153DAD030 ...

Page 51: ...SSEMBLY Remove the gear from differential case and bolt 1 3 B153DAD031 Extract the spring pin 2 B153DAD032 Pull out the pinion gear shaft 3 B153DAD033 Separate the pinion gear 2pcs from differential assembly 4 B153DAD034 ...

Page 52: ...e side gear from differential 5 B153DAD035 Extract the side gear washer 6 B153DAD036 Put disassembled parts in order by groups and be careful not to lose bulk parts such as bolts washers and snap ring etc 7 B153DAD037 ...

Page 53: ...tall the washer 2pcs to the case assembly putting the grease 1 Install the side gear 2pcs to the case assembly 2 1 B153DAA001 B153DAA002 Install the pinion gear 2pcs to the case assembly 3 B153DAA003 After adjusting the hole of spring 4 B153DAA004 ...

Page 54: ... Install the gear to case assembly 6 B153DAA006 After putting loctite 277 secure them by tightening the bolts to specified torque ÂTightening torque 10 9 15 1kgfÂm 79 109lbfÂft 7 B153DAA007 Install the ball bearing 2pcs to case assembly 8 B153DAA008 ...

Page 55: ... Press the bearing cup 1 2 B153DAA009 Press the opposite bearing cup 2 B153DAA010 Install the tapered roller bearing to the wheel hub 3 B153DAA011 After putting the TB 1102 install the oil seal retainer to the wheel 4 B153DAA012 ...

Page 56: ...153DAA013 Fill a wheel hub center about 50 70 full with grease 6 B153DAA014 Install the brake drum and the wheel hub 7 B153DAA015 After putting loctite 277 secure them by tightening the bolts to specific torque ÂTightening torque 15 6 21 4kgfÂm 112 8 155lbfÂft 8 B153DAA016 ...

Page 57: ...IVE AXLE ASSEMBLY Press the taper roller bearing to a gear 1 3 B153DAA017 Press the bearing cup 2 B153DAA018 Install the gear to case 3 B153DAA019 Insert the gauge for a gap measurement to a gear 4 B153DAA020 ...

Page 58: ...ge to case 5 B153DAA021 Measure a gap between the case and gauge 6 B153DAA022 Press the bearing cup 7 B153DAA023 Insert the distance piece the same thickness and number as those removed during disassembly 8 B153DAA024 ...

Page 59: ...bfÂft 9 B153DAA025 Measure the tightening torque of taper roller bearing ÂPre load Torque 0 04 0 06kgfÂm 0 3 0 43lbfÂft 10 B153DAA026 Secure it with nut tightening to specified torque lock the nut 11 B153DAA027 Install the ball bearing to the gear 12 B153DAA028 ...

Page 60: ... bearing on the opposite side 13 B153DAA029 Install the ball bearing to the gear 14 B153DAA030 Install the differential subassembly to the case 15 B153DAA031 Confirm a attachment condition of the ball bearing 16 B153DAA032 ...

Page 61: ...e of packing for the case 17 B153DAA033 Install the case assembly to the case 18 B153DAA034 Install the bolts after putting the loctite 227 ÂTightening torque 0 9 13 3kgfÂm 6 5 96 2lbfÂft 19 B153DAA035 Insert the dowel pin to the case 20 B153DAA036 ...

Page 62: ...he gear to the case 21 B153DAA037 Install the gear to the case 22 B153DAA038 Put the liquid gasket TB 1215 on both side of packing for the case 23 B153DAA039 Install the case fitting into the dowel pin 24 B153DAA040 ...

Page 63: ...nstall the bolts after putting the loctite 277 ÂTightening torque 11 15kgfÂm 79 108lbfÂft 26 B153DAA042 Install the oil seal on both sides Put the liquid gasket on the circumfe rence section and the grease on the lib 27 B153DAA043 After putting the grease install the O ring to the drive support 28 B153DAA044 ...

Page 64: ... support to the case tube 29 B153DAA045 Install the righthand and lefthand brake respectively 30 B153DAA046 After putting the loctite 277 install the bolt and plane washer 31 B153DAA047 Install the hub drum sub 32 B153DAA048 ...

Page 65: ...um 33 B153DAA049 Install the adjust nut on both sides ÂTightening torque 3 5kgfÂm 21 7 36lbfÂft 34 B153DAA050 Measure the pre load torque of taper roller bearing 35 B153DAA051 If it satisfy the preload secure the lock washer to nut groove 36 B153DAA052 ...

Page 66: ...e outer nut 37 B153DAA053 Bend the lock washer to outer side 38 B153DAA054 Put the liquid gasket TB 1215 39 B153DAA055 Install the shaft to distinguish between the two shaft Righthand long lefthand short 40 B153DAA056 ...

Page 67: ...t loctite 572 41 B153DAA057 Fill in the gear oil SAE 85W 140 until flat part of check plug After putting the loctite 572 install the check plug 42 B153DAA058 After putting the loctite 572 install the air breather PT1 2 43 B153DAA059 ...

Page 68: ...SECTION 4 BRAKE SYSTEM Group 1 Structure and function 4 1 Group 2 Operational checks and troubleshooting 4 5 Group 3 Test and adjustment 4 8 ...

Page 69: ...ondary shoes this type provides a large amount of brake force In addition the brake equipped with automatic adjusters which constantly adjust the clearance between the shoe and the drum compensation for wear due to the shoe friction and thus keeping the clearance constant GROUP 1 STRUCTURE AND FUNCTION SECTION 4 BRAKE SYSTEM 1 OUTLINE Item Type Brake shoe size Wheel cylinder bore diameter Master c...

Page 70: ...the brake shoe through a brake cable to activate the brake when the brake lever is operated The wheel brake is a dual servo type in which the actuating force is applied to both the primary and secondary shoes Even if the applied force is small a large braking force will be obtained These brakes are equipped with self adjusters which continuously adjusts the brakes in small increments in direct pro...

Page 71: ...ained within the hub assembly The inside of the hub is machined and acts as the brake drum 1 1 Back plate assy LH RH 2 Lined shoe assy 3 Wheel cylinder assy 4 Bolt set 5 Adjuster assy LH RH 6 Pin 7 Spring 8 Washer 9 Bush 10 Plate 11 Lever actuator LH RH 12 Lever pawl LH RH 13 Stopper 14 Spring 15 Retaining ring 16 Strut 17 Spring 18 Parking cable assy LH RH 19 Plug 20 Spring 21 Bleed screw 22 Blee...

Page 72: ...l oils When using alcohol do not leave rubber parts in the liquid for more than 30 seconds Inspect the inside wall of the master cylinder and if any faults are found replace the cylinder assembly Replace the boot 10 the primary cup 3 piston 2 if deformation or any other defect is found ASSEMBLY Prior to assembly make sure again of no contaminant of the components Apply a thin coat of brake oil to ...

Page 73: ...ovement of shoe Remove brake shoe from anchor pin and check for rust or wear When assembling coat sliding parts with special brake grease BRAKE DRUM Measure inside diameter of drum and check that it is within 254mm 10in Tighten mounting bolt of drum BACKING PLATE Check visually for deformation or cracks Check particularly for deformation at outside circumference of plate and at mounting bolt Coat ...

Page 74: ...c system clogged ÂAdjust tire pressure ÂAdjust ÂClean or replace ÂClean ÂRepair by polishing or replace ÂRepair by polishing ÂReplace ÂRepair or replace ÂRepair or replace ÂAdjust ÂRetighten or replace ÂReplace ÂAdjust or replace ÂClean ÂRepair and add oil ÂBleed air ÂClean or replace ÂRepair by polishing or replace ÂReplace ÂRepair or replace ÂClean c cause Remedy Brake trailing ÂPedal has no pla...

Page 75: ...lty ÂFlow control valve orifice clogged ÂAdjust ÂBleed air ÂCheck and repair or add oil ÂReplace ÂRepair ÂRepair ÂAdjust ÂReplace ÂClean or replace Brake squeaks ÂLining surface roughened ÂLining worn ÂPoor shoe to lining contact ÂExcessively large friction between shoe and back plate ÂForeign matter on drum sliding surfa ce ÂDrum sliding surface damaged or di storted ÂBrake shoe deformed or poorl...

Page 76: ...heat of brake drum at 4 points to confirm that brakes are not dragging After adjusting confirm that brake stopping distance is within standard range 2 3 2 AIR BLEEDING OF BRAKE SYSTEM Air bleeding should be performed by two persons One rides on truck for depressing and releasing brake pedal the other person is on the ground and removes cap from air vent plug on wheel cylinder Block the front wheel...

Page 77: ...NT OF PEDAL BRAKE PEDAL Pedal height from floor plate Adjust with stopper bolt ÂPedal height 140 145mm 5 5 5 7in P Play Adjust with rod of master cylinder ÂPlay 8 12mm 0 31 0 47in 1 1 2 Floor plate 140 145mm 22B7BS07 ...

Page 78: ...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 79: ...e steering force given to the steering wheel enters the steering unit through the steering column The required oil flow is sensed by the function of the control section of the unit and pressurized oil delivered from the hydraulic gear pump is fed to the steering cylinder The force produced by the steering cylinder moves the knuckle of steering tires through the intermediate link The axle body is u...

Page 80: ...IC CIRCUIT M T LS P L R 10MPa LS EF CF P 3 4 1 10 7 11 Return line MCV 22B7SS02 1 Hydraulic gear pump with priority valve 3 Steering unit 4 Steering cylinder 7 Suction strainer 10 Return filter 11 Hydraulic oil tank ...

Page 81: ...d so control spool G does not move The oil from hydraulic tank 11 enters to hydraulic gear pump 1 and pressurized so that the oil flows into the inlet port P of steering unit 3 and the spool K moves to the right Most of pump oil flows to MCV through the EF port and partially flows into the hydraulic tank 11 through the spool K ...

Page 82: ...hand direction As this time the oil discharged from hydraulic gear pump 1 flows into the spool G of the steering unit 3 through the inlet port P and flows to gerotor H Oil flow from the gerotor flows back into the spool G where it is directed out to the left work port L Oil returned from cylinder 4 returns to hydraulic tank 11 When the above operation is completed the machine turns to the left LEF...

Page 83: ...and direction As this time the oil discharged from hydraulic gear pump 1 flows into the spool G of the steering unit 3 through the inlet port P and flows to gerotor H Oil flow from the gerotor flows back into the spool G where it is directed out to the right work port R Oil returned from cylinder 4 returns to hydraulic tank 11 When the above operation is completed the machine turns to the right RI...

Page 84: ...rust bearing 5 Ball 6 Pin 7 Spacer 8 Centering spring 9 Washer 10 O ring 11 O ring 12 Rolled screw 13 Gerotor set 14 Bearing race 15 Bore screw 16 Drive 17 End cap 18 Gland bushing 19 Plate 20 Cap screw 21 Housing 22 Spool 23 Sleeve 24 Plate spring 27 P port check valve 27 1 Plug 27 2 Poppet 27 3 Spring seat 27 4 Spring 29 Relief valve 29 1 Spool 29 2 Bushing 29 3 Spring 29 4 Spring seat 29 5 Plug...

Page 85: ... to run by oil pressure and the sleeve is caused to run through the drive shaft and cross pin Therefore when the spool is turned the spool turns by the same value in such a manner that it follows the motion of the spool Steering motion can be accomplished when this operation is performed in a continuous state If the hoses of the steering system are incorrectly connected the steering wheel can turn...

Page 86: ... nipple 1 5 Set screw 1 6 Hexagon nut 1 7 Bolt 1 8 Hexagon nut 1 9 Hexagon bolt 1 11 Hardened washer 1 12 Link pin 1 13 Inner race bushing 1 14 Thrust bearing 1 15 Needle bearing 1 16 Plug plate 1 17 Retaining ring 1 18 King pin 1 19 Hub bolt 1 20 Taper roller bearing 1 21 Taper roller bearing 1 22 Oil seal 1 23 Washer 1 24 Nut 1 25 Split pin 1 26 Hub cap 1 27 Shim 0 2 t 1 28 Shim 0 5 t 1 29 Speci...

Page 87: ... ft Apply loctite 277 Apply loctite 277 55 61kg m 398 441lb ft 20BC7SS09 Type Structure of knuckle Toe in Camber Caster King pin angle Maxsteeringangleof wheels Inside Outside Tread Unit degree degree degree degree degree mm in Elliott type 0 1 0 0 87 56 22 910 35 8 Center pin support single shaft ...

Page 88: ...sure camber If camber is not within 1Ü0 5ä rear axle is bent Ask assistant to drive machine at minimum turning radius Fit bar and a piece of chalk at outside edge of counterweight to mark line of turning radius If minimum turning radius is not withinÜ100mm Ü4in of specified value adjust turning angle stopper bolt Min turning radius Outside Refer to page 1 5 Specifications     2 2 TROUBLESHOOTI...

Page 89: ...ficient or variable oil flow ÂFlow control valve orifice clogged ÂClean Insufficient or variable dischar ge pressure Piping ÂPipe from tank to pipe dented or clogged ÂRepair or replace Steering cylinder head leakage Piston rod ÂPacking foreign material ÂPiston rod damage ÂRod seal damage and distortion ÂChrome gilding damage ÂReplace ÂGrind surface with oil stone ÂReplace ÂGrind Steering cylinder ...

Page 90: ...ust the pressure Irregular or no response ÂBroken pump ÂExcessive heat ÂBroken centering spring ÂMisalignment with column ÂIncorrect piping to the four port ÂParts missing ÂHigh back pressure ÂCorrosion on the moving parts ÂReplace it ÂLocate the heat source and remove it ÂReplace it ÂDisassemble and adjust it ÂCorrect it ÂInstall the parts correctly ÂAdjust the pressure ÂReplace it Oil leakage ÂF...

Page 91: ...l 3 Cap seal 4 Thrust bearing 5 Ball 6 Pin 7 Spacer 8 Centering spring 9 Washer 10 O ring 11 O ring 12 Rolled screw 13 Gerotor set 14 Bearing race 15 Bore screw 16 Drive 17 End cap 18 Gland bushing 19 Plate 20 Cap screw 21 Housing 22 Spool 23 Sleeve 24 Plate spring 27 P port check valve 27 1 Plug 27 2 Poppet 27 3 Spring seat 27 4 Spring 29 Relief valve 29 1 Spool 29 2 Bushing 29 3 Spring 29 4 Spri...

Page 92: ...5 14 TOOLS Holding tool 2 1 Assembly tool for O ring and kin ring 2 Assembly tool for lip seal 3 Assembly tool for cardan shaft 4 5 69 1 5 69 2 5 69 3 5 69 4 ...

Page 93: ...r 13mm ring spanner 6 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 6 5 70 1 5 70 2 D353SE23 TIGHTENING TORQUE L Left port R Right port T Tank P Pump 3 Port L R T P Mounting bolt Size 3 4 UNF 16 3 4 UNF 16 3 4 UNF 16 3 4 UNF 16 M10Ý1 5 Torque kgfÂm lbfÂft 6 1 Ü0 6 44 1Ü4 3 6 1 Ü0 6 44 1Ü4 3 6 1 Ü0 6 44 1Ü4 3 6 1 Ü0 6 44 1Ü4 3 4 0 Ü0 5 29Ü3 6 ...

Page 94: ...the steering unit in the holding tool Screw out the screws in the end cover 6 off plus one special screw 4 1 Remove the end cover sideways 2 Lift the gearwheel set With spacer if fitted off the unit Take out the two O rings 3 Remove cardan shaft 4 5 72 1 5 72 2 5 72 3 5 72 4 ...

Page 95: ...5 17 Remove distributor plate 5 Screw out the threaded bush over the check valve 6 Remove O ring 7 Shake out the check valve ball 8 5 73 1 5 73 2 5 73 3 B20H7SS09 ...

Page 96: ...spool and sleeve close to one of the slots for the neutral position springs See drawing If the mark is not visible remember to leave a mark of your own on sleeve and spool before the neutral position springs are disassembled ö 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 ...

Page 97: ...eir slots in the spool 13 Remove dust seal and O ring 14 Disassembling the pressure relief valve Screw out the plug using an 8mm hexagon socket spanner Remove seal washers 15 Carefully press the spool out of the sleeve 12 5 74 4 5 75 1 5 75 2 D353SE10 ...

Page 98: ...ting screw using an 8mm hexagon socket spanner 16 Shake out spring and piston The valve seat is bonded into the housing and cannot be removed 17 The pressure relief valve is now disassem bled 18 D353SE11 D353SE12 D353SE13 ...

Page 99: ... spring slots Place the slots and holes opposite each other so that parts of the holes in the sleeve are visible through the slots in the spool 5 1 ö Place the two flat neutral position springs in the slot Place the curved springs between the flat ones and press them into place see assembly pattern 2 Line up the spring set 3 5 76 1 5 76 2 5 76 4 Guide the spool into the sleeve Make sure that spool...

Page 100: ...tral position springs into place in the sleeve 5 Line up the springs and center them 6 Guide the ring down over the sleeve The ring should be able to rotate free of the springs 7 ö 5 77 2 5 77 3 5 77 4 Fit the cross pin into the spool sleeve 8 5 78 1 ...

Page 101: ...tern for standard bearings 1 Outer bearing race 2 Thrust bearing 3 Inner bearing race 4 Spool 5 Sleeve ö Installation instruction for O ring Turn the steering unit until the bore is horizontal Guide the outer part of the assembly tool into the bore for the spool sleeve 10 5 78 2 5 78 3 5 78 4 ...

Page 102: ...them on the tool 11 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 12 Press and turn the O ring into position in the housing 13 5 79 1 5 79 2 5 79 3 5 79 4 ...

Page 103: ...l with hydraulic oil and place it on the assembly tool 15 Guide the assembly tool right to the bottom 16 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 14 5 80 1 5 80 2 5 80 3 5 80 4 ...

Page 104: ...it until the bore is vertical again Put the check valve ball into the hole indicated by the arrow 20 Press and turn the lip seal into place in the housing 17 With a light turning movement guide the spool and sleeve into the bore Fit the spool set holding the cross pin horizontal 18 ö 5 81 1 5 81 2 5 81 3 5 81 4 ...

Page 105: ...shaft down into the bore so that the slot is parallel with the connection flange 24 Screw the threaded bush lightly into the check valve bore The top of the bush must lie just below the surface of the housing 21 Grease the O ring with mineral oil approx viscosity 500 cSt at 20ä C 22 5 82 1 5 82 2 5 82 3 5 82 4 ...

Page 106: ...the seven through holes match the holes in the housing 27 Fit the spacer if any 28 Place the cardan shaft as shown so that it is held in position by the mounting fork 25 Grease the two O rings with mineral oil approx viscosity 500 cSt at 20ä C and place them in the two grooves in the gear rim Fit the gearwheel and rim on the cardan shaft 26 5 83 1 5 83 2 5 83 3 5 83 4 ...

Page 107: ...ghten all the screws and the rolled pin ÂTightening torque 4 0Ü0 5kgfÂm 28 9Ü3 6lbfÂft 31 Place the dust seal ring in the housing 32 Place the end cover in position 29 Fit the special screw with washer and place it in the hole shown 30 5 84 1 5 84 2 5 84 3 5 84 4 ...

Page 108: ...5 30 Fit the dust seal ring in the housing 33 Press the plastic plugs into the connection ports Do not use a hammer 34 ö 5 85 1 5 85 2 ...

Page 109: ...LINDER STRUCTURE 1 2 4 3 5 9 6 7 8 10 4 9 10 5 6 7 8 12 12 11 3 B207SE21 1 Tube assembly 2 Rod assembly 3 Gland 4 Bushing 5 Rod seal 6 Back up ring 7 Dust wiper 8 Snap ring 9 O ring 10 O ring 11 Piston seal 12 Bushing 1 ...

Page 110: ... Check item Remedy Criteria Clearance between piston cylindertube Clearance between cylinderrod bushing Seals O ring Cylinder rod Cylinder tube Replace piston seal Replace bushing Replace Replace Replace 0 064 0 137 0 0025 0 0054 0 024 0 112 0 0009 0 0044 Damage Dents Biting Standardsize Repairlimit 0 180 0 0070 0 120 0 0049 3 3 mm in ASSEMBLY Install a new piston seal the groove on the piston Be ...

Page 111: ...d calking again never using previous calking position 6 ö D353SE31 Move the piston rod back and forth several times for the full distance of its stroke This helps to seat the ring and seals before applying full hydraulic pressure to the cylinder Install cylinder into trail axle While idling the engine with the rear wheels off the ground operate the steering wheel left and right alternately Then re...

Page 112: ...Knuckle 1 3 Link 1 4 Grease nipple 1 5 Set screw 1 6 Hexagon nut 1 7 Bolt 1 8 Hexagon nut 1 9 Hexagon bolt 1 11 Hardened washer 1 12 Link pin 1 13 Inner race bushing 1 14 Thrust bearing 1 15 Needle bearing 1 16 Plug plate 1 17 Retaining ring 1 18 King pin 1 19 Hub bolt 1 20 Taper roller bearing 1 21 Taper roller bearing 1 22 Oil seal 1 23 Washer 1 24 Nut 1 25 Split pin 1 26 Hub cap 1 27 Shim 0 2 t...

Page 113: ...bnormal noise defective rotation Check item Diameter of king pin Vertical play of knuckle Diameter of center pin Rear axle hub knuckle bearing Remedy Replace Adjust with shims Replace Replace Standard size 35 1 38 50 2 0 34 8 1 370 0 2 0 008 49 5 1 9 No Repair limit A B C mm in ...

Page 114: ...l hub together with the bearing Be very careful because just before the hub comes off tapered roller bearing will fall out After wheel hub is removed take off the inner race of bearing Pull out oil seal Don t use same oil seal twice Repeat the same procedure for the other side Moreover when disassembling is completed part the slotted nut in the knuckle to protect the threaded portion 4 5 6 ö 7 1 2...

Page 115: ...the special bolt side Do not hammer to drive in thrust bearing 1 14 because it will be broken Always use drive in tool In assembling the thrust bearing 1 14 be sure that the fixed ring of the bearing is placed in position facing the knuckle 1 2 Wheel hub Mount oil seal 1 22 and inner race of tapered roller bearing 1 20 on the knuckle 1 2 The bearing should be well greased before assembling Install...

Page 116: ...SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function 6 1 Group 2 Operational checks and troubleshooting 6 16 Group 3 Disassembly and assembly 6 20 ...

Page 117: ...B 3A 3B 4A 4B 1A LS EF CF P 3 4 9 8 6 5 2 1 10 7 11 LIFT TILT AUX 1 AUX 2 22B7HS01 1 Hydraulic gear pump with priority valve 2 Main control valve 3 Steering unit 4 Steering cylinder 5 Tilt cylinder 6 Lift cylinder 7 Suction strainer 8 Down control valve 9 Down safety valve 10 Return filter 11 Hydraulic oil tank ...

Page 118: ...ift 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 2 and then goes to the large chamber of lift cylinder 6 by pushing the load check valve of the spool The oil from the small chamber of lift cylinder 6 returns to hydraulic oil tank 11 at the same time When this happens the forks go up ...

Page 119: ... WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 2 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 120: ...lt control lever is pushed forward the spool on the second block is moved to tilt forward position The oil from hydraulic gear pump 1 flows into main control valve 2 and then goes to the large chamber of tilt cylinder 5 by pushing the load check valve of the spool The oil at the small chamber of tilt cylinder 5 returns to hydraulic tank 11 at the same time When this happens the mast tilt forward ...

Page 121: ...e tilt control lever is pulled back the spool on the second block is moved to tilt backward position The oil from hydraulic gear pump 1 flows into main control valve 2 and then goes to the small chamber of tilt cylinder 5 by pushing the load check valve of spool The oil at the large chamber of tilt cylinder 5 returns to hydraulic tank 11 at the same time When this happens the mast tilt backward ...

Page 122: ...ver 4 Front cover 5 Half thrust plate 6 Half thrust plate 7 Drive shaft 8 Drive gear 9 Driven gear 10 Screw 11 Screw 12 Grub screw 13 Throttling screw 14 Washer 15 Seal 16 Seal 17 Seal 18 Seal 19 Square section seal 20 Shaft seal 21 Ring 22 Back up ring 23 Spool 24 Filter 25 Steel flange 26 Spring seat 27 Splined conn shaft 28 Spring 29 Spring 30 Dowel pin 31 Dowel pin 32 Steel plug 33 Plug 34 Spr...

Page 123: ...AUX1 AUX2 OUTLET INLET 22B7HS07 1 Inlet block assy 2 Lift block assy 3 Tilt block assy 4 Aux 1 block assy 5 Aux 2 block assy 6 Outlet block assy 7 Main relief valve assy 8 Auxiliary relief valve assy 9 Long bolt 10 Nut 1 Port name Inlet port Outlet port Work port Work port Size 7 8 14UNF 7 8 14UNF 7 8 14UNF 3 4 16UNF Port P T 1A 2A 2B 3A 3B 4A 4B ...

Page 124: ...UX1 AUX2 OUTLET INLET 22B7HS08 1 Inlet block assy 2 Lift block assy 3 Tilt block assy 4 Aux 1 block assy 5 Aux 2 block assy 6 Outlet block assy 7 Main relief valve assy 8 Auxiliary relief valve assy 9 Long bolt 10 Nut 11 Solenoid valve Port name Inlet port Outlet port Work port Work port Size 7 8 14UNF 7 8 14UNF 7 8 14UNF 3 4 16UNF Port P T 1A 2A 2B 3A 3B 4A 4B ...

Page 125: ...T P T 190bar INLET 3 1 22B7HS09 Operation of relief valve at setting pressure When the pressure at inlet reaches to setting pressure the pilot poppet which is in the main relief valve is opened by pressure At this condition the flow divert from the pump directly to the outlet tank 2 P T 190bar P T 22B7HS10 ...

Page 126: ...ting gravity returns the mast to the lowered position The lift section also contains part of the components which comprise the safety features There is a lift lock check valve At the neutral position pressures in the lock valve are equalized across the lift lock poppet In this manner the spring bias keeps the lift lock valve closed and prevents lowering of the mast Lifting When the operator shifts...

Page 127: ... an internal plunger which acts to stop tilt forward actuation when the battery power is off Tilt forward When the seated operator shifts the lever forward pressure is applied to the head of the tilt cylinder and the forks tilt forward Oil is directed from the high pressure parallel passage past the load check valve past the spool metering notches and towards the cylinder head Simultaneously the h...

Page 128: ...ns can be controlled by the auxiliary spool sections In general one work port is pressurized by high pressure oil from the parallel passage past the load check valve past the metering notches and to the cylinder Simultaneously oil from the other work port is directed across the spool metering notches to tank 6 1 3A 4A AUX 3B 4B 22B7HS15 ...

Page 129: ...i cavitation feature 7 1 OUTLET 130bar 22B7HS17 Operation of relief valve at setting pressure When the pressure at outlet reaches to setting pressure the pilot poppet which is in the main relief valve is opened by pressure At this condition the flow divert from the pump directly to the tank line 2 OUTLET 130bar 22B7HS18 ...

Page 130: ... limited Relief valve pressure varies by 130kgf cm2 in accordance with 1 revolution of adjust bolt 8 14 3 6 7 8 9 10 15 16 1 4 5 11 12 13 17 2 2 2 2 2 22B7HS20 1 Pilot seat 2 O ring 3 Main poppet 4 Back up ring 5 O ring 6 Socket 7 Main spring 8 Piston 9 Body 10 O ring 11 Back up ring 12 O ring 13 Pilot poppet 14 Pilot spring 15 Adjust screw 16 O ring 17 Lock nut ...

Page 131: ... 14 Spacer 15 O ring 5 TILT CYLINDER 23 18 19 20 21 22 12 13 8 17 16 11 10 15 14 9 1 2 6 4 5 3 7 24 24 20BC7HS24 1 Tube assembly 2 Rod 3 Piston 4 Glyd ring 5 Wear ring 6 O ring 7 Nylon nut 8 Gland 9 Du bushing 10 Rod seal 11 Back up ring 12 Dust wiper 13 Snap ring 14 O ring 15 Back up ring 16 O ring 17 Lock washer 18 Rod eye 19 Spherical bearing 20 Hexagon bolt 21 Spring washer 22 Hexagon nut 23 G...

Page 132: ...own and amount mast tilts forward ÂC Check condition Hydraulic oil Normal operating temp 50Á C Mast substantially vertical Rated capacity load ÂH Hydraulic drift Down Downward movement of forks Within 100mm 3 9in Forward Extension of tilt cylinder Within 5Á If the hydraulic drift is more than the specified value replace the control valve or cylinder packing Check that clearance between tilt cylind...

Page 133: ... ÂExcessive restriction of oil flow on pump suction side ÂRelief valve fails to keep specified pressure ÂPoor sealing inside cylinder ÂHigh hydraulic oil viscosity ÂMast fails to move smoothly ÂOil leaks from lift control valve spool ÂOil leaks from tilt control valve spool ÂExcessive restriction of oil flow pump suction side ÂGear or bearing in hydraulic pump defective ÂForeign matter jammed betw...

Page 134: ...fittings check condition of line ÂDrain reservoir fill with non foaming oil ÂReplace shaft seal ÂReplace drive shaft and seal C Cause Remedy HYDRAULIC GEAR PUMP 2 MAIN RELIEF VALVE A good pressure gauge must be installed in the line which is in communication with the main relief A load must be applied in a manner to reach the set pressure of the main relief unit Then follow these steps Loosen lock...

Page 135: ...d ÂO ring damaged ÂScores on inner surface of tube ÂUnallowable score on the inner surface of tube ÂForeign matters in piston seal ÂExcessive clearance between cylinder tube and wear ring ÂInsufficient lubrication of anchor pin or worn bushing and pin ÂBent tilt cylinder rod ÂReplace packing ÂSmooth rod surface with an oil stone ÂReplace dust seal ÂReplace rod ÂReplace O ring ÂSmooth rod surface w...

Page 136: ... smear a clean grease on the shaft end extension to avoid any damaging lip of the shaft seal when removing the mounting flange 2 22B7HS32 Remove the mounting flange taking care to keep the flange as straight as possible during removal If mounting flange is stuck tap around the edge with rubber mallet in order to break away from the body Ensure that while removing mounting flange shaft and other co...

Page 137: ...ront plate 4 22B7HS34 Remove driven gear and pressure plate also keeping all as straight as possible And now 1st section is completely disassembled 5 22B7HS35 After removing intermediate section disassemble 2nd section following same ways for 1st section 22B7HS36 6 ...

Page 138: ...om the cover with not sharp end rod while paying attention not to give any scratch on the surface of shaft seal 2 22B7HS39 Clean surface contact shaft seal 3 22B7HS40 Smear grease on the hole for shaft seal before fitting shaft seal into it to prevent any damage on the surface of shaft seal while inserting 4 ...

Page 139: ...ol 5 22B7HS42 Fit the snap ring in pre arranged position with proper tool 6 REPLACING SEALS FOR PRESSURE PLATE 22B7HS43 Before replacing seals for pressure plate make it sure that rubber spring is in right position 1 3 22B7HS44 Posit two left right parts of pressure plate as shown on the picture 2 ...

Page 140: ...ing and back up ring 3 22B7HS46 ASSEMBLING LS BLOCK 22B7HS47 Prepare all components needed to assemble LS Block Pay attention the position of each component 1 4 22B7HS48 Insert the spool into the body with care not to make any scar on the surface of spool 2 ...

Page 141: ...nged square ring on both side on the LS block 1 5 22B7HS51 Insert pressure plate and to the end very carefully while pushing two rubber springs O ring side should face covers not gears Then insert driving and driven gear And locate another pressure plate into the body 2 ö 22B7HS52 Locate intermediate plate and through shaft on the driving gear Then load 3 ...

Page 142: ...ears at right position and pressure plate and mounting flange also 5 22B7HS54 Tighten the bolts with washer in a crisscross pattern ÂTightening torque 4 59kgfÂm 33 2lbfÂft 6 22B7HS55 Check that the pump rotate freely when the drive shaft is turned by hand If not a pressure plate seal may be pinched 7 22B7HS56 ...

Page 143: ...etween the spool sections Stack the valve sections such that all the work ports are facing up the spool ends are all in the same direction and they are resting on a flat within 0 2mm uniform surface Insert all the tie rods through the drilled holes in each of the housings Press the sections together being carefully not to damage sealing surfaces or seals Install nuts to both ends of all tie rods a...

Page 144: ... the lift spool the return spring one spring seat on either end of the spring the seal plate a spool seal and a dust wiper All of these are assembled on the end of the spool opposite the clevis Insert the clevis end of the spool into the right hand side of the spool bore the tallest end of the housing Place the spool cap over the spool and spring assembly and connect the cap to the housing using t...

Page 145: ... and two bolts Torque both bolts alternatively until a torque of 1 0 1 5kgfÂm 7 2 10 8lbfÂft is reached on both bolts The load check assembly is inserted into the top center cavity Torque to 3 5 4 0kgfÂm 25 3 30lbfÂft Install the anti cavitation check valve in the housing cavity on the clevis end directly above the spool assembly Torque to 4 5 5 0kgfÂm 32 5 36 2lbfÂft Install the plug in the housi...

Page 146: ... over the clevis end of the spool and retain with a seal plate and two bolts Torque both bolts alternatively until a torque of 1 0 1 5kgfÂm 7 2 10 8lbfÂft is reached on both bolts The load check assembly is inserted into the top center cavity Torque to 3 5 4 0kgfÂm 25 3 30lbfÂft 6 ö Η Θ Ι Κ Lift lock check valve 32 5 36 2 lbf ft 4 5 5 0 kgf m Seal Dust wiper Seal plate Secondary main relief valve ...

Page 147: ...nd remove the tie rods from the valve sections Remove O rings between valve sections and set aside to avoid damage Spools relief valves load check valves lift lock poppet solenoid valves and plugs can all be removed from the valve sections Refer to the associated assembly procedures above for specific torque and handling details Inspect and repair or replace the assemblies as complete units as may...

Page 148: ...2 3 5 4 6 1 11 7 C P C P Down control valve A B Down safety valve A B 22B7HS26 1 Tube assy 2 Rod assy 3 Piston 4 Piston seal 5 Back up ring 6 Wear ring 7 Retaining ring 8 Gland 9 Dust wiper 10 Rod seal 11 O ring 12 Guide 13 Du bushing 14 Spacer 15 O ring ...

Page 149: ... guide can be removed 2 3 1 ASSEMBLY Soak the piston ring in hydraulic oil at a temperature of 40 to 50Á C expand the inside diameter and assemble on the piston Install a piston seal Bend the edge of the guide and rotate it to install the guide completely 4 4 1 Check item Standard size Remedy Repair limit Clearance between cylinder rod bushing Clearance between piston ring tube 0 072 0 288 0 003 0...

Page 150: ...d 9 Du bushing 10 Rod seal 11 Back up ring 12 Dust wiper 13 Snap ring 14 O ring 15 Back up ring 16 O ring 17 Lock washer 18 Rod eye 19 Spherical bearing 20 Hexagon bolt 21 Spring washer 22 Hexagon nut 23 Grease nipple 24 O ring seal lock type 2 8 11 3 4 5 6 7 1 23 18 19 21 20 22 13 12 16 17 15 14 10 9 24 22B7HS23 ...

Page 151: ...e cylinder head from cylinder tube When doing this wind tape round the threaded part of the rod and be careful not to damage the dust seal and rod seal inside cylinder head 2 1 Check item Standard size Remedy Repair limit Clearance between cylinder rod bushing Clearancebetweenrod head bushing pin 0 072 0 288 0 003 0 011 0 10 0 35 0 004 0 014 0 5 0 020 0 6 0 024 Replace bushing Replace bushing CHEC...

Page 152: ...SECTION 7 ELECTRICAL SYSTEM Group 1 Component location 7 1 Group 2 Electrical circuit 7 2 Group 3 Electric components 7 3 ...

Page 153: ... switch 2 Parking switch 3 High horn 4 Drive motor 5 Pump motor 6 Flasher unit 7 Lamp relay 8 Fuse box assy 9 Contactor 10 Pump controller 11 Back up alarm 12 Traction controller 13 SBR switch assy 14 Working lamp opt 15 Beacon lamp opt 16 Accelerator assy 17 DC DC converter 18 Display 19 Working lamp switch opt 20 Beacon lamp switch opt ...

Page 154: ...EV LAMP S W 02Q 46 C INPUT OUTPUT IN OUT DC DC CONVERTER GND GND 20 22 KO 21B HORN 29A KO 49A 02T MC COIL BATTERY 36 48V LINE CONTACTOR B B PARKING 400A B TRACTION INVERTER AC 3 TEMP SENSOR C25 PTHERM 21D M W U V TRACTION A24 NTHERM A1 ENCODER VCC A2 ENCODER GND A13 ENCODER A A14 ENCODER B 142 144 146 140 KEY A33 SEAT A4 KO ACCEL BACKWARD A6 PARKING A9 EN ACCEL A7 PB A8 COMMON A30 199 100A 195 190...

Page 155: ...ection and to control the speed of driving motor The CONTROL SYSTEM includes some protective circuits that protect the equipment and components from malfunctioning A MONITORING SYSTEM is installed in the monitor panel which monitors the equipment and working condition and let the operator take proper action For the monitoring system there are many sensors such as current sensors hydraulic pressure...

Page 156: ...otective tube 4 9 10 11 12 8 7 6 5 1 2 3 20BC7EL03 1 Cells 2 Steel box 3 Cell connector 4 Common connector 5 Row connector 6 Positive leading cable 7 Negative leading cable 8 Plug 9 Handle Red 10 Screw 11 Spring washer 12 Nut 1 ...

Page 157: ...L04 SPECIFICATION AND SERVICE DATA 3 Fully charged specific gravity End of discharge specific gravity Discharge end voltage Electrolyte Replenishment fluid Insulation resistance 1 280 25Á C 1 130 25Á C 48V option 36V Refined dilute sulfuric Refined water pure water More than 1Mɮ Item Type Rated voltage Capacity Electrolyte Dimension WÝDÝH Connector CE spec Weight Max Min V AH hr mm kg Unit Lead Ac...

Page 158: ...ercharge the battery OPERATION PRECAUTIONS Avoid over discharge If over discharged it will be difficult to restore the batteries to the original state by recharge In order to maintain the batteries in use for long period of time it is recommended to use the batteries with discharge amount not exceeding 80 of the rated capacity Further care should be taken for preventing the unit cell voltage from ...

Page 159: ... unit cell mean voltage reaches down to 1 7V at the electrolyte temperature of 30Á C That is the capacity is indicated by AH ampere hour being calculated as the product of ampere A and time H However even in the same type of batteries the capacity varies with the discharge conditions discharge current battery temperature and specific gravity of electrolyte Even if the batteries discharged its full...

Page 160: ...te rated capacity of the batteries At immediately after charging the charge current is allowed up to 3 times 5 hour rate current For charger provided with a timer the charge will terminate automatically if the timer is set at the specified time according to the operation manual Equalizing charge When large number of cells are used in a set of battery the voltage and specific gravity of respective ...

Page 161: ...ng charging Charge the battery in an area free from iron working welding etc Further the battery generates hydrogen oxygen acid mist and on rare occasions hydrogen sulfide during charging depending on the case Special care may be required in the case of equipment and objects near the battery that may contaminated or damaged Do not pull out the charging plug during charging as it will cause sparks ...

Page 162: ...fires such as lighted cigarettes or burning matches during charge Others Storage of batteries When batteries are stored keep them distant from room heaters or other heat generating sources Clean cool and dry place where no direct sunlight is directed is suited for battery storage Before putting into storage it is important to charge the batteries and keep the electrolyte level at the specified lev...

Page 163: ...creased that plate is de posed ÂWhen concentration of electrolyte rises ÂWhen impurities are mixed in electrolyte ÂRise of temperature due to such trouble ÂWhen left long period with out refilling of water ÂShort circuit ÂDiluted sulfuric acid is used in refilling ÂWhen the electrolyte level excessively drops ÂReplace ÂReplace or install a new one ÂReplace ÂNeed equalizing charge ÂNeed equalizing ...

Page 164: ...5 20BC7EL07 1 1 Rotor 2 Circlip 3 Stator 4 Terminal board 5 Screw 6 Hexagon nut 7 Hexagon nut 8 Disc 9 Terminal base 10 End shield 11 Ball bearing 12 Circlip 13 Oil seal 14 Screw 15 Commutator end plate 16 Sensor bearing 17 Spring washer 18 O ring 19 Cable 20 Cylinder screw 21 Screw ...

Page 165: ...cessary to remove the bearings in case of repair they should be replaced In any case the sealing parts shaft sealing ring etc have to be replaced If a bearing which is to be replaced has only one sealing lip this should be greased with quality bearing grease After approximately 10 000 operating hours the bearings have to be replaced Disassembly and assembly The motor is assembled and disassembled ...

Page 166: ...13 12 3 6 5 4 22B7EL08 1 1 Rotor 2 Stator 3 Terminal 4 Screw 5 Hexagon nut 6 Crinkle washer 7 End shield drive end 8 Oil seal 9 Ball bearing 10 Locking ring 11 Locking ring 12 Screw 13 End shield non drive end 14 Sensor bearing 15 Spring washer 16 O ring ...

Page 167: ...d it be necessary to remove the bearings in case of repair they should be replaced In any case the sealing parts shaft sealing ring etc have to be replaced If a bearing which is to be replaced has only one sealing lip this should be greased with quality bearing grease After approximately 10 000 operating hours the bearings have to be replaced Disassembly and assembly The motor is assembled and dis...

Page 168: ...6 5 CONTROLLER SYSTEM STRUCTURE 1 20BC7EL10 Specifications 1 20 25 30 32BC 7 Model Model AC3 AC3 Traction Pump MOSFET MOSFET 36 48V 600A 36 48V 600A 600A 3min 600A 3min Application Type Power Current limit ...

Page 169: ...n perform an electrical stop on a ramp the machine is electrically hold on a slope for a programmable time Electronic differential feature with torque balance between external and internal wheel Regenerative release braking based upon deceleration ramps Regenerative braking when the accelerator pedal is partially released deceleration Direction inversion with regenerative braking based upon decele...

Page 170: ...signal Active HIGH Forward direction request signal Active HIGH Reverse direction request signal Active HIGH Traction or backing request signal Active HIGH Pedal brake request signal Active HIGH Speed reduction signal or hand brake or exclusive hydro input Active LOW Microswitch open If not connected to safety out the MC coil power output will be disabled It can also be used as a general purpose i...

Page 171: ...r Output of main contactor coil driver drives to BATT Positive of main contactor coil Common of FW REV HB PB SEAT ENABLE SR EX HYDRO BACKING microswitches Connected to the power supply through a microswitch CH with a 10A fuse in series Positive serial reception Negative serial reception Positive serial transmission Negative serial transmission Negative console supply Positive console supply It mus...

Page 172: ...have different electronic output A1 12V Positive of encoder power supply A2 GND Negative of encoder power supply A13 A Phase A of encoder A14 B Phase B of encoder Connection of encoder with open collector output 5V power supply Η Θ Connection of encoder with open collector output 12V power supply Ι 20B7EL26 The encoder power supply voltage and output electronic has to be communicated to ZAPI in or...

Page 173: ...r lifting enable input it is active HIGH Input for tilt up and tilt down digital input it is active HIGH Input for aux in and aux out digital input it is active HIGH Input for shift right and shift left digital input it is active HIGH Input for side battery removal digital input Active low Speed reduction input Active low If not connected to batt the MC coil power output will be disabled It can al...

Page 174: ...oil power output will be disabled It can also be used as a general purpose output Common of digital microswitches This input allows the customer to select the software for traction or lifting application To be connected with A35 Connected to the power supply through a microswitch CH with a 10A fuse in series Batt Batt Positive serial reception Negative serial reception Positive serial transmission...

Page 175: ...ed to 60Hz Lift cutout When the alarm BATTERY LOW appears if this option is programmed to ON the lift function is disabled Hydro key on ON OFF If this option is programmed ON the traction inverter manages an hydraulic steering function when the key is switched ON Stop on ramp ON The stop on ramp feature truck electrically hold on a ramp is managed for a fixed time 6 sec OFF The stop on ramp featur...

Page 176: ...pedal brake is pressed If set to off the traction current is reduced to the half of the maximum current Submenu ADJUSTMENTS Set pot brake min It records the minimum value of braking pedal potentiometer when the braking pedal switch is closed the procedure is similar to the Program Vacc function see page 7 37 This procedure must be carried out only if the Pedal braking option is programmed as Analo...

Page 177: ...ry voltage exceed this total value the software recognize charging and battery charge percentage increase to correct value also if battery isn t fully charged Main cont voltage This parameters adjusts the line contactor coil voltage PWM output C26 Aux output voltage This parameters adjusts the solenoid coil voltage PWM output C28 Adjustment 04 This parameter determines the motor temperature level ...

Page 178: ...ITAL A digital ON OFF motor thermal sensor is connected to A25 input ANALOG An analog motor thermal sensor is connected A25 the curve can be customized on a customer request NONE No motor thermal sensor switch is connected Digital lift OFF The lift sensor includes a lift switch and an analogue lift sensor Lift speed can be controlled proportionally with lever position ON The lift sensor includes a...

Page 179: ...POINT VACC MAX V 20B7EL17 VACC MIN and VACC MAX are values programmable by the PROGRAM VACC function Adjustment 04 This parameter determines the motor temperature level at which the MOTOR TEMPERATURE alarm is signalled This parameter must be adjusted only if the SET TEMPERATURE menu SET OPTION parameter is programmed ANALOG PWM on main contactor OFF The inverter applies the battery voltage to the ...

Page 180: ... CONSOLE Option Adjustment of parameters and changes to the inverter s configuration are made using the digital console The console is connected to the B connector of the inverter Descriptions of console 5 ö Inverter B connector Console connector Display Buttons 20B7EL15 Digital consoles used to communicate with AC inverter controllers must be fitted with EEPROM CK ULTRA minimum Release number 3 0...

Page 181: ...7 29 Description of standard console menu Traction controller Η 20BC7EL18 2 ...

Page 182: ...7 30 Pump controller Θ 20BC7EL20 ...

Page 183: ...7 31 Display Ι 20B7EL27 ...

Page 184: ...y Press ENTER to go into the general menu The display will show Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appear on the display The display shows Press ENTER to go into the ALARMS function The display will show the most recent alarm Each press of the ROLL UP button brings up following alarms Pressing ROLL DOWN returns to the most recent If an alarm has not occurred the display will ...

Page 185: ...pear on the display The display shows Press ENTER to go into the PROGRAM VACC routine The display will show the minimum and maximum values of potentiometer wiper output Both directions can be shown Press ENTER to clear these values Display will show 0 0 Select forward direction close any interlock switches that may be in the system Slowly depress the accelerator pedal or tiller butterfly to its ma...

Page 186: ...m heat sink holding the MOSFET devices Temperature 1 This is the temperature of the right motor if the option is programmed None see page 7 24 it shows 0Á T Temperature 2 This is the temperature of the left motor if the option is programmed None see page 7 24 it shows 0Á Accelerator The voltage of the accelerator potentiometer s wiper CPOT The voltage level is shown on the left hand side of the co...

Page 187: ...ive hydro switch ON VB Input active switch closed OFF GND Input non active switch open Brake pedal pot Voltage of the brake potentiometer s wiper CPOTB The parameter is active only if the PEDAL BRAKING parameter is set ANALOG Hand brake The level of the handbrake microswitch ON GND Input active switch opened OFF VB Input non active switch closed Voltage booster This is the booster of the voltage s...

Page 188: ...urrent Temperature The temperature measured on the aluminum heat sink holding the MOSFET devices Motor temperature This is the temperature of the motor if the option is programmed None it shows 0Á L Lifting switch Status of the lifting switch ON VB Active entry of closed switch OFF GND Non active entry of open switch Descent switch Status of the lowering speed switch of the pump ON VB Active entry...

Page 189: ... tilt analogue signal The voltage is shown on the left hand side of the display and the value in percentage on the right hand side Shift request Level of the shift analogue signal The voltage is shown on the left hand side of the display and the value in percentage on the right hand side Aux request Level of the auxiliary analogue signal The voltage is shown on the left hand side of the display an...

Page 190: ...attery value is greater the MOS may fail if it is lower the control unit does not power up During battery charge disconnect the controller from the battery Do not connect the controller to a battery with a nominal voltage different than the value indicated on the controller label A higher battery voltage may cause power section failure A lower voltage may prevent the logic operating Before doing a...

Page 191: ...dbrake warning lamp 7 Key 1 button 8 Key 2 button 9 Key 3 button 10 Key 4 button 11 Key 5 button 12 Key 6 button 13 LCD function 7 8 10 11 9 12 1 2 3 4 5 6 M P 13 H Y U N D A I 15B7OM65 STRUCTURE The instrument panel has six built in red LED which provide the operator with an easy information about the status of some truck devices 1 6 DISPLAY ...

Page 192: ...rature öIMS Input motor switch Thermometer warning lamp 3 16B7OM61 16B7OM62 16B7OM63 This LED lights when the operator is not on the seat Seat warning lamp 4 16B7OM64 This LED lights when the handbrake is activated Handbrake warning lamp 6 16B7OM65 1 This LED lights to signal that the seat belt is not correctly fastened To connect the Seat belt sensor to the Analogue Input 2 Seat belt warning lamp...

Page 193: ...ushed OFF Input not active button release Key 6 button 6 16B7OM72 Status of Esc keyboard button ON Input active button pushed OFF Input not active button released Key 5 button 5 16B7OM71 Status of keyboard button ON Input active button pushed OFF Input not active button released Key 1 button 1 16B7OM67 Key 2 button 16B7OM68 Status of TURTLE keyboard button ON Input active button pushed OFF Input n...

Page 194: ...ars in the rectangle displayed in the top right side of the unit 2 shows the performance mode which is being used in the controller Performances can be scrolled pressing button When one performance is selected the related information will be sent via can bus to traction and pump controllers that will manage this data The standard functioning reduces truck performance passing from the high to econo...

Page 195: ...or level indication is displayed on the central top side of the unit 5 it is shown by ten notches When the accelerator level is minimum only a notch is displayed when the accelerator level is maximum all the ten notches are displayed Each notch represents 1 10 of the difference between maximum and minimum accelerator level Speed The number displayed under the accelerator notches on the center of t...

Page 196: ...erformance OPTION 2 N Normal performance OPTION 3 E Economic performance Hour counter It sets the hour counter displayed OPTION 1 The key hour meter is displayed OPTION 2 The traction hour meter is displayed OPTION 3 The pump hour meter is displayed Auxiliary output 1 The options are PRESENT An external load is connected between PAUX and NAUX The related diagnosis are enabled ABSENT No external lo...

Page 197: ...t S Seat belt status It sets the ÎSeat beltÏ diagnostic LED indication in the following way OPTION 1 No ÎSeat beltÏ indication The diagnostic LED is not used OPTION 2 If the seat belt are not fastened at Key ON the diagnostic LED blinks for three times than it turns off OPTION 3 The diagnostic LED blinks until the seat belt is fastened than it turns off S Submenu ADJUSTMENTS Delay display OFF This...

Page 198: ...f another menu is displayed press ROLL UP or ROLL DOWN until SET MODEL appears Press ENTER to go into the SET MODEL The display will shows the first option only CONNECTED TO option is present in this menu Press SET UP or SET DOWN buttons in order to select the desired value for selected option New desired value appears Press OUT to exit the menu The display will ask ARE YOU SURE Press ENTER for YE...

Page 199: ...UP or ROLL DOWN buttons until desired option appears Desired option appears Press SET UP or SET DOWN buttons in order to modify the value for selected option New value for selected option appears Press OUT to exit the menu Confirmation request appears Press ENTER to accept the changes or press OUT if you do not accept the changes SET OPTIONS menu appears Press OUT again Display now shows the openi...

Page 200: ... tested is shown on the display Press either ROLL UP or ROLL DOWN buttons Next variable for measurement appears When you have finished press OUT The Display will show TESTER Press OUT again and return to opening Zapi menu 20B7EL30 Η Θ Ι Κ Λ Μ Ν Ξ Ο Π Ρ F Flow chart showing how to use the TESTER function of the digital console 3 Remember it is not possible to make any changes using TESTER All you c...

Page 201: ...ning Zapi menu Press ENTER to go into the MAIN MENU The display will show Press ROLL UP or ROLL DOWN until ALARMS menu appears on the display The display will show Press ENTER to go into the ALARMS menu The display will show the most recent alarm Each press of ROLL UP button brings up following alarms Pressing ROLL DOWN returns to the most recent If an alarm has not occurred the display will show ...

Page 202: ...k speed in km h or mph it depends on SPEED UNIT parameter and key traction pump hour meter see HOUR COUNTER option if alarms are present it will show alarm code node initials in which alarm has occurred and alarm description From the main page it is possible to have access to the ALARM page if alarms occur and to MENUS page The CHANGE PASSWORD MENU is always accessible and visible while the others...

Page 203: ...seco nds 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 16B7SM23 ENTER USER PASSWORD ENTER PASSWORD SERVICE ENGINEERING D 247 CAN BUS KO PERFORMANCE ROLLING H high N normal E economy TRACK MENU MAINTENANCE CHANGE PASSWORD MENUS ...

Page 204: ... ZAPI CONSOLE The display will act like a Zapi console SET MAINTENANCE HOURS 00000 CHANGE PASSWORD ENTER OLD PASSWORD ENTER OLD PASSWORD ENTER NEW PASSWORD PASSWORD HAS BEEN CHANGED PRESS OUT MAIN PAGE 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 ...

Page 205: ... console Buttons of membrane keyboard do the same functions of Zapi console keys Button 1 Performs function of the ROLL UP console key Button 2 Performs function of the ROLL DOWN console key Button 3 Performs function of the SET DOWN console key Button 4 Performs function of the SET UP console key Button 5 Performs function of the OUT console key Button 6 Performs function of the ENTER console key...

Page 206: ...o the very first check to carry out concerns connections between dashboard outputs and loads B In case no failures problems have been found externally the problem is in the logic card which has to be replaced DRIVER SHORTED Cause The driver of the auxiliary electro valve coil is shorted Troubleshooting A Check if there is a short or a low impedance pull down between NAUX CNB 1 and BATT B The drive...

Page 207: ...rk with the Graphic Display parameters default values Troubleshooting Try to execute a CLEAR EEPROM operation refer to console manual Switch the key off and on to check the result If the alarm occurs permanently it is necessary to replace the logic If the alarm disappears the previously stored parameters will have been replaced by the default parameters MAINTENANCE NEEDED Cause This is just a warn...

Page 208: ...power section or in the Logic PCB or in the driver PCB or in the motor If the alarm is present in Init status remove the alarm condition If the alarm has occurred in standby or running mode it is necessary to remove alarm condition and to activate a traction request To remove alarm condition activation of traction request To remove alarm condition activation of traction request To recycle the key ...

Page 209: ...t in accelerator negative NPOT input circuit Alarm The battery voltage does not correspond to SET BATTERYprogram ming Alarm Master ʂ C detects a Slave ʂ C malfunctioning If the alarm is present in Init status remove the alarm cause If the alarm has occurred in standby or running mode it is necessary to remove alarm cause and to activate traction request To remove alarm cause and to activate tracti...

Page 210: ...Warning Acc signal CPOT voltage higher than VACC MIN 1V while the traction en able switch is open Warning Wrong trac tion request sequence Warning Forward and reverse inputs are both active Warning Master or slave temp sensor is out of range Warning Master ʂ C signals that slave or pump ʂ C is in alarm status Alarm Master Slave has lost Can communication with X Alarm Inverter has lost Can communic...

Page 211: ...seat pedal and levers commands Alarm Master has lost can communication with the display Warning The chat time has expired Warning The display enable signal has not been received to operate the truck Warning A warning is active on the pump module Warning The encoder signal is constantly zero or opposite to applied frequency when the maximum torque is applied to the motor Warning A warning is active...

Page 212: ...BATTERY CHARGER 1 Notice on caring chargers If any abnormal status is found while using a charger immediately stop using and check the charger If it is impossible to take an appropriate measure for yourself please apply for A S While charging hydrogen and oxygen gas is produced Use or approach of fire should be strictly prohibited Keep clean to prevent from sneak current and attack on the interfac...

Page 213: ...each part independent items BR7BAT30 1 Main PCB board 2 Main trans Class H 3 Cooling fan 4 SCR module 5 Shunt 6 NFB 7 MG S W 8 Assistant trans 9 Resistance RD 10 Resistance DR 11 TAP changer 1 2 7 8 5 6 9 10 3 4 11 3 ...

Page 214: ...necter and charger connecter  ÂAccording to charging condition If there is no abnormality found when the charger checks itself for 3 4 seconds after inputting AC input power source the charger slowly increases the electric flow for charging and the charging condition lamp in the lower part of the front panel for floating charging of input is on When charging is processed about 80 yellow lamp in t...

Page 215: ...battery is over discharged When there is large deviation of voltage and specific gravity between battery cells When change or supply electrolyte of battery 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 lamp is on over 85 charged the equal...

Page 216: ...ge setting value Ą 220V 380V Between terminals No 2 No 4 220V 380V Between terminals No 2 No 6 220V 380V Between terminals No 4 No 6 220V 380V Above cases are under normal operations When installing charger for the first time or moving its location check and make it sure if the voltage is appropriately connected Refer to No 2 of the charger installation method for the terminal connection method In...

Page 217: ...ter 15 seconds next to turn the manual switch on Yellow charging condition lamp is on while charging After green lamp becomes on measure the output voltage of the battery connector by multi measure If measured voltage is between 62 5V 63 5V it is normal Rated voltage 63V After 30 seconds next to turn on the manual switch if buzzer rings for 10 seconds and END lamp is on it is under normal conditio...

Page 218: ...he voltage doesn t go over 52V for 2 hours Check the battery Transformer over heat Stop charging when it is over 160Á C If input voltage is high output current is over normal value and there is heat in the trans because of SCR control part fault Check the output current and PCB control board Heatsink over heat Stop charging when it is over 100Á C Check the cooling fan SCR connection cable contact ...

Page 219: ...ase power source is normal with AC voltage meter A O Error on selection of input power source of 220V or 380V Check it appropriately with full three phases A C Check if the input power source 220V or 380V is normal O C Check the electric current as charging current of the battery is over standards condition O V Check the voltage as charging voltage of the battery is over voltage condition 66V Norm...

Page 220: ...ven after starting charging Charger TRIP is occurred after abnormality lamp is on In case error code is O V Charger TRIP is occurred after abnormality lamp is on In case error code is O C Charger TRIP is occurred after it started charging and charging completion lamp is on Charger has no response even the battery connector is connected 1 Η Θ Ι Κ Λ Μ 6 6 ...

Page 221: ...r part of PCB to manual AC INPUT MS switch ON PCB LP lamp ON Check the rated voltage YES YES NO Input power source is not provided Check external lead cable Check the connection of external input connecter Check external NFB TRIP Â Â Â Apply multi tester for input voltage change over tab no 6 Measure voltage between input tab no 8 PCB CN4 and contact points with red reed putting black reed on the ...

Page 222: ...e condition Is MS on NO YES NO Exceed Standard current Adjust output current within PCB Re adjust to VR OUTPUT CURRENT YES Separate the battery connector and tune the charger off Check SCR Module YES Check MAIN TRANS VOLT Change PCB NO Change SCR MODULE NO Check the normal operating condition of the charger Refer to SCR Module checking method TH Setting fault Re adjust TH setting value   TH TRIP...

Page 223: ...B anti clockwise rotation Set the voltage same as 62 5V Check the voltage of the output connecter 62 63V NO In crease De crease Re establish voltage establishment volume 17 0V on the lower right side of PCB as turning it anti clockwise rotation YES Measure the voltage of the output connecter 62 63V YES OK NO Check the detect voltage of the J3 connector YES In crease De crease VOLT Measure the volt...

Page 224: ...of PCB as turning it anti clockwise rotation Measure the output current by DC current measure AH 8 NO YES Re establish or release the output over current volume 9 OC on the lower left side of PCB as turning it anti clockwise rotation Restart the charger as pushing reset switch in the monitor Measure the output current by DC current measure Decrease Increase YES Change PCB NO After RESET Check char...

Page 225: ...re Is it normal NO Measure the output voltage 62 63V YES Contact fault between the battery connector and charger connector Battery is over discharged Check SCR Module Is it ok YES NO Change PCB Change SCR Module Re establish voltage establishment volume 17 0V on the lower right side of PCB as turning it anti clockwise rotation After connecting the battery connector TRIP is not occurred and hold th...

Page 226: ...arger BATTERY Connector contact fault BATT SHUNT CN 6 PCB PCB Module BATT PCB Voltage is over 12V On the left side of PCB Is LP LED ON NO Change PCB Refer to the error detection No Η Check the input power wire line in the charger Change RD 300 500W Check the cable and contact point status at PCB connector J3 YES Convert the automatic manual selection switch to manual and turns it to automatic afte...

Page 227: ... and wire on the terminal SURGE PCB No 1 2 3 4 Measuring point Real diagram No 1 No 3 No 2 No 3 G1 K1 G1 K2 Measure value Forward Under 100 k ohm Reverse Infinity Forward Infinity Reverse Infinity Forward Under 100 ohm Reverse Under 100 ohm But It depends on the module If it is not 0 ohm It is Ok Forward Infinity Reverse Infinity 7 7 ...

Page 228: ...urrent detect 5 Adjust charging current 6 Adjust charging voltage 7 Over voltage 8 Monitor level yellow 9 Monitor level green 10 Under current 11 Over current 12 Set input over voltage 13 Set input over current 14 Auto manual switch 15 SCR control connector 16 CN4 RY contact point 1 2 7 8 5 6 9 10 3 4 15 14 13 12 11 16 8 ...

Page 229: ...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 230: ...AST V MAST 20BC7MS01 1 Outer mast 2 Inner mast 3 Roller 4 Tilt cylinder pin 5 Mast support cap 6 Bushing 7 Chain sheave 8 Lift chain 9 Anchor bolt 10 Roller 11 Retaining ring 12 Chain guard 13 Clamp 14 Back up liner 15 Shim 0 5 1 0t 16 Shim 0 5 1 0t ...

Page 231: ...ST TF MAST 20BC7MS02 1 Outer mast 2 Middle mast 3 Inner mast 4 Roller 5 Shim 0 5 1 0t 6 Lift chain 7 Anchor bolt 8 Sheave bracket 9 Chain guard 10 Chain sheave 11 Retaining ring 12 Mast support cap 13 Tilt cylinder pin ...

Page 232: ...8 3 3 CARRIAGE BACKREST AND FORK 22BHA7MS20 1 Backrest 2 Carriage 3 Load roller 4 Side roller 5 Fork assembly 6 Extension fork ...

Page 233: ...8 4 4 INTEGRAL SIDE SHIFT BACKREST AND FORK 6 5 3 3 4 2 1 22BHA7MS21 1 Backrest 2 Integral side shift 3 Load roller 4 Side roller 5 Fork assembly 6 Extension fork ...

Page 234: ... mast vertical raise forks about 10cm from ground and check front to rear clearance and left to right clearance between inner mast and fork carriage and between outer mast and inner mast Use these figures to judge if there is any play at roller or rail ÂFront to rear clearance Within 2 0mm 0 08in ÂLeft to right clearance Within 2 5mm 0 10in Check that there is an oil groove in bushing at mast supp...

Page 235: ...ormed mast assembly ÂFaulty hydraulic equipment ÂDeformed mast assembly ÂDeformed masts or carriage ÂFaulty hydraulic equipment ÂDamaged load and side rollers ÂUnequal chain tension between LH RH sides ÂLH RH mast inclination angles are unequal Mast assembly is twisted when tilted ÂDisassemble repair or replace ÂSee troubleshooting hydraulic pump and cylinders in section 6 hydraulic system ÂDisass...

Page 236: ...nevenly ÂDifference in fork tip height Fatigue failure may result from the fatigue crack even though the stress to fork is below the static strength of the fork Therefore a daily inspection should be done ÂCrack on the fork heel ÂCrack on the fork weldments If the measured value is below the wear limit replace fork If the measured value exceeds the allowance replace fork Repair fork by expert In c...

Page 237: ...nce between the roller side face and mast at the closest position on the opposite side to the following value by inserting the inner outer mast roller shim ÂStandard clearance A B 0 3 0 6mm ÂShim thickness 0 5 1 0mm Distribute the shim thickness equally to the left and right roller Refer to Mast load roller and back up liner removal and Installation After the adjustment check that the inner mast m...

Page 238: ...te side to the following value by inserting the inner and middle mast roller shim respectively ÂStandard clearance A 0 3 0 6mm ÂShim thickness 0 5 1 0mm Distribute the shim thickness equally to the left and right roller Refer to Mast load roller and back up liner removal and Installation After the adjustment check that the inner mast moves smoothly in the middle mast and the middle mast moves smoo...

Page 239: ...ller is 100mm from the top of the inner mast Measure the clearance at upper lower rollers after loosen the adjust screws from the side rollers Shift the carriage to one side to bring the roller into contact with the inner mast and measure the clearance between the roller side face and mast at the closest position on the opposite side to the following value by inserting the carriage roller shim ÂSt...

Page 240: ...LY CARRIAGE With the mast vertical raise the carriage high enough to place blocks under the load forks This is done to create slack in the load chains when the carriage is lowered Lower the carriage all the way down to the floor Make sure the carriage is level this will prevent any binding when the mast is raised While supporting lift chains remove the split pin and slide out chain anchor pins fro...

Page 241: ...proximately 1 10 turn on screw and tighten nut to lock screw in place Run carriage up and down for the inner mast to be sure the carriage has free movement and does not stick Also make sure chains are properly adjusted Refer to chain adjustment paragraph Make adjustment when necessary and recheck operation of carriage 2 1 2 3 4 ö C CARRIAGE LOAD ROLLER Remove carriage as outlined in the carriage a...

Page 242: ... the inner mast high enough to clear lift cylinder After lowering the lift cylinder rods and disconnecting lift cylinder hose tilt the lift cylinders LH and RH and them with ropes to the outer mast Using the overhead hoist lower inner mast until top and bottom rollers and back up liners are exposed Using a pryer remove load rollers from load roller bracket Remove back up liners and shims Thoroughl...

Page 243: ...ock of wood under the free lift cylinder bracket of the inner mast then lower mast sections this will create slack in the chains Remove retaining rings securing chain sheaves to sheave support brackets While support chains remove chain sheaves and let chains hang free The upper outer and lower middle mast rollers and back up liners are now exposed Using a player remove load rollers from load brack...

Page 244: ...free lift cylinder hose Drain hose into a suitable pan or container and cap hose While supporting free lift cylinder assembly remove bolts and washers securing cylinder to mast crossmember Place a sling around free lift cylinder and attach to an overhead hoist Slowly raise and move cylinder to one side Attach chains or sling to the inner mast section at top crossmember Using an overhead hoist slow...

Page 245: ...everse the above to assemble and install Use new split pins in chain anchor pins 6 1 Η Θ Ι Κ Λ Μ Outer mast Chain Sheave Inner mast Carriage Anchor bolt 22BHA7MS23 Middle mast Chain Sheave Chain Free lift cylinder Carriage Anchor bolt Anchor bolt Inner mast 22BHA7MS25 Rear chain sheave TF mast Raise and securely block carriage and inner mast section Remove the split pin securing the chain anchor p...

Page 246: ... for Load chain lubrication and adjustment Carriage chain Place a sling around carriage front plate and attach to an overhead hoist Lift and secure carriage high enough so that split and chain anchor pins on carriage can be easily be removed Remove chain anchor pins from carriage and drape chains out over carriage Place a wooden block under the carriage and lower the carriage on the block While su...

Page 247: ...ate edges Oil rusty chains and replace chains with bent or peened components P Protruding or turned pins Heavily loaded chains operating with lube generate tremendous friction between pins and plates In extreme cases the frictional torque in the joint can actually turn pins in the press fit outside plates If chain is allowed to operate in this condition the pins slowly work out of the chain causin...

Page 248: ... a film of oil between mating parts to prevent rapid wear Oil must penetrate the chain joint to prevent wear Applying oil to external surfaces will prevent rust but oil must flow into the live bearing surfaces for maximum wear life Frequency of re lube will vary with operating conditions and environment the best estimate of lube period is 200 hours Trucks parked outdoors or trucks in extremely sev...

Page 249: ...er stretching of chains ÂPrevent chains from jumping off sheaves if they are too loose A Adjustment procedure ÂWith mast in its fully collapsed and vertical position lower the fork to the floor ÂAdjust the chain length by loosening or tightening nut on the chain anchor After making adjustment on the mast be sure to tighten the nut Ι Ι Κ ...

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