15, 18, 20 BT-9

SERVICE MANUAL
Forklift Battery
15/ 18/ 20 BT-9
HYUNDAI FORKLIFT TRUCK
Kiều Văn Trung

Tell: 0936.359.363
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.
Â Oil is a dangerous substance. Never handle
oil, grease or oily clothes in places where
there is any fire of flame.
As preparation in case of fire, always know
the location and directions for use of fire
D50ASF01
extinguishers and other fire fighting
equipment.
Â 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.
D50ASF02
Â Flames should never be used instead of

lamps. Never use a naked flame to check
leaks or the level of oil or electrolyte.
D50ASF03
Â When working on top of the machine, be

careful not to lose your balance and fall.
D50ASF06
1-1
Â Hand a caution sign in the operator's
compartment (For example Do not start or
Maintenance in progress).
This will prevent anyone from starting or
moving the machine by mistake.
D50ASF07
When inspecting running parts or near such

parts, always stop the machine first.
Before checking or servicing accumulator or
piping, depress brake pedal repeatedly to
release pressure.
Â Park the machine on firm, flat ground.
Lower the fork to the ground and stop the
engine.
Return each lever to NEUTRAL and apply
D50ASF08
the brake lock.
Â 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
D50ASF09
Â When working with others, choose a group

leader and work according to his instructions.
Do not perform any maintenance beyond the
agreed work.
D50ASF10
1-2
Â Always remember that the hydraulic oil circuit
is under pressure. When feeding or draining
the oil or carrying out inspection and
maintenance, release the pressure first.
D50ASF11
Â Unless you have special instructions to the contrary, maintenance should always be carried out with
the machine stopped. If maintenance is carried out with the machine running, there must be two
men present : one sitting in the operator's seat and the other one performing the maintenance. In
such a case, never touch any moving part.
Â Thoroughly clean the machine. In particular, be careful to clean the filler caps, grease fittings and the
area around the dipsticks. Be careful not to let any dirt or dust into the system.
Â Always use HYUNDAI Forklift genuine parts for replacement.
Â Always use the grades of grease and oil recommended by HYUNDAI Forklift.
Choose the viscosity specified for the ambient temperature.
Â Always use pure oil or grease, and be sure to use clean containers.
Â When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into
the oil.
Â Before draining the oil, warm it up to a temperature of 30 to 40Á C.
Â After replacing oil, filter element or strainer, bleed the air from circuit.
Â When the strainer is located in the oil filler, the strainer must not be removed while adding oil.
Â When changing the oil filter, check the drained oil and filter for any signs of excessive metal particles
or other foreign materials.
Â When removing parts containing O-ring, gaskets or seals, clean the mounting surface and replace
with new sealing parts.
Â After injecting grease, always wipe off the oil grease that was forced out.
Â Do not handle electrical equipment while wearing wet places, as this can cause electric shock.
Â During maintenance do not allow any unauthorized person to stand near the machine.
Â Be sure you fully understand the contents of the operation. It is important to prepare necessary tools
and parts and to keep the operating area clean.
Â When checking an open gear case there is a risk of dropping things in. Before removing the covers
to inspect such cases, empty everything from your pockets. Be particularly careful to remove
wrenches and nuts.
Â 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
it.
1-3
GROUP 2 SPECIFICATIONS
1. GENERAL LOCATIONS
1 13
2
12
6
3 11
10
4 9
8
7
15BT9OM113
1 Mast 6 Dash board 11 Seat

2 Lift cylinder 7 Frame 12 Steering wheel
3 Carriage and backrest 8 Steering axle 13 Overhead guard
4 Forks 9 Counterweight
5 Drive unit 10 Battery cover
1-4
2. SPECIFICATIONS
C C'
M'
D
A
M
H
R
I
E
W
B
F
T
K
L G
15BT9SP01
Model Unit 15BT-9 18BT-9 20BT-9
Capacity kg (lb) 1500 (3310) 1800 (3970) 2000 (4410)

Load center R mm (ft-in) 500 (1' 8") ← ←
Weight kg (lb) 2990 (6590) 3275 (7220) 3480 (7670)
Lifting height A mm (ft-in) 3025 (9' 11") ← 3030 (9' 11")
Free lift B mm (in) 35 (1.4") ← 40 (1.6")
Lifting speed[Unload/Load] mm/sec 500/300 ← ←
Fork
Lowering speed[Unload/Load] mm/sec 450/500 ← ←
900×100×35 900×100×40
L×W×T L,W,T mm (in) ←
(35.4×3.9×1.4) (35.4×3.9×1.6)
Tilt angle forward/backward C/C' degree 5/7 ← ←
Mast Max height D mm (ft-in) 4020 (13' 2") ← ←
Min height E mm (ft-in) 1970 (6' 6") ← 2129
Travel speed[Unload/Load] km/h 16 ← ←
Body Gradeability[Load] % 29.5 27.5 24.5
Min turning radius[Outside] F mm(ft-in) 1525 (5' 0") 1620 (5' 4") 1650 (5' 5")
Max hydraulic pressure kgf/cm 2
190 ← ←
ETC
Hydraulic oil tank ℓ(usgal) 20 ← ←
Overall length G mm (ft-in) 1885 (6' 2") 1980 (6' 6") 2015 (6' 7")
Overall width H mm (ft-in) 1074 (3' 6") 1105 (3' 8") ←
Overhead guard height I mm (ft-in) 2065 (6' 9") ← ←
Ground clearance(Mast) J mm (in) 85 (3.4") ← 94 (3.7")
Wheel base K mm (ft-in) 1335 (4' 5") 1420 (4' 8") ←
895/170 905/170
Wheel tread front/Rear M mm (ft-in) ←
(2' 11"/0' 7") (3' 0"/0' 7")
1-5
3. SPECIFICATION FOR MAJOR COMPONENTS
1) CONTROLLER
Item Unit Traction motor controller Pump motor controller
Model SKAI 20A2 MM10-3010K SKAI 25A2 MD10-3011K
Type MOSFET ą
Dimension mm 220Ý300Ý138 200Ý250Ý130.8
Current limit A 330A+330A 450A
Communication CAN ą
2) MOTOR
Item Unit Traction Pump
Model R10ME-3M403 R10ME-3M392
Type AC AC
Rated voltage Vac 32 30
Output kW 4.7 15.8
Insulation Class F Class F
3) BATTERY
Item Unit 15BT-9 18/20BT-9
Rated voltage V 48 ą
Dimension(WÝLÝH) mm 978Ý545Ý635 978Ý630Ý635
Min. Battery weight kg 780 950
Max. Battery weight kg 900 1050
Connector(CE spec) SB 350 (SBE 320)
4) CHARGER
Type Constant current, constant voltage
Battery capacity for charge V-AH 48-440~520 48-530~600
Triple phase 410
Single phase 220
AC input V
Triple phase 220/380
Triple phase 440
DC output V 62Ü1 ą
Charge time hr 6Ü2 ą
Connector (CE spec) SB 350 (SBE 320) ą
1-6
5) GEAR PUMP
Item Unit Specification
Type - Fixed displacement gear pump

Capacity cc/rev 19.6
Maximum operating pressure bar 210
Rated speed(max/min) rpm 3000/500
6) MAIN CONTROL VALVE

Type - 3 spool, 4 spool

Operating method - Mechanical
Main relief valve pressure bar 190
2nd relief valve pressure bar 130
7) DRIVE UNIT
Max. axle load kg/lb 2700/5953

Max. input speed rpm 5000
Max. output torque (wheel) N·m 2260
Gear ratio - 20
Weight without fluid kg/lb 35 kg (77 lb)/EA
Oil quantity ℓ/U.S·qt 0.6/0.63
8) WHEELS
Item 15BT-9 18BT-9 20BT-9
Type (STD/OPT) SOLID Non-marking

Quantity(front/rear) 2/2
Front-drive 18×7-8 200×50-10 ←
Rear-steering 15×4.5-8 15×4.5-8, 15×5.5-9 (wide tire)
9) BRAKES & STEERING

Item Specification
Travel Front wheel, wet disc brake

Brakes
Parking Ratchet type
Type Full hydraulic, power steering
Steering
Steering angle 90°to both right and left angle, respectively
1-7
4. TIGHTENING TORQUE FOR MAJOR COMPONENTS
NO Items Size kgfÂm lbfÂft

1 Electric Hyd pump motor mounting bolt M 8 Ý1.25 2.5Ü0.5 18.1Ü3.6
2 system Traction motor mounting bolt M 8 Ý1.25 2.5Ü0.5 18.1Ü3.6
3 Hydraulic pump mounting bolt M 8 Ý1.25 2.5Ü0.5 18.1Ü3.6
4 MCV mounting bolt, nut M 8 Ý1.25 2.5Ü0.5 18.1Ü3.6
Hydraulic
5 system Steering unit mounting bolt M10Ý1.5 5Ü1 36Ü7.2
6 Brake cylinder mounting bolt M10Ý1.5 5Ü1 36Ü7.2
7 Hydraulic oil tank mounting bolt M 8 Ý1.25 2.5Ü0.5 18.1Ü3.6
8 Drive axle mounting bolt, nut M14Ý2.0 13.8Ü1.2 99.8Ü8.7
9 Power Steering axle mounting bolt, nut M14Ý2.0 16Ü2.0 115.7Ü14.5
train
10 system Front wheel mounting nut M14Ý1.5 14Ü1.5 101Ü10.8
11 Rear wheel mounting nut M14Ý1.5 14Ü1.5 101Ü10.8
12 Counterweight mounting bolt M30Ý3.5 199Ü15 1439Ü108
13 ETC Seat mounting bolt M 8 Ý1.25 2.5Ü0.5 18.1Ü3.6
14 Head guard mounting bolt M12Ý1.75 12.8Ü3.0 93Ü22
1-8
5. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 6 Ý 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 Ý 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 Ý 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 Ý 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 Ý 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 Ý 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 Ý 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 Ý 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 Ý 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 Ý 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 Ý 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 Ý 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 8 Ý 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 Ý 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 Ý 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 Ý 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 Ý 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 Ý 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 Ý 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 Ý 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 Ý 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 Ý 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 Ý 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-9
2) PIPE AND HOSE(FLARE TYPE)
Thread size Width across flat mm kgfÂm lbfÂft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
3) PIPE AND HOSE(ORFS TYPE)
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253
4) FITTING
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
1-10
6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature Á
C(Á
F)
Service Kind of
Capacity ˶ (U.S. gal -20 -10 0 10 20 30 40
point fluid
(-4) (14) (32) (50) (68) (86) (104)
0.6
Axle Gear oil MOBIL FLUID 424
(0.16)
ISO VG 22
Hydraulic Hydraulic 20
oil tank oil (5.2) ISO VG 46
ISO VG 68
Brake 0.5
Brake oil HYDRAULIC OIL SAE (AZOLA ZS10)
system (0.13)
Fitting NLGI No.1

0.1
(Grease Grease
(0.03)
nipple) NLGI No.2
ÂAPI : American Petroleum Institute

ÂSAE : Society of Automotive Engineers
ÂISO : International Organization for Standardization
ÂNLGI : National Lubricating Grease Institute
1-11
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; therefore, even if no apparent wear is found, always replace
with new parts within the prescribed period of replacement(Or earlier if trouble is found).
Note that periodic replacement has nothing to do with guarantee service.
ö Replacement of consumable service parts is not covered under warranty.
No. Description Period of replacement
1 Hydraulic oil Every 1 year

2 Brake fluid Every 1 year
3 Differential oil Every 1 year
4 Gear oil Every 1 year
5 Wheel bearing grease Every 1 year
6 Power steering hose Every 1 year
7 Rubber parts of the power steering inside Every 2 year
8 Cups and dust seals etc. of cylinder Every 2 year
9 Reservoir tank tube Every 1 year
10 Lift chain Every 2 year
11 Hydraulic equipment hose Every 2 year
12 Brake switch(hydraulic) Every 2 year
1-12
SECTION 2 REMOVAL & INSTALLATION OF UNIT
GROUP 1 MAJOR COMPONENTS
1
21
2
22
20
4 18,19
17
5
6
7 8 9 10 11 12 13 14 1516
15BT9RE01
1 Lift cylinder 9 Drive unit 17 Counterweight

2 Mast 10 Drive motor 18 Traction controller
3 Steering unit 11 Pump motor 19 Pump controller
4 Backrest 12 Hydraulic pump 20 Seat
5 Tilt cylinder 13 Main control valve 21 Overhead guard
6 Priority valve 14 Battery 22 Steering wheel
7 Forks 15 Rear wheel
8 Front wheel 16 Steering axle
2-1
GROUP 2 REMOVAL AND INSTALLATION OF UNIT
Remove and install following units as explained in the flow chart.
1. MAST
1) REMOVAL
(1) Forks
Knob
Η Lower the fork carriage until the forks are Rolled pin Backrest
approximately 25mm(1in) from the floor. Spring

Θ Turn knob up and slide one fork at a time
toward the center of the carriage where a
notch has been cut in the bottom plate for
Pin
easy removal.
Ι Remove only one fork at a time. Carriage
ö On larger forks it may be necessary to
Fork
use a block of wood.
Center notch
15BT9RE04
(2) Backrest(If necessary)

Backrest
Η Remove bolts securing backrest to fork
carriage. Disassemble the backrest from
the carriage. Bolt
Carriage
15BT9RE03
(3) Carriage Crane

Η 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 Block
the mast is raised. 15BT9RE10
2-2
Θ While supporting lift chains, remove the
Lift chain
split pins and slide out chain anchor pins Outer mast
from the chain anchors of stationary
upright.
Nut
Split pin
20B7RE05
Ι Pull the chains out of the sheaves and

drape them over the front of the carriage.
Mast
Carriage
Lift chain
Block
20B7RE06
Κ Slowly raise inner mast upright until mast

clears top of fork carriage. Move
carriage to work area and lower the Inner mast
mast.
Make sure that carriage remains on
floor and does not bind while mast
is being raised.
Λ Inspect all parts for wear or damage.
Replace all worn or damaged parts.
Lift chain Carriage

15BT9RE07
2-3
(4) Piping
Η Loosen the bolts (2EA) of the weld-
connector (2) from low crossmember of Inner mast
the outer mast.
Θ Disconnect the connectors from the lift
cylinders.
Ι Disassemble the velocity fuse valve (1),
hoses, and weld-connector (2). Lift cylinder
Outer mast
2
Bolt
1
15BT9RE08
(5) Lift cylinder

Η Loosen hexagonal bolts and remove Inner mast
washers securing the lift cylinders to
Stud bolt
outer mast. Bolt
Θ Bind the lift cylinder with overhead hoist
rope and pull up so that the rope has no
slack or binding.
Clamp
Make sure that the lift cylinder be
tightened firmly for safety.
Ι Loosen and remove hexagon bolts and
Lift cylinder
clamp securing the lift cylinder to outer
mast. Outer mast
Κ Using an overhead hoist, slowly raise the
inner mast high enough to clear lift
cylinder.
Λ Using an overhead hoist, draw out lift
Bolt
cylinder carefully and put down on the
work floor. 15BT9RE09
2-4
(6) Inner mast
Η Using an overhead hoist raise the inner
mast straight and carefully draw out of
outer mast section.
Inner mast
Be careful the mast not to swing or
fall.
Outer mast
15BT9RE12
(7) Tilt cylinder pin

Η Attach a crane to the stay at the top of
the outer mast, and raise enough to
sustain jacked up machine.
ö 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
Outer mast
on impact wrench.
Θ Remove the socket bolts, washers from
the mast mounting pins and take out the
mast mounting pins, and then slowly
raise up the outer mast Tilt cylinder
Pin
Socket bolt
Washer
Bushing
Mast mounting pin
15BT9RE11
2-5
2) INSTALLATION
After assembling mast components totally without piping connections, install mast assembly to the
equipment.
ö Installation procedure for each of mast component is the reverse of the removal procedure.
(1) Brone bushings
Η Check the inside of the bronze bushings for wear which are the contact area with the mast
mounting pins.
Θ Jack up the machine so that the front is raised and then using an overhead hoist assemble outer
mast to drive axle unit.
(2) Tilt cylinder pin
Hold the mast with a crane, operate the tilt control lever and align the holes, then knock the pin.
(3) Lift cylinder installation and adjustment
Η Assemble the lift cylinder inside the outer
mast, then tighten the stopper bolt. If the
cylinder assembly has been replaced,
adjust as follows so that the left and right
cylinders are synchronized at the
maximum lifting height.
Θ Assemble the cylinder rod to the inner
mast, and check the left-to-right play of
the mast at the maximum lifting height.
ö If play is to LEFT, install adjustment shim
to LEFT cylinder.
ö If play is to RIGHT, install adjustment
L15C3RE12
shim to RIGHT cylinder.
ÂShim thickness : 1.0mm(0.04in)
2-6
2. POWER TRAIN ASSEMBLY
1) REMOVAL
Mast &
Counterweight
B153RE00
(1) Mast and counterweight

Refer to section on mast(Page 2-5) Crane
ö After removing mast, remove the
counterweight to prevent the truck from
turning over.
Mounting bolt
15BT9RE12A
(2) Brake piping

Disconnect the brake piping from the drive
Drive unit Brake master
unit. cylinder
Drive line
assy-RH
Drive line
assy-LH
15BT9RE13
(3) Parking brake cable

Disconnect parking brake cable from the
drive unit.
Parking brake
lever
Drive line Parking brake

assy-RH cable
Drive line
assy-LH
15BT9RE14
2-7
(4) Drive unit & motor assy
ö Drain the oil before disassembling the Frame
drive unit.
Η Unscrew five wheel nuts and remove the Motor
wheel. wiring
Drive unit &

motor assy
Wheel nut
20B7RE15
Θ Remove three hexagon bolts holding the

drive motor in place. Drive motor
Ι Carefully remove the drive motor from the
drive unit. Drive unit
Bolt
15BT9RE17
Κ Loosen seven mounting bolts on the

truck frame and carefully take out the
drive unit.
Frame
Drive unit
Mounting bolt
15BT9RE16
2) INSTALLATION
Installation is the reverse order of removal, Frame
but be careful of the following tightening
torque. Motor
Drive tire
wiring
ÂTightening torque
Item kgfÂm lbfÂft

Drive motor (1) 2.0 ~ 3.0 14.5 ~ 21.6 2 1
3
Drive unit (2) 12.5 ~ 15 90.4 ~ 109 20B7RE18
Wheel nut (3) 12.5 ~ 15.5 90.4 ~ 112
2-8
3. ELECTRICAL COMPONENTS
Before removing each component, disconnect cables and earth lines attached to the component.
1) REMOVAL
B15T5RE001
(1) Battery
Before pulling out the battery plug, tilt the mast forward a little, and lower the fork to
the lowest position.
The batteries weigh from around 710kg to 1140kg so the extreme care must be taken
when handling them.
Η Disconnect the battery connector.

Release the battery cover latch and open
the battery cover. Connector
Latch Battery
cover
15BT9RE19
Θ Using a battery hanger, carefully raise the Hanger

battery assembly.
ö Be careful not to damage overhead
guard or control system.
Battery
cover
15BT9RE20
2-9
(2) Pump motor
Η Lower the fork to floor.
15BT9RE21
Θ Remove floor mat and rear floor plate.

Floor mat
Disconnect the wiring of pump motor.
Floor plate
Disconnect
wiring
15BT9RE22
Ι Remove elbow and connector and then

disconnect the hydraulic hose from the Hydraulic hose
gear pump. Pump motor
Remove the gear pump from pump

Gear pump
motor.
Remove the tightening nuts of the motor
mounting bracket. Connector
Remove the pump motor from mounting
Elbow
bracket. Nut
Nut
Bracket
15BT9RE23
2-10
4. STEERING AXLE
1) 15/18/20BT-9
(1) Removal
Counter Hose Mounting

Counterweight
weight Rear wheels
bolt
B15T5RE91
ö Before removing counterweight apply the parking brake.
Crane
Mounting bolt 15BT9RE24
Η Counterweight
Install a lifting tool in the counterweight, and raise with a crane.
Remove the mounting bolts, raise slightly and move to the rear.
ÂWeight of counterweight(standard)
15BT-9 575kg (1270lb)
18BT-9 665kg (1470lb)
20BT-9 795kg (1750lb)
ÂTightening torque : 184~214 kgfÂm (1330~1550lbfÂft)
Θ Battery connector
Disconnect the battery connector.
Pull with handle
Disconnect
B15T5RE18
2-11
Ι Hose
Disconnect the hoses from steering Steering hyd
motor
hydraulic motor. P
T
R
L
Steering
unit
Hose
15BT9RE25
Κ Loosen socket bolts and remove steering

Socket
hydraulic motor assy from steering axle bolt
bracket. Steering hyd
motor
Steering axle
15BT9RE26
Λ Jacking up the chassis of truck.

Loosen the hub nut and take off the
steering wheel tire assembly.
Steering
wheel
tire assy
Hub nut
20B7RE27
Μ Remove the hub cap.

Steering axle assy
Pull out split pin and remove castle nut
Bearing
and washer.
Castle nut
Split pin
Hub cap
Washer
15BT9RE28
2-12
Ν Loosen bolts and remove steering axle
assy from chassis.
Bolt
Steering axle
assy
15BT9RE29
2-13
SECTION 3 POWER TRAIN SYSTEM
GROUP 1 STRUCTURE AND OPERATION
1. DRIVE UNIT
1) STRUCTURE
(1) Drive unit assembly
3,4
9
1,2
11
12 10
14 13
21
15
23 22
9
20
10 5,6 20
16 7,8
17 18
10
19
15BT9PT01
1 Dirve unit assembly (LH) 13 Snap ring (for shaft)

2 Dirve unit assembly (RH) 14 Snap ring (for hole)
3 Housing sub assembly (LH) 15 Air breather
4 Housing sub assembly (RH) 16 Breather
5 Cover out sub assembly (LH) 17 Rubber cap
6 Cover out sub assembly (RH) 18 O-ring
7 Parking sub assembly (LH) 19 Brake plug
8 Parking sub assembly (RH) 20 Plug
9 Dowel pin 21 Magnetic plug
10 Socket bolt 22 Set screw
11 Input pinion 23 Hex nut
12 Ball bearing
3-1
(2) Housing sub assembly
9 8
6
10
5
10
1, 2
25 19
3,4 11,12,13,14
9 15
16 17
18
19
23 26
20
21
22 21
24
21
15BT9PT02
1 Housing sub assembly (LH) 15 Planetary carrier

2 Housing sub assembly (RH) 16 Lock nut
3 Housing carrier (LH) 17 Thrust washer
4 Housing carrier (RH) 18 Needle bearing
5 Oil seal 19 Planetary gear
6 Gamma seal 20 Snap ring
7 Wheel hub 21 Special bolt
8 Hub bolt 22 Back plate
9 Taper roller bearing 23 Friction disc
10 Needle bearing 24 Plate
11 Shim 25 Set screw
12 Shim 26 Thrust washer
13 Shim
14 Shim
3-2
(3) Cover out sub assembly
13
12
11
10
1, 2
9
6
5
3, 4
15BT9PT03
1 Cover out assembly (LH) 8 Ball bearing

2 Cover out assembly (RH) 9 Snap ring
3 Cover out (LH) 10 Actuator
4 Cover out (RH) 11 Return spring
5 Parallel pin 12 Sun pinion
6 Friction block 13 Socket bolt
7 Ring gear (83T)
3-3
(4) Parking sub assembly
11
1, 2
10
13
5
12
9
8
6
7
3, 4
15BT9PT04
1 Parking sub assembly (LH) 8 Quad ring

2 Parking sub assembly (RH) 9 Backup ring
3 Parking cover (LH) 10 Shaft
4 Parking cover (RH) 11 Lever
5 Piston 12 Snap ring
6 Quad ring 13 O-ring
7 Backup ring
3-4
2) SPECIFICATION
Max. output torque (wheel) NÂm 2260

Max. axle load kg/lb 2700/5953
Max. input speed rpm 5000
Gear ratio 20
Weight without fluid kg/lb 35/77
Oil quantity(ATF) ˶/U.S.Âqt 0.67/0.71
3-5
3) PRINCLPLE OF OPERATION
(1) Outline of the power transmission system
The drive units are composed of the drive unit (LH) and the drive unit (RH) which are connected
with the motor as a power transmission system to assemble the drive wheel for the battery type
fork lift.
1 2 3
15BT9PT05
1 Drive unit (LH)

2 Motor
3 Drive unit (RH)
The power of the drive motor which is received from signal of the controller transmits to the dirve
gear and the power transfered from the drive gear transmits to the drive wheel via the planetary
gear and wheel hub. As a result, it is able to drive to forward and reverse of the fork lift.
3-6
(2) Principle of the operation
Η Structure of the drive unit
5 6 4
7 8 9
15BT9PT06
1 Input pinion 6 Housing (Ring gear)

2 Ring gear 7 Sun pinion
3 Brake piston 8 Planetary carrier
4 Planetary gear 9 Wheel hub
5 Brake pack
3-7
Θ The path of the power transmission
Driving : Motor Ą Input pinion Ą Ring gear Ą Sun pinion Ą Planetary gear Ą Wheel hub
Ą Dirve wheel
Braking : Pressurization of hydraulic power through the brake port
Forwarding of the brake piston Ą Forwarding of the actuator
Ą Contact between plate and friction disc
Ą Holding back the revolution of the planetary carrier
Ą Holding back the revolution of the wheel hub Ą Holding back of the driving
Braking method
- Service brake (Hydraulic)
- Parking brake (Lever)
Driving
Braking
15BT9PT07
3-8
GROUP 2 TROUBLESHOOTING
Problem Cause Remedy

1. Consecutive noise in the ÂLack of oil ÂRefill the oil
housing ÂIncorrect contact between planetary ÂDisassemble, check and readjusting
gear and driving gear
ÂDamage, wear planetary gear and ÂReplace damaged or wear gear
driving gear
ÂLoosened or worn wheel hub bearing ÂDisassemble, check and readjusting
or replace the components
2. Abnormal noise during ÂExcessive back lash the driving gear ÂReplace the driving gear and the
rotation and planetary gear planetary gear
ÂDamage, worn of the gear ÂReplace the gear
ÂDamage, worn of the bearing ÂDisassemble, check and readjusting
or replace the bearing
3. Oil leakage ÂOverfill to the specified level ÂReadjust oil level
ÂPluged air breather ÂClean or replace the air breather
ÂDamage, worn, poor assembly for oil ÂReplace oil seal
seal of wheel hub
ÂPoor assembly of the drain plug ÂDisassemble, check and readjusting
ÂDamage O-ring for motor connection ÂReplace the O-ring
4. No rotation of the drive ÂBreakage, deformation the shaft ÂReplace the shaft
wheel ÂDamage, breakgae the gear ÂReplace the gear
ÂDamage, breakgae the bearing ÂReplace the bearing
5. Brake
No operation the brake ÂDamage, deformation the friction disc ÂDisassemble, check, replace
or plate
No smooth operation the ÂDamage, deformation the friction disc ÂDisassemble, check, replace
brake pedal of the brake
No release the brake ÂDefect the brake disc assembly ÂDisassemble, check, replace
Frequent refilling the ÂLeakage from the piston seal ÂDisassemble the piston seal and
brake oil replace it
Available braking when ÂExcessive clearance of the discs due ÂAdjust the stroke of the brake pedal
depressing the brake to wear of the friction disc for ÂDisassemble the brake pack, check
pedal with maximum operation and replace it
ÂReadjust the stroke of the piston
3-9
GROUP 3 DISASSEMBLY AND ASSEMBLY
1. DISASSEMBLY
Drain oil from transmission before removal of the drive unit. Loosen and remove the wheel nuts as
well as take off the drive wheel. For further work on the drive motor of the drive unit see chapter.
1) REMOVAL OF THE DRIVE UNIT
(1) Removal of Drive unit. (refer to see page 2-8)
Drive motor
Tire & rim assy
Drive unit
Hub nut
15BT9PT10
2) REMOVAL OF THE DRIVE MOTOR

(1) Drive motor and accessories mounted to Drive motor
the drive motor have to be disconnected.
(2) Take off cautiously the drive motor from Drive unit
the drive unit.
Bolt
Do not damage the teeth of the
motor pinion and the spur gear.
Damages can cause louder running
noises.
ö In case of an inadequate removal of the 15BT9RE17
drive motor from the drive unit there is

danger to damage the sealing surface for
the O-ring in the housing.
If only the drive motor is removed, the
released drive unit opening is to be sealed
in order to avoid that dirt can get inside the
drive unit.
3-10
2. GENERAL INSTRUCTIONS FOR CORRECT DISASSEMBLY AND REASSEMBLY
Cleanliness is essential for a correct work.
Drive unit removed from the vehicle have to be cleaned prior to opening.
Special care and cleanliness are essential for a correct disassembly and reassembly of the unit as well
as for the installation of each spare part. A fault during installation can result in an early wear and
chips as well as foreign particles in the unit could cause fatal damage in the drive unit.
Prior to reassembly all parts must be cleaned and inspected for wear and other defects.
It would be a false economy to reinstall parts which are not in a perfect condition.
All parts have to be oiled carefully during reassembly. Apply a sealing compound onto housing-and
cover faces, which must be tight towards the outside.
For heating of bearings etc. use heating plates, heating elements or heating furnaces.
Never heat directly with an open flame.
This avoids damage to the bearings.
If not otherwise indicated heat ball bearings, gears, flanges etc. to approx. 90-100Á
C.
Á
Parts which have been mounted in a warm condition must be subsequently installed after cooling
down to ensure a perfect contact.
Lubricate both parts before shafts, bearings etc. are pressed into position.
For reassembly all of the indicated setting values, test data and tightening torques must be observed.
HYUNDAI-units will be filled with oil after repair work.
ö The following description of disassembly and reassembly serves to inform both the after-sales
service centers of HYUNDAI and of the vehicle manufacturer, where adequate workshop facilities
and trained specialists are present.
3-11
3. DISASSEMBLY OF THE DRIVE UNIT
1) Disassembly of the drive unit assy.

ö Always keeps clean working area when
disassebling the drive unit.
15BT9DU001
2) Drain out oil in the drive unit assy by

removing the magnetic plug.
15BT9DU002
3) Disassemble the external components of

the drive unit assy.
Disassemble brake plug, breather, cap, set
screw and nut form the drive unit assy.
ö The components stock to the proper place
and they should be replaced with new O-
ring when reassembling.
15BT9DU003
3-12
4) Loosen 6-socket bolts which are fixing for
the parking sub assy.
15BT9DU004
5) Disassemble the parking sub assy.
15BT9DU005
6) Disassemble the piston sub assy after

pushing away the lever of the parking sub
assy.
15BT9DU006
7) Remove the quad ring and back up ring

from the piston sub assy.
15BT9DU007
3-13
8) Remove the O-ring from the parking sub
assy.
15BT9DU008
9) Disassemble the snap rings, lever, and

shaft from the parking sub assy.
15BT9DU009
10) Loosen the socket bolts (8EA) from the

dirve unit assy.
15BT9DU010
11) Disassemble the cover out sub assy from

the housing sub assy.
15BT9DU011
3-14
12) Remove the snap ring from the housing
sub assy.
15BT9DU012
13) Disassemble the input pinion assembly

from the housing sub assembly.
15BT9DU013
DISASSEMBLY OF THE COVER OUT SUB ASSY

14) Cover out sub assy.
15BT9DU014
15) Loosen the socket bolts (6EA) from the

cover out sub assy.
15BT9DU015
3-15
16) Disassemble the sun pinion and return
springs (3EA) from the cover out sub assy.
15BT9DU016
17) Disassemble the actuator from the cover

out sub assy.
15BT9DU017
18) Remove the snap ring from the cover out

sub assy.
15BT9DU018
19) Disassemble the ring gear from the cover

out sub assy.
15BT9DU019
3-16
20) Remove the bearing form the ring gear.
15BT9DU020
21) Remove the friction block and the parallel

pin from the cover out sub assy.
15BT9DU021
DISASSEMBLY OF THE HOUSING SUB ASSY

22) Housing sub assy.
15BT9DU022
23) Loosen the special bolts (3EA) from the

housing sub assy.
15BT9DU023
3-17
24) Disassemble the friction disc (3EA), plates
(2EA), back plate (1EA).
15BT9DU024
25) Remove the snap rings (3EA) from the

housing sub assy.
15BT9DU025
26) Remove the thrust washers (3EA) from the

housing sub assy.
15BT9DU026
27) Disassemble the planetary gears (3EA)

from the housing sub assy.
15BT9DU027
3-18
28) Remove the thrust washers (3EA), the
needle bearings (3EA) from the housing
sub assy.
15BT9DU028
29) Remove the set screw from the housing

sub assy.
15BT9DU029
30) Remove the lock nut from the housing sub

assy.
ö When removing the lock nut from the
housing sub assy, it should be used the
special tool.
15BT9DU030
31) Disassemble the planetary carrier and

bearing cone from the housing sub assy.
15BT9DU031
3-19
32) Remove the bearing cap from the housing
sub assy.
15BT9DU032
33) Remove the shims from the housing sub

assy.
ö If the bearings are not replaced with new
one, take care to safe keep the shims to
the proper place.
15BT9DU033
34) Disassemble the wheel hub sub assy from

the housing sub assy.
15BT9DU034
35) Remove the Gamma seal from the

housing carrier.
15BT9DU035
3-20
36) Remove the bearing cup from the housing
carrier.
15BT9DU036
37) Remove the oil seal from the housing

carrier.
15BT9DU037
3-21
4. ASSEMBLY OF THE DRIVE UNIT
1) ASSEMBLY OF THE HOUSING SUB ASSY
(1) Assembly of the parking sub assy.
15BT9DU038
(2) Assemble the shaft to the parking cover.
15BT9DU039
(3) Assemble the snap rings (3EA) to the

shaft.
15BT9DU040
3-22
(4) Assemble the parking lever to the shaft
and fix with snap ring.
ö Be sure that the marking
on the parking lever gets
into inline to the marking
on the shaft (Refer to
VIEW "A")
15BT9DU041
(5) Assemble the O-ring to the parking cover.

ö Apply oil on the O-ring surface prior to
assembling.
15BT9DU043
(6) Assemble the backup ring and the quad

ring.
ö Apply oil on the quad ring surface before
assembling and check the twisting for
quad ring after assembling.
15BT9DU044
(7) Assemble the piston to the parking sub

assy.
15BT9DU045
3-23
(8) Completion of assembly of the parking
sub assy.
15BT9DU046
2) ASSEMBLY OF THE COVER OUT SUB ASSY
(1) Assemble the friction block after inserting

the parallel pin.
ö When assembling the friction block, take
care to the direction of assembling of it.
Refer to the follwing
figure for the location
of the lubrication hole.
15BT9DU047
(2) Assemble the ball bearing to the ring gear.
15BT9DU049
3-24
(3) Assemble the ring gear to the cover out
assy.
15BT9DU050
(4) Assemble the snap ring to the cover out

assy.
15BT9DU051
(5) Assemble the actuator to the cover out

assy.
15BT9DU052
(6) Assemble the sun pinion after assembling

the return springs (3EA).
15BT9DU053
3-25
(7) Assemble the bolts (6EA) to the sun
pinion.
ÂTightening torque : 3.5~3.8 kgfÂm
ö Apply the Loctite #277 on the thread of the
bolts.
When assembling the
bolts, it should be fixed
the ring gear using the
filter wrench.
15BT9DU054
3) ASSEMBLY OF THE HOUSING SUB ASSY
15BT9DU056
(1) Assemble the oil seal in the housing sub

assy.
ö When assembling the oil seal to the
special tool.
ÂInner race : Apply with grease
ÂOuter race : Apply with Loctite #592
15BT9DU057
3-26
(2) Assemble the bearing cup in the housing
sub assy.
ö When assembling the bearing cup, it
should be used the special tool.
15BT9DU058
(3) Assemble the Gamma seal in the housing

sub assy.
ö When assembling the Gamma seal in the
special tool.
ÂSeal : Apply with grease
ÂCompression area (steel) : Apply with
Loctite #609
15BT9DU059
(4) Assemble the wheel hub sub to the

housing carrier.
15BT9DU060
(5) Assemble the shims to the housing carrier.
15BT9DU061
3-27
MEASURING METHOD OF THE REQUIRING SHIMS.
15BT9DU062
A : Distance from the assembly surface of the housing to the assembly surface of the shims.
B : Distance from the assembly surface of the housing to the assembly surface of the planetary carrier
of the wheel hub.
C : Distance to the bottom surface of the planetary carrier and the bearing cup.
ÂRequiring shims = A - (B - C) + 0.03
(6) Assemble the bearing cup in the housing

carrier.
ö It should be used the special tool when
assembling the bearing cup in the housing
carrier.
15BT9DU063
3-28
(7) Assemble the planetary carrier and
bearing cone in the housing carrier.
15BT9DU064
(8) Assemble the lock nut in the housing

carrier.
ö Apply with Loctite #277 after removing the
oil and the foreign material on the thread
of the bolts.
ÂTightening torque : 25~28 kgfÂm
ÂPreload : 0.4~0.5 kgfÂm
15BT9DU065
ö If it is not gotten the specified free load,

rework repeatedly according as (5)~(8)
procedure and it should be set with the
specifed preload as an adding or
removing the shims properly.
15BT9DU066
(9) Assemble the set screw to the housing

carrier.
ÂApply with Loctite #242
ö Take care to confirm the
assembly location. (Refer
to the right figure)
15BT9DU067
3-29
(10) Assemble the components according as
the following sequence.
Thrust washer 1 Ą Needle bearing
Ą Planetary gear Ą Thrust washer 2
ö Apply with oil to the roller area of the
needle bearing
ö Take care to observe the assembly
sequence of the thrust washers.
15BT9DU069
15BT9DU070
(11) Assemble the snap rings (3EA) in the

housing carrier.
15BT9DU071
(12) Assemble the components according as

the following sequence.
Back plate Ą (Friction plate Ą plate)Ý2
Ą Friction plate
15BT9DU072
3-30
(13) Assemble the special bolts (3EA) to the
housing carrier.
ö Apply with Loctite #242 on the thread of
the special bolts.
15BT9DU073
(14) Assemble the cover out sub to the

housing carrier.
ö Apply with Loctite #5127 on the surface of
the assembly.
15BT9DU074
(15) Assemble the socket bolts (8EA) to the

housing carrier.
the socket bolts.
15BT9DU075
(16) Assemble the input pinion in the housing

carrier.
15BT9DU076
3-31
(17) Assemble the snap ring to the housing
carrier.
15BT9DU077
(18) Assemble the parking cover sub to the

housing carrier.
15BT9DU078
(19) Assemble the bolts (6EA) to the housing

carrier.
the bolts.
15BT9DU079
(20) Assemble the brake plug, O-ring, air

breather, and cap to the housing carrier.
ö Apply with oil on the O-ring surface.
15BT9DU080
3-32
(21) Assemble the set screw and hex nut to
the housing carrier.
15BT9DU081
(22) SETTING OF THE PISTON STROKE (1mm)

Η Retain the space between the piston and
the lever by pouring the hydraulic
pressure or air pressure into the brake
plug.
Θ Insert 1mm thickness plate between lever
and piston.
Ι Tighten the set screw which is
assembled to the lever with maximum. 15BT9DU082
Κ After the set screw is rotated with 2

revolution to counterclockwise, remove
1mm thickness plate.
Λ Tighten the set screw with 2 revolution to
clockwise.
Μ Assemble the hex nut after completion of
the setting for the piston stroke.
15BT9DU083
(23) Assemble the air breather and plug to the

housing carrier.
- Air breather
Tightening torque : 3.0~4.1 kgfÂm
- Plug
Tightening torque : 3.0~4.1 kgfÂm
Apply with Loctite #577
15BT9DU084
3-33
SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
There are two brake systems, the service brake system and the parking brake system.
In the service brake system, oil pressure is generated in the master cylinder by treading on the brake
pedal. This pressure causes the brake lever to press the pressure pin which gives braking pressure to
the disk carrier.
In the parking brake system, the brake lever is operated by cable. Therefore the pressure pin makes
braking pressure onto the disk carrier.
2. SPECIFICATION
1) BRAKE
Brake type - Wet disc brake

Brake fluid - Hydraulic oil SAE10W (AZOLA Z10)
Max. brake torque NÂm (at 60bar) 2450
Max. braking pressure bar 140
Oil volume (Never use disc) cc 1.6
2) PARKING BRAKE
Item Specification
Type Ratchet, internal expanding mechanical type

Parking lever stroke (Ħ) 18.6
Parking cable stroke 60mm
4-1
3. BRAKE PEDAL AND PIPING
Drive line
assembly(RH)
Drive line
assembly(LH)
15BT9BS01
1 Brake pedal & bracket assy 3 Reservoir tank assy

2 Parking lever assy 4 Brake master cylinder
4-2
4. BRAKE MASTER CYLINDER
1) STRUCTURE
9
14
15
16
15
10
6
5
4
2
13
11
12
20B7BS03
1 Body 7 Spring 13 Plate

2 Secondary cup 8 Check valve assembly 14 Cap
3 Piston 9 Union bolt 15 Gasket
4 Spacer 10 Cap 16 Union
5 Primary cup 11 Retaining ring
6 Spring seat 12 Boot
4-3
2) DISASSEMBLY AND ASSEMBLY
(1) Remove the boot(12).
(2) Take out the retaining ring(11) and plate(13).
(3) Take out the piston(3), secondary cup(2), spacer(4), primary cup(5), spring seat(6), spring(7) and
check valve assembly(8) from cylinder.
(4) Perform assembly in reverse order of disassembly and add special working.
ÂBody and metallic parts should be washed and cleaned with petroleum solvents then dry the
parts by air. Rubber parts should be washed with brake oil.
ÂCoat the rubber grease inner surface of cylinder.
2) INSPECTION
(1) Cylinder
Check the corrosion and pitching of inner surface of cylinder.
If any defects are noted, replace the parts.
(2) Piston
Check for wear of piston, replace the piston if necessary.
Item Standard gap Allowable limit
Gap of cylinder and piston 0.020~0.080mm 0.2mm
(3) Rubber parts

Check for wear of secondary cup and primary cup and replace them with new ones if necessary.
4-4
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
1) BRAKE PIPING
(1) Check pipes, hoses and joints for damage, oil leakage or interference.
(2) 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.
2) BRAKING FORCE
(1) Select a dry, flat, paved surface and, drive truck at maximum speed. When signal is given, stop
truck immediately and measure distance from point where signal was given to point where truck
stopped(unloaded)
ÂStopping distance : Within 5m(16' 5")
(2) Check that there is no pulling of steering wheel, pulling by brakes to one side or abnormal noise
when making emergency stops.
3) PARKING BRAKE
(1) Operating force of parking lever is 20 - 30
kgfÂm(144 - 217lbfÂft).
(2) Check that parking brake can hold Release
machine in position when loaded on 15%
slope. If there is no slope available, travel Lock
at low speed and check braking effect of
parking brake.
15BT9BS04
4-5
2. TROUBLESHOOTING
Brakes do not work ÂOil leakage in the system or oil to low ÂRepair oil leakage. After bleeding fill
low in tank. fill oil tank of master cylinder to speci-
fied level with brake oil.
ÂAir trapped in the system. ÂBleed air completely from the brake
lever.
ÂWorn out of deteriorated piston cup in ÂInspect cylinder and piston for degree
master cylinder resulting in oil leakage of wear. On satisfactory, replace cup.
Brake pedal travel too large ÂAir trapped in the system. ÂBleed air completely out.
ÂInspect oil tube joints & connections
and replace leaking parts.
Wheel feel heavy ÂReturn port in master cylinder closed ÂInspect master cylinder.
by piston cup. ÂRepair or replace pedal return spring.
4-6
GROUP 3 ADJUSTMENTS
1. ADJUSTMENT OF PEDAL
1) BRAKE PEDAL
(1) Pedal height from floor plate adjust with
stopper bolt.
140~145mm
ÂPedal height : 140~145mm (5.5~5.7in)
(2) Play
Adjust with rod of mast cylinder.
ÂPedal play : 4~6mm (0.16~0.23in) Floor plate
15BT9BS09
4-7
SECTION 5 STEERING SYSTEM
1. OUTLINE
Steering wheel
Steering motor
Steering axle
T
L Steering unit
P
R LS
Priority valve
Hyd tank
Hyd gear pump
Hyd tank
15BT9SS01
The steering system for this truck is composed of steering wheel assembly, steering unit, steering motor,
steering axle and pipings. The 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 pump is fed to the steering motor.
5-1
2. HYDRAULIC CIRCUIT
15BT9SS26
1 Hydraulic gear pump 8 Suction strainer

2 Priority valve 9 Return filter
4 Steering unit 12 Hydraulic tank
5 Hydraulic motor
5-2
(1) NEUTRAL
15BT9SS04
The steering wheel is not being operated so control spool(G) does not move.
The oil from hydraulic tank(12) enters hydraulic gear pump(1) and pressurized so that the oil flows into
the inlet port(P) of steering unit(4).
Oil flows out of T port to the hydraulic tank(12).
5-3
(2) LEFT TURN
15BT9SS06
When the steering wheel is turned to the left, the spool(G) within the steering unit(4) connected with
steering column turns in left hand direction.
At this time, the oil discharged from hydraulic gear pump(1) flows into the spool(G) of the steering unit(4)
through the inlet port(P) and flows to gerotor(H).
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 hydraulic motor(5) returns to hydraulic tank(12).
When the above operation is completed, the machine turns to the left.
5-4
(3) RIGHT TURN
15BT9SS08
When the steering wheel is turned to the right, the spool(G) within the steering unit(4) connected with
steering column turn in right hand direction.
At this time, the oil discharged from hydraulic gear pump(1) flows into the spool(G) of the steering unit(4)
through the inlet port(P) and flows to gerotor(H).
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 hydraulic motor(5) returns to hydraulic tank(12).
When the above operation is completed, the machine turns to the right.
5-5
3. STEERING UNIT
1) STRUCTURE
23-1
25-2
23-3 25-1
1 20
23-2
23-4
23-5
23-6 2
17
24-4 24-3 3
24-2 10
24-1 5 13
14 4
13
21
6
22
15
27
7
9 27
18
9
12
9 19
26
16
11
20B7SS09
1 Dust seal 14 Bore screw 23-4 Spring

2 Retaining ring 15 Drive shaft 23-5 Spool
3 Cap seal 16 End cap 23-6 Bushing
4 Thrust bearing 17 Bushing 24 P-port check valve
5 Ball 18 Plate 24-1 Plug
6 Pin 19 Cap screw 24-2 Poppet
7 Center spring 20 Housing 24-3 Spring seat
8 Washer 21 Spool 24-4 Spring
9 O-ring 22 Sleeve 25 Suction valve
10 O-ring 23 Relief valve 25-1 Roll pin
11 Rolled screw 23-1 Plug 25-2 Ball
12 Gerotor set 23-2 O-ring 26 Spacer
13 Bearing race 23-3 Spring seat 27 Plate spring
5-6
2) OPERATION
The steering unit is composed of the control valve(rotary valve) and the metering device. The control
valve controls the flow of oil from the pump in the interior of the unit depending on the condition of the
steering wheel. The metering device is a kind of hydraulic motor composed of a stator and a rotor. It
meters the required oil volume, feeds the metered oil to the power cylinder and detects cylinder’s
motion value, that is, cylinder’s motion rate.
When the steering wheel is turned, the spool turns, the oil path is switched and the oil is fed into the
metering device. As a result, the rotor is caused 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 very rapidly when the key switch is ON. Keep clear of the steering wheel when the
key switch is ON.
The centering spring for the spool and sleeve is provided to cause the valve to return to the neutral
position. It is therefore possible to obtain a constant steering feeling, which is transmitted to the hands
of the driver. Return to the center position occurs when the steering wheel is released.
5-7
4. STEERING AXLE
1) STRUCTURE
STEERING SENSOR
9
10
14
15
4
13
8 11
12
1-14
STEERING
1-4 HYD MOTOR
2
3 5
1-2
1-15
1-3
6
1-5
7
4
1-6
1-7 1-12
1-9
1-1
1-8
1-10
1-11
1-13
20B7SS10
1-1 Steering axle 1-11 Split pin 7 Bolt-w/washer

1-2 Bracket 1-12 Hub bolt 8 Lever
1-3 Taper roller bearing 1-13 Hub cap 9 Hexagon bolt
1-4 Taper roller bearing 1-14 Steering gear assy 10 Spring washer
1-5 Oil seal 1-15 Bearing 11 Plain washer
1-6 Oil seal 2 Hexagon bolt 12 Hexagon nut
1-7 Taper roller bearing 3 Spring washer 13 Bracket
1-8 Taper roller bearing 4 Spring pin 14 Socket bolt
1-9 Steering axle hub 5 Pinion 15 Spring washer
1-10 Plain washer 6 Special washer
5-8
2) TIGHTENING TORQUE AND SPECIFICATION
rn(90 )
Right tu
De
B
fa
u lt
A
(6 0
.5
A
)
B
Le
ft t
urn SECTION B - B
(90
)
9~12kgf.m
(65~87lbf.ft)
Apply loctite #277.
14~18kgf.m
(101~130lbf.ft)
Apply loctite #277.
2~3kgf.m
(15~22lbf.ft)
SECTION A - A
20B7SS11
5-9
Check item Checking procedure
Steering wheel Â 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.
(1.2-2.4 in)
Range should be 30~60mm at rim of steering wheel. If play is too large, adjust
at gear box.
Test steering wheel play with forklift stopped.
Knuckle Â Check knuckle visually or use crack detection method. If the knuckle is bent, the
tire wear is uneven, so check tire wear.
Steering axle Â Ask assistant to drive machine at minimum turning radius.
Â Fit bar and a piece of chalk at outside edge of counterweight to mark line of
turning radius.
Â Min turning radius(Outside) : Refer to page 1-5 (Specifications)
Hydraulic pressure of power Remove cap from check port of priority valve and install oil pressure gauge.
steering Turn steering wheel fully and check oil pressure.
ö Oil pressure : 120 kgf/cm2 (1710 psi)
2. TROUBLESHOOTING
1) STEERING SYSTEM
Steering wheel drags. ÂLow oil pressure. ÂCheck lockout. Repair.
ÂBearing faulty. ÂClean or replace.
ÂSpring spool faulty. ÂClean or replace.
ÂReaction plunger faulty. ÂReplace.
ÂBall-and-screw assembly faulty. ÂClean or replace.
ÂSector shaft adjusting screw excessi- ÂAdjust.
vely tight.
ÂGears poorly meshing. ÂCheck and correct meshing.
ÂFlow divider coil spring fatigued. ÂReplace.
Steering wheel fails to return ÂBearing faulty. ÂClean or replace.
smoothly. ÂReaction plunger faulty. ÂReplace.
ÂBall-and-screw assy faulty ÂClean or replace.
ÂGears poorly meshing. ÂCheck and correct meshing.
5-10
Steering wheel turns unstea- ÂLockout loosening. ÂRetighten.
dily. ÂMetal spring deteriorated. ÂReplace.
Steering system makes abn- ÂGear backlash out of adjustment. ÂAdjust.
ormal sound or vibration. ÂLockout loosening. ÂRetighten.
ÂAir in oil circuit. ÂBleed air.
Abnormal sound heard when Valve
steering wheel is turned fully ÂFaulty. (Valve fails to open.) ÂAdjust valve set pressure and check
for specified oil pressure.
Piping
ÂPipe(from pump to power steering ÂRepair or replace.
cylinder) dented or clogged.
Piping makes abnormal Oil pump
sounds. ÂLack of oil. ÂAdd oil.
ÂOil inlet pipe sucks air. ÂRepair.
ÂInsufficient air bleeding. ÂBleed air completely.
Valve or valve unit makes Oil pump
abnormal sounds. ÂOil inlet pipe sucks air. ÂRepair or replace.
Valve
ÂFaulty. (Unbalance oil pressure) ÂAdjust valve set pressure and check
specified oil pressure.
Piping
ÂPipe(from pump to power steering) ÂRepair or replace.
dented or clogged.
ÂInsufficient air bleeding. ÂBleed air completely.
Insufficient or variable oil flow. ÂFlow control valve orifice clogged. ÂClean
Insufficient or variable dischar- Piping
ge pressure. ÂPipe(from tank to pipe) dented or ÂRepair or replace.
clogged.
Steering cylinder head ÂPacking foreign material. ÂReplace
leakage (Piston rod) ÂPiston rod damage. ÂGrind surface with oil stone.
ÂRod seal damage and distortion. ÂReplace
ÂChrome gilding damage. ÂGrind
Steering cylinder head thread ÂO-ring damage. ÂReplace
(A little bit leak is no problem)
Welding leakage ÂCylinder tube damage. ÂTube replace.
Rod ÂTube inside damage. ÂGrind surface with oil store.
ÂPiston seal damage and distortion ÂReplace
Piston rod bushing inner ÂBushing wear. ÂReplace
diameter excessive gap
5-11
2) POWER STEERING UNIT

Oil leakage ÂFittings loose, worn, or damaged. ÂCheck and replace the damaged
parts.
ÂDeteriorated seals by excessive heat. ÂReplace the seals.
ÂLoose screw or its deteriorated ÂReplace the sealing and tighten
sealing. screw appropriately.
ÂInternal seals worn or damaged. ÂReplace it.
ÂDamaged seal grooves. ÂReplace the unit or related parts.
ÂHousing crack. ÂReplace the unit.
Noise or vibration ÂAir inclusion in the system. ÂBleed the air.
ÂValve timing error when the unit is ÂCorrect the timing.
assembled.
ÂHydraulic pipe noise interference. ÂConsult the component manufacturer.
ÂControl valve damage or clogging. ÂReplace the valve.
Heavy steering operation ÂLack of sufficient oil supply. ÂCheck the pump and the line.
ÂExcessive heat. ÂLocate the heat source and correct it.
ÂBroken pump. ÂReplace it.
ÂLeakage in the line or connections. ÂReplace it.
ÂClogged orifice. ÂDisassemble, clean, and reassemble
it.
ÂHigh back pressure. ÂAdjust the pressure.
Irregular or no response ÂBroken pump. ÂReplace it.
ÂExcessive heat. ÂLocate the heat source and remove it.
ÂBroken centering spring. ÂReplace it.
ÂMisalignment with column. ÂDisassemble and adjust it.
ÂIncorrect piping to the four port. ÂCorrect it.
ÂParts missing. ÂInstall the parts correctly.
ÂHigh back pressure. ÂAdjust the pressure.
ÂCorrosion on the moving parts. ÂReplace it.
5-12
1. STEERING UNIT
1) STRUCTURE
23-1
25-2
23-3 25-1
1 20
23-2
23-4
23-5
23-6 2
17
24-4 24-3 3
24-2 10
24-1 5 13
14 4
13
21
6
22
15
27
7
9 27
18
9
12
9 19
26
16
11
20B7SS09
1 Dust seal 14 Bore screw 23-4 Spring

2 Retaining ring 15 Drive shaft 23-5 Spool
3 Cap seal 16 End cap 23-6 Bushing
4 Thrust bearing 17 Bushing 24 P-port check valve
5 Ball 18 Plate 24-1 Plug
6 Pin 19 Cap screw 24-2 Poppet
7 Center spring 20 Housing 24-3 Spring seat
8 Washer 21 Spool 24-4 Spring
9 O-ring 22 Sleeve 25 Suction valve
10 O-ring 23 Relief valve 25-1 Roll pin
11 Rolled screw 23-1 Plug 25-2 Ball
12 Gerotor set 23-2 O-ring 26 Spacer
13 Bearing race 23-3 Spring seat 27 Plate spring
5-13
2) TOOLS
(1) Holding tool.
5-69(1)
(2) Assembly tool for O-ring and kin-ring.
5-69(2)
(3) Assembly tool for lip seal.
5-69(3)
(4) Assembly tool for cardan shaft.
5-69(4)
5-14
(5) Assembly tool for dust seal.
5-70(1)
(6) Torque wrench 0~7.1kgfÂm

(0~54.4lbfÂft)
13mm socket spanner
6, 8mm and 12mm hexagon sockets
12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon socket spanners
Plastic hammer
Tweezers 5-70(2)
3) TIGHTENING TORQUE
L : Left port
R : Right port
T : Tank
P : Pump
D353SE23
Port Size Torque [kgfÂm(lbfÂft)]

L 3/4 UNF - 16 6.1 Ü0.6 (44.1Ü4.3)
R 3/4 UNF - 16 6.1 Ü0.6 (44.1Ü4.3)
T 3/4 UNF - 16 6.1 Ü0.6 (44.1Ü4.3)
P 3/4 UNF - 16 6.1 Ü0.6 (44.1Ü4.3)
Mounting bolt M10Ý1.5 5 Ü1 (36Ü7.2)
5-15
4) DISASSEMBLY
(1) 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)
(2) Remove the end cover, sideways.
5-72(2)
(3) Lift the gearwheel set(With spacer if fitted)

off the unit.
Take out the two O-rings.
5-72(3)
(4) Remove cardan shaft.
5-72(4)
5-16
(5) Remove distributor plate.
5-73(1)
(6) Screw out the threaded bush over the

check valve.
5-73(2)
(7) Remove O-ring.
5-73(3)
(8) Shake out the check valve ball.
B20H7SS09
5-17
(9) 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.
5-73(4)
(10) Take ring, bearing races and thrust

bearing from sleeve and spool. The outer
(Thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.
5-74(1)
(11) Press out the cross pin. Use the special

screw from the end cover.
5-74(2)
ö A small mark has been made with a

pumice stone on both 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.
5-74(3)
5-18
(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.
Remove seal washers.
D353SE10
5-19
(16) Unscrew the setting screw using an 8mm
hexagon socket spanner.
D353SE11
(17) Shake out spring and piston. The valve

seat is bonded into the housing and cannot
be removed.
D353SE12
(18) The pressure relief valve is now disassem-

bled.
D353SE13
5-20
5) ASSEMBLY
(1) Assemble spool and sleeve.
ö 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.
Place the slots and holes opposite each 5-76(1)
other so that parts of the holes in the
sleeve are visible through the slots in the
spool.
(2) 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).
5-76(2)
(3) Line up the spring set.
5-76(4)
(4) Guide the spool into the sleeve. Make

sure that spool and sleeve are placed
correctly in relation to each other.
5-77(1)
5-21
(5) Press the springs together and push the
neutral position springs into place in the
sleeve.
5-77(2)
(6) Line up the springs and center them.
5-77(3)
(7) Guide the ring down over the sleeve.

ö The ring should be able to rotate free of
the springs.
5-77(4)
(8) Fit the cross pin into the spool / sleeve.
5-78(1)
5-22
(9) Fit bearing races and needle bearing as
shown on below drawing.
5-78(2)
ö Assembly pattern for standard

1
bearings
2
1 Outer bearing race 3
2 Thrust bearing
3 Inner bearing race
4 Spool 4
5 Sleeve
5
5-78(3)
Installation instruction for O-ring

(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
5-78(4)
5-23
(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.
5-79(3)
(13) Press and turn the O-ring into position in

the housing.
5-79(4)
5-24
(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.
5-80(2)
5-80(3)
(16) Guide the assembly tool right to the

bottom.
5-80(4)
5-25
(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.
ö Fit the spool set holding the cross pin
horizontal.
5-81(2)
(19) The spool set will push out the assembly

tool guide.
The O-ring are now in position.
5-81(3)
(20) Turn the steering unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.
5-81(4)
5-26
(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 20ä
C.
5-82(2)
(23) Place the distributor plate so that the

channel holes match the holes in the
housing.
5-82(3)
(24) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.
5-82(4)
5-27
(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 20ä C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
5-83(2)
(27) Important
Fit the gearwheel(Rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
5-83(3)
(28) Fit the spacer, if any.
5-83(4)
5-28
(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.
ÂTightening torque : 4.0Ü0.5kgfÂm
(28.9Ü3.6lbfÂft)
5-84(3)
(32) Place the dust seal ring in the housing.
5-84(4)
5-29
(33) Fit the dust seal ring in the housing.
5-85(1)
(34) Press the plastic plugs into the connection

ports.
ö Do not use a hammer.
5-85(2)
5-30
2. STEERING AXLE
1) STRUCTURE
STEERING SENSOR
9
10
14
15
4
13
8 11
12
1-14
STEERING
1-4 HYD MOTOR
2
3 5
1-2
1-15
1-3
6
1-5
7
4
1-6
1-7 1-12
1-9
1-1
1-8
1-10
1-11
1-13
20B7SS10
1-1 Steering axle 1-11 Split pin 7 Bolt-w/washer

1-2 Bracket 1-12 Hub bolt 8 Lever
1-3 Taper roller bearing 1-13 Hub cap 9 Hexagon bolt
1-4 Taper roller bearing 1-14 Steering gear assy 10 Spring washer
1-5 Oil seal 1-15 Bearing 11 Plain washer
1-6 Oil seal 2 Hexagon bolt 12 Hexagon nut
1-7 Taper roller bearing 3 Spring washer 13 Bracket
1-8 Taper roller bearing 4 Spring pin 14 Socket bolt
1-9 Steering axle hub 5 Pinion 15 Spring washer
1-10 Plain washer 6 Special washer
5-31
2) CHECK AND INSPECTION
Apply grease on the surface of

seal lip when assembling.
Fill 70% of the space in the
bracket with lithium grease.
20B7SS15
Η Check for any bend or twist. Slight bend or twist can be straightened by press, however, if not,
replace the axle.
Θ Make visual check for cracks or other defects, also check the condition of fit of bearings.
Ι Check play of axle and sleeve bearing of bracket.

Replace the bracket if the play is excessive.
5-32
3) DISASSEMBLY
Socket bolt
Steering motor Steering
hyd motor
ö Before dismounting steering motor
disconnect all hydraulic pipes from the
steering motor.
Η Loosen socket bolts connecting motor
with axle.
Steering axle
assembly
20B7SS16
Motor bracket
Η Remove motor bracket with steering Steering sensor
sensor.
Motor bracket
Lever
Spring pin
Steering axle
assembly
20B7SS17
Steering gears
Η Remove castle nut and pull out steering
gear. Castle nut Split pin
Θ By loosening hexagon bolt pull out pinion

gear from axle bracket. Steering gear
Pinion gear
Axle bracket
Steering axle
assembly
Special
washer
Hex bolt
20B7SS18
5-33
Axle bracket
Η Take off the axle bracket together with the
bearing. Be very careful because just
before the axle bracket comes off, Axle bracket
tapered roller bearing will fall out.

Taper roller
Θ After axle bracket is removed take off the bearing
inner race of bearing. Oil seal
Ι Pull out oil seal. Don't use same oil seal
twice.
Steering axle
assembly
20B7SS19
Hub
Η Pull out split pin and remove castle nut
and washer.
Θ Take off the wheel hub together with the
bearing. Be very careful because just
before the hub comes off, tapered roller
bearing will fall out.
Ι After wheel hub is removed take off the Oil seal
inner race of bearing. Hub
Κ Pull out oil seal. Don't use same oil seal
Washer
twice. Split pin
Taper roller bearing
Castle nut
Hub cap
20B7SS20
5-34
4) ASSEMBLY
In reassembling, have all parts washed,
grease applied to lubricating parts, and all
expendable items such as oil seal and
spring washers replaced by new ones.
Perform the disassembly in reverse order.
Wheel hub
Η Mount oil seal and inner race of tapered
roller bearing on the axle beam.
The bearing should be well greased
before assembling.
Θ Install the outer race of bearing in the
wheel center and assemble to the axle
beam.
Ι Put washer in place, tighten with nut and Oil seal
lock with split pin, in locking with split pin, Hub
locate the hole for the split pin by turning
Washer
the nut back 1/6 of a turn. Adjust the Split pin
preload of bearing.
ÂBearing preload : Taper roller bearing
0.30 ~ 0.35kgfÂm (0.20 ~ 0.25lbfÂft) Castle nut
Κ Mount the hub cap. Bearing should be Hub cap
well greased before assembling.
20B7SS20
Axle bracket
Η Mount oil seal and inner race of tapered
roller bearing on the axle beam. The
Axle bracket
bearing should be well greased before
assembling. Taper roller
Θ Install the outer race of the bearing in the bearing
axle bracket center and assemble the Oil seal
axle beam.
Ι Put gear and washer in place, tighten
with nut and lock with split pin.
In locking with split pin, locate the hole for
the split pin by turning the nut back 1/6 of Steering axle
a turn. Adjust the preload of bearing. assembly
ÂBearing preload :
0.30 ~ 0.35kgfÂm (0.20 ~ 0.25lbfÂft)
20B7SS19
5-35
Steering gears
ö Before assembling, gears should be well
greased. Castle nut Split pin
Η Install pinion gear and tighten hexagon

bolt. Steering gear
Θ Put the steering gear on the axle beam Pinion gear
and then assemble the castle nut with the
pin.
ö When mounting steering axle assembly, Axle bracket
remove steering gear and then mount the Steering axle

axle to the frame before reassembling assembly
steering gear and castle nut. Castle nut Special
washer
should be tightened until bracket fixed
Hex bolt
and then loosen to the starting torque of
0.30 ~ 0.35kgfÂm (0.20 ~ 0.25lbfÂft)
before locking it with a spring pin.
ö Pinion gear should be assembled with a
parallel key(A8x7x32) included in the
hydraulic motor assembly. 20B7SS18
Motor bracket
Η Assemble motor bracket with steering
Steering sensor
sensor.
ö Be careful of correct position of each
parts. Motor bracket
Lever
Spring pin
Steering axle
assembly
20B7SS17
5-36
3. HYDRAULIC MOTOR
1) DISASSEMBLY
(1) Seal plugs
Put the motor in a holding tool, with the
output shaft downward.
For end port version, use 10mm(0.4in)
hexagon socket spanner.
Seal plug
B15T5SM01
(2) Drain plug & washer Drain plug

A/flat, other version : 19mm(0.75in)
Washer
Not SAE washer.
B15T5SM02
(3) Screws, washers(7 off)

Use a 13mm(0.5in) spanner socket. 7 screws
7 washers
B15T5SM03
(4) End cover, gear wheel set, O-ring(2 off)

Remove end cover sideways.
End cover
Keep fingers under the gear wheel set to
prevent the parts from falling out. O-ring
Caution!
Parts can fall Gear wheel set
O-ring
B15T5SM04
5-37
(5) Cardan shaft, plate, O-ring.
Remove orderly. Distributor plate
O-ring
Cardan shaft
B15T5SM05
(6) Output shaft

Shaft and bearings should normally not be
removed from housing. However, if
necessary for inspecfion and cleaning,
Output shaft
remove the shaft from the housing front
end. The rear bearing can thus remain in
the housing. After this, turn the motor.
Do not disassemle unless necessary !

B15T5SM06
(7) Screws, spigot flange

Use torques-spanner type T30, 9mm
Housing
(0.35in)screw driver or hexagon socket
spanner 4 or 5mm(0.16 or 0.20in).
Spigot flange
Screw
B15T5SM07
(8) O-ring, bearing race, shaft seal

Use a 2mm(0.08in) screw driver.
Housing
Bearing race
O-ring
Shaft seal
B15T5SM08
5-38
(9) Dust seal, needle bearing
Use a 4mm(0.16in) screw driver.
Housing
Needle bearing
Dust seal
B15T5SM09
5-39
2) ASSEMBLY
Â Clean all parts carefully with low aromatic
kerosine
Â Check all parts carefully and replace if
necessary
Â Before assembly, lubricate all parts with
hydraulic oil and grease rubber parts with
vaseline.
(1) Needle bearing

Place needle bearing onto the output shaft
side.
Housing
Needle bearing
B15T5SM11
(2) Shaft seal

Knock the seal into position in the spigot
flange. Check that the seal lies against Housing
the cover recess.
Shaft seal
B15T5SM12
(3) Dust seal ring

Place the dust seal ring in the spigot
flange and knock it into position with a Housing
plastic hammer and appropriate mandrel.
Dust seal
B15T5SM13
5-40
(4) Bearing race, O-ring
Grease the O-ring with vaseline and fit the
bearing race and O-ring into the spigot Housing
flange.
Bearing race
O-ring
B15T5SM14
(5) Spigot flange

Turn so that the holes line up.
Housing
Spigot flange
B15T5SM15
(6) Screws(6 off)

ÂTightening torque
Η Slotted screw M6
Housing
0.5~0.8kgfÂm(3.6~5.8lbfÂft)
Θ Hexagon socket screws M5
Ι Hexagon socket screws M6
1.2~1.5kgfÂm(8.7~10.8lbfÂft) Screw
Κ Torx screws M6
B15T5SM16
ö Omit spring washer, if the screw head is
protruding from spigot flange when screw
has been tightened (old OMR metric
version only). After this, turn the motor.
5-41
(7) Output shaft(1 1/4inch splined shaft)
The rear shaft end of 1 1/4inch splined
shafts must be marked before fitted. Output shaft
The mark must be positioned vertically
above a communication slot leading up to
the front annular channel.
Grease the journals with hydraulic oil.
B15T5SM17
(8) O-ring, distributor plate

Grease the O-ring and put it in the O-ring
Distributor plate
groove of the housing.
Turn the distributor plate so that the holes
O-ring
line up.
B15T5SM18
(9) Cardan shaft

Guide the cardan shaft down into the
motor housing. Cardan shaft
B15T5SM19
(10)Gear wheel set, O-rings

Place the O-rings(greased) in the O-ring O-ring
grooves of the gearwheel.
In gearwheels with non through splines Caution!
place the gearwheel with the recess in the
spline hole facing down towards the
housing. O-ring
B15T5SM20
5-42
(11) Gear wheel set
Place the gearwheel set on the cardan Caution!
shaft so that the top of a tooth in the
external teeth of the gearwheel are
vertically above the key slot in the output
shaft(cylindrical or tapered) or the top of a
tooth on a 1 inch splined shaft. In motors
with 1 1/4 inch splined shaft the tooth top
must be positioned vertically above the
B15T5SM21
mark, see point 13.
Turn the gearwheel set counter clockwise
until the cardan shaft and the gearwheel
start to mesh(15Á).
Turn the gearwheel rim so that the holes
made for the screws line up.
(12)End cover
Turn the end cover so that the holes line End cover
up.
Housing
B15T5SM22
(13)Washer, screws(7 off)

Use a 13mm spanner socket. 7 screws
ÂTightening torque : 7 washers

3.0~3.5kgfÂm(21.7~25.3lbfÂft)
B15T5SM23
5-43
(14)Washer, drain plug
Drain plug
Use a 19mm spanner socket.
ÂTightening torque : Washer
3~6kgfÂm(21.7~43.4lbfÂft)
B15T5SM24
(15)Seal plugs(threaded plugs)

Side port version.
Screw plastic plugs.
Seal plug
B15T5SM25
5-44
SECTION 6 HYDRAULIC SYSTEM
1. HYDRAULIC CIRCUIT
15BT9HS01
1 Hydraulic gear pump 7 Lift cylinder

2 Priority valve 8 Suction strainer
3 Main control valve 9 Return filter
4 Steering unit 10 Down safety valve
5 Hydraulic motor 11 Down control valve
6 Tilt cylinder 12 Hydraulic oil tank
6-1
1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION
Steering system
Return line
Load check valve
15BT9HS02
When the lift control lever is pulled back, the spool on the first block is moves to lift position.
The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large
chamber of lift cylinder(7) by pushing the load check valve of the spool.
The oil from the small chamber of lift cylinder(7) returns to hydraulic oil tank(12) at the same time.
When this happens, the forks go up.
6-2
2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION
Steering system
Return line
Load check valve
15BT9HS03
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.
6-3
3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION
Steering system
Return line
Load check valve
15BT9HS04
When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward
position.
The oil from hydraulic gear pump(1) flows into main control valve (3) and then goes to the large
chamber of tilt cylinder(6) by pushing the load check valve of the spool.
The oil at the small chamber of tilt cylinder(6) returns to hydraulic tank(12) at the same time.
When this happens, the mast tilt forward.
6-4
4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION
Steering system
Return line
Load check valve
15BT9HS05
When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward
position.
The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the small
chamber of tilt cylinder(6) by pushing the load check valve of spool.
The oil at the large chamber of tilt cylinder(6) returns to hydraulic tank(12) at the same time.
When this happens, the mast tilt backward.
6-5
2. HYDRAULIC GEAR PUMP
1) STRUCTURE
9
3 14
13
11
2
7
8
1
5
11
9
6
8
7
10
12
BRJ7HS19
1 Mounting flange 6 Bearing block 11 Dowel pin

2 End cover 7 Backup ring 12 Start ring
3 Gear housing 8 Seal 13 Socket head bolt
4 Drive gear 9 O-ring 14 Spring washer
5 Idler shaft 10 Shaft seal
2) OPERATION
This pump comprises of an rear cover, a body, bushings and a housing bolted together with bolts.
The gear journals are supported in side plate within pressure balanced bushings to give high
volumetric and mechanical efficiencies.
6-6
3. MAIN CONTROL VALVE (without OPSS)
1) STRUCTURE (3 Spool)
A
6 2 3 4 5
8
T 2A 3A
P 2B 3B
9 1 7
INLET LIFT TILT AUX1 OUTLET
1A
130K
190K
T
1A 2A 2B 3A 3B
VIEW A
15BT9HS07
Port name Size Port
Inlet port 7/8-14UNF P

Outlet port 7/8-14UNF T
Work port 7/8-14UNF 1A
Work port 3/4-16UNF 2A, 2B, 3A, 3B
1 Inlet block assy 6 Main relief valve assy

2 Lift block assy 7 Auxiliary relief valve assy
3 Tilt block assy 8 Long bolt
4 Aux 1 block assy 9 Nut
5 Outlet block assy
6-7
A
7 2 3 4 5 6 9
T 2A 3A 4A
P 2B 3B 4B
10 1 8
INLET LIFT TILT AUX1 AUX2 OUTLET
1A 130K
190K
1A 2A 2B 3A 3B 4A 4B
VIEW A
Port name Size Port

Work port 3/4-16UNF 2A, 2B, 3A, 3B, 4A, 4B
22B7HS07
1 Inlet block assy 6 Outlet block assy

2 Lift block assy 7 Main relief valve assy
3 Tilt block assy 8 Auxiliary relief valve assy
4 Aux 1 block assy 9 Long bolt
6-8
3) INLET SECTION
(1) Operation
The inlet section contains the pump inlet connection and main relief valve.
P T
INLET
P 190bar
22B7HS09
(2) 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.
P T
P 190bar
22B7HS10
6-9
4) LIFT SECTION
(1) Operation
The lift section has a single work port to direct flow to the lift cylinder. Only one work port is used,
because the lift cylinder is single-acting(gravity returns the mast to the lowered position).
The lift section also contains part of the components which comprise the safety features. There is
a lift lock check valve. 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.
Η Lifting
When the operator shifts the lever backwards, the spool is extended out of the valve, and this
opens the internal fluid passages that lift the mast. Oil flows through the high pressure parallel
cavity, past the load check valve, through the spool metering notches, past the lift lock check
valve, and to the head side of the lift cylinder.
LIFT
Lift lock
valve
1A
22B7HS11
Θ Lowering
When the seated operator shifts the lever forwards, the spool retracts into the valve, and the oil is
directed from the cylinder, past the lift lock check valve, past the spool metering notches, and to
the common tank cavity.
LIFT
Lift lock
valve
1A
22B7HS12
Pressure is limited by the main relief valve.
6-10
5) TILT SECTION
(1) Operation
The tilt spool contains an internal plunger which acts to stop tilt forward actuation when the battery
power is off.
Η 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 high pressure acts upon the end of the tilt lock plunger to move it towards the
spring end of the spool. This plunger movement opens additional spool metering notches which
control oil flow from the rod end of the cylinder to the tank return line.
TILT
2A 2B
22B7HS13
Θ Tilt back
When the seated operator shifts the lever back, the high pressure oil from the parallel passage is
directed past the load check valve, past the spool metering notches, and to the rod side of the
cylinder. Exhaust oil from the head side of the cylinder is directed past the spool metering notches
to tank.
TILT
2A 2B
22B7HS14
6-11
6) AUXILIARY SECTIONS
(1) Operation
Many different functions can be controlled by the auxiliary spool sections. In general, one work
port is pressurized by high pressure oil from the parallel passage, past the load check valve, past
the metering notches, and to the cylinder. Simultaneously, oil from the other work port is directed
across the spool metering notches to tank.
AUX
3A/4A 3B/4B
22B7HS15
AUX
3A/4A 3B/4B
22B7HS16
Pressure is limited by the secondary main relief valve.
6-12
7) OUTLET SECTION
(1) Operation
The outlet section contains the tank port and the secondary relief valve(with built-in anti-cavitation
feature).
OUTLET
130bar
22B7HS17

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.
OUTLET
130bar
22B7HS18
6-13
8) MAIN RELIEF VALVE
This valve is a type of pilot piston to prevent hydraulic components and pipes from being broken by
high pressure so, it keeps under pressure limited.
Relief valve pressure varies by 130kgf/cm2 in accordance with 1 revolution of adjust bolt.
2 11 4 5 12 1 13 14 17
6 3 7 8 10 16 9 15
22B7HS20
1 Pilot seat 7 Main spring 13 Pilot poppet

2 O-ring 8 Piston 14 Pilot spring
3 Main poppet 9 Body 15 Adjust screw
4 Back up ring 10 O-ring 16 O-ring
5 O-ring 11 Back up ring 17 Lock nut
6 Socket 12 O-ring
6-14
MAIN CONTROL VALVE (with OPSS)
A
6 3 4 5 10
8
T 2A 3A
P 2B 3B
9 1 2 7
Needle valve
(Emergency)
INLET LIFT TILT AUX1 OUTLET
130K
P
1A
190K
T
1A 2A 2B 3A 3B
VIEW A
Port name Size Port

15BT9HS08
Work port 3/4-16UNF 2A, 2B, 3A, 3B

5 Outlet block assy 10 Solenoid valve
6-15
A
7 3 4 5 6 11
9
T 2A 3A 4A
P 2B 3B 4B
10 1 2 8
Needle valve
(Emergency)
INLET LIFT TILT AUX1 AUX2 OUTLET
130K
P
1A
190K
T
1A 2A 2B 3A 3B 4A 4B
VIEW A
Port name Size Port

Outlet port 7/8-14UNF T 22B7HS08

Work port 3/4-16UNF 2A, 2B, 3A, 3B, 4A, 4B

5 Aux 2 block assy 11 Solenoid valve
6 Outlet block assy
6-16
3) INLET SECTION
(1) Operation
The inlet section contains the pump inlet connection and main relief valve.
P T
INLET
P 190bar
22B7HS09

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.
P T
P 190bar
22B7HS10
6-17
4) LIFT SECTION
(1) Operation
The lift section has a single work port to direct flow to the lift cylinder. Only one work port is used,
because the lift cylinder is single-acting(gravity returns the mast to the lowered position).
The lift section also contains part of the components which comprise the safety features. There is
a lift lock check valve. 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.
Η Lifting
When the operator shifts the lever backwards, the spool is extended out of the valve, and this
opens the internal fluid passages that lift the mast. Oil flows through the high pressure parallel
cavity, past the load check valve, through the spool metering notches, past the lift lock check
valve, and to the head side of the lift cylinder.
LIFT
Needle
valve
Lift lock
valve
Solenoid v/v "B"
1A
22B7HS11S
Θ Lowering
When the seated operator shifts the lever forwards, the spool retracts into the valve, and the oil is
directed from the cylinder, past the lift lock check valve, past the spool metering notches, and to
the common tank cavity.
LIFT
Needle
valve
Lift lock
valve
Solenoid v/v "B"
1A
22B7HS12S
6-18
Ι Secondary lowering method : A secondary lowering method is available in the event of the
loss of battery power that is needed to energize the normally closed solenoid valve.
Important note : Before opening the secondary needle valve, make sure personnel and
equipment are safely positioned to avoid accidents. Be careful to operate this secondary valve
slowly, as heavy loads may be suspended.
A manual valve(needle valve) is located on the lift section, and it can be operated by opening the
vehicle cowling and rotating the manual valve(needle valve ) counterclockwise with a wrench.
Open the manual valve (needle valve) approximately 2 turn (do not rotate more than 3 turns).
Then shift the lift spool slowly for controlled lowering. This should be just enough for slow,
controlled movement of the mast.
LIFT
Needle valve
Needle
valve
Lift lock
valve
Solenoid v/v "B"
1A
22B7HS12AS
6-19
5) TILT SECTION
(1) Operation
The tilt spool contains an internal plunger which acts to stop tilt forward actuation when the battery
power is off.
Η 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 high pressure acts upon the end of the tilt lock plunger to move it towards the
spring end of the spool. This plunger movement opens additional spool metering notches which
control oil flow from the rod end of the cylinder to the tank return line.
TILT
2A 2B
22B7HS13
Θ Tilt Back
When the seated operator shifts the lever back, the high pressure oil from the parallel passage is
directed past the load check valve, past the spool metering notches, and to the rod side of the
cylinder. Exhaust oil from the head side of the cylinder is directed past the spool metering notches
to tank.
TILT
2A 2B
22B7HS14
6-20
6) AUXILIARY SECTIONS
(1) Operation
Many different functions can be controlled by the auxiliary spool sections. In general, one work
port is pressurized by high pressure oil from the parallel passage, past the load check valve, past
the metering notches, and to the cylinder. Simultaneously, oil from the other work port is directed
across the spool metering notches to tank.
AUX
3A/4A 3B/4B
22B7HS15
AUX
3A/4A 3B/4B
22B7HS16
Pressure is limited by the secondary main relief valve.
6-21
7) OUTLET SECTION
(1) Operation
The outlet section contains the tank port and the secondary relief valve(with built-in anti-cavitation
feature).
OUTLET
130bar
22B7HS17

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.
OUTLET
130bar
22B7HS18
6-22
This valve is a type of pilot piston to prevent hydraulic components and pipes from being broken by
high pressure so, it keeps under pressure limited.
Relief valve pressure varies by 130kgf/cm2 in accordance with 1 revolution of adjust bolt.
2 11 4 5 12 1 13 14 17
6 3 7 8 10 16 9 15
15BT9HS20
1 Pilot seat 7 Main spring 13 Pilot poppet

2 O-ring 8 Piston 14 Pilot spring
3 Main poppet 9 Body 15 Adjust screw
4 Back up ring 10 O-ring 16 O-ring
5 O-ring 11 Back up ring 17 Lock nut
6 Socket 12 O-ring
6-23
4. LIFT CYLINDER
9 10 8 11 13 12 1 2 14 15 3 7 6 4,5
D255HS18
1 Tube assembly 6 Wear ring 11 O-ring

2 Rod 7 Retaining ring 12 Guide
3 Piston 8 Gland 13 DU bushing
4 Piston seal 9 Dust wiper 14 Spacer
5 Back up ring 10 Rod seal 15 O-ring
5. TILT CYLINDER
24 18 19 20,21,22 8,7 3 11 12 6,5 10,9 4 1 2 16 14 15 13 17 23
20B7HS07
1 Tube assembly 9 O-ring 17 Nylon nut

2 Rod 10 Back up ring 18 Rod eye
3 Gland 11 Lock washer 19 Spherical bearing
4 Bushing 12 O-ring 20 Hexagon bolt
5 Rod seal 13 Piston 21 Hexagon nut
6 Back up ring 14 Piston seal 22 Spring washer
7 Dust wiper 15 Wear ring 23 Bushing
8 Snap ring 16 O-ring 24 Grease nipple
6-24
1) CHECK ITEM
Within 100mm(3.91in)
(1) Check visually for deformation, cracks or
damage of rod.
(2) Set mast vertical and raise 1m from
(after 10min)
ground. Wait for 10 minutes and measure
hydraulic drift(amount forks move down
and amount mast tilts forward).
ÂCheck condition 20B7HS08
- Hydraulic oil : Normal operating temp
(50ÁC)
- Mast substantially vertical.
- Rated capacity load. Within 5 (after 10min)
ÂHydraulic drift
- Down(Downward movement of forks)
: Within 100mm (3.9in)
- Forward(Extension of tilt cylinder)
: Within 5Á
(3) If the hydraulic drift is more than the
specified value, replace the control valve
or cylinder packing.
Check that clearance between tilt cylinder
20B7HS09
bushing and mounting pin is within
standard range. mm (in)
Standard Under 0.6 (0.02)
2) HYDRAULIC OIL
(1) Using dipstick, measure oil level, and oil if
Highest
necessary.
level
(2) When changing hydraulic oil, clean
suction strainer(screwed into outlet port
pipe) and line filter(screwed into inlet pipe).
Line filter uses paper element, so replace Lowest
periodically(every 6 months or 1000 level
hours) B15AOM116
3) CONTROL VALVE
(1) Raise forks to maximum height and
measure oil pressure.
Check that oil pressure is 190kgf/cm2.
(2700psi)
6-25
2. TROUBLESHOOTING
1) SYSTEM
Large fork lowering speed ÂSeal inside control valve defective. ÂReplace spool or valve body.
ÂOil leaks from joint or hose. ÂReplace.
ÂSeal inside cylinder defective. ÂReplace packing.
Large spontaneous tilt of mast ÂTilting backward : Check valve defec- ÂClean or replace.
tive.
ÂTilting forward : tilt lock valve defect- ÂClean or replace.
ive.
ÂSeal inside cylinder defective. ÂReplace seal.
Slow fork lifting or slow mast ÂLack of hydraulic oil. ÂAdd oil.
tilting ÂHydraulic oil mixed with air. ÂBleed air.
ÂExcessive restriction of oil flow on ÂClean filter.
pump suction side.
ÂRelief valve fails to keep specified ÂAdjust relief valve.
pressure.
ÂPoor sealing inside cylinder. ÂReplace packing.
ÂHigh hydraulic oil viscosity. ÂChange to ISO VG46.
ÂMast fails to move smoothly. ÂAdjust roll to rail clearance.
ÂOil leaks from lift control valve spool. ÂReplace spool or valve body.
ÂOil leaks from tilt control valve spool. ÂReplace spool or valve body.
Hydraulic system makes ÂExcessive restriction of oil flow pump ÂClean filter.
abnormal sounds suction side.
ÂGear or bearing in hydraulic pump ÂReplace gear or bearing.
defective.
Control valve lever is locked ÂForeign matter jammed between sp- ÂClean.
ool and valve body.
ÂValve body defective. ÂTighten body mounting bolts uniform-
ly.
High oil temperature ÂLack of hydraulic oil. ÂAdd oil.
ÂHigh oil viscosity. ÂChange to ISO VG46.
ÂOil filter clogged. ÂClean filter.
6-26
2) HYDRAULIC GEAR PUMP

Pump does not develop full ÂSystem relief valve set too low or ÂCheck system relief valve for proper
pressure leaking. setting.
ÂOil viscosity too low. ÂChange to proper viscosity oil.
ÂPump is worn out. ÂRepair or replace pump.
Pump will not pump oil ÂReservoir low or empty. ÂFill reservoir to proper level.
ÂSuction strainer clogged. ÂClean suction strainer.
Noisy pump caused by ÂOil too thick. ÂChange to proper viscosity.
cavitation ÂOil filter plugged. ÂClean filters.
ÂSuction line plugged or too small. ÂClean line and check for proper size.
Oil heating ÂOil supply low. ÂFill reservoir to proper level.
ÂContaminated oil. ÂDrain reservoir and refill with clean oil.
ÂSetting of relief valve too high or too ÂSet to correct pressure.
low.
ÂOil viscosity too low. ÂDrain reservoir and fill with proper
viscosity.
Foaming oil ÂLow oil level. ÂFill reservoir to proper level.
ÂAir leaking into suction line. ÂTighten fittings, check condition of
line.
ÂWrong kind of oil. ÂDrain reservoir, fill with non-foaming
oil.
Shaft seal leakage ÂWorn shaft seal. ÂReplace shaft seal.
ÂWorn shaft in seal area. ÂReplace drive shaft and seal.

Can’t get pressure ÂPoppet D, E or K stuck open or ÂCheck for foreign matter between
contamination under seat. poppets D, E or K and their mating
parts. Parts must slide freely.
Erratic pressure ÂPilot poppet seat damaged. ÂReplace the relief valve.
ÂPoppet C sticking in D. ÂClean and remove surface
marks for free movement.
Pressure setting not correct ÂNormal wear. Lock nut & adjust ÂSee øTest of main control valve.
screw loose.
Leaks ÂDamaged seats. ÂReplace the relief valve.
ÂWorn O-rings. ÂInstall seal and spring kit.
ÂParts sticking due to contamination. ÂDisassemble and clean.
ø 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:
Â Loosen lock nut.
Â Set adjusting nut to desired pressure setting.
Â If desired pressure setting cannot be achieved, add or remove shims as required.
Â Tighten lock nut.
Â Retest in similar manner as above.
6-27
4) LIFT CYLINDER

Oil leaks out from rod cover ÂForeign matters on packing. ÂReplace packing.
through rod ÂUnallowable score on rod. ÂSmooth rod surface with an oil stone.
ÂUnusual distortion of dust seal. ÂReplace dust seal.
ÂChrome plating is striped. ÂReplace rod.
Oil leaks out from cylinder rod ÂO-ring damaged. ÂReplace O-ring.
cover thread
Rod spontaneously retract ÂScores on inner surface of tube. ÂSmooth rod surface with an oil stone.
ÂUnallowable score on the inner ÂReplace cylinder tube.
suface of tube.
ÂForeign matters in piston seal. ÂReplace piston seal.
Wear(clearance between ÂExcessive clearance between ÂReplace wear ring.
cylinder tube and wear ring) cylinder tube and wear ring.
Abnormal noise is produced ÂInsufficient lubrication of anchor pin or ÂLubricate or replace.
during tilting operation worn bushing and pin.
ÂBent tilt cylinder rod. ÂReplace.
6-28
1. HYDRAULIC GEAR PUMP

ö Tools required
ÂMetric socket set
ÂInternal snap ring pliers
ÂShaft seal sleeve
ÂTorque wrench
(1) It is very important to work in a clean work
area when repairing hydraulic products.
Plug ports and wash exterior of pump with
a proper cleaning solvent before continu-
ing.
(2) Remove port plugs and drain oil from
pump.
(3) Use a permanent marker pen to mark a
line across the mounting flange, gear
housing and end cover. This will assure
proper reassembly and rotation of pump.
(4) Remove key from drive shaft if applicable.
PUMP 01
(5) Clamp mounting flange in a protected jaw

vise with pump shaft facing down.
(6) Loosen the four metric hexagon head
bolts.
(7) Remove pump from vise and place on
clean work bench, remove the four hexagon
head bolts and spacers applicable.
PUMP 02
6-29
(8) Lift and remove end cover.
PUMP 03
(9) Carefully remove gear housing and place

on work bench. Make sure the rear
bearing block remains on the drive and
idler shafts.
PUMP 04
(10) Remove rear bearing block from drive and

idler shafts.
PUMP 05
(11) Remove idler shaft from bearing block.
PUMP 06
6-30
(12) Remove drive shaft from mounting flange.
There is no need to protect the shaft seal
as it will be replaced as a new item.
PUMP 07
(13) Remove the front bearing block.
PUMP 08
(14) Turn mounting flange over, with shaft seal

up, and remove the retaining ring with
proper snap ring pliers.
PUMP 09
(15) Remove the oil seal from mounting flange,

be careful not to mar or scratch the seal
bore.
(16) Remove the dowel pins from the gear
housing. Do not lose pins.
PUMP 10
6-31
(17) Remove seals from both bearing blocks
and discard.
PUMP 11
2) INSPECT PARTS FOR WEAR

(1) Clean and dry all parts thoroughly prior to
inspection. It is not necessary to inspect
the seals as they will be replaced as new
items.
(2) Check drive shaft spline for twisted or
broken teeth, check keyed drive shaft for
broken or chipped keyway. No marks or
grooves on shaft in seal area, some
discoloration of shaft is allowable.
(3) Inspect both the drive gear shaft and idler
gear shafts at the bearing points and seal
area for rough surfaces and excessive
wear.
PUMP 12
(4) Inspect gear face for scoring or excessive

wear. If the face edge of gear teeth are
sharp, they will mill into the bearing blocks.
If wear has occurred, the parts are
unusable.
PUMP 13
6-32
(5) Inspect bearing blocks for excessive wear
or scoring on the surfaces which are in
contact with the gears. Also inspect the
bearings for excessive wear or scoring.
(6) Inspect the area inside the gear housing.
It is normal for the surface inside the gear
housing to show a clean "wipe" on the
inside surface on the intake side. There
should not be excessive wear or deep
scratches and gouges. PUMP 14
ö General information
It is important that the relationship of the
mounting flange, bearing blocks and gear
housing is correct. Failure to properly
assemble this pump will result with little or
no flow at rated pressure.
ö This pump is not bi-rotational.
6-33
3) ASSEMBLY
ö New seals should be installed upon
reassembly of pump.
(1) Install new shaft seal in mounting flange
with part number side facing outboard.
Press the seal into the seal bore until the
seal reaches the bottom of the bore.
Uniform pressure must be used to prevent
misalignment or damage to the seal.
PUMP 15
(2) Install retaining ring in groove in seal bore

of mounting flange.
PUMP 16
(3) Place front and back bearing blocks on a

clean surface with the E-seal grooves
facing up. Apply a light coating of
petroleum jelly in the grooves. Also coat
the E-seal and backup with the petroleum
jelly, this will help keep the seals in place
during assembly.
PUMP 17
(4) Place the E-seals, flat side outward, into

the grooves in both bearing blocks. Follow
by carefully placing the backup ring, flat
side outward, in the groove made by the
E-seal and the groove in the bearing
block.
(5) Place mounting flange, with shaft seal
side down, on a clean flat surface.
(6) Apply a light coating of petroleum jelly to
PUMP 18
the exposed face of the front bearing
block.
6-34
(7) Insert the drive end of the drive shaft
through the bearing block with the seal
side down, and the open side of the E-
seal pointing to the intake side of the
pump.
(8) Install the seal sleeve over the drive shaft
and carefully slide the drive shaft through
the shaft seal. Remove the seal sleeve
from shaft.
PUMP 19
(9) Install the idler gear shaft in the remaining

position in the bearing block. Apply a light
coat of clean oil to the face of the drive
and idler gears.
PUMP 20
(10) Pick up the rear bearing block, with seal

side up and with open end of the E-seal
facing the intake side of the pump, place
over the drive and idler gear shafts.
(11) Install two dowel pins in the holes in the
mounting flange or two long dowel pins
through gear housing if pump is a multiple
section pump.
PUMP 21
(12) To install the O-rings in the gear housing,

apply a light coating of petroleum jelly in
the grooves on both sides of the gear
housing.
Also coat the new O-ring and install them
in the grooves.
PUMP 22
6-35
(13) Gently slide the gear housing over the rear
bearing block assembly, slide housing
down until the housing engages the dowel
pins. Press firmly in place with hands, do
not force or use any tool.
Check to make sure the intake port in the
housing in on the same side as the open
end of the E-seal and that the marked
lines on the mounting flange and gear
housing are in alignment. PUMP 23
(14) The surface of the rear bearing block

should be slightly below the face of the
gear housing. If the bearing block sits
higher then the rear face of the gear
housing then the E-seal or O-ring have
shifted out of the groove. If this is the
case, remove the gear housing and check
for proper seal installation.
(15) Install the two remaining dowel pins in the

rear of the gear housing and place the
end cover over the back of the pump.
PUMP 24
(16) Install the four spacers and hexagon head

bolts through the bolt holes in the end
cover, hand tighten.
PUMP 25
6-36
(17) Place mounting flange of the pump back
in the protected jawed vise and alternately
torque the bolts.
ÂTighten torque : 6~7kgfÂm
(43.4~50.6lbfÂft)
(18) Remove pump from vise.
(19) Place a small amount of clean oil in the
inlet of the pump and rotate the drive shaft
away from the inlet one revolution. If the
PUMP 26
drive shaft binds, disassemble the pump
and check for assembly problems, then
reassemble the pump.
6-37
2. MAIN CONTROL VALVE (with OPSS)
1) ASSEMBLY
(1) General
Η Ensure that the assembly area will be clean and free of contamination.
Θ Use a flat(within 0.2mm) work surface when bolting the valve sections together.
Ι Use calibrated torque wrenches and instrumentation.
Κ Additional auxiliary valve sections may be added to the main control valve in a similar manner as
indicated below.
(2) Block subassembly
NUT
2.4~2.9 kgf.m
(17.4~21 lbf.ft)
22B7HS21
Η Attach all the O-rings to the appropriate grooves between the spool sections.
Θ 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.
Ι Insert all the tie rods through the drilled holes in each of the housings.
Κ Press the sections together, being carefully not to damage sealing surfaces or seals.
Λ Install nuts to both ends of all tie rods and progressively torque in a circular pattern until reaching
a torque of 2.4~2.9kgfÂm(17.4~21lbfÂft) on all tie rods. Periodically, make sure that the valve
remains flat while applying torque.
6-38
Lift lock check valve
4.5~5.0 kgf m Solenoid v/v coil
(32.5~36.2 lbf ft) 0.5~1.0 kgf.m
.
(3.6~7.2 lbf ft)
Plug Spring
4.5~5.0 kgf.m Solenoid valve
(32.5~36.2 lbf.ft) Load check valve cartidge
3.5~4.0 kgf.m (Normally closed)
(25.3~30 lbf.ft) 3.5~4.0 kgf.m
S
Y (25.3~30 lbf.ft)
S
A
Needle valve
L
O
O
1.0~1.5 kgf .m
P
S
Y
X
S
U
S
A
(7.2~10.8 lbf .ft)

A
L
O
O
P
S
X
U
Y
A
S
S
A
L
O
O
P
S
T
Y
IL
S
T
S
A
L
O
O
P
S
T
F
Dust wiper Seal

LI
Main relief valve

4.5~5.0 kgf.m
(32.5~36.2 lbf.ft)
Cap Seal plate
Bolt : M6X1.0 Bolt : M6X1.0

Auxiliary relief valve
1.0~1.5 kgf.m 1.0~1.5 kgf.m 4.5~5.0 kgf.m
(7.2~10.8 lbf .ft) (7.2~10.8 lbf .ft) (32.5~36.2 lbf.ft)
15BT9HS25S
(3) Inlet section

Η Install the main relief valve assembly into the lower side cavity of the inlet section, as illustrated.
Torque to 4.5~5.0kgfÂm(32.5~36.2lbfÂft).
Θ Install the plug assembly in the tank port of the inlet section. Torque to 4.5~5.0kgfÂm
(32.5~36.2lbfÂft)
(4) Lift section

Η The spool assembly should already consist of 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.
Θ 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 two bolts. Torque both bolts alternatively until a torque of 1.0~1.5kgfÂm
(7.2~10.8lbfÂft) is reached on both bolts.
Ι Install the second spool seal and dust wiper 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.
Κ The load check assembly is inserted into the top center cavity. Torque to 3.5~4.0kgfÂm
(25.3~30lbfÂft)
Λ The normally closed solenoid is installed in the rightmost cavity on the top of the section. Torque
to 3.5~4.0kgfÂm (25.3~30lbfÂft)
Μ Install the lift lock check valve assembly in the remaining open cavity in the top of the housing.
Torque to 4.5~5.0kgfÂm(32.5~36.2lbfÂft)
Ν Install the needle valve subassembly in the cavity on the inlet-facing surface of the housing.
Torque to 1.0~1.5kgfÂm (7.2~10.8lbfÂft)
6-39
(32.5~36.2 lbf ft) 0.5~1.0 kgf.m
.
(3.6~7.2 lbf ft)
Plug Spring
(25.3~30 lbf.ft) 3.5~4.0 kgf.m
(25.3~30 lbf.ft)
Y
S
S
A
Needle valve
L
O
O
1.0~1.5 kgf .m
P
S
Y
X
S
U
S
A
(7.2~10.8 lbf .ft)

A
L
O
O
P
S
X
U
Y
A
S
S
A
L
O
O
P
S
T
Y
IL
S
T
S
A
L
O
O
P
S
T
F
Dust wiper Seal

LI
Main relief valve

4.5~5.0 kgf.m
(32.5~36.2 lbf.ft)
Cap Seal plate

1.0~1.5 kgf.m 1.0~1.5 kgf.m 4.5~5.0 kgf.m
15BT9HS25S
(5) Tilt section

Η The spool assembly should already consist of the tilt spool(with tilt plunger and spring inserted
into the bore on the spring end), 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.
(25.3~30lbfÂft).
Λ 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).
Μ Install the plug in the housing cavity above the spool assembly. Torque to 3.5~4.0kgfÂm
(25.3~30lbfÂft).
6-40
(32.5~36.2 lbf ft) 0.5~1.0 kgf.m
.
(3.6~7.2 lbf ft)
Plug Spring
(25.3~30 lbf.ft) 3.5~4.0 kgf.m
(25.3~30 lbf.ft)
Y
S
S
A
Needle valve
L
O
O
1.0~1.5 kgf .m
P
S
Y
X
S
U
S
A
(7.2~10.8 lbf .ft)

A
L
O
O
P
S
X
U
Y
A
S
S
A
L
O
O
P
S
T
Y
IL
S
T
S
A
L
O
O
P
S
T
F
Dust wiper Seal

LI
Main relief valve

4.5~5.0 kgf.m
(32.5~36.2 lbf.ft)
Cap Seal plate

1.0~1.5 kgf.m 1.0~1.5 kgf.m 4.5~5.0 kgf.m
15BT9HS25S
(6) Auxiliary section

ö Same procedure for all aux sections, but spool assembly components may vary.
Η The spool assembly should already consist of the proper aux 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.
(25.3~30lbfÂft).
(7) Outlet section
Η Install the secondary main relief valve into the cavity on the clevis end of the housing.
Torque to 4.5~5.0kgfÂm(32.5~36.2lbfÂft)
6-41
2) DISASSEMBLY
(1) General
Η Subassemblies (such as relief valves, check valves, and spools) may be removed without having
to loosen the tie rods and disassembling the entire valve.
Θ Disassemble the valve sections on a flat working surface.
Ι Ensure that the disassembly area will be clean and free of contamination.
Κ Keep the disassembly area neat to avoid loss or damage of parts.
(2) Disassembly
Η Loosen the tie rod nuts and remove the tie rods from the valve sections.
Θ Remove O-rings between valve sections and set aside to avoid damage.
Ι 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 be necessary.
Κ Valve components are precision items, and care must be taken when handing them to avoid
damage or the introduction of contamination that could adversely affect performance.
6-42
3. MAIN CONTROL VALVE
Solenoid valve for lift
Lift section block
Solenoid valve for tilt
Tilt section block
Roll pin
Reach & auxiliary section block
Adapter
Roll pin End plate
Adapter
23Nm
15BT9HS34
1) ASSEMBLY INSTRUCTION
(1) General
Η Ensure that the assembly area will be clean and free of contamination.
Θ Use a flat(within 0.5mm) work surface when bolting the valve sections together.
Ι Use calibrated torque wrenches and instrumentation.
(2) Block subassembly

Η Attach all the O-rings to the appropriate grooves between the spool sections.
Θ Stack the valve sections as below picture on a flat surface.
Ι Insert all the tie rods through the drilled holes in each of the housings.
Κ Press the sections together being careful not to damage sealing surfaces or seals.
Λ Install nuts to tie rods and progressively torque in a circular pattern until reaching a torque of 2.3
kgfÂcm2(23Nm) on all tie rods.
6-43
(3) Lift block solenoid assembly
Η The solenoide is installed upper side and below side cavities in lift block. Torque to 4.1kgfÂcm2
Θ (40Nm)
Ι Install the O-ring, coil, O-ring and washer to the assemblied cartridge.
Insert the lock washer to the groove of the cartridge.
(4) Tilt & Auxiliary section assembly
Η The solenoid is installed upper side and below side in tilt & auxiliary block with bolts.
Torque to 1kgfÂm (10Nm)
Θ Install the coil, O-ring and washer to the assemblied cartridge.
Ι Insert the snap ring to the groove of the cartridge.
Κ Insert the roll pin to the pin hole on the front side of each block.
Λ Place the O-rings in the O-ring grooves.
Μ Insert the ancillary blocks to the each body with bolts.
2) DISASSEMBLY INSTRUCTION
(1) General
Η Disassemble the valve sections on a flat working surface.
Θ Ensure that the disassembly area will be clean and free of contamination.
Ι Keep the disassembly area neat to avoid loss or damage of parts.
(2) Perform the assembly in reverse order

Η Remove the solenoid valves and ancillary blocks from the main blocks.
Θ Loosen the tie-rods from the valve section.
Ι Remove the seals between valve section.
Κ Valve components are precision items, and care must be taken when handing them to avoid
damage or the introduction of contamination that could adversely affect performance.
6-44
4. LIFT CYLINDER
1) STRUCTURE
10
16 5
15 4
3
13
6
14 7
8
17 9
11
18 12
19
2 1
20
Â I.D ÝO.DÝStroke (standard)
45Ý55Ý1645mm
(1.8Ý2.2Ý65 in)
Â Rod O.D : 35mm (1.4 in)
15BT9HS14
1 Tube assy 8 Spacer 15 Dust wiper

2 Rod 9 Retaining ring 16 Retaining ring
3 Piston 10 Stop ring 17 Rod bush
4 U-packing 11 Cushion seal 18 Spacer
5 Back up ring 12 Retaining ring 19 O-ring
6 Wear ring 13 Rod cover 20 Stop ring
7 Check valve 14 U-packing
6-45
2) DISASSEMBLY
(1) Hold the cylinder tube in a vice, loosen the Guide
cylinder head and remove it.
Remove the spacer from the cylinder tube
and knock out the bushing. Hook a
wrench in the hole in the retainer at the
piston end and turn. Lever up the edge of
the guide, then turn the guide in again and
the guide can be removed. D35ACO168
3) CHECK AND INSPECTION mm(in)

Check item Standard size Repair limit Remedy
Clearance between 0.072~0.288 0.5 Replace

cylinder rod & bushing (0.003~0.011) (0.020) bushing
Clearance between 0.05~0.030 0.5 Replace
piston ring & tube (0.002~0.012) (0.020) piston ring
4) ASSEMBLY
(1) 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.
D35ACO169
6-46
5. TILT CYLINDER
1) STRUCTURE
24
23 1
24
17
15
14 25
13
16
9
2
10
12
11
5
6
4
7
8
18
20
22
21
19 24
20B7HS10
1 Tube assy 10 Back up ring 18 Rod eye

2 Rod 11 Lock washer 19 Spherical bearing
3 Gland 12 O-ring 20 Hexagon bolt
4 Bushing 13 Piston 21 Hexagon nut
5 Rod seal 14 Piston seal 22 Spring washer
6 Back up ring 15 Wear ring 23 Bushing
7 Dust wiper 16 O-ring 24 Grease nipple
8 Snap ring 17 Nylon nut 25 O-ring
9 O-ring
6-47
2) DISASSEMBLY
(1) 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.
When doing this, wind tape round the D35ACO171
threaded part of the rod and be careful not
to damage the dust seal and rod seal
inside cylinder head.
3) CHECK AND INSPECTION mm(in)

Check item Standard size Repair limit Remedy
Clearance between 0.072~0.288 0.5

Replace bushing
cylinder rod & bushing (0.003~0.011) (0.020)
Clearance between rod 0.10~0.35 0.6
Replace bushing
head bushing & pin (0.004~0.014) (0.024)
6-48
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
25 2
1
3
6 4
23
24
5
8
14
22 21
10
9
7
11
20 12
13
19
15
17 27 28
18 26
29
30
15BT9EL02
1 Combination switch 11 Main fuse cover 22 Horn high

2 Display 12 Back buzzer 23 Accelerator assy
3 DC-DC converter 13 Steering senser 24 Parking switch assy
4 Beacon lamp 14 Traction controller 25 Key switch assy
5 Tilt switch assy 15 Fuse & relay cover assy 26 Head lamp switch
6 Pressure sensor 17 Relay 27 Work lamp switch
7 Fan 18 Flasher unit assy 28 Beacon switch
8 Pump controller 19 Pump motor 29 Emergency switch
9 SBR switch assy 20 Traction motor 30 Socket assy
10 Contactor 21 Fan
7-1
ELECTRICAL CIRCUIT (NON-UL)
FUSE BOX ASS'Y
2
F3 F4 F5 F6 F8 F9 F10 F11 F12 F13 F14

10A 2A 5A 5A 5A 5A 5A 5A 5A 10A 10A
20 922 23 24 26 27 REVERSE 25 55 52 FAN 6 8

25A 25A 52A
27A RR+ RELAY FR+ RELAY
02C B FLAS WORK BEACON
C- E -HER 221A LAMP LAMP 120A
KO S/W S/W
HEAD L UNIT
LAMP
S/W 41
21B 22 BRAKE
T/S LAMP
INPUT OUTPUT 43 44 44A S/W SWITCH
10 49 49B
40 5 09
KEY 42A
42 RR- 59 47 FR-
S/W SOC
45A 45 46A OPT KET
DC-DC
EMERGENCY 21 CONVERTER 40A
SWITCH 5A 5B 5C 5D 5D
43A 43A 44A 44A 46B 46A 59A 47A
49B 49A
822
46
GND GND M M M M
(IN) (OUT)
TAIL STOP T/S B/U TAIL STOP T/S B/U HORN TNR REAR LAMP FAN- FAN- FAN- FAN-
02A LH LAMP RH T/S T/S LAMP BEA TNR
-S/W LAMP LAMP WORK -S/W CON -S/W RH CONT LH RH
COMBI. COMBI. BACKUP
-LH -RH LAMP LAMP MOTOR MOTOR
LAMP LAMP BUZZER
00A 02M 02D 02Q -LH 02H -RH 02H 02M 02Q 02E 02G 02B 02H 02N 02H 02N 02T 02S 02K 02P 02F 02R 02T
KO KI B- C-
LINE CONTACTOR
TRACTION PUMP
F1 F2
INVERTER 300A INVERTER
10W 300 350A
DUAL AC SINGLE AC PUMP
MOTOR
TRACTION TIB+ 21C 21E PIB+
MOTOR-LH US KEY A5 KO KO A5 KEY U
M VS V M
21D 21F
WS BATT+ A34 A34 +BATT W
SEAT S/W
196 92 122 222 296
A27 (PTHERM_L) SEAT A10 A6 COMMON MTEMP_POS A25
FWD S/W LIFT S/W

195 90 122D 222A 60 295
A26 (NTHERM_L) FORWARD A7 A7 LIFT ENABLE MTEMP_NEG A24
TEMP SENSOR TEMP SENSOR
PARKING TILT S/W
194 99 122B 222A 61 294
A3 (PENC_L) PARKING A21 A8 1st SPEED (ENC VCC) A1
ACCEL. S/W AUX1 S/W

192 95 122C 222F 62 292
A4 (NENC_L) ENABLE A9 A9 2nd SPEED (ENC GND) A2
REV S/W AUX2 S/W

B+ 193 91 122D 222G 63 293
A15 (PHA_L) REVERSE A8 A10 3rd SPEED (ENC A) A13
BRAKE S/W TILT LEVEL
S/W
191 98 122D 222B 66 291
A16 (PHB_L) BRAKE A20 A16 TILT LEVELING (ENC B) A14
LIFT LIMIT
TRACTION 122A 222C S/W 67 65
MOTOR-RH UM COMMON A6 A15 LIFT LIMIT 12V PPOT A28
M VM
SBR
FR+ 222D 68 64 LIFT
WM A20 SBR CPOT A29
POTENTIOMETER
EMERGENCY
SWITCH BRAKE OIL S/W
ELECTRIC FORKLIFT DISPLAY 222E
396 120A 69 03
A25 (PTHERM_R) PLC A11 A3 BRAKE OIL NPOT A30
00B 21A EMERGENCY
LC COIL B- A1 -BATT KEY A6 KO SWITCH
395 01 420 222G 422 72
BATTERY A24 (NTHERM_R) NLC A35 A22 SAFETY 12V PPOT A17
36/48V TEMP SENSOR 21F
BATT+ A5
394 09 00C 70 TILT ANGLE
A1 (PENC_R) NLC A23 FR- B- A4 -BATT CPOT A18 POTENTIOMETER
392 93 04
A2 (NENC_R) 12V PPOT A28 NPOT A19
CAN-L CAN-H
393 94 ACCELERATOR
A3 A2 75 RR+
A13 (PHA_R) CPOT A29 A33 12V PPOT
PEDAL
125A 126A 221A

391 07 LOAD SENSING 74 221
A14 (PHB_R) NPOT A30 A32 CPOT PHYDRO A11
POTENTIOMETER
MCV SOL.
97 00C 05 08 221A
A33 12V PPOT BATT- A22 B- A31 NPOT NHYDRO A35
STEER 96 126 126A 10

A32 CPOTST CAN_H B2 B2 CAN_H NLC A12 RR-
SENSOR
06 125 125A
A31 NPOTST CAN_L B1 B1 CAN_L
TIB- PIB-
15BT9EL01
B-
7-2
ELECTRICAL CIRCUIT (UL)
PUMP INVERTER
A33 A17
FUSE BOX ASS'Y 275 272
F3 F4 F5 F6 F8 F9 F10 F11 F12 F13 F14

10A 2A 5A 5A 5A 5A 5A 5A 5A 5A 5A
20 922 23 24 26 27 REVERSE 25 55 52 FAN

25A 25A 52A
27A RR+ RELAY FR+ RELAY
02C B FLAS WORK BEACON
72
LAMP LAMP 75
C- E -HER 221A 120A
KO S/W S/W
HEAD L UNIT
LAMP LOAD TILT
S/W 41 SENSING ANGLE
21B 22 BRAKE
T/S LAMP
INPUT OUTPUT 43 44 44A S/W SWITCH
10 49 49B
40 5 09
KEY 42A
42 RR- 59 47 FR-
S/W 45A 46A
45
DC-DC
EMERGENCY 21 CONVERTER 40A
SWITCH 5A 5B 5C 5D 5D
43A 43A 44A 44A 46B 46A 59A 47A
49B 49A
822
46
GND GND M M M M
(IN) (OUT)
TAIL STOP T/S B/U TAIL STOP T/S B/U HORN TNR REAR LAMP FAN- FAN- FAN- FAN-
02A LH LAMP RH T/S T/S LAMP BEA TNR
-S/W LAMP LAMP WORK -S/W CON -S/W RH CONT LH RH
COMBI. COMBI. BACKUP
-LH -RH LAMP LAMP MOTOR MOTOR
LAMP LAMP BUZZER
00A 02M 02D 02Q -LH 02H -RH 02H 02M 02Q 02E 02G 02B 02H 02N 02H 02N 02T 02S 02K 02P 02F
KO KI B- C-
LINE CONTACTOR
TRACTION PUMP
F1 F2
350A INVERTER INVERTER
10W 300 300A
DUAL AC SINGLE AC PUMP
MOTOR
TRACTION TIB+ 21C 21E PIB+
MOTOR-LH US KEY A5 KO KO A5 KEY U
M VS V M
21D 21F
WS BATT+ A34 A34 +BATT W
SEAT S/W F22 F23

5A 5A
196 496 92 122 222 522 596 296
A27 (PTHERM_L) SEAT A10 A6 COMMON MTEMP_POS A25
TEMP SENSOR F15 TEMP SENSOR
5A FWD S/W LIFT S/W
195 90 122D 222A 60 295
A26 (NTHERM_L) FORWARD A7 A7 LIFT ENABLE MTEMP_NEG A24
PARKING TILT S/W

194 494 99 122B 222A 61 594 294
A3 (PENC_L) PARKING A21 A8 1st SPEED (ENC VCC) A1
F16 F24
5A ACCEL. S/W AUX1 S/W 5A
192 95 122C 222F 62 292
A4 (NENC_L) ENABLE A9 A9 2nd SPEED (ENC GND) A2
REV S/W AUX2 S/W

B+ 193 91 122D 222G 63 293
A15 (PHA_L) REVERSE A8 A10 3rd SPEED (ENC A) A13
BRAKE S/W TILT LEVEL
S/W
191 98 122D 222B 66 291
A16 (PHB_L) BRAKE A20 A16 TILT LEVELING (ENC B) A14
F20 LIFT LIMIT
TRACTION 322 5A 222C S/W 67 265 65
UM 122A
MOTOR-RH COMMON A6 A15 LIFT LIMIT 12V PPOT A28
M VM
SBR
F25
5A
222D 68 64 LIFT
WM FR+ A20 SBR CPOT A29
POTENTIOMETER
EMERGENCY
SWITCH BRAKE OIL S/W
396 696 120A ELECTRIC FORKLIFT DISPLAY 222E 69 03
A25 (PTHERM_R) PLC A11 A3 BRAKE OIL NPOT A30
TEMP SENSOR
F17 00B 21A EMERGENCY
5A LC COIL B- A1 -BATT KEY A6 KO SWITCH
395 01 420 222G 422 272 72
BATTERY A24 (NTHERM_R) NLC A35 A22 SAFETY 12V PPOT A17
36/48V 21F F14
BATT+ A5 5A
394 694 09 00C 70 TILT ANGLE
A1 (PENC_R) NLC A23 FR- B- A4 -BATT CPOT A18 POTENTIOMETER
F18
5A
392 793 93 04
A2 (NENC_R) 12V PPOT A28 NPOT A19
F21
5A CAN-L CAN-H
393 94 ACCELERATOR A3 A2 75 275
A13 (PHA_R) CPOT A29 PEDAL
A33 12V PPOT RR+
F13 F26
125A 126A 5A 5A 221A
391 07 LOAD SENSING 74 521
A14 (PHB_R) NPOT A30 POTENTIOMETER A32 CPOT PHYDRO A11
MCV SOL.
97 797 00C 05 08 221A
A33 12V PPOT BATT- A22 B- A31 NPOT NHYDRO A35
F19
5A
STEER 96 125 126A 10
A32 CPOTST CAN_L B1 B2 CAN_H NLC A12 RR-
SENSOR
06 126 125A
A31 NPOTST CAN_H B2 B1 CAN_L
TIB- PIB-
15BT9EL01A
B-
7-3
GROUP 3 ELECTRIC COMPONENTS
1. FUNCTIONS OF BATTERY FORKLIFT TRUCK AND ELECTRIC COMPONENTS.

The major functions of forklift truck can be divided into DRIVING FUNCTION and LOADING &
UNLOADING FUNCTION.
All the components that work DRIVING and LOADING & UNLOADING functions are driven by AC
MOTORS. And as the BATTERY works as power source of these motors, a charging device is
needed.
To drive the fork lift truck, a DRIVING CONTROL SYSTEM and some electric components such as
direction change lever(forward/reverse section switch) and accelerator are required to select the
driving direction 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 sensors, and temperature sensors. The
HYUNDAI Battery forklift trucks are equipped with the most advanced DRIVING CONTROL SYSTEM
currently available world-widely. The operator friendliness features enable him to set the truck
conditions properly according to each working circumstance easily on his seat, and the SELF-
DIAGNOSTIC function displays current status of truck in working.
7-4
2. BATTERY
1) STRUCTURE
2
6 7,9,10,11,12
5
1 3
Protective tube
15BT9EL03
1 Cells 7 Plug
2 Steel box 8 Spacer
3 Cell connector 9 Handle (Red)
4 Row connector 10 Screw
5 Positive leading cable 11 Spring washer
6 Negative leading cable 12 Nut
7-5
2) GENERAL
As in the battery forklift, the battery is an
energy source, the handling of the battery
is very important. The life and performan-
ce of the battery greatly depend on the
ordinary handling and maintenance.
Therefore, be sure to check and maintain
the battery so that it may be kept best.
15BT9EL04
3) SPECIFICATION AND SERVICE DATA

Type VCI 510 VCI 585
Rated voltage V 48
Capacity AH/hr 510/5 585/5
Electrolyte WET
Dimension(WÝDÝH) mm 978Ý545Ý635 978Ý630Ý635
Connector SB350
Weight(Max/Min) kg 900/780 1050/950
Fully charged specific gravity 1.280(25ÁC)

End of discharge specific gravity 1.130(25ÁC)
Discharge end voltage 48V(option 36V)
Electrolyte Refined dilute sulfuric
Replenishment fluid Refined water(pure water)
Insulation resistance More than 1Mɮ
7-6
4) SAFETY PRECAUTIONS
(1) When a sulfuric acid contact with skin
For acid contact with skin, eye or clothing, flush with water immediately. If swallowed, drink a large
amount of water or milk. Seek medical attention immediately. When handling acid, always wear
eye goggles or a face shield and rubber gloves.
(2) Strict prohibition of fire and ventilation
Since batteries generate explosive hydrogen gas, no fire should be drawn near. Before the battery
charging, keep the battery cover open and check the ventilation status. Charging in an enclosed
space can cause a explosion.
(3) Never place metallic articles on the batteries
If done so, it may cause “short circuit” accidents(dangerous especially while charging).
Sparks will be generated which is equally dangerous as open fires.
(4) Handling of charger
When connecting or disconnecting a battery from a charger or attempting maintenance, make
sure switches are all off. Ensure that the charger and the battery are matched. If a 300Ah battery
is used with a charger designed to charge a 500Ah battery, it will severely overcharge the battery.
5) OPERATION PRECAUTIONS
(1) 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 falling below 1.5V.
(2) Avoid over-charge
If overcharged, the rise in battery temperature will become excessive, resulting in deterioration of
plates and other parts and markedly shortening of battery life.
(3) Avoid excessive elevation of temperature
Be sure to open the cover of battery housing tray before charging. If there is a possibility of
temperature to exceed 55Á
C, discontinue the charge operation temporarily, or reduce the charge
current.
6) INSTRUCTION
(1) Unpacking
Electric traction storage batteries(herein after refer to as “batteries”) are delivered to customers in
dry-charged condition. At unpacking, check whether the batteries and accessories have been
damaged. If there are observed defects, you should notify the condition to our branch office or
agent. Never remove the sealing plug until the battery is put into service.
7-7
(2) Performance and maintenance of batteries
Η Initial charge
Wet-charged battery gradually decrease its capacity during storage. In order to provide sufficient
discharge capacity in the first discharge, the good initial charge is required. The conditions of
initial charging are seen as below at room temperature.
a. By modified constant voltage charger
Connect the battery to the charger and turn on the equalizing charge “ON”. The battery will be
fully charged and terminated automatically.
b. By constant voltage constant current charger
Connect the battery to the charger and turn on the equalizing charge “ON”. The battery will be
fully charged and terminated automatically.
c. By constant current charger
Connect the charger to the battery and charge the battery by 0.1CÝ5 hour rate nominal
capacity current for 24 hours or more. The charge shall be terminated when one of the following
condition is identified.
ÂWhen a constant value is indicated for more than 1 hour after the battery voltage has reached
the maximum value.
ÂWhen more than 1 hour of charge is continued after the electrolyte specific gravity has risen
fully and becomes constant.
Θ Discharge and capacity
The capacity of batteries is indicated at 5 hour rate capacity which means the battery can be
discharged for 5 hours with the discharge current calculated by dividing the capacity value by 5
until the unit cell mean voltage reaches down to 1.7V at the electrolyte temperature of 30ÁC.
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 capacity, if immediately charged to full, there will be no
harmful effects remained. Ideal charging amount(AH) is 110-125% of the amount of previous
discharge.
Ι Specific gravity of electrolyte
Specific gravity of electrolyte drops at discharge and rises at charge. When the batteries are fully
charged, it becomes almost constant and shows no further rise. The specific gravity value varies
with the change in temperature. Therefore specific gravity measurement should be made with
temperature of electrolyte at the same so the measured specific gravity value could be corrected
to that at the standard temperature of 25Á C by the following formula.
S25 = St + 0.0007(t-25)
Where, S25 : Specific gravity at 25Á
C
St : Actually measured specific gravity at t Á
C
t : Electrolyte temperature (ÁC)
The standard specific gravity for this type of battery is 1.280Ü0.01(25Á C) at full charge condition.
If the electrolyte is decreased naturally while using, distilled water shall be replenished up to the
specified level. (Never refill sulfuric acid)
Only when large quantity of electrolyte is lost due to spillage, etc., dilute sulfuric acid specified in
gravity shall be added.
7-8
Κ Normal charge
Charge the discharged batteries as quickly as possible. The temperature of electrolyte before
starting the charging operation shall preferably be below 45Á C, and the temperature during the
charge should be maintained at no higher than 55Á C. (Under any unavoidable situations, it should
never be above 55Á C). Methods of charging varies in precise meaning with the types of chargers
used. A standard charging method is described hereunder. (If a special method is mentioned to
be adopted, follow that instruction).
a. Charging by modified constant voltage automatic charger
There is almost automatic charger today which complete the charging just only connecting the
plug between battery and charger without outer operating timer but if your charger has it, after
setting the timer for 3-4 hours and turn on the charger and the charger is left as it is, then the
charge will be made automatically. In principle, regardless of the amount of previous discharge,
it is not required to alter the setting of timer time. The recommendable current value of this type
of charger is “5 hour rate current Ý1.0~1.5” at the start of charging, and at the final stage it is “5
hour rate current Ý0.15~0.25”. Normally the charge is terminated within 8~12 hours
automatically.
b. Charging by constant current constant voltage automatic charger
After a lapse of specified charging time after the switch is turned on, the charge will be
completed by turning off the switch. The charging time can be calculated by the following
formula.
Amount of previous discharge(AH)
Charging time = + 2~3(H)
Capacity of charger(A)
When the amount of previous discharge is not known, use the 5 hour rate 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.
Λ Equalizing charge
When large number of cells are used in a set of battery, the voltage and specific gravity of
respective cells tend to become unequal, resulting in necessity of charging all the cells at an
appropriate time in order to equalize them. This is called equalizing charge. Normally the
equalizing charge should be carried out once every month. The methods are in normal type
charger, extend the charge for 5 more hours after full charge at the final stage current, and in
automatic charger which are in most cases provided with timer, extend the time setting for 3-6
more hours.
Μ Water replenishment
Only the water content of electrolyte is decreased due to electrolysis of 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. If the electrolyte level is lowered, replenish distilled water up to the specified
level. In this case, never attempt to replenish sulfuric acid or tap water. Use only distilled water
for battery replenishment. If the amount of water required for weekly addition to a unit cell for
100AH of battery capacity is in excess of 45cc, it is assumed that the cell is receiving overcharge.
Accordingly, be sure to reduce slightly the daily charge amount. Under the normal conditions, the
addition of water per week is 45cc or less. Incidentally, water replenishment should be made
before charging to the contend of minimum level.
7-9
(for the purpose of uniform stirring of electrolyte by charging). If the electrolyte level is improper
after completion of charging, you may topping up the electrolyte level to the maximum level .
a. Determination of replenishment time and methods(cell with ONE TOUCH CAP)
Confirm the electrolyte level by looking at the float in the ONE TOUCH CAP. If too low as shown
in figure, replenish water. Replenishment shall be performed after opening the cover of the plug
using syringe and jug. When refilling is completed, close each cover completely until “click”
sound is heard.
Minimum Level Maximum Level
Cell cover
Cell cover
Float Float
B153EL041 B153EL042
Ν 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. In the case of plastic containers or covers, never use such organic solvents
as paint thinner and gasoline. If used, the plastic containers or covers may suffer cracking. If you
are forced to use them, be sure to use white kerosene.
Ξ Notice on charging
The charging area must be well ventilated to facilitate exhaust of gas generated from the battery
during 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. Since hydrogen gas generated during charging may
remain in the area surrounding the battery after charging, never bring fire or flame close to this
area. In case of counter-balance type vehicles, open the battery cover before charging.
Ο Repair of failure cell
a. To remove a cell from the circuit or battery from steel tray, it is first necessary that the intercell
connector be removed.
b. Before performing any repairs, you must open one-touch caps for gas purging of all cells. After
you have finished that, must remove connector covers and on-touch caps from failure cell
including surrounding cells. All vent holes of cells removed of one-touch caps must cover by
four layers of water dampened cloth and then proceed with repairs. Using an acid syringe
withdraw sufficient electrolyte from failure cell to reduce the liquid levels until minimum level
indicating of one touch caps.
c. The safe and most efficient method of removing a connector is with hand or electric drill(͚25mm)
from failure cell as well as all surrounding cells.
7-10
You must make sure to clear of explosive hydrogen gas in the cells before repairs.
Be careful not to drill to far into the cell and damage the unit. During drilling
operation make sure lead curls produced do not contact opposite cell poles and
cause a spark.
d. Upon completion of drilling the intercell connectors, can be lifted off.
e. Lifted off the failure cell from circuit after removing of intercell connector.
f. Installing new cell and connector.
g. With surfaces properly cleaned and neutralized, position the connectors.
h. Place damp rags around each lead head. Hold tip of the welder in center of post move welder
completely around top of post and out to the area where the post meets the connector. Move
welder back to center of post and add molten lead until area is filled to top of connector. Again,
move welder completely around area, with tip on molten lead. If you have jig for welding
connector, have easier and better welding work.
i. When replacing electrolyte in a repaired cell, use sulphuric acid of the same specific gravity that
is found in the balance of the battery.
j. Finally, rejoin connector covers and one-touch caps to the cells.
Π Summary of daily maintenance
a. Avoid overcharge. After discharge, charge the batteries immediately. The standard frequency
of equalizing charge is more than once every month.
b. Check the electrolyte level once a week. If found decreased, replenish distilled water up to the
specified level.
c. The top surface of battery cells should be kept clean and dry.
d. Be sure to keep open the cover of battery housing tray during charge.
e. Never draw near open fires such as lighted cigarettes or burning matches during charge.
(3) Others
Η 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 level. When the temperature in storage location is higher than
20ÁC, check the specific gravity once a month, and when lower than 20Á C, check it once every
two months. If the measurements show values lower than 1.230(20Á C), it is required to charge
the battery in accordance with the method described in NORMAL CHARGE.
Θ Maintenance record
It is recommended to keep maintenance record in order to know the operational conditions of
batteries. Daily charge and discharge, equalizing charge requirements, and water replenishment
requirements can be clarified at a glance. Measurements of specific gravity and temperatures
once every two to four months after equalizing charge and maintenance thereof will serve for
battery health diagnosis.
Ι Electrolyte temperature
The operating temperature range of batteries is -10~45Á C(temperature of electrolyte). If the
batteries are exposed to cold atmosphere in discharged condition, the electrolyte may freeze, and in
extreme cases, the capacity will be decreased, but, if not frozen, no adverse effects will be exerted
over the life. Contrarily if the temperature is high, especially if used at above 55Á
C, the battery life
will be considerably shortened. Care must be taken so that the temperature during charge will be
maintained at 55Á C or lower. Even under unavoidable circumstances it should not exceed 55Á C.
7-11
7) TROUBLESHOOTING
Nature of trouble Symptoms Causes Repair

Deformation ÂDeformation of container, ÂExcessive temperature ris- ÂReplace
lid or one touch cap ing or external impact
Breakage ÂElectrolyte leakage acco- ÂExternal impact, improper ÂReplace or install a new
rding to breakage of cont- handling, excessive vibrat- one
ainer, lid or one touch cap ion
ÂTermination of connector ÂExcessive temperature ÂReplace
or pole post etc. rising or vibration/external
impact
Sulfate ÂSpecific gravity drops and ÂWhen left in state of disch- ÂNeed equalizing charge
capacity is decreased. arge or left long without
equalizing charge.
ÂCharge voltage rises rapi- ÂInsufficient charge. ÂNeed equalizing charge
dly with immature gassing ÂWhen electrolyte is so de- ÂNeed equalizing charge
in earlier stage but specific creased that plate is de-
gravity does not rise and posed.
charge can’t be carried ÂWhen concentration of ÂAdjust specific gravity
out. electrolyte rises.
ÂWhen impurities are mixed ÂReplace electrolyte
in electrolyte.
Decrease and ÂMay be easily detected by ÂRise of temperature due to ÂReplace
falling of specific measurement of the spec- such trouble.
gravity ific gravity. ÂWhen left long period with- ÂRefill water in regular per-
out refilling of water. iod
ÂShort circuit. ÂReplace
Rise of specific ÂMay be easily detected by ÂDiluted sulfuric acid is ÂAdjust specific gravity after
gravity measurement of the spec- used in refilling. full charge.
ific gravity. ÂWhen the electrolyte level ÂRefill distilled water.
excessively drops.
Mixing of impurities ÂDecrease of capacity. ÂMetals such as iron, copper, ÂUnder a fully discharged
nickel and manganese. condition, pour out the
ÂDrop of charge and disch- ÂImpurities such as sea electrolyte. Then pour in
arge voltage. water, chloric acid, nitric an acid of the specific
acid etc. gravity higher by 0.03~0.05
ÂOdor of generated gas and ÂFilling of impure water. than that of the drained
coloring of the electrolyte. acid. Charge fully and
adjust the specific gravity to
the specified value.
7-12
3. DRIVE MOTOR
1) STRUCTURE
11
10
2
1
9
8
15BT9EL07
1 Rotor assy 5 Sensor bearing 9 O-ring

2 Startor assy 6 Bearing 10 Terminal block
3 Front endbell 7 Winding sensor 11 Wrench bolt
4 Rear endbell 8 Oil seal
7-13
2) SPECIFICATION
Type - FK115TT100403A
Rated voltage V 48
Rated output kW 4.7
Insulation - Class F
3) MAINTENANCE INSTRUCTION
ö Before starting the maintenance please disconnect the power supply.
(1) Ball bearing
Both ball bearing are maintenance free. Should 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.
(2) Disassembly and assembly
The motor is assembled and disassembled according to the relevant sectional drawing and part
list. (See page 7-13)
7-14
4. PUMP MOTOR
1) STRUCTURE
11
10
15BT9EL16
1 Rotor assy 5 Sensor bearing 10 Terminal block

2 Startor assy 6 Bearing 11 Wrench bolt
3 Front endbell 7 Winding sensor
4 Rear endbell 8 Oil seal
7-15
2) SPECIFICATION
Type - FL107DP200407A
Rated voltage V 48
Rated output kW 15.8
Insulation - Class F
3) MAINTENANCE INSTRUCTION
ö Before starting the maintenance please disconnect the power supply.
(1) Ball bearing
Both ball bearing are maintenance free. Should 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.
(2) Disassembly and assembly
The motor is assembled and disassembled according to the relevant sectional drawing and part
list. (See page 7-15)
7-16
5. CONTROLLER SYSTEM
1) STRUCTURE
Traction controller Pump controller
15BT9EL10
(1) Specifications
Model Model Application Type Power Current limit
SKAI20A2MM10-3010K Traction AC 36-48V, 330A+330A 330A / 3min
15/18/20BT-9
SKAI25A2MD10-3011K Pump AC 36-48V, 450A 450A / 3min
7-17
2) OPERATIONAL FEATURES
(1) Features
Η Speed control
Optimal speed control is performed with the feedback of the torque applied to the motor according
to the accelerator pedal operation.
Θ Prevention of unwanted roll-back on a slope
Regardless of forward/reverse lever set point, stop the vehicle or control at specified speed
downwards according to the option.
If the vehicle rolls back even when the pedal brake or hand brake is applied, the vehicle is
controlled in stop status.
Ι Electronic differential feature with torque balance between outside and inside wheel.
Κ Constant speed control according to the travel direction and accelerator pedal both on
decelerating and accelerating ramp.
Automatic regenerative braking or release according to the situation.
Λ Optimum sensitivity at low speeds.
Μ Efficient motor drive by vector control.
Control to provide the maximum torque at start up and overload.
Efficient use of motor and battery by optimized control.
Ν BDI algorithm.
Ξ Operation on console or instrument board.
Option, function and performance can be controlled.
Motor and controller statues can be monitored.
Ο Information displayed on instrument board.
Error messages for traction and hydraulic system, 5 messages respectively.
Hour meter display
Language and time setting
Π Major parameters inspection and self diagnosis function.
Ρ Detail monitoring through serial link.
΢ Software download through CANBUS.
(2) Self diagnosis

The self diagnosis is made in 4 points.
Η Self diagnosis when key switch is turned on that checks : watchdog circuit, current sensor, battery
type, capacitor charging, motor wiring, CAN BUS, operation switch sequence, analog input
device.
Θ Self diagnosis in standby that checks : Watchdog circuit, current sensor, contactor driver, CAN
BUS.
Ι Self diagnosis during operation that checks : Watchdog circuits, contactor driver, current sensors,
CAN BUS, over-voltage, over-current, encoder.
Κ Continuous self diagnosis that checks : Temperature of the stack in inverter, motor temperature.
Failure information can be checked with DISPLAY and console.
7-18
3) DESCRIPTION OF THE CONNECTORS
(1) Traction controller
22BH9EL11
No. of Pin Function Description

A1 PENC_R Positive of right motor encoder power supply (14V)
A2 NENC_R Negative of right motor encoder power supply
A3 PENC_L Positive of left motor encoder power supply (14V)
A4 NENC_L Negative of left motor encoder power supply
A5 KEY Connected to + batt trough an emergency switch and a 10 A fuse in series
A6 CM Common of FW / REV / PARKING / BRAKE / SEAT / ENABLE microswitches
A7 FORWARD Forward direction request signal
A8 REVERSE Reverse direction request signal
A9 ENABLE Traction or backing request signal
A10 SEAT Seat presence signal
A11 P_POS Main contactor/positive of cooling fan relay
A13 PHA_R Right motor encoder phase A
A14 PHB_R Right motor encoder phase B
A15 PHA_L Left motor encoder phase A
A16 PHB_L Left motor encoder phase B
A20 BRAKE Pedal brake request signal
A21 PARKING Hand brake input
A22 -BATT Negative of battery
A23 P_NEG2 Negative of cooling fan relay
A24 NTHERM_R Negative of right traction motor temperature sensor
A25 PTHERM_R Positive of right traction motor temperature sensor
A26 NTHERM_L Negative of left traction motor temperature sensor
A27 PTHERM_L Positive of left traction motor temperature sensor
A28 PPOT Positive of traction accelerator pedal potentiometer
A29 CPOT Traction accelerator pedal potentiometer wiper signal
A30 NPOT Negative of traction accelerator pedal potentiometer
A31 NPOTST Negative of steering potentiometer
A32 CPOTST Steering potentiometer wiper signal
A33 PPOTST Positive of steering potentiometer
A34 P_POS+ Battery +
A35 P_NEG1 Negative of main contactor coil
7-19
22BH9EL12

B1 CAN_L Low level CANBUS
B2 CAN_H High level CANBUS
B3 CAN_BMS Select CANBUS boot mode
B4 SI_PWR +12V power for external console
B5 CAN_HT CAN BUS output. Internally connected via CAN_H and 120̫.
B6 SI_RXD Serial communication reception line
B7 SI_TXD Serial communication transmission line
B8 CAN_GND CAN BUS GND
7-20
(2) Encoder installation
Η To control AC motor with the inverter, it is necessary to install an incremental encoder with 2
phases shifted of 90 degrees. The encoder power supply is +14V.
A1/A3 : +14V : Positive of encoder power supply.
A2/A4 : GND : Negative of encoder power supply.
A13/A15 : A : Phase A of encoder.
A14/A16 : B : Phase B of encoder.
Θ Connection of encoder with open collector output ;
22BH9EL13
7-21
(3) Hydraulic controller
22BH9EL11

A1 PENC Positive of motor encoder power supply (14V)
A2 NENC Negative of motor encoder power supply
A3 BRAKE OIL Brake oil sensor signal
A4 -BATT Negative of battery
A5 KEY Connected to + batt trough an emergency switch and a 10 A fuse in series.
A6 CM Common power supply for Lift/Tilt/Aux1/Aux2/Tilt Lever/Lift Limit/SBR/
Brake Oil microswitches.
A7 LIFT ENABLE Potentiometer lifting enable input for potentiometer
A8 TILT ENABLE Lifting enable input for potension
A9 AUX_1 Aux 1 input (generally, side shift)
A10 AUX_2 Aux 2 input
A11 P_POS Solenoid coil /positive of reverse relay
A13 PHA Motor encoder phase A.
A14 PHB Motor encoder phase B.
A15 LIFT LIMIT Lift limit input switch signal (option)
A16 TILT LEVEL Auto Tilt Leveling input switch signal (option)
A17 PPOTAUX2 Positive of tilt angle potentiometer for Auto Tilt Leveling (option)
A18 CPOTAUX2 Wiper signal for tilt angle potentiometer for Auto Tilt Leveling (option)
A19 NPOTAUX2 Negative of tilt angle potentiometer for Auto Tilt Leveling (option)
A20 SBR Side battery cover input signal
A21 SR Speed reduction switch signal (option)
A23 P_NEG2 Negative of reverse relay
A24 NTHERM Negative of hydraulic motor temperature sensor.
A25 PTHERM Positive of hydraulic motor temperature sensor.
A28 PPOT Positive of lifting potentiometer
A29 CPOT Lifting potentiometer wiper signal.
A30 NPOT Negative of lifting potentiometer
A31 NPOTAUX1 Positive of load sensing potentiometer (option)
A32 CPOTAUX1 Load sensing potentiometer wiper signal (option)
A33 PPOTAUX1 Negative of load sensing potentiometer (option)
A34 P_POS+ +BATT
A35 P_NEG1 Negative of solenoid coil
7-22
22BH9EL12

B1 CAN_L Low level CANBUS
B2 CAN_H High level CANBUS
B3 CAN_BMS Select CANBUS boot mode
B4 SI_PWR +12V power for external console
B5 CAN_HT CAN BUS output. Internally connected via CAN_H and 120̫.
B6 SI_RXD Serial communication reception line
B7 SI_TXD Serial communication transmission line
B8 CAN_GND CAN BUS GND
7-23
4) FUNCTION CONFIGURATION
ÿ TRACTION CONTROLLER
Using the TRACTION menu of the programming console, the user can configure the following
functions ;
(1) Submenu "SET OPTION"
Η Power mode (performance mode)
Set up the performance mode of the equipment. The performance value varies by H, N, and E
mode.
- H : High. The fastest mode consuming greatest power.
- N : Normal. Normal speed.
- E : Economic. The slowest speed mode consuming the least power.
Θ Turtle mode
- ON : The speed is limited by TURTLE SPEED (PERFORMANCE, default value 70Hz).
- OFF : Speed according to the mode without speed limit.
Ι DISPLAY CHECK (display CAN communication)
- ON : DISPLAY needs to be connected for the vehicle to move.
- OFF : DISPLAY needs not be connected for the vehicle to move.
Κ FAN CONTROL (cooling fan operation)
- ON : When the controller temperature exceeds the FAN RUN TEMP (in the PERFORMANCE,
default value 40ä C), the fan beside the controller is started. After the fan start up, when
the controller temperature drops below the setpoint by 5ä C or more, the fan is stopped.
- OFF : The fan keeps running after key on.
Λ BATT CHECK (battery check)
- ON : When the BDI level falls below 10%, the maximum current is limited to 50% or less of
torque current and maximum speed is reduced to 60Hz.
- OFF : No limit is applied to performance.
Μ SAFETY BELT (select belt operation mode)
- WARN : Safety belt warning lamp blinks 3 times at engine start up.
- WEEP WARN : The safety belt warning lamp keeps blinking until the belt is fastened. (The
vehicles equipped with optional safety belt switch.)
- Clean : Keeps blinking until safety belt is fastened and the vehicle cannot travel. (An option for
clean work place.)
- NONE : The option for the vehicles without SAFETY BELT. Makes no response related with the
seat belt.
Ν SEQUENCE (operating sequence)
When this option is set to ON, the forward/reverse lever must be at Neutral for engine start up.
- ON : Required sequence :
ÂOperator seat - direction lever - accelerator pedal, or
Â Operator seat - accelerator pedal - direction lever (within SEQ. DELAY
(PERFORMANCE, default value 2 seconds).
- OFF : Required sequence (operable without SEAT sequence)
ÂDirection lever - accelerator pedal, or
ÂAccelerator pedal - direction lever (within SEQ. DELAY (PERFORMANCE, default
value 2 seconds).
7-24
Ξ HYDRO ON (select hydraulic steering mode)
- ON : When key-on, the hydraulic pump is operated and steering is always enabled.
- OFF : Hydraulic pump is operated to enable hydraulic steering only when the direction lever is in
forward or reverse position.
Ο ANTIROLLBACK (prevent roll back on a slope)
- ROLLBACK : If the vehicle rolls down at the speed exceeding the set-up ARB TRIGGER (within
Performance, default value 4 RPM) on a slope, this function controls the vehicle to
move slowly at ARB SPEED (within Performance, default value 0.3 Hz).
- STOP : If the vehicle rolls down at the speed exceeding the set-up ARB TRIGGER on a slope,
this function stops the vehicle completely for HOLDING TIME (within Performance,
default value 6 seconds) and changes it to ROLLBACK mode.
Π BRAKE TYPE (brake pedal type)
- DIGITAL : The mechanical brake pedal is only equipped with switch without a potentiometer, and
the accelerator pedal is released and brake pedal is selected (switch closed),
electrical braking is applied according to BRAKE DELAY (PERFORMACE, default
value 0.8 second).
- ANALOG : If the mechanical brake pedal is equipped with a potentiometer, the level of electrical
braking is controlled according to the magnitude of the analog brake signal.
Ρ MOTOR TEMP TYPE (motor temperature sensor type)
- DIGITAL : Turns on at the set-up alarm temperature.
- ANALOG : The analog signal from the motor temperature sensor is processed and the
temperature is displayed.
- NONE : Motor temperature sensor is not used. ("NONE" setting enables vehicle traction in case
of temperature sensor failure.)
΢ ACC&SPD DISPLAY (accelerator pedal display)
- ACCEL : Accelerator pedal position is reported to and displayed on DISPLAY.
- SPEED : Vehicle speed is reported to and displayed on DISPLAY.
Σ ACC&BRAKE MODE (accelerator pedal & bake mode)
- ON : Current and speed are limited to 50% of accelerator pedal command.
- OFF : Stops if both accelerator pedal and brake pedal are simultaneously depressed.
Τ STEER TABLE (setting table for the vehicle steering)
- 3WHEEL : Set to a 3-wheel vehicle regardless of parameter, and differential-controlled by
steering.
- AUTO : 3-wheel or 4-wheel is determined by steering parameter.
If the STEER RIGHT value of ADJUSTMENTS is greater than STEER LEFT,
determined to 3-wheel, otherwise, 4-wheel.
7-25
(2) Submenu "ADJUSTMENTS"
Η BATTERY TYPE
Selects battery voltage (24V, 36V, 48V, 80V, 96V)
Θ BATTERY CAPACITY
Rated capacity of battery.
Ι ADJUST BDI#1 (adjust BDI1)
Standard voltage at specific gravity 1.28, BDI 100% state.
Κ ADJUST BDI#2 (adjust BDI2)
Standard voltage at specific gravity 1.15, BDI 20% state.
Λ BDI RESET (BDI reset)
BDI is reset to initial value if there is a difference between the BDI reset level and the BDI value at
the previous termination, which is equal to the set up value at key on.
Μ ACCEL MIN (accelerator pedal minimum value)
When the accelerator pedal is fully closed, the minimum input value of the pedal is recorded. : set
up with VASS function. [See page 7-62], This can be set up manually.
Ν ACCEL MAX (accelerator pedal maximum value)
When the accelerator pedal is fully closed, the maximum input value of the pedal is recorded. : set
up with VASS function. [See page 7-62], This can be set up manually.
Ξ STEER RIGHT (right side steering value)
The sensing voltage at the wheel turned to the right fully (maximum range of steering
potentiometer) is recorded. : set up with VASS function. [See page 7-62], This can be set up
manually.
Ο STEER LEFT (left side steering value)
The sensing voltage at the wheel turned to the left fully (maximum range of steering
potentiometer) is recorded: set up with VASS function. [See page 7-62], This can be set up
manually.
Π STEER CENTER (value at steering shaft arranged at center)
The sensing voltage at the wheel at center is recorded: set up with VASS function. [See page 7-
62], This can be set up manually.
Ρ LC VOLTAGE (analog output 1 voltage)
Analog output voltage value. Adjusts the voltage of the line connector coil. (PWM output A35)
΢ AO2 VOLT (analog output 2 voltage)
Analog output voltage value. Adjusts the voltage of the fan relay coil. (PWM OUTPUT A23)
Σ AO3 VOLT (analog output 3 voltage)
Analog output voltage value. (PWM output A12)
7-26
(3) Submenu "PERFORMANCE"
Η ACCEL DELAY (acceleration gradient)
Adjust the time required for acceleration after stepping down the accelerator pedal. (Unit : second)
Θ RELEASE DELAY (deceleration gradient)
Adjusts the time required for stopping the vehicle after releasing the accelerator pedal. (Unit :
second)
Ι INVERSE DELAY (speed gradient at direction change)
Adjusts the time required for stopping the vehicle when the direction switch (forward-reverse
switch) is changed. (Unit : second)
Κ BRAKE DELAY (brake pedal deceleration gradient)
Adjusts the time required for stopping the vehicle after depressing the brake pedal and releasing
the accelerator pedal. (Unit : second)
Λ DECEL DELAY (speed change gradient)
Determines deceleration gradient when the output of accelerator pedal is decreasing.
Μ SR DELAY (deceleration signal gradient) (for SR option)
The gradient of deceleration made by speed reduction switch (SR: SPEED REDUCTION)
(*option).
Ν MAX FORWARD (maximum forward speed)
Determines the forward traction speed at the maximum input voltage of accelerator pedal.
Ξ MAX BACKWARD (maximum reverse speed)
Determines the reverse traction speed at the maximum input voltage of accelerator pedal.
Ο ACCEL CURVE (acceleration curve)
Adjusts the beginning part of the acceleration gradient.
Π DECEL CURVE (deceleration curve)
Adjusts the ending part of the decceleration gradient.
Ρ DEAD ZONE (set up acceleration dead band)
Establishes a dead band of acceleration input curve. (See the curve below.)
΢ X POINT (throttle X point)
This parameter changes the characteristics of acceleration input curve. (See the curve below.)
Σ Y POINT (throttle Y point)
This parameter changes the characteristics of acceleration input curve. (See the curve below.)
SPEED f(Hz)
MAX SPEED
TROTTLE Y
POINT
FREQ. CREEP
V
VACC THROTTLE 0 THROTTLE X VACC

MIN ZONE POINT MAX
20B7EL17
ACCEL MIN and ACCEL MAX values can be programmed using the VASS function.
7-27
Τ CURVE CUTBACK (curve deceleration gradient)
Indicates the deceleration when the vehicle doing a curve. At the point of time when the inner
wheel rotates backwards (about 67 degrees for 3-wheel vehicles) or stops (for 4-wheel vehicles,
the inner wheel almost stops at maximum steering) when the vehicle turns its direction, the speed
is reduced at preset ratio with reference to the speed of the outer wheel in straight forward travel.
Υ HOLDING TIME (time required for stopping when antirollback function is set up)
When performing the slope rollback prevention function, if ANTIROLLBACK (option) is set to
STOP, the vehicle is stopped for the preset time, before performing the function in the direction of
slope. (default value : 6sec).
SEQ. DELAY (direction change lever delay time)
Effective delay time from depression of accelerator pedal to the shifting of forward/reverse lever.
INCORRECT START (see Failure Code 7.1 page 7-78) is triggered if the forward/reverse lever is
not operated within the preset time after the depression of the accelerator pedal.
SEAT DELAY TIME (time allowed for leaving operator's seat)
If the operator leaves the seat exceeding the preset time, an INCORRECT START error is
triggered and traction limitation is applied.
CHAT TIME (chatting time setting)
If no action signal is received from traction or hydraulic system for a preset time, a CHAT TIME
OVER error [see (Error Code 7.1)] is triggered. See accelerator pedal, forward/reverse lever signal
for traction and lift, tilt, and shift signal for hydraulic system.
CREEP FREQ (pedal minimum speed)
The speed when forward/reverse signal is received and the voltage signal of the accelerator pedal
is minimum.
ARB SPEED (rollback speed on a slope)
If the rollback speed of the vehicle on a slope exceeds ARB TRIGGER, this function slows down
the rollback speed to preset speed.
ARB TRIGGER (speed at antirollback function is activated)
If the rollback speed on a slope exceeds the preset speed, antirollback function is activated.
TURTLE SPEED
When TURTLE MODE is set up, the maximum speed is the setting speed regardless of POWER
MODE.
TRAC SR PERCENT (deceleration limit setting) (for SR option)
When SR (SPEED REDUCTION) switch signal is received, traction speed is reduced by a preset
ratio (default value is 60%).
FAN RUN TEMP (cooling fan operating temperature setting)
When the COOLING FAN (cooling fan operation - in Set Option) is ON and the controller
temperature exceeds the setpoint, the fan beside the controller starts operation. After the fan start
up, when the controller temperature drops below the setpoint by 5ä C or more, the fan is stopped.
SPEED FACTOR
Speed factor is adjusted to display correct speed in DISPLAY. This factor is adjusted by the
following formula according to the mechanical characteristics of the lift truck ;
Speed Factor = 2*π *R*60*0.001/G*100000
where, R = tire radius (m)
G = gear ratio
7-28
ÿ PUMP CONTROLLER
Using the PUMP menu of the programming console, the user can configure the following functions ;
(1) Submenu "SET OPTION"
Η POWER MODE (performance mode)
Set up the performance mode of the equipment. The performance value varies by H, N, and E
mode.
H : High. The fastest mode consuming greatest power.
N : Normal. Normal speed.
E : Economic. The slowest speed mode consuming the least power.
Θ BATTERY CHECK (lift cutback)
ON : When the BDI level falls below 10%, lift speed is limitted by 60HZ and activated for 15
seconds after turning on the key switch).
OFF : No change.
Ι DISPLAY CHECKT (display CAN communication)
ON : DISPLAY needs to be connected for the vehicle to move.
OFF : DISPLAY needs not be connected for the vehicle to move.
Κ FAN CONTROL (cooling fan operation)
ON : When the controller temperature exceeds the FAN RUN TEMP (in the PERFORMANCE,
basic value of 40äC), the fan beside the controller is started. After the fan start up, when the
controller temperature drops below the setpoint by 5ä C or more, the fan is stopped.
OFF : The fan keeps running after key on.
Λ MOTOR TEMP TYPE (motor temperature sensor type)
DIGITAL : Turns on at the set-up alarm temperature.
ANALOG : The analog signal from the motor temperature sensor is processed and the
temperature is displayed.
NONE : Motor temperature sensor is not used. ("NONE" setting enables vehicle operation in case
of temperature sensor failure.)
Μ CONTROL LEVER (lever type setting)
MANUAL : The general type of lift lever is stick type.
FINGERTIP : Used in the model using fingertip. For this, turn on the CAN EXPAND.
JOYSTICK : Used in the model using joystick.
Ν AUX1 FUNCTION (auxiliary device 1)
When ON is selected, Side Shift can be used.
Ξ AUX2 FUNCTION (auxiliary device 2)
When ON is selected, auxiliary device can be used.
Ο AUX3 FUNCTION (auxiliary device 3)
When ON is selected, auxiliary device can be used.
Π DIGITAL LIFT
ON : Operates lift at maximum speed by enable signal.
OFF : Lift speed is controlled at enable signal and analog signal according to the magnitude of the
signal.
7-29
Ρ TILT ANGLE LIMIT (option)
Not used.
΢ TILT ANGLE (tilt angle sensor setting)
ON : Activate this function for the models equipped with tilt angle sensor.
-> TILT MIN ANG, MAX ANG, and CENTER ANG menus of ADJUSTMENTS are enabled.
Σ LOAD WEIGHT (load weight sensor setting)
ON : Activate this function for the models equipped with load weight sensor.
-> LOAD WEIGHT MIN/MAX menus of ADJUSTMENTS are enabled.
Τ MAST HEIGHT
Not used.
Υ CAN EXPANSION
ON : Communicate with external fingertip controller connected via CAN to use fingertip devices.
OFF : The models not using fingertip device shall be set up to OFF.
7-30
(2) Submenu "ADJUSTMENTS"
Η BATTERY TYPE
Selects battery voltage (24V, 36V, 48V, 80V, 96V)
Θ LIFT MIN (minimum lifting value)
When the lift lever is pulled to the maximum, the minimum value of the lift sensor input voltage
after lift enable signal has been turned on is recorded: set up using VASS function. [See page 7-
63, 8], This can be set up manually.
Ι LIFT MAX (maximum lifting value)
When the lift lever is pulled to the maximum, the maximum value of the lift sensor input voltage is
recorded: set up using VASS function. [See page 7-64, 8], This can be set up manually.
# This appears when the TILT ANG and LOAD WEIGHT of SET OPTION is ON.
Κ TILT ANGLE MIN (tilt angle minimum voltage - applicable for vehicles equipped with
Auto Tilt Leveling option)
As a minimum voltage value of tilt angle sensor, if the value is not accurate, fine tuning is allowed
using the menu.
Λ TILT ANGLE MAX (tilt angle maximum voltage - applicable for vehicles equipped with
As a maximum voltage value of tilt angle sensor, if the value is not accurate, fine tuning is allowed
using the menu.
Μ TILT ANGLE CENTER (tilt angle center voltage - applicable for vehicles equipped with
As a central voltage value of tilt angle sensor, if the value is not accurate, fine tuning is allowed
using the menu.
Ν LOAD WEIGHT MIN (load weight sensor minimum voltage - vehicle equipped with
LOAD WEIGHT Sensor option)
As a minimum voltage value of load weight sensor, if the value is not accurate, fine tuning is
allowed using the menu.
Ξ LOAD WEIGHT MAX (load weight sensor maximum voltage - vehicle equipped with
LOAD WEIGHT Sensor option)
As a maximum voltage value of load weight sensor, if the value is not accurate, fine tuning is
allowed using the menu.
Ο AO1 VOLTAGE (analog output 1 voltage - solenoid)
Analog output 1 voltage value. Adjusts the voltage of the solenoid coil.
Π AO2 VOLTAGE (analog output 2 voltage - line contactor)
Analog output 2 voltage value. Adjusts the voltage of the line contactor.
Ρ AO3 VOLTAGE (analog output 3 voltage)
Analog output voltage 3.
7-31
# The followings appear when CAN EXPANSION (in the SET OPTION) is ON.
΢ LIFT MIN (fingertip lift lever minimum value)
The minimum value of fingertip lift lever entering via CAN EXPANSION (setpoint via VASS)
Σ LIFT MAX (fingertip lift lever maximum value)
The maximum value of fingertip lift lever entering via CAN EXPANSION (setpoint via VASS)
Τ LOWER MIN (fingertip lower lever minimum value)
The minimum value of fingertip lower lever entering via CAN EXPANSION (setpoint via VASS)
Υ LOWER MAX (fingertip lower lever maximum value)
The maximum value of fingertip lower lever entering via CAN EXPANSION (setpoint via VASS)
TILTUP MIN (fingertip tilt up lever minimum value)
The minimum value of fingertip tilt up lever entering via CAN EXPANSION (setpoint via VASS)
TILTUP MAX (fingertip tilt up lever maximum value)
The maximum value of fingertip tilt up lever entering via CAN EXPANSION (setpoint via VASS)
TILTDOWN MIN (fingertip tilt down lever minimum value)
The minimum value of fingertip tilt down lever entering via CAN EXPANSION (setpoint via VASS)
TILTDOWN MAX (fingertip tilt down lever maximum value)
The maximum value of fingertip tilt down lever entering via CAN EXPANSION (setpoint via VASS)
AUX1 IN MIN (fingertip auxiliary 1 IN lever minimum value)
The minimum value of fingertip AUX1 IN lever entering via CAN EXPANSION (setpoint via VASS)
AUX1 IN MAX (fingertip auxiliary 1 IN lever maximum value)
The maximum value of fingertip AUX1 IN lever entering via CAN EXPANSION (setpoint via VASS)
AUX1 OUT MIN (fingertip auxiliary1 OUT lever minimum value)
The minimum value of fingertip AUX1 OUT lever entering via CAN EXPANSION (setpoint via VASS)
AUX1 OUT MAX (fingertip auxiliary1 OUT lever maximum value)
The maximum value of fingertip AUX1 OUT lever entering via CAN EXPANSION (setpoint via VASS)
AUX2 IN MIN (fingertip auxiliary 2 IN lever minimum value)
AUX2 IN MAX (fingertip auxiliary2 IN lever maximum value)
AUX3 IN MIN (fingertip auxiliary3 IN lever minimum value)
AUX3 IN MAX (fingertip auxiliary3 IN lever maximum value)
7-32
(3) Submenu "PERFORMANCE"
Η ACCEL DELAY (acceleration gradient)
Adjusts the time required for hydraulic motor to be accelerated from stand still to maximum speed
(unit: second).
Θ DECEL DELAY (deceleration gradient)
Adjust the time required for stopping hydraulic motor. (Unit : second)
Ι LIFT MIN SPEED (minimum lifting speed)
Motor speed at the lift sensor voltage of LIFT MIN (ADJUSTMENTS).
Κ LIFT MAX SPEED (maximum lifting speed)
Motor speed at the lift sensor voltage of LIFT MAX (ADJUSTMENTS).
Λ DEAD ZONE (set up acceleration dead band)
Established dead band of acceleration input curve.
Μ X POINT (throttle X point)
Modifies the characteristics of acceleration input curve.
Ν Y POINT (throttle Y point)
Modifies the characteristics of acceleration input curve.
Ξ TILT SPEED
Motor speed in tilting operation
Ο AUX1 SPEED (speed of auxiliary device 1)
Motor speed in side shift operation
Π AUX2 SPEED (speed of auxiliary device 2)
Motor speed when auxiliary device 2 is activated.
Ρ AUX3 SPEED (speed of auxiliary device 3)
Motor speed when auxiliary device 3 is activated.
΢ IDLE SPEED (IDLE drive speed for steering)
Motor speed for steering device when forward/reverse lever is operated.
When the HYDRO ON (SET OPTION) of traction controller is ON, the hydraulic motor is always
driven at preset speed.
Σ IDLE TIME (IDLE drive time for steering)
When traction is in neutral position. Hydraulic motor is driven at IDLE SPEED for preset time
when accelerator or brake pedal is depressed.
Τ LIFT SR PERCENT (lift limit speed)
At receiving LIFT LIMIT SWITCH signal limit the lift speed by the preset %. (This option is not
available for 15/18/20BT-9 series)
Υ FAN RUN TEMP (cooling fan operating temp setup)
When the cooling fan is ON(cooling fan operation in the set option) and the controller temperature
exceeds preset temperature, the fan beside the controller starts operation. After the fan start up,
when the controller temperature drops below the setpoint by 5äC or more, the fan is stopped.
7-33
# This appears when the LOAD WEIGHT of the SET OPTION is ON. (for LOAD
WEIGHT SENSOR option)
LOADWGT MIN
The weight corresponding to the minimum voltage of LOAD WEIGHT SENSOR set up with
VASS.
LOADWGT MAX
The weight corresponding to the maximum voltage of LOAD WEIGHT SENSOR set up with
VASS.
# This appears when the MAST HEIGHT of the SET OPTION is ON (for MASTER
HEIGHT option).
7-34
5) PROGRAMMING & ADJUSTMENTS
There are two ways to adjust parameter via a console or buttons on the instrument panel.
ö Adjustments via buttons on the instrument panel, please refer to the section [6. Instrument Panel,
Page 7-53].
Adjustments via console (option)
Parameter adjustment and inverter characteristics modification shall be conducted via the console
after 8-pins communication line of the extension adaptor connects to the 8-pins connector of the
traction controller and the pump controller. Connect the console to the CAN communication port of
the extension adaptor of the traction controller and the pump controller. The figure below shows the
extension adaptor.
22BH9EL35
(1) Descriptions of console

The figure below shows the digital console.
22BH9EL15
7-35
(2) Description of standard console menu
Η
22BH9EL16
7-36
Θ Traction controller
22BH9EL19
7-37
Ι Pump controller
22BH9EL20
7-38
(3) Description of alarm and fault menu
The microprocessor in the controller records the last five faults that have occurred. The items
remembered relative to each fault are: the code of the fault, the number of times the particular fault
occurred, type of the fault, and the hour meter count.
This function permits a deeper diagnosis of problems as the recent history can now be accessed..
The flow chart below shows how to use the Fault function via the console.
Η Connect the console to the CAN communication

port of the extension adaptor of the traction
controller and the pump controller.
Θ Press FUN key to go to TRACTION or PUMP

window, press Up/Down keys to go to the Fault
window.
Ι Press Enter key to enter the Fault window.

Latest 5 faults can be looked up using the
Up/Down keys.
Κ Press ESC key to exit the window.
22BH9EL21
7-39
(4) Description of the menu function
a. Access to set option menu

Θ Press FUN key to go to TRACTION or PUMP

window, press Up/Down keys to go to the Set
Option window.
Ι Press Enter key to enter the Set Option window.

The latest parameter will appear.
Go to the desired parameter by pressing the
Up/Down key.
Κ To modify parameter value, press ENT key, and

Press Right key to change the unit, or change
the parameter value by pressing the Up/Down
key, and
Press ENT key to save the changed prameter
value.
Λ Press ESC key to exit the Set Option menu.
22BH9EL22
7-40
b. Access to adjustment menu
Η Press FUN key to go to TRACTION or PUMP

window, press Up/Down keys to go to the
Adjustment window.
Θ Press Enter key to enter the Adjustment window.

Up/Down key.
Ι To modify parameter value, press ENT key, and

Press Right key to change the unit, or change
the parameter value by pressing the Up/Down
key, and press ENT key to save the changed
prameter value.
Κ Press ESC key to exit the Adjustment menu.
22BH9EL22-1
7-41
c. Access to performance menu

Performance window.
Θ Press Enter key to enter the Performance

window.
The latest parameter will appear..
Up/Down key.
Ι To modify parameter value, press ENT key, and

Press Right key to change the unit, or the
changed prameter value by pressing the
Up/Down key, and press ENT key to save the
changed prameter value. According to the
Power mode of the Option menu, N, E, or H is
attached to the end of the parameter name.
Κ Press ESC key to exit the Performance menu.
22BH9EL22-2
7-42
d. Access to monitoring menu

Monitoring window.
Θ Press Enter key to enter the Monitoring window.

Go to the parameter to be monitored by pressing
the Up/Down key.
Ι Press ESC key to exit the Monitoring menu.
22BH9EL22-4
7-43
(5) Function of the console parameter READ/COPY
The console has the READ function which reads the parameters of traction and hydraulic
controllers and saves them in the console memory and the COPY function which writes the saved
parameters into the traction and hydraulic controllers. The parameters available for READ and
COPY are Set Option, Adjustment and Performance menus.
a. READ function
Θ Press FUN key to enter the READ COPY

window.
Ι Press ENT key to pop up the message asking

READ or not of the traction controller parameter.
Κ Press ESC key to pop up the message asking

READ or not of the pump controller parameter.
Λ Press ENT key begin parameter reading.
Μ When READ has been completed, following

message appears.
Ν Press ESC key to exit the window.
22BH9EL23
7-44
b. COPY function
Θ Press FUN key to enter the READ COOPY

window.
Ι Press COPY key to enter the Copy Parameter

window.
Κ Press ENT key to pop up the message asking

COPY or not of the traction controller parameter.
Λ Press ESC key to pop up the message asking

COPY or not of the pump controller parameter.
Μ Press ENT key begin parameter copying.
Ν When COPY has been completed, following

message appears.
Ξ Press ESC key to exit the window.
22BH9EL23-1
7-45
6) MONITORING MENU
(1) Traction controller
Η RH MOTOR VOLT (right hand motor voltage)
The line RMS (effective) voltage of the right hand side motor, fed by the controller. The voltage
indicated on the motor name plate is rated line RMS voltage.
Θ LH MOTOR VOLT (left hand motor voltage)
The line RMS (effective) voltage of the left hand side motor, fed by the controller.
Ι RH REF FREQ (right hand motor speed - controller)
Reference speed value of the right hand motor (speed value instructed from controller to the
motor).
Κ LH REF FREQ (left hand motor speed - controller)
Reference speed value of the left hand motor (speed value instructed from controller to the
motor).
Λ RH ENC FREQ (right hand motor speed - motor sensor)
Actual value of the right hand motor speed (measured and calculated using the speed sensor of
the motor).
Μ LH ENC FREQ (left hand motor speed - motor sensor)
Actual value of the left hand motor speed (measured and calculated using the speed sensor of
the motor).
Ν RH CURRENT (right hand motor RMS current)
RMS (effective) current of the right hand motor.
Ξ LH CURRENT (left hand motor RMS current)
RMS (effective) current of the left hand motor.
Ο RH INV TEMP (right hand controller temperature)
Inside temperature of the right hand controller.
Π LH INV TEMP (left hand controller temperature)
Inside temperature of the left hand controller.
Ρ RH MTR TEMP (right hand motor temperature)
Temperature of the right hand motor, indicated by '0' if MTR TEMP TYPE (in the SET OPTION) is
NONE or DIGITAL.
΢ LH MTR TEMP (left hand motor temperature)
Temperature of the left hand motor, indicated by '0' if MTR TEMP TYPE (in the SET OPTION) is
NONE or DIGITAL.
Σ ACCEL POT (accelerator pedal output value)
Output voltage of the accelerator pedal sensor.
Τ BRAKE POT (brake pedal output value)
Sensor output voltage of analog type brake pedal.
Υ STEER POT (steering angle sensor output value)
Output voltage of the steering angle sensor.
STEER ANGLE (steering angle)
The steering angle measured and calculate with steering sensor.
BATTERY VOLT (battery voltage)
Battery voltage.
BDI LEVEL (residual capacity of battery)
Remaining capacity of battery. Expressed by % unit.
7-46
SPEED (vehicle speed)
Vehicle speed in Km/H unit, which is the same as displayed on the DISPLAY main screen.
FORWARD SW (forward switch)
Status of forward lever;
- ON : forward lever is engaged
- OFF: neutral or reverse
BACKWARD SW (reverse switch)
- ON : reverse lever is engaged
- OFF: neutral or forward
ACC ENABLE SW (accelerator pedal digital input signal)
The status of the digital input signal installed in the accelerator pedal.
- ON : recognized as the accelerator pedal is depressed.
- OFF : recognized as the accelerator pedal is inactive.
SEAT SW (seat switch)
The seat switch checks whether it is seated;
- ON : the seat is occupied
- OFF : the seat is empty.
PEDAL BRK SW (brake pedal switch)
Pedal brake switch.
- ON : recognized as the brake pedal is depressed.
- OFF : recognized as the brake pedal is released.
HAND BRK SW (hand brake switch)
ON : recognized as the hand brake pedal is engaged.
OFF : recognized as the hand brake pedal is released.
SOFT VER. (software version)
The version of the program installed in the controller.
RUN HOUR (travel drive hours)
Accumulative time while the traction motor has been GATE ON. That is, the total traction time of
the vehicle.
KEY HOUR (vehicle powered time)
Accumulative time while the vehicle has been KEY ON. That is, the total time while the vehicle
has been powered.
(2) Pump Controller
Η MOTOR VOLT (motor voltage)
The line RMS (effective) voltage of the pump motor, fed by the controller. The voltage indicated on
the motor name plate is rated line RMS voltage.
Θ REF FREQ (motor speed - controller)
Reference speed value of the pump motor (speed value instructed from controller to the motor).
Ι ENC FREQ (motor speed - motor sensor)
Actual value of the pump motor speed (measured and calculated using the speed sensor of the
motor).
Κ CURRENT (motor RMS current)
RMS (effective) current of the pump motor.
Λ INV TEMP (controller temperature)
Inside temperature of the pump controller.
7-47
Μ MTR TEMP (motor temperature)
Temperature of the pump motor, indicated by '0' if MTR TEMP TYPE (in the SET OPTION) is
NONE or DIGITAL.
Ν LIFT POT (lift sensor value)
Analog output of lift lever.
Ξ TILT ANG POT (tilt angle sensor value)
Potentiometer output voltage of the tilt angle sensor.
ö Available only for the vehicles equipped with Auto Tilt Leveling option. Other
vehicles show '0' value.
Ο LOAD WGT POT (load weight sensor output)
Potentiometer output voltage of the load pressure sensor.
ö Available only for the vehicles equipped with Load Weight Sensor option. Other
Π TILT ANGLE (tilt angle value)
Tilt angle calculated from the output of the tilt angle sensor.
ö Available only for the vehicles equipped with Auto Tilt Leveling option. Other
Ρ LOAD WEIGHT (load weight value)
The load weight calculated from the load weight sensor output.
ö Available only for the vehicles equipped with Load Weight Sensor option. Other
΢ BATT VOLT (battery voltage)
Battery voltage. Synchronized with traction controller via CAN communication. However, if the
difference between the measured volts of the traction and pump controllers exceeds 3V, self-
measured voltage is displayed.
Σ LIFT SW (lift switch signal)
Digital input status of lift lever.
- ON : recognized as the lift lever is engaged.
- OFF : recognized as the lift lever is not engaged.
Τ TILT SW (tilt switch signal)
Digital input status of tilt lever.
- ON : recognized as the tilt lever is engaged.
- OFF : recognized as the tilt lever is not engaged.
Υ AUX1 SW (auxiliary device 1 switch signal)
Digital input status of side shift lever.
- ON : recognized as the side shift lever is engaged.
- OFF : recognized as the side shift lever is not engaged.
AUX2 SW (auxiliary device 2 switch signal)
Digital input status of auxiliary device 2.
SBR SW (battery removal/installation switch signal)
Acronym of Side Battery Removal. When safety device is applied after battery installation, the
SBR switch on the safety device turns ON.
BRAKE OIL SW (brake oil switch signal)
Turns ON when brake oil level drops below preset level.
LIFT LIMIT SW (for LIFT LIMIT SWITCH option)
Lift limit switch input signal. Presently, this option is not in use.
7-48
TILT LEVEL SW (for option)
Tilt leveling switch input signal.
SR SW (speed reduction switch signal) (for SR option)
SR (SPEED REDUCTION) switch input status. (This option is not available for this model)
MODE1 SW (controller application selector switch 1)
This switch used to select the application of controller is set up according to the table below ;
MODE2 SW (controller application selector switch 2)
This switch used to select the application of controller is set up according to the table below ;
MODE1 SW MODE2 SW Controller application
0 0 Pump controller
0 1 NA
1 0 Traction controller master
1 1 Traction controller slave
In the 15/18/20BT-9 vehicle, both MODE1 and MODE2 SW must be '0.'

AUX3 SW (auxiliary device 3 switch signal)
Digital input status of auxiliary device 3.
Software version
The version of the program installed in the controller.
RUN HOUR (pump motor drive hours)
Accumulative time while the pump motor has been GATE ON. That is, the total time of pump
motor has operated.
KEY HOUR (vehicle powered time)
Accumulative time while the vehicle has been KEY ON. That is, the total time while the vehicle
has been powered.
The followings monitoring items appear when CAN EXPANSION in the SET OPTION is ON.
CAN AI1 (CAN analog input 1)
The voltage value of the first analog signal entered via CAN EXPANSION.
The voltage value of the second analog signal entered via CAN EXPANSION.
The voltage value of the third analog signal entered via CAN EXPANSION.
The voltage value of the fourth analog signal entered via CAN EXPANSION.
The voltage value of the fifth analog signal entered via CAN EXPANSION.
The voltage value of the sixth analog signal entered via CAN EXPANSION.
The voltage value of the seventh analog signal entered via CAN EXPANSION.
The voltage value of the eighth analog signal entered via CAN EXPANSION.
The voltage value of the ninth analog signal entered via CAN EXPANSION.
7-49
The voltage value of the tenth analog signal entered via CAN EXPANSION.
CAN DI1 (CAN digital input 1)
The first digital signal entered via CAN EXPANSION.
The second digital signal entered via CAN EXPANSION.
The third digital signal entered via CAN EXPANSION.
The fourth digital signal entered via CAN EXPANSION.
The fifth digital signal entered via CAN EXPANSION.
The sixth digital signal entered via CAN EXPANSION.
The seventh digital signal entered via CAN EXPANSION.
The eighth digital signal entered via CAN EXPANSION.
CAN ENCODER 1 (CAN motor sensor signal 1)
Motor sensor signal 1
CAN ENCODER 2 (CAN motor sensor signal 2)
Motor encoder signal 2
CAN EV1 KP (CAN proportional control gain 1)
The proportional control gain which opens/closes the valve that generates the first analog signal
entered via CAN EXPANSION.
The proportional control gain which opens/closes the valve that generates the second analog
signal entered via CAN EXPANSION.
The proportional control gain which opens/closes the valve that generates the third analog signal
The proportional control gain which opens/closes the valve that generates the fourth analog signal
The proportional control gain which opens/closes the valve that generates the fifth analog signal
The proportional control gain which opens/closes the valve that generates the sixth analog signal
The proportional control gain which opens/closes the valve that generates the seventh analog
The proportional control gain which opens/closes the valve that generates the eighth analog
7-50
The proportional control gain which opens/closes the valve that generates the ninth analog signal
The proportional control gain which opens/closes the valve that generates the tenth analog signal
MAST HEIGHT1 (CAN mast height 1)
This option is not in use.
MAST HEIGHT2 (CAN mast height 2)
This option is not in use.
7-51
7) GENERAL SUGGESTION FOR SAFETY
For a proper installation take care of the following recommendations :
After operation, even with the key switch is turned off, the internal capacitors of the controller 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.
Do not connect the controller to a battery with a nominal value different from the value indicated on
the plate. If the battery value is greater, the SMPS or FET elements may fail; if it is lower, the
controller does not "power up."
During battery charge, disconnect the controller from the battery.
Before doing any operation, ensure that the battery is disconnected and when all the installation is
completed start the machine with the drive wheels raised from the floor to ensure that any
installation error do not compromise safety.
Take care all the inductive devices in the truck (horn, solenoid valves, coils, contactors) have a
proper transient suppression device.
7-52
6. INSTRUMENT PANEL : DISPLAY
1) 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
22BH9OM65
7-53
2) WARNING LAMP
(1) Brake oil level warning lamp
Blinks when the brake oil level in the reservoir is below the lower
limit.
22BH9EFD01
(2) Wrench warning lamp

This LED blinks when an electric device (controller, motor, cable,
etc.) is in alarm condition.
22BH9EFD02
(3) Thermometer warning lamp

This LED blinks when the controller or motor temperature is
high.
22BH9EFD03
(4) Seat warning lamp

This LED blinks when the operator is not on the seat.
22BH9EFD04
(5) Seat belt warning lamp

(1) This LED blinks when the seat belt is not correctly fastened.
22BH9EFD05
(6) Handbrake warning lamp

(1) This LED blinks when the handbrake is activated.
22BH9EFD06
7-54
3) TESTER MENU
(1) UP button
Press to select upward move
22BH9EFD07
(2) DOWN button (DOWN/TURTLE button)

Press to select downward move
TURTLE MODE ON/OFF
22BH9EFD08
(3) LEFT/MENU button

Press to select leftward move
Go into the menu
22BH9EFD09
(4) RIGHT/PERFORMANCE button

Press to select rightward move
POWER MODE H/N/E
22BH9EFD10
(5) Cancel (ESC) button

Press to select cancel
Keep pressing this button shows PASSWORD entry field.
22BH9EFD11
(6) ENTER button

Press to select Enter
22BH9EFD12
7-55
4) LCD FUNCTION
1 6
2 10
3
7
5
8
22BH9EFD13
1 Current time 6 Hour meter

2 Turtle mode 7 Wheel position and running direction
3 Truck speed pointer 8 Power mode
4 Accelerator level 9 BDI (battery's state of charge)
5 Truck speed 10 Load weight (option)
(1) Current time

The number shows the current time according to the setting, which can be changed by DISPLAY
Setting [6. 5) (1), Page 7-58].
(2) Turtle mode
The turtle symbol is normally off. When this symbol appears, the Turtle Mode is activated
regardless of the Power Mode of the truck to reduce the maximum speed to the setpoint. This
mode can be activated by pressing the button.
7-56
(3) Truck speed pointer
The speed of the truck is indicated with a pointer.
(4) Accelerator level
The level of the accelerator pedal is shown with total ten bars, each of which indicates the
maximum, minimum and one tenth of the accelerator pedal level.
When the ACC&SPD DISPLAY (an option for Traction Controller) is selected to SPD, this indicator
shows the truck speed same as the (3) Speed pointer.
(5) Truck speed
The truck speed is shown in number. According to the DISPLAY setting (see 6. 5) (1), Page 7-58),
km/h or mph unit is available.
(6) Hour meter

The number shows the hours worked. The letter present near the hour meter shows which hour
meter is displayed.
- hK: the Key Hour shows the truck Key ON time;
- hT: the Traction Hour shows the Gate ON (driven) time of the traction motor.
- hP: the Pump Hour shows the Gate ON (driven) time of the pump motor.
(7) Wheel position and running direction
The arrow point is up when the truck is forward running and points down when the truck is reverse
running. The arrow point is moved to the leftward or the rightward according as the direction of the
steering angle.
(8) Power mode
The letter; H, N, or E, shows the Power Mode which is being used in the controller. The mode can
be scrolled by pressing the button sequentially. When a mode is selected, the related
information will be sent via CAN-BUS to traction and pump controllers that will manage this data.
H (High) - corresponds to the highest performance
N (Normal) - corresponds to normal performance
E (Economic) - corresponds to economic performance
(9) BDI (battery state of charge)
The battery state of charge is shown by ten bars. Each bar represents the 10% of the battery
charge. As the battery becomes discharged, the bars turn off progressively, one after another, in
proportion to the value of the residual battery charge. When the residual battery charge is 20% or
under, the bars displayed become red.
7-57
5) HOW TO USE DISPLAY MENU
(1) User menu setting
22BH9EFD14
7-58
22BH9EFD15
7-59
6) DESCRIPTION OF THE CONTROLLER MENU
(1) Access to controller menu
If this button is pressed long, the PASSWORD dialog appears.
Enter correct PASSWORD and press button to access the controller menu.
(2) How to change detail menus
The detail items of menu can be changed as follows ;
22BH9EL24
Selection can be made in 3 methods as follows ;
22BH9EL25
7-60
7) FAILURE HISTORY MENU
(1) Failure history
Failure history can be looked up as follows ;
22BH9EL26
At the failure list step, press button long to delete all the failure history list.
(2) Detail failure history
22BH9EL27
Η Failure code No.

Θ Failure name
Ι Frequency of continual failures
Κ Expressed with the related information, current, voltage, temperature etc., at the time of failure
occurred.
Λ Failure occurrence Key On hour meter time
7-61
8) VASS SET UP 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 operation
is conducted after performing ; Truck Menu -> SETTING -> VASS functions; and by pedal, lift lever,
and steering wheel. The flow chart below shows how to use the VASS function of DISPLAY.
(1) ACCEL VASS setting method
22BH9EL28
(2) LIFT VASS setting method
22BH9EL29
7-62
(3) STEERING VASS setting method
22BH9EL30
22BH9EL31
7-63
* VASS setting (other versions)
22BH9EL32
22BH9EL32-1
7-64
22BH9EL33
9) STRUCTURE OF CLUSTER MENU
22BH9EL36
22BH9EL37
7-65
22BH9EL38
22BH9EL39
7-66
22BH9EL40
22BH9EL41
7-67
22BH9EL42
22BH9EL43
7-68
22BH9EL44
22BH9EL45
22BH9EL46
7-69
22BH9EL47
22BH9EL48
7-70
22BH9EL49
22BH9EL50
7-71
22BH9EL51
22BH9EL52
7-72
22BH9EL53
22BH9EL54
7-73
22BH9EL55
22BH9EL56
7-74
22BH9EL57
22BH9EL58
7-75
22BH9EL59
22BH9EL60
7-76
22BH9EL61
10) ANALYSIS OF THE CLUSTER DISPLAYS RELATED WITH WARNING

See 7. FAILURE AND WARING CODE, CONTROLLER PCB MODEL
7-77
7. FAILURE AND WARNING CODE, CONTROLLER PCB MODEL
1) FAILURE AND WARNING CODE
(1) Traction failure code
Code Failure Description Corrective Action

1 WATCH DOG Interruption fails Restart
Reinstall the software
Replace control board of controller
2 FET DRIVE1 FET element in the controller failed Restart
Check the battery, replace controller
3 FET DRIVE2 FET element in the controller stack failed Restart
Check battery
Replace controller
4 PSU UNDER VOLT Occurs when control board of controller Restart
voltage falls below 9.6V Replace SMPS in the controller
5 OVER VOLTAGE Occurs when battery rated voltage Check battery
exceeds 150% of rated voltage Limit quick speed change
6 OVER CURRENT1 When RH motor current (rms) exceeds Overload, over speed
180% of the rated current Limit quick speed change
Check battery
7 OVER CURRENT2 When LH motor current (rms) exceeds Overload, over speed
180% of the rated current Limit quick speed change
Check battery.
8 PCB OVER TEMP Temperature of the controller PCB Check cooling fan,
exceeds 85ä
C If the controller temperature sensor
has failed, replace the controller
9 INV. OVER TEMP1 Temperature of the stack in the Check cooling fan,
controller exceeds 140ä
. has failed, replace the controller
10 INV. OVER TEMP2 Temperature of the stack in the Check cooling fan,
controller exceeds 140ä
11 ENCODER PWR1 The connector of the encoder measuring Check the motor encoder wiring and
RH motor speed is Open line short circuit
12 ENCODER PWR2 The connector of the encoder measuring Check the motor encoder wiring and
LH motor speed is Open line short circuit
13 CONTACT DRIVER Analog output PWM drive short circuit Restart
Replace control board
14 SW UNDERVOLT Battery voltage is less than the UNDER Check battery
VOLT(in Engineer) % of the rated voltage Limit overload, quick speed acceleration
15 SW OVERVOLT Battery voltage exceeds the OVER Check battery
VOLT(in Engineer) % of the rated voltage Limit quick speed reduction
16 SW OVER RH motor current (rms) exceeds the Limit overload, over speed, quick
CURRENT1 OVER CURRENT (in Engineer) % of the speed change.
maximum allowable current (rms) of the
controller
7-78
17 SW OVER LH motor current (rms) exceeds the Limit overload, over speed, quick
CURRNET2 OVER CURRENT (in Engineer) % of the speed change
controller
18 SW OVER TEMP1 Temperature of the RH controller stack
Check cooling fan. If the controller
exceeds 125ä
C temperature sensor has failed,
replace the controller
19 SW OVER TEMP2 Temperature of the LH controller stack Check cooling fan. If the controller
exceeds 125ä C temperature sensor has failed,
replace the controller
20 MTR OVER TEMP1 Temperature of the RH motor exceeds 145ä
C Limit operation, check the motor
21 MTR OVER TEMP2 Temperature of the LH motor exceeds 145ä
C Limit operation, check the motor
22 POWER CABLE1 Cable between the controller and RH Check wiring
motor is open
23 POWER CABLE2 Cable between the controller and LH Check wiring
motor is open
24 CT SENSOR1 When the controller gate is off, and the Check the CT (current) connector of
RH motor current (rms) exceeds 30A the control board
Replace the control board.
25 CT SENSOR2 When the controller gate is off, and the Check the CT (current) connector of
LH motor current (rms) exceeds 30A the control board
Replace the control board
26 ENCODER PHASE1 RH motor encoder signal failure RH motor UVW connection check.
Check encoder wiring.
27 ENCODER PHASE2 LH motor encoder signal failure LH motor UVW connection check.
Check encoder wiring.
28 CAN PUMP KO Pump controller CAN communication Check the 8-pin connector for
failure communication.
If pump controller is unusable,
replace it.
29 CAN DISP KO DISPLAY CAN communication failure Check the 8-pin connector for
communication.
Check molex pin for DISPLAY
communication.
If DISPLAY is unusable, replace it
30 CAN EPS KO EPS controller CAN communication Check the 8-pin connector for
Check EPS side communication line.
31 WRONG SET BATT Occurs when battery voltage is below Check BATTERY TYPE
90% or exceeds 120% of rated voltage. (ADJUSTMENT)
BATTERY TYPE setting in the Check battery specification
ADJUSTMENTS is incorrect
32 BATT LOW LEVEL Occurs when residual battery capacity Charge the battery immediately
drops below the setpoint
7-79
33 ACCEL SENSOR Occurs when the accelerator pedal wiper Check acceleration pedal connection
KO voltage entering the controller is less than the Check ACCEL MIN, MAX (VASS)
minimum value, or exceeds the maximum
set up with VASS by a certain level
34 BRAKE SENSOR KO NA NA
35 STEER SENSOR Occurs when the steering sensor wiper Check steer sensor connection
KO voltage entering the controller differs Check STEER setpoint
from the range set up with VASS by a Retry VASS
certain level
36 LC COIL SHORT When CONTACTOR DRIVE error has Check contactor short circuit.
occurred and the current of PWM output Replace the control board.
1 exceeds 700mA. Replace the contactor if it has an
(Line contactor output part) error
37 AO2 COIL SHORT When CONTACTOR DRIVE error has Check contactor short circuit.
occurred and the current of analog PWM Replace the control board.
output 2 exceeds 700mA. Check the objective part (connected
to the output part)
38 AO3 COIL SHORT When CONTACTOR DRIVE error has Check contactor short circuit.
occurred and the current of analog PWM Replace the control board.
output 3 exceeds 700mA. Check the objective part (connected
to the output part)
39 LC CIRCUIT OPEN When the current of analog PWM output Check contactor open, wiring, replace
1 is less than 100mA for 1.5s. the part
(Line contactor output part).
40 AO2 CIRCUIT When the current of analog PWM output Check contactor open, wiring, replace
OPEN 2 is less than 100mA for 1.5s. the part
42 LC CIRCUIT CLOSE When CONTACTOR DRIVE has not Check contactor open, wiring, replace
occurred and the current of analog PWM the part
output 1 exceeds 700mA.
(Line contactor output part)
43 AO2 CIRCUIT When CONTACTOR DRIVE has not Check contactor open, wiring, replace
CLOSE occurred and the current of analog PWM the part
45 CAPACITOR When the battery voltage measured by the Check contactor operation
CHARGE controller is less than 85% of rating after 3 Check main fuse
seconds from contact point ON command. Replace controller
46 MODEL MISS PCB MODEL(in Engineer) + MODEL Check PCB MODEL + MODEL
MATCH SELECT(in SET OPTION) value does SELECT
not exist or not corresponding to the
pump controller model
7-80
(2) Traction warning code
Code Warning Description Corrective Action

1 EEPROM WARN Data read from EEPROM differs from Restart, replace control board
the data saved
2 BATTERY LOW Occurs when residual battery capacity Charge the battery
drops below 10%
3 INCORRECT START Case 1. Occurs when one of pedal For Case 1 : pedal brake, accelerator
brake, accelerator pedal, or forward/ pedal, and forward/reverse lever are
reverse lever is ON at Key On. all OFF.
Case 2. According to the status of For Case 2-1 and 2-2 : accelerator
SEQUENCE option (in SET OPTION); pedal and forward/reverse lever are
SEQUENCE ON : when the seat switch all OFF.
is ON (seated), forward/reverse lever is For Case 2-3 : accelerator pedal is
in neutral, this occurs after SEQ. DELAY OFF.
(in PERFORMANCE) time from
depressing accelerator pedal. (Case 2-
1).
Occurs when seat switch is OFF
(unseated), and accelerator pedal is
depressed or forward/reverse lever is
engaged. (Case 2-2).
SEQUENCE OFF : regardless of the
seat switch status, this occurs after
SEQ. DELAY (in PERFORMANCE)
time from depressing accelerator pedal.
(Case 2-3).
4 FORWARD+BACKW Both forward and reverse levers are ON Restart, replace control board
ARD at the same time
5 HANDBRAKE Occurs when accelerator pedal is Release the hand brake
depressed while hand brake is applied
6 CHAT TIME OVER Occurs when there has been no signal Feed accelerator pedal, brake pedal
from accelerator pedal, brake pedal, or or forward/reverse lever signal.
forward/reverse lever for the CHATTIME
(in ADJUSTMENT).
7 MOTOR STALL Occurs when the motor input current Open acceleration pedal.
(rms) exceeds 95% of the current Check motor encoder.
allowable for the controller, accelerator Check drive unit.
pedal has been operated from more
than 15 seconds, but the motor speed
remains below the minimum speed.
8 ACCEL SET WARN Triggered when the difference between Change the accelerator pedal signal
the max and Min values of the setting via VASS. Replace the pedal if
accelerator pedal signals set up via it has failed.
VASS is 0.1V or less
7-81
9 THROTTLE SET Triggered when X POINT (in Set the X point greater than DEAD
WARN PERFORMANCE menu) setpoint is less ZONE and less than ACCEL MAX.
than DEAD ZONE (in PERFORMANCE
menu)
10 BDI SET WARN Occurs when ADJUST BDI#1 (in Set the ADJUST BDI#1 and #2
PERFORMANCE menu) exceeds 120% values within the specified range.
of the rated voltage, or set less than the
rated voltage.
Or occurs when ADJUST BDI#2 (in
PERFORMANCE menu) is less than
90% of the rated voltage, or set higher
than the rated voltage.
11 MAX SPEED WARN Occurs when set-up MAX FORWARD/ Set up the (MAX FORWARD and
BACKWARD (in PERFORMANCE MAX BACK WARD) speeds having a
menu) speed is faster than the H mode difference not exceeding 15 Hz from
basic speed of the model by 15Hz or the default speed of the model.
more.
12 CREEP SET WARN Occurs when Y POINT (in PERFORMANCE Increase Y point setting greater than
menu) is set less than CREEP FREQ (in CREEP FREQ.
PERFORMANCE menu, default value
0.3Hz).
13 DELAY SET WARN Occurs when one or more of the ACCEL Increase the setting value greater
DELAY, RELEASE DELAY, INVERSE than the error condition.
DELAY, SR DELAY set up in the
PERFORMANCE menu is less than 1
second, or BRAKE DELAY is set less
than 0.5 second, or DECEL DELAY is
set less than 3 seconds.
14 AO SET WARN Occurs when the LC VOLTAGE, AO2 Reduce the setting to less than the
VOLTAGE, AO3 VOLTAGE settings in rated voltage.
the ADJUSTMENT menu is higher than
the rated voltage.
7-82
#1 Occurence
Case 1. Occurs when one of pedal brake, accelerator pedal, or forward/reverse lever is ON at Key On.
Case 2. According to the status of SEQUENCE option (in SET OPTION);
SEQUENCE ON : when the seat switch is ON (seated), forward/reverse lever is in neutral, this occurs
after SEQ. DELAY (in PERFORMANCE) time from depressing accelerator pedal.
(Case 2-1).
Occurs when seat switch is OFF (unseated), and accelerator pedal is depressed or
forward/reverse lever is engaged. (Case 2-2).
SEQUENCE OFF : regardless of the seat switch status, this occurs after SEQ.
DELAY (in PERFORMANCE) time from depressing accelerator pedal. (Case 2-3).
#2 Reset
Of the #1 above ;
For Case 1: pedal brake, accelerator pedal, and forward/reverse lever are all OFF.
For Case 2-1 and 2-2: accelerator pedal and forward/reverse lever are all OFF.
For Case 2-3: accelerator pedal is OFF.
7-83
(3) Hydraulic failure code
1 WATCH DOG Interruption fails Restart
2 FET DRIVE FET element in the controller stack failed Restart
Check battery
Replace controller
3 PSU UNDER VOLT Occurs when controller voltage falls Restart.
below 9.6V Replace SMPS in the controller
4 OVER VOLTAGE Occurs when battery voltage exceeds Check battery
150% of rated voltage. Limit quick speed reduction
5 OVER CURRENT When pump motor current (rms) Limit overload, over speed, quick
exceeds 180% of the rated current speed change
Check battery
6 PCB OVER TEMP Temperature of the controller PCB Check cooling fan.
exceeds 85ä
7 INV. OVER TEMP Temperature of the stack in the Check cooling fan.
C
controller exceeds 140ä If the controller temperature sensor
8 ENCODER PWR Pump motor encoder connector is open Check the motor encoder wiring and
line short circuit
9 CONTACT DRIVER Analog output PWM drive short circuit Restart
10 SW UNDERVOLT Battery voltage is less than the UNDER Check battery quick
VOLT(in Engineer) % of the rated voltage Limit overload, speed acceleration
11 SW OVERVOLT Battery voltage exceeds the OVER Check battery
VOLT(in Engineer) % of the rated voltage Limit quick speed reduction
12 SW RH motor current (rms) exceeds the Limit overload, over speed, quick
OVERCURRENT OVER CURRENT (in Engineer) % of the speed change
controller
13 SW OVERTEMP Temperature of the stack in the pump Check cooling fan,
motor current controller exceeds 125äC If the controller temperature sensor
14 MTR OVER TEMP Temperature of the pump motor Limit operation, check the motor
exceeds 145ä C
15 POWER CABLE Cable between the controller and pump Check wiring
motor is open
16 CT SENSOR When the controller gate is off, and the Check the CT (current) connector of
pump motor current (rms) exceeds 30A. the control board
17 ENCODER PHASE Pump motor encoder signal failure Pump motor UVW connection check
Check encoder wiring
7-84
18 CAN TRACT KO Traction controller CAN communication Check the 8-pin connector for
If traction controller is unusable,
replace it
19 CAN DISP KO DISPLAY CAN communication failure Check the 8-pin connector for
communication.
Check molex pin for DISPLAY
communication.
If DISPLAY is unusable, replace it
20 CAN EXPAN KO CAN EXPANDER communication failure Check the 8-pin connector for
communication.
Check fingertip communication line
21 WRONG SET BATT Occurs when battery voltage is below Check BATTERY TYPE (option)
90% or exceeds 120% of rated voltage. Check battery specification
BATTERY TYPE setting in the
ADJUSTMENTS is incorrect
22 LIFT SENSOR KO While there is no enable signal for lift Check lift sensor connection.
switch (digital micro-switch), the wiper Check LIFT MIN, MAX values at
voltage of the lift sensor (potentiometer) VASS
is detected to be above the mean value,
less than the minimum value, or above
the maximum value.
23 TILT SENSOR KO (Vehicles with AUTO TILT LEVELING Check tilt angle sensor connection
option).
Tilt angle sensor failure.
24 LOAD SENSOR KO (Vehicles with Load Weight Sensor Load weight sensor failure
option)
Load weight sensor failure.
25 AO1 CIRCUIT When CONTACTOR DRIVE error has Check contactor short circuit.
SHORT occurred and the current of analog PWM Replace the control board.
output 1 exceeds 700mA. Replace the contactor if it has an
(Line contactor drive part) error
SHORT occurred and the current of analog PWM Replace the control board.
output 2 exceeds 700mA. Check the objective part
(Solenoid valve driver) (connected to the output part)
SHORT occurred and the current of analog PWMReplace the control board.
output 3 exceeds 700mA. Check the objective part
(connected to the output part)
28 LC CIRCUIT OPEN When the current of analog PWM output Check contactor open, wiring, replace
1 is less than 100mA for 1.5sec. the part
OPEN 2 is less than 100mA for 1.5sec. the part
(Solenoid valve driver)
7-85
31 LC CIRCUIT CLOSE When CONTACTOR PRIVE error has Check contactor open, wiring, replace
not occurred and the current analog the part
PWM output 1 exceeds 700mA.
34 CAPACITOR When the battery voltage measured by Check contactor operation.
CHARGE the controller is less than 85% of rating Check main fuse.
after 3 seconds from contact point ON Replace controller.
command.
35 FINGERTIP LIFT Occurs when fingertip lift lever signal Conduct VASS again, replace
KO exceeds the specified range fingertip lever, replace CAN
EXPANSION. Keep the signal wire
away from power cable to prevent
noise
36 FINGERTIP TILT Occurs when fingertip tilt lever signal Conduct VASS again, replace
noise
37 FINGERTIP AUX1 Occurs when fingertip AUX1 lever signal Conduct VASS again, replace
(In general, SIDE SHIFT) EXPANSION. Keep the signal wire
noise
noise
noise
40 CAN ENCODER1 CAN ENCODER 1 failure Replace CAN TILLER, replace
encoder
41 CAN ENCODER2 CAN ENCODER 2 failure Replace CAN TILLER, replace
encoder
7-86
42 MODEL MISS PCB MODEL (in Engineer) + MODEL Check PCB MODEL + MODEL
MATCH SELECT (in SET OPT) value does not SELECT
exist or not corresponding to the pump
controller model.
43 SBR SW Loose SBR switch. Check battery lock device.
SBR sensor failure. Check SBR sensor.
44 CAN FINGER KO Failed to receive data from fingertip Check CAN communication cable
controller connection and line resistance.
Replace fingertip controller
7-87
(4) Hydraulic warning code

1 EEPROM WARN Data read from EEPROM differs from Restart, replace control board.
the data saved
2 MOTOR STALL Occurs when the motor input current Open acceleration pedal.
(rms) exceeds 95% of the current Check motor encoder.
allowable for the controller, accelerator Check drive unit.
pedal has been operated from more
than 15 seconds, but the motor speed
remains below the minimum speed.
3 INCORRECT START Case 1. Occurs when the lift, tilt, or side For Case 1 : lift, tilt, and side shift
shift lever is On at Key On. lever are all OFF.
Case 2. With SEQUENCE option (in For Case 2 : forward/reverse lever is
SET OPTION) in ON status and seat OFF.
switch at OFF (unseated), the forward/
reverse lever is not at Neutral position.
4 LIFT SET WARN Occurs when the difference between the Reset the lift wiper signal using
max. and min. values of the lift VASS. Replace potentiometer if
potentiometer wiper signals is 0.1V or necessary.
less.
5 THROTTLE SET Triggered when X POINT (in Set the X point greater than DEAD
WARN PERFORMANCE menu) setpoint is less ZONE and less than LIFT MAX.
than DEAD ZONE (PERFORMANCE
menu) or greater than LIFT MAX (in
ADJUSTMENT menu)
6 BDI SET WARN Occurs when ADJUST BDI#1 (in Set the ADJUST BDI#1 and #2
PERFORMANCE menu) exceeds 120% values within the specified range.
of the rated voltage, or set less than the
rated voltage.
Or occurs when ADJUST BDI#2 (in
PERFORMANCE menu) is less than
90% of the rated voltage, or set higher
than the rated voltage.
7 MAX SPEED WARN Occurs when the set-up LIFT MAX Set up the LIFT MAX SPEED having
SPEED (in PERFORMANCE menu) is a difference not exceeding 15 Hz
faster than the H mode basic speed of from the default speed of the model.
the model by 15Hz or more.
8 DELAY SET WARN Occurs when ACCEL DELAY or DECEL Increase the setting value greater
DELAY set up in PERFORMANCE than the error condition.
menu is set less than 1 second
9 AO SET WARN Occurs when one or more of the AO1
VOLTAGE, AO2 VOLTAGE, AO3
VOLTAGE settings in the ADJUSTMENT
menu is higher than the rated voltage.
7-88
10 FINGERTIP WARN Occurs when the sum of the signals A Reset the fingertip lever in VASS, or
and B of the fingertip lever exceeds the replace the lever as necessary. Keep
range of 4.6V~5.4V. the fingertip signal wire away from the
power cable to prevent noise.
11 LIFT SPD SET Occurs when the difference between the Set the LIFT MAX SPEED and LIFT
WARN LIFT MAX SPEED and LIFT MIN MIN SPEED with a difference greater
SPEED in the PERFORMANCE menu than 10Hz.
is 10HZ or less
#1 Occurrence :
Case 1. Occurs when the lift, tilt, or side shift lever is On at Key On.
Case 2. With SEQUENCE option (in SET OPTION) in ON status and seat switch at OFF (unseated), the
forward/reverse lever is not at Neutral position.
#2 Reset
Of the #1 above ;
For Case 1 : lift, tilt, and side shift lever are all OFF.
For Case 2 : forward/reverse lever is OFF.
2) VEHICLE MODEL TABLE

The setting window configuration is as follows;
7-89
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) BASIC INFORMATION
(1) What is charger
Charger is a device which makes a battery accept D.C electricity under optimal condition as it
transforms A.C provided from external source of electricity.
The charger is a constant-current and constant-voltage way, SCR type charger that it has
advantages as follows
Η Even though A.C input voltage fluctuates within 10% of rated voltage (220/380/410/440V), the
current and voltage provided to the battery are stable.
Θ As minimizing the increase of temperature while charging a battery, it minimizes the stress on the
battery.
Ι The noisy of charger is minimal but the charging efficiency is very high.
Κ It prevents from under charging and overcharging.
Therefore, it helps the battery to maintain its performance for longer time and to prolong the life of
the battery.
(2) Notice on caring chargers

Η 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.
Θ While charging, hydrogen and oxygen gas is produced. Use or approach of fire should be strictly
prohibited.
Ι Keep clean to prevent from sneak current and attack on the interface and surroundings of the
battery.
Κ Check the electrolyte of the battery every week and provide distilled water immediately if it is
required. ( Electrolyte has to be provided between 10~12mm level on the positive plate inside
storage battery)
Λ If battery liquid temperature becomes over 55ÁC, charging should be stopped.
If it is continued,
- the appearance is transformed
- and metal area can be attacked as electrolyte overflows
Μ Electric forklift truck using battery should be charged as soon as the charging lamp is on while
driving. As batteries are internally discharged naturally if they are deposed for a long time, charge
them once or twice a month to prevent from reducing the lives of batteries.
Ν When a green sign is on among charging status indication lamps, please notify that it is not
converted as equalized charge for stabilization of charging status.
7-90
(3) Names of each part (independent items)
1 2 3
4 5
6 7 8 9 10
BOP7BAT30
1 Main PCB board 5 Monitor PCB 9 Resistance (RD)

2 Main trans (Class H) 6 Overload 10 Resistance (DR)
3 Cooling fan 7 MG S/W
4 SCR module 8 Assistant trans
7-91
2) CHARGER INSTALLATION METHOD
(1) Location for charger installation
Η Dry and well ventilated place.
Θ No inflammable and B7 fire are near by.
Ι Safe place where no collision possibility
with people or equipment is.
(2) Check points before installing charger
Η Enough capacity of AC input power
source to operate charger.
Θ Standard electric wire for power source BOP7BAT01
by capacity.
3) HOW TO USE A CHARGER

Display
(1) General charging method (Floating
charging) 85%
2
Η Charging by this method supplies electric 1
power to the charger as operating 80%
external AC power switch of the charger. 3 2
Θ Connect battery connecter and charger
connecter. 1
ÂAccording to charging condition

BOP7BAT02
Η 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.
Θ When charging is processed about 80%,
yellow lamp in the middle of the front
panel, which shows that the charging
condition is in the middle, is on and then
green lamp is on when charging is
processed over 85% until charging is
completed.
Ι When charging is completed, "charging is
completed" lamp is on in the monitor and
other lamps of all monitors become off.
7-92
(2) Equalized charging
Η Equalized charging is
Equalized charging is to correct the
battery when it does not normally
perform its functions as the voltage
differences are too big between cells of a
battery.
When equalized charging is
- required?
When re-operates the battery after
- having left the battery for a long time.
- When a battery is over-discharged.
When there is large deviation of voltage
and specific gravity between battery
- cells.
When change or supply electrolyte of
Θ battery.
Tips for equalized charging
If once push the equalized charging
button on the monitor in the beginning of
charging, the equalized charging lamp
ö becomes on and starts charging.
When the green charging condition
lamp is on ( over 85% charged), the
equalized charging switch is locked
Equalized charging switch
that it does not operate even BOP7BAT03
pushing the button.
7-93
4) HOW TO CHECK THE CHARGER'S NORMAL OPERATION
After changing SCR module or PCB (SE-
5000SN), the charger's normal operation
should be checked.
ÂChecking order
(1) Separate the charger and battery
connector.
(2) Separate lower cover in the front of the
charger.
(3) Check the AV input voltage used from the
input switch terminal in the lower left side
of the inside of the charger.
Checking method between terminals.
Input voltage setting value Ą 220V 380V BOP7BAT04/05
- Between terminals No. 2 - No. 4 220V 380V

ö Above cases are under normal
operations.
ö When installing charger for the first
time or moving its location, check
and make it sure if the voltage is
appropriately connected.
220V BOP7BAT06
Refer to No. 2 of the charger

installation method for the terminal
connection method.
- In case of 220V : (2), (4), (6), (8)
- In case of 380V : (1), (3), (5), (7)
It should be connected to the terminal.
380V BOP7BAT06-1
7-94
(4) Convert the automatic / manual switch to
manual.
The automatic/manual switch is located in
the lower left part of the PCB
Be sure to check if battery connector
is separated in advance.
(5) MG/SW operation (Refer to error sheet)
(6) Check the charging voltage soft start
function (refer to the monitor) BOP7BAT08
Η After 5 seconds next to turn the manual

switch on.
Input, floating charge and red charging
condition lamp is on.
Θ After 15 seconds next to turn the manual
switch on.
Yellow charging condition lamp is on
while charging.
Ι After green lamp becomes on, measure
the output voltage of the battery BOP7BAT09
connector by multi measure. If measured

voltage is between 62.5V ~ 63.5V, it is
normal. (Rated voltage : 63V)
Κ After 30 seconds next to turn on the
manual switch, if buzzer rings for 10 Η
seconds and END lamp is on, it is a Ι
normal condition. Θ
ö When yellow lamp under charging

condition is on after 1~2 times
repetition, convey the automatic/
BOP7BAT10
manual switch to the automatic and
check if the charger trips
automatically.
7-95
(7) If charger's out voltage is under 60V, it is
abnormal.
Please refer to the error sheet.
(8) When the charging voltage is indicated as
normal condition (64V), convert automatic
/ manual switch to automatic and start
charging.
ö Display error code on the front cover
BOP7BAT11
as following table.
No Code Description of error
1 E.F EPROM fail

2 O.V Over voltage - Refer to page 7-112
3 O.C Over current - Refer to page 7-111, 7-113.
4 F.B Battery error (After starting charging, the voltage doesn't go over 52V for 2 hours.)
Check the battery.
5 O.T Transformer over heat (Stop charging when it is over 160ÁC).
- 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
6 O.H Heatsink over heat (Stop charging when it is over 100ÁC).
- Check the cooling fan, SCR connection cable contact point and control part.
7 A.O Power supply error (input power 220/380V wrong wiring). - Refer to page 7-110.
8 A.F Power supply error (absent phase) - Check if input cable is open.
9 A.C AC fail (black out) - Check if input voltage is right.
10 L.C Low current (If this sign is on for setting value (60 sec), charging is over).
11 F Manual stop.
7-96
5) CHECK POINTS BEFORE APPLYING
A/S
(1) AC input power source switch is input.
(2) Check if the battery connector of the order
picker truck and charger's connector are
connected.
(3) Check points when "Error" lamp is on in
the front monitor of the charger.
(4) Check the front cover indicator. BOP7BAT12
Η A.F : Input three phase power source

continuity check = Check if input three
phase power source is normal with AC
voltage meter.
Θ A.O : Error on selection of input power
source of 220V or 380V - Check it
appropriately with full three phases.
Ι A.C : Check if the input power source
(220V or 380V) is normal.
Κ O.C : Check the electric current, as
charging current of the battery is over-
standards condition.
Λ O.V : Check the voltage, as charging
voltage of the battery is over-voltage
condition (66V).
Normally it is 63VÜ1.5V.
(5) Check other abnormalities as well.
Then apply for A/S when on-site
measurements are not applicable.
7-97
6) ERROR DETECTION
(1) Error list
Η Only floating charge lamp is on in the
monitor but it is not charged.
Θ ON and OFF is repeated with a few
minutes intervals even after starting
charging.
Ι Charger TRIP is occurred after
abnormality lamp is on.
In case error code is "O.V"
Κ Charger TRIP is occurred after
abnormality lamp is on.
In case error code is "O.C"
Λ Charger TRIP is occurred after it started
charging and charging completion lamp
is on.
Μ Charger has no response even the
battery connector is connected.
7-98
(2) Troubleshooting
Η Only floating charge lamp is on after indicating "A.O", It's not charged.
Â 220/380V Model : Measure the TB.4 (380V) TB.8(220V)

voltage between input voltage
change over tabs 2-4 2-6 4-6 70̫/
Â 220,380,410,440V Model : 30W
Measure the voltage in front of In front of MS Manual/Auto TAP Changer M/S
AC INPUT MS S/W B
T.B
After separating short 7 8
bar
battery connecter, AC
PCB PCB RY
Check convert the INPUT (LP lamp)
YES YES LP YES Voltage
the rated automatic/manual MS
lamp tap
voltage selection switch on switch
ON?
the lower part of ON J2
PCB to manual.
NO NO
TH
Apply multi tester for input voltage change Change PCB Manual
over tab no. 6 /Auto S/W
Measure voltage between input tab no.8, CN4 contact fault
M/S
PCB CN4, and contact points with red reed PCB RY contact fault COIL FAN
NO putting black reed on the other side
Apply multi tester for input voltage change
TB.6
over tab no. 6
M/S electrical circuit
TH contact fault
Voltage NO CN4 contact fault

Input power source is not 220V?
PCB RELAY fault
provided.
YES TH manual
Â Check external lead cable.
restoration release
Â Check the connection of MS COIL fault CN4 RY
external input connecter
Â Check external NFB TRIP
7-99
Θ ON and OFF is repeated with a few minutes intervals after starting charging.
Indicate "O.C" on the monitor.
- TH is operated (AC input over-current TRIP).
OUTPUT
CURRENT
DE- IN-
CREASE CREASE
Serious
trans noisy Measure output Current Exceed Adjust output current
NO NO
under the current using DC value : 15~20A Standard AMP, VR within PCB
condition. current measure /100AH current Re-adjust to VR
Is MS
on? YES
Â TH Setting fault
YES
Â Re-adjust TH TH. TRIP Change TH
setting value
NO
* Refer to SCR Rated
Complete Current
YES Module checking
method SETTING
YES NO
Complete Change PCB
NO Change
SCR MODULE
Separate the battery Check
connector and tune SCR
the charger off Module
YES Check
Check the normal
MAIN NO Change
operating condition
TRANS PCB
of the charger
VOLT
YES
7-100
Ι Charger TRIP is occurred after abnormality lamp is on.
In case error code is "O.V" Ą Over-voltage output / Set at 66Vdc (In case of BATT 48V)
Check Turning charging voltage volume in

After separating the battery connecter,
the center of the right-hand side of
turn on MS as converting the voltage of the NO
PCB anti-clockwise rotation
automatic/manual selection switch on output connecter
Set the voltage same as actual
lower part of PCB to manual 63V? output voltage
Reset voltage as turning

YES De- In-
volume volt for setting voltage crease crease
on the center of PCB
Measure
YES the voltage of the VOLT
Adjust voltage so as
output connecter
to have same output
105V?
between actual output
Check contact error
voltage and indication
or breaking of wiring NO Change
of display
De- In- OK NO of the detect cable PCB
crease crease
connecter pin
Check Check
whether the charger
the detect
is normal condition after
YES voltage of the J3 NO
connecting the
battery connector
105V?
NO
YES
Change PCB
OK
7-101
Κ Charger TRIP is occurred after abnormality lamp is on.
After opening the cover which is located on the front bottom side of the charger.
In case error code is "O.C" Ą Output over current, established as 110~120% of the
rated current.
De- In-
crease crease
Measure
the output current Check contact error or breaking of wiring
Restart the charger as pushing NO
by DC current measure for current connection the right side of the
reset switch in the monitor.
15-20A/ PCB(Clean, connection of wiring)
100AH
YES
Re-establish charge current

Measure
volume (AMP) on the center
the output current
side of PCB as turning it anti
by DC current
clockwise rotation
measure
YES NO
After RESET, request Change

OK
After-Service if it is not correct PCB
De- In-
crease crease
7-102
Λ 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)
Restore the charger as pushing reset switch.
Measure
After separating battery connector,
the output current by NO Measure the output
put the automatic/manual selection
DC current measure voltage 64V
switch to manual
Is it normal?
YES
YES
Change PCB or NO
Request After-Service
Contact fault between
Check
the battery connector
SCR Module
and charger connector
Is it ok? Battery is over-
discharged
NO YES
Change Change
SCR Module PCB
7-103
Μ 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 the input voltage is normal - Refer to the error detection No. Η )
NO Charger BATTERY
Connector contact fault
Battery
Measure Measure the
NO voltage
the battery voltage voltage within the is normal
Is it under RD of the charger (Over
35V? BATT(+) SHUNT 35V)
J.3
YES RD PCB(+) YES
PCB(-)
BATT(-)
PCB
(+)(-) Voltage Check the cable and contact
is over YES point status at PCB connector(J3)
12V
On the
Convert the automatic/manual selection switch
left side of PCB
to manual and turns it to automatic after 1/2~1
Is LP LED
hour and make it charge normally. NO NO
ON?
If the battery voltage is not increased after
automatic 1 hour charging is started, battery YES Change
check is required. PCB
Refer to the error detection No.Η

Change Check the input power wire line
RD 340/50W in the charger
LED
7-104
7) HOW TO CHECK THE SCR MODULE
Circuit Real diagram
K2 K2
G1
K1 G1
3 2 1 K1
* Before checking SCR MODULE, be sure to disconnect bus bar and wire on the terminal.
Measuring point Measure value
No. SURGE PCB
(Real diagram) (Measurement of digital tester)
1 No.1 ~ No.3 Forward : Under 100 k ohm

Reverse : Infinity ( ∞ )
2 No.2 ~ No.3 Forward : Infinity ( ∞ )

3 G1 ~ K1 Forward : Under 100 k ohm

Reverse : Under 100 k ohm
But It depends on the module.
If it is not 0 ohm, It is Ok.
4 G1 ~ K2 Forward : Infinity ( ∞ )
7-105
8) PCB MAJOR PARTS (NAME AND LOCATION)
ΘLp lamp
ΣAuto/manual
switch ΚSHUNT
current
detect
΢Auxiliary ΙVoltage
power detect
supply
ΝAdjust
ΜAdjust CPU
ΛAdjust voltage
charging charging
voltage current
ΞMonitor
display output
ΠSCR control
ΗMicro control unit #1
ΤSCR control ΟTemperature

connector sensor
ΡBuzzer
BOP7BAT26
1 Micro control unit #1 6 Adjust charging voltage 11 Buzzer

2 Lp lamp 7 Adjust CPU voltage 12 Auxiliary power supply
3 Voltage detect 8 Monitor display output 13 Auto/manual switch
4 SHUNT current detect 9 Temperature sensor 14 SCR control connector
5 Adjust charging current 10 SCR control
7-106
SECTION 8 MAST
GROUP 1 STRUCTURE
1. 2 STAGE MAST(V MAST)
8
2
12
13
3
10
9 1
CARRIAGE
LIFT CYLINDER
TILT CYLINDER
4
7
6
5
13
11
15BT9MS01
1 Outer mast 6 Bushing 10 Chain wheel bearing

2 Shim (0.5, 1.0t) 7 Inner mast 11 Roller
3 Roller 8 Lift chain 12 Back up liner
4 Tilt cylinder pin 9 Anchor bolt 13 Shim(0.5, 1.0t)
5 Mast mounting pin
8-1
2. 3 STAGE MAST(TF MAST)
10
9 54
7
5
4
9
9
10 1
8
7
10 7 LIFT
CYLINDER
7
TILT
CYLINDER
2
13
CARRIAGE
12
11
3
5
4
FREE LIFT
CYLINDER
5
4
15BT9MS02
1 Outer mast 6 Lift chain 11 Mast mounting pin

2 Middle mast 7 Anchor bolt 12 Bushing
3 Inner mast 8 Sheave bracket 13 Pin
4 Roller 9 Sheave
5 Shim(0.5, 1.0t) 10 Retaining ring
8-2
3. CARRIAGE, BACKREST AND FORK
15BT9MS03
1 Backrest 3 Load roller 5 Fork assembly

2 Carriage 4 Side roller 6 Extension fork
8-3
1) FORKS
(1) Measure thickness of root of forks and
check that it is more than specified value.
EX : ˶=900mm(35.4in)
mm(in)
STD Fork assy Applicable model Standard Limit
64FY-12030 15/18BT-9 35(1.4) 32(1.3)
64HM-11010 20BT-9 40(1.6) 36(1.4)
B153FK01
(2) Set forks in middle and measure

difference in height at top of forks.
Fork length Height
Model (mm) difference(mm)
equal or below 1200 3
15/18/20BT-9
above 1200 6
Difference in height
at tip of forks
D255FK02
(3) Most force is concentrated at root of fork

and at hook, so use crack detection
method to check cracks.
2. MAST
1) Check for cracks at mast stay, tilt cylinder bracket, guide bar, fork carriage and roller shaft weld.
Check visually or use crack detection method. Repair any abnormality.
2) Set 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)
3) Check that there is an oil groove in bushing at mast support.
4) Set mast vertical, raise forks about 10cm from ground, and push center of lift chain with finger to
check for difference in tension.
If there is any difference in tension, adjust chain stopper bolt.
5) Check visually for abnormalities at thread of chain anchor bolt, and at contact surface between
chain wheel and chain.
Rotate chain wheel by hand and check for any play of bearing.
8-4
2. TROUBLESHOOTING
1) MAST
Forks fail to lower. ÂDeformed mast or carriage. ÂDisassemble, repair or replace.
Fork fails to elevate ÂFaulty hydraulic equipment. ÂSee troubleshooting hydraulic pump
and cylinders in section 6, hydraulic
system.
ÂDeformed mast assembly. ÂDisassemble mast and replace
damaged parts or replace complete
mast assembly.
Slow lifting speed and ÂFaulty hydraulic equipment. ÂSee troubleshooting hydraulic pump
insufficient handling capacity. and cylinders in section 6, hydraulic
system.
ÂDeformed mast assembly. ÂDisassemble mast and replace
damaged parts or replace complete
mast assembly.
Mast fails to lift smoothly. ÂDeformed masts or carriage. ÂDisassembly, repair or replace.
ÂFaulty hydraulic equipment. ÂSee Troubleshooting Hydraulic
Cylinders, pump and control valve in
section 6, hydraulic system.
ÂDamaged load and side rollers. ÂReplace.
ÂUnequal chain tension between ÂAdjust chains.
LH & RH sides.
ÂLH & RH mast inclination angles ÂAdjust tilt cylinder rods.
are unequal. (Mast assembly is
twisted when tilted)
Abnormal noise is produced ÂBroken load roller bearings. ÂReplace.
when mast is lifted and lower- ÂBroken side roller bearings. ÂReplace.
ed. ÂDeformed masts. ÂDisassemble, repair or replace.
ÂBent lift cylinder rod. ÂReplace.
ÂDeformed carriage. ÂReplace.
ÂBroken sheave bearing. ÂReplace.
Abnormal noise is produced ÂInsufficient lubrication of anchor ÂLubricate or replace.
during tilting operation. pin, or worn bushing and pin.
ÂBent tilt cylinder rod. ÂReplace.
8-5
2) FORKS

Abrasion Long-time operations causes the fork to If the measured value is below the wear
wear and reduces the thickness of the limit, replace fork.
fork.
Inspection for thickness is needed.
ÂWear limit : Must be 90% of fork
thickness
Distortion Forks are bent out of shape by a If the measured value exceeds the
number of reasons such as allowance, replace fork.
overloading, glancing blows against
walls and objects, and picking up load
unevenly.
ÂDifference in fork tip height
Height
Fork length (mm) difference(mm)
equal or below 1200 3
above 1200 6
Fatigue Fatigue failure may result from the Repair fork by expert.
fatigue crack even though the stress to In case of excessive distortion, replace
fork is below the static strength of the fork.
fork. Therefore, a daily inspection
should be done.
ÂCrack on the fork heel.
ÂCrack on the fork weldments.
8-6
GROUP 3 ADJUSTMENT
1. MAST LOAD ROLLER(V MAST)
1) INNER/OUTER MAST ROLLER
CLEAR-ANCE ADJUSTMENT
(1) Measure the clearance with the mast
overlap at near 480mm.
(2) Shift the inner mast to one side to bring
the roller into contact with the outer mast,
and adjust the clearance between the
roller side face and mast at the closest
position on the opposite side to the 15L7MS04
following value by inserting the inner/outer

mast roller shim.
ÂStandard clearance A, B = 0.3 ~ 0.6mm
ÂShim thickness 0.5, 1.0mm
(3) Distribute the shim thickness equally to
the left and right roller. Refer to Mast load
roller and back up liner, removal and
Installation.
(4) After the adjustment, check that the inner
mast moves smoothly in the outer mast.
15L7MS05
8-7
2. MAST LOAD ROLLER(TF MAST)
1) INNER AND MIDDLE MAST ROLLER
CLEARANCE ADJUSTMENT
the roller into contact with the outer mast
and the middle mast, and adjust the
clearance between the roller side face and
mast at the closest position on the 15L7MS06
opposite side to the following value by

inserting the inner and middle mast roller
shim, respectively.
ÂStandard clearance A = 0.3~0.6mm
the left and right roller. Refer to Mast load
roller and back up liner, removal and
Installation.
(4) After the adjustment, check that the inner
mast moves smoothly in the middle mast,
and the middle mast moves smoothly in
the outer mast.
2) OUTER AND MIDDLE MAST UPPER

ROLLER CLEARANCE ADJUSTMENT.
the roller into contact with the outer mast
and the middle mast, and adjust the
clearance between the roller side face and
mast at the closest position on the 15L7MS07

inserting the outer and middle mast roller
shim, respectively.
ÂStandard clearance B = 0.3~0.6mm
(3) Distribute the shim thickness equally to the left and right roller. Refer to Mast load roller and back
up liner, removal and lnstallation.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast, and the
middle mast moves smoothly in the outer mast.
8-8
3) CARRIAGE LOAD ROLLER
(1) Measure the clearance when the center of
the carriage upper roller is 100mm from
the top of the inner mast.
(2) Measure the clearance at upper, middle
and lower rollers after loosen the adjust
screws from the side rollers. Shift the
carriage to one side to bring the roller into
contact with the inner mast, and measure
the clearance between the roller side face 15L7MS08
and mast at the closest position on the

inserting the carriage roller shim.
ÂStandard clearance C = 0.3~0.6mm
the left and right roller. Refer to Carriage
assembly.
(4) After the adjustment, the carriage should
move smoothly along the overall mast
length.
4) MAST BACK UP LINER

(1) Measure the clearance with the middle
mast at the bottom position.
(2) With the middle mast in contact with the
outer mast roller, adjust the clearance
between the mast back up liner and
middle mast to the following value by
inserting the back up liner shim.
ÂStandard clearance E = 0.2 ~ 0.6mm 15L7MS09

(3) After the adjustment, the mast should
move smoothly.
8-9
GROUP 4 REMOVAL AND INSTALLATION
1. FORKS
1) Lower the fork carriage until the forks are
Knob
approximately 25mm(1inch) from the floor. Pin
2) Turn the knob up and slide forks, one by
one, toward the center of the carriage Spring
where a notch has been cut in the bottom
Pin
plate for easy fork removal.
3) Remove the fork one by one. On larger forks
it may be necessary to use a block of wood.
4) Reverse the above procedure to install load
15BT9MS10
forks.
2. BACKREST
Backrest
1) Remove bolts securing backrest to fork
carriage. Disassemble the backrest from
the carriage. Bolt
2) Position backrest on carriage and lower in
place. Install and tighten bolts.
Carriage
15BT9RE03
3. CARRIAGE ASSEMBLY
1) CARRIAGE
(1) 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.
(2) While supporting lift chains, remove the split pin and slide out chain anchor pins from the chain
anchors of stationary upright.
(3) Pull the chains out of the sheaves and drape them over the front of the carriage.
(4) Slowly raise elevating upright until mast clears top of fork carriage. Move carriage to work area
and lower mast.
Make sure carriage remains on floor and does not bind while mast is being raised.
(5) Inspect all parts for wear or damage. Replace all worn or damaged pars.
(6) Reverse the above steps to reinstall.
Replace the split pin of chain anchor with new one.
8-10
2) SIDE ROLLER
(1) Remove carriage as outlined in the carriage Side roller
assembly and removal paragraph.
(2) Loosen and remove nuts, adjust screws
and side rollers from carriage side pate.
(3) Thoroughly clean, inspect and replace all
worn or damaged parts.
(4) Reverse the above procedure to assembly.
ö Adjustment
Â Once carriage is properly installed,
loosen nuts and adjust screws, (if not
already done) allowing carriage to be
centered in the inner mast.
Â Adjust side roller by tightening screw until
side roller just makes contact with mast. 20B7MS04
Back off approximately 1/10 turn on

screw and tighten nut to lock screw in
place.
Â 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.
3) CARRIAGE LOAD ROLLER

(1) Remove carriage as outlined in the Carriage
carriage assembly removal paragraph. load roller
(2) Loosen and remove flat head bolts and
plain washers from top load roller bracket.
(3) Using a pryer, remove load rollers from
load roller bracket.
(4) Reverse the above procedure to assemble.
Refer to MAST ROLLER ADJUSTMENT
paragraph.
20B7MS05
8-11
4) MAST LOAD ROLLER AND BACK UP
LINER Chain
(1) 2 stage mast(V mast)
Η Remove the carriage assembly and
move them to one side.
Θ Loosen and remove hexagon bolts and Inner
mast Stud
washers securing lift cylinders to inner
bolt
mast.
Ι Loosen and remove hexagon bolts and
Back up
nuts securing lift cylinders to inner mast. liner
Κ Attach chains or sling to the inner mast
section at top crossmember. Using an
overhead hoist, slowly raise the inner
mast high enough to clear lift cylinder.
Λ After lowering the lift cylinder rods, and Clamp
disconnecting lift cylinder hose, tilt the lift
cylinders LH and RH and them with Lift cylinder
ropes to the outer mast.
Μ Using the overhead hoist, lower inner
mast until top and bottom rollers and
back up liners are exposed.
Ν Using a pryer, remove load rollers from
load roller bracket. Remove back up
liners and shims. Mast
load
Ξ Thoroughly clean, inspect and replace all roller
Ο Reverse the above procedure to Bolt
assemble. Refer to MAST LOAD Outer
ROLLER ADJUSTMENT paragraph. mast
15BT9MS14
8-12
(2) 3 stage mast(TF mast)
Η Remove the carriage assembly and
move it to one side.
Θ Loosen and remove hexagon bolt
securing bottom cylinder from outer mast.
Ι Loosen and remove band and special
washers securing lift cylinders to middle Chain
mast. Remove the spring pin.
Κ Attach chains or sling to the inner and
middle mast section at top crossmember. Inner
mast
Using an overhead hoist, slowly raise the
uprights high enough to clear lift cylinder.
Λ After lowering the lift cylinder rods, and Middle mast
disconnecting lift cylinder hose, tilt the lift
cylinders LH and RH and tie them with
ropes to the outer mast. Stud
Μ Using the overhead hoist raise inner and bolt
Back up Lift cylinder
middle masts. Place 4 inch block of liner
wood under the free lift cylinder bracket of
the inner mast then lower mast sections
(this will create slack in the chains).
Ν Remove retaining rings securing chain
Clamp
sheaves to sheave support brackets.
While support chains, remove chain
sheaves and let chains hang free. The
upper outer and lower middle mast rollers Mast
and back up liners are now exposed. load
roller
Ξ Using a player, remove load rollers from
load bracket. Remove back up liners and
shims.
Ο Attach chains or sling to the middle mast
section at top crossmember. Using an
Bolt
overhead hoist, slowly raise the middle Outer
mast until top and bottom rollers are mast
exposed.
Π Using a pryer, remove load rollers from
load roller bracket.
Ρ Thoroughly clean, inspect and replace all
΢ Reverse the above procedure to
assemble. Refer to MAST LOAD
ROLLER ADJUSTMENT paragraph.
15BT9MS15
8-13
5) ELEVATING MAST
(1) Inner mast (V mast)
Η 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.
Θ Lift inner mast upright straight up and out of outer mast section.
Ι Replace and reverse above procedure to install. Make all necessary measurements and
adjustments.
(2) Inner and middle mast(TF mast)
Η After completing all necessary steps for load rollers and back up liner removal. Remove rear
chains and sheave support if not already done.
Θ Disconnect free lift cylinder hose. Drain hose into a suitable pan or container and cap hose.
Ι While supporting free lift cylinder assembly, remove bolts and washers securing cylinder to mast
crossmember.
Κ Place a sling around free lift cylinder and attach to an overhead hoist. Slowly raise and move
cylinder to one side.
Λ Attach chains or sling to the inner mast section at top crossmember. Using an overhead hoist
slowly raise the upright straight up and out of middle mast section.
Μ Attach chains or sling to the middle mast section at top crossmember. Using an overhead hoist
slowly raise the upright straight up and out of outer mast section.
Ν Replace upright and reverse above procedure to install. Make all necessary measurements and
adjustments.
8-14
6) CHAIN
(1) Chain sheave(V mast)
Η Place a sling around carriage and attach
Chain
to an overhead hoist. Lift carriage high
enough so that the tension on the chain Anchor
bolt
over sheaves is relieved after the carriage
is blocked. Position wooden blocks under
the carriage and lower it.
Θ Remove the split pin securing the chain
anchor pins and discard.
While supporting the chains, remove the
chain anchor pins and drape the chains
over the carriage. Sheave
Ι Remove retaining ring securing sheaves
Carriage
to sheave support. Remove sheaves
with bearings.
Κ Remove bearing retaining ring from Inner mast
sheave and press bearings from
sheaves.
Λ Thoroughly clean, inspect and replace all
Μ Reverse the above to assemble and
install. Use new split pins in chain anchor
pins. 15BT9MS16
(2) Rear chain sheave(TF mast)

Η Raise and securely block carriage and
inner mast section. Chain
Θ Remove the split pin securing the chain Sheave

anchor pins and discard. While Middle mast
Anchor
supporting the chains, remove the chain bolt
anchor pins from outer mast section. Chain
Sheave
Ι Remove chains.
Κ Remove retaining ring securing chain
sheaves to sheave support. Pry off Anchor
bolt
Anchor
sheaves with bearings. Anchor bolt
Λ Remove bearing retaining ring from bolt
sheave and press bearings from

sheaves.
Carriage
Μ Thoroughly clean, inspect and replace all Inner mast
Ν Reverse the above procedure to
assemble and install. Use new split pins Free lift
cylinder
in chain anchor pins.
15BT9MS17
8-15
(3) Chain wheel bearing support(TF mast)
Η Remove the carriage assembly and move to one side.
Θ 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. Move assembly to work area.
Ι Remove retaining ring securing chain wheel bearing to chain wheel bearing support.
Κ Remove bearing retaining ring from chain wheel bearing and press bearings from chain wheel
bearings.
Λ Thoroughly clean, inspect and replace all worn or damaged parts.
Μ Reverse the above procedure to install.
(4) Rear chain(TF mast)
Η Remove the carriage assembly and move to one side. Refer to carriage removal and installation.
Θ Raise and securely block truck approximately 6 inches from the floor.
Ι Using a sling or chain around inner mast section attached to an overhead hoist, slowly raise inner
mast until there is enough slack in the chains to remove them. Block inner mast section.
Κ Remove split pins and chain anchor pins securing chains to chain anchor(part of inner mast).
Λ While supporting the chains, remove split and chain anchor pins securing chains to chain
anchors attached to outer mast section.
Μ Remove chains.
Ν Reverse the above to assemble and install. Use new split pins in chain anchor pins. Refer to this
section for Load chain lubrication and adjustment.
(5) Carriage chain
Η 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.
Θ Place a wooden block under the carriage and lower the carriage on the block.
Ι While supporting the chains, remove split pins and chain anchor pins from chain anchors.
Κ Remove chains and wash them with solvent. Refer to this section for Load chain inspection and
maintenance.
Λ Reverse the above procedure to assemble and install. Use new split pins in chain anchor pins.
Refer to this section for Load chain lubrication and adjustment.
(6) Load chain inspection and maintenance
After every 200 hours of truck operation, lift chains should be inspected and lubricated inspect for
the following chain conditions :
Η Wear
As the chain flexes on and off the chain wheel bearings, the joints very gradually wear. The
stretch a chain develops in service is due to material being worn off pin outer diameter and pitch
hole inner diameter on the inside plate.
Chain wear can be measured using a wear scale or steel tape. When chains have elongated
2%, they should be discarded. When checking chain wear, be sure to measure a segment of
chain that operates over a sheave. Do not repair chains by cutting our the worn section and
splicing in a new piece. If part of the chain is worn, replace all the chains on the truck.
8-16
Θ 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.
Ι Cracked plate
The most common cause of plate cracking is fatigue failure. Fatigue is a phenomenon that
affects most metals and many plastics. After many repeated heavy loads, the plates may crack
and the chains will eventually break. Fatigue cracks are almost always found through the pitch
holes perpendicular to the pitch line. Contrast this failure mode to the random failures caused by
stress-corrosion cracking. If cracks are present, replace all the chain on the truck. Noise in the
chain indicates that the plate is on the verge of cracking and will be failed before long.
Κ Tight joints
All joints in lift chain should flex freely. Tight joints resist flexure, increase internal friction, thus
increasing chain tension required to lift a given load. Increased tension accelerates wear and
fatigue problems.
Tight joints in lift chains can be caused by :
ÂBent pins or plates.
ÂRusty joints.
ÂPeened plate edges.
Oil rusty chains and replace chains with bent or peened components.
Λ 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
causing chain failure. Turned pins can be quickly spotted because the flats on the V heads are
no longer in line. Chains with turned or protruding pins should be replaced immediately. Do not
attempt to repair the chain by driving pins back into the chain.
Μ Chain side wear
A wear pattern on pin heads and outside plates indicates misalignment. This condition damages
chain and sheaves as well as increasing internal friction in the chain system.
Ν Chain anchors and chain wheel bearings
An inspection of the chain system includes a close examination of chain anchors and chain
wheel bearings. Check chain anchors for wear, breakage and misalignment.
Anchors with worn or broken fingers should be replaced. Anchors should be adjusted to
eliminate twisting or other misalignment in the chain. When chain is misaligned, load is not
distributed uniformly between the plates. Prolonged operation will result in premature fatigue
failure. Chain wheel bearings with badly worn flanges and outside diameter should be replaced.
Heavy flange wear indicates chain misalignment.
8-17
Ξ 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.
Check the chain at this point with a scale. The wear scale has instructions printed on the sides
for use in determining chain stretch and are as follows :
ÂDetermine pitch length of chain using 6 inch scale on one side of wear scale.
ÂIf pitch is 1/2(12.7mm), 3/4(19.05mm), 1(25.4mm), 1-1/2(38.1mm), 2(50.8mm), use side A of scale.
ÂIf pitch is 5/8(15.875mm), 1-1/4(31.75mm) or 2(50.8mm), use side B.
ÂAlign point A or B to center of a pin and note position of the opposite A or B point.
ÂIf other point also lines up with a pin, the chain is worn and should be replaced.
If any of the above conditions exists(cracked plates, turned pins, stretching etc), the chains should
be replaced in pairs as a complete assembly. Order chains by part number to insure the correct
chain length, pitch and material specifications.
(7) Load chain lubrication and adjustment
Η Lubrication
The most important consideration in field maintenance of lift chains is lubrication. Hard working,
heavily loaded chains cannot be expected to give satisfactory wear life without scheduled
periodic re-lubrication. Like all bearing surfaces, the precision manufactured, hardened steel,
joint-wearing surfaces require 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 severe service, may require more frequent re-lube to
maintain an oil film on all chain surface.
ÂWipe off the old oil with a clean cloth and blow out the remaining dirt with compressed air.
Wear eye protection.
ÂWith a clean brush, apply EP-140 extreme pressure lubricant or heavy motor oil(40W).
Θ Replacement
Replace chains as a pair. It will be virtually impossible to maintain uniform loading between the
strands if a new chain is put into service opposite an old chain. The joints in the old chain will be
greater than that on the new chain, greatly complicating the problem of maintaining equal chain
tension. The new chain will wear more slowly causing it to bear the major portion of the load
resulting in premature wear and fatigue failure. Don’t steam clean or decrease new chains.
The manufacturer’s grease is effective in reducing wear and corrosion. If the original factory lube
is dried out or wiped off, soak the new chain in heavy engine oil for at 1/2 hour prior to installing
on truck. After the old chains have been stripped from the mast, very carefully inspect chain
anchors and chain wheel bearing. Broken, cracked or worn anchor must be replaced using the
new anchor pin and split pin. Do not paint newly replaced chain after it has been installed.
8-18
Ι Adjustment
Chain adjustments are important for the following reasons :
ÂEqual loading of chain.
ÂProper sequencing of mast.
ÂPrevent over-stretching of chains.
ÂPrevent chains from jumping off sheaves if they are too loose.
Κ 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.
8-19

15, 18, 20 BT-9

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SERVICE MANUAL

HYUNDAI FORKLIFT TRUCK

Kiều Văn Trung

Careless performing of the easy work may

Â Wear well-fitting helmet, safety shoes and

Â Flames should never be used instead of

Â When working on top of the machine, be

When inspecting running parts or near such

Â Immediately remove any oil or grease on the

Â When working with others, choose a group

1 Mast 6 Dash board 11 Seat

Model Unit 15BT-9 18BT-9 20BT-9

Capacity kg (lb) 1500 (3310) 1800 (3970) 2000 (4410)

Type - Fixed displacement gear pump

6) MAIN CONTROL VALVE

Type - 3 spool, 4 spool

Max. axle load kg/lb 2700/5953

Type (STD/OPT) SOLID Non-marking

9) BRAKES & STEERING

Travel Front wheel, wet disc brake

NO Items Size kgfÂm lbfÂft

(2) Fine thread

Thread size Width across flat mm kgfÂm lbfÂft

3) PIPE AND HOSE(ORFS TYPE)

Thread size Width across flat mm kgfÂm lbfÂft

Thread size Width across flat mm kgfÂm lbfÂft

Fitting NLGI No.1

ÂAPI : American Petroleum Institute

No. Description Period of replacement

1 Hydraulic oil Every 1 year

1 Lift cylinder 9 Drive unit 17 Counterweight

Remove and install following units as explained in the flow chart.

approximately 25mm(1in) from the floor. Spring

(2) Backrest(If necessary)

(3) Carriage Crane

Ι Pull the chains out of the sheaves and

Κ Slowly raise inner mast upright until mast

Lift chain Carriage

(5) Lift cylinder

(7) Tilt cylinder pin

(1) Mast and counterweight

(2) Brake piping

(3) Parking brake cable

Drive line Parking brake

Drive unit &

Θ Remove three hexagon bolts holding the

Κ Loosen seven mounting bolts on the

Item kgfÂm lbfÂft

Wheel nut (3) 12.5 ~ 15.5 90.4 ~ 112

Η Disconnect the battery connector.

Θ Using a battery hanger, carefully raise the Hanger

Θ Remove floor mat and rear floor plate.

Ι Remove elbow and connector and then

gear pump. Pump motor

Remove the gear pump from pump

Counter Hose Mounting

Mounting bolt 15BT9RE24

Κ Loosen socket bolts and remove steering

Λ Jacking up the chassis of truck.

Μ Remove the hub cap.

1 Dirve unit assembly (LH) 13 Snap ring (for shaft)

1 Housing sub assembly (LH) 15 Planetary carrier

1 Cover out assembly (LH) 8 Ball bearing

1 Parking sub assembly (LH) 8 Quad ring