PDF Service Manual Hyundai 15BR-9E Forklift - 1 MB
This is the comprehensive service manual for the Hyundai 15BR-9E forklift.
It provides detailed instructions for maintenance, troubleshooting, and repair procedures.
Technicians will find this manual invaluable for keeping the forklift operating at peak performance and safety.
It covers all major systems, including hydraulics, electrical, and mechanical components, with clear diagrams and specifications.
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--- Page 1 ---
CONTENTS
SECTION 1 GENERAL
Group 1 Safety hints ------------------------------------------------------------------------------------------------------ 1-1
Group 2 Specifications -------------------------------------------------------------------------------------------------- 1-4
Group 3 Periodic replacement -------------------------------------------------------------------------------------- 1-12
SECTION 2 REMOVAL & INSTALLATION OF UNIT
Group 1 Major components ----------------------------------------------------------------------------------------- 2-1
Group 2 Removal and installation of unit -------------------------------------------------------------------- 2-2
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and operation --------------------------------------------------------------------------------- 3-1
Group 2 Troubleshooting ---------------------------------------------------------------------------------------------- 3-4
Group 3 Disassembly and assembly -------------------------------------------------------------------------- 3-6
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function ------------------------------------------------------------------------------------ 4-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------ 4-9
Group 3 Test and adjustment --------------------------------------------------------------------------------------- 4-11
SECTION 5 STEERING SYSTEM
Group 1 Structure and function ------------------------------------------------------------------------------------ 5-1
Group 2 Disassembly and assembly --------------------------------------------------------------------------- 5-3
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function ------------------------------------------------------------------------------------ 6-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------ 6-21
Group 3 Disassembly and assembly --------------------------------------------------------------------------- 6-25
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component location --------------------------------------------------------------------------------------- 7-1
Group 2 Electrical circuit ----------------------------------------------------------------------------------------------- 7-2
Group 3 Electric components --------------------------------------------------------------------------------------- 7-3
SECTION 8 MAST
Group 1 Structure ---------------------------------------------------------------------------------------------------------- 8-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------ 8-4
Group 3 Adjustment ------------------------------------------------------------------------------------------------------ 8-7
Group 4 Removal and installation -------------------------------------------------------------------------------- 8-9
--- Page 3 ---
GROUP 1 SAFETY HINTS
Careless performing of the easy work may
cause injuries.
Take care to always perform work safely, at least
observing the following.
 Oil is a dangerous substance. Never handle
oil, grease or oily clothes in places where
there is any fire of flame.
As preparation in case of fire, always know the
location and directions for use of fire extinguishers
D50ASF01
and other fire fighting equipment.
 Wear well-fitting helmet, safety shoes and
working clothes. When drilling, grinding or
hammering, always wear protective goggles.
Always do up safety clothes properly so that
they do not catch on protruding parts of
machines. Do not wear oily clothes.
When checking, always release battery plug.
D50ASF02
 Flames should never be used instead of
lamps. Never use a naked flame to check
leaks or the level of oil or electrolyte.
D50ASF03
 When working on top of the machine, be
careful not to lose your balance and fall.
D50ASF06
1-1
--- Page 4 ---
6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Capacity˶(U.S. gal Ambient temperature °C (°F)
Service
Kind of fluid -50 -30 -20 -10 0 10 20 30 40
point 15BR-9E
(-58) (-22) (-4) (14) (32) (50) (68) (86) (104)
1.6
Drive unit Gear oil SAE 80W-90
(0.42)
★ISO VG 15
Hydraulic Hydraulic 18
ISO VG 46
oil tank oil (4.0)
ISO VG 68
Fitting ★NLGI No.1
0.1
(Grease Grease
(0.03)
nipple) NLGI No.2
★ : Cold region
Russia, CIS, Mongolia
1-11
--- Page 5 ---
(5) Remove steering joint parts.
Sprocket
Pin
Universal joint
BR7RE13
(6) Remove brake cable.
Bracket
Wrench
Brake cable
15BR9ERE16
(7) Disconnect the wiring.
Η Drive motor wiring
Θ EPS motor wiring.
Drive motor
EPS
motor
15BR9ERE17
(8) Jack up the frame and support both side
of frame on wood block.
Wood block
18BR9JB09
2-8
--- Page 6 ---
4. CASTER LINK ASSEMBLY
BR7RE003
1) REMOVAL
(1) Disconnect the battery cable.
Disconnect
battery cable
15BR9ERE12B
(2) Remove floor mat and floor plate.
Floor mat
Floor plate
15BR9ERE28
(3) Jack up the frame and support both side
of frame on wood block.
Wood block 15BR9ERE49A
2-18
--- Page 7 ---
Problem Probable cause Remedy
Oil leakage on oil filler or oil ÂDirt between sealing ring and ÂCleaning required.
drain plug housing.
ÂOld sealing ring was used. ÂUse new sealing ring
ÂBolts not tightened according to ÂTighten bolts with the specified
the specified tightening torque. tightening torque.
Oil leakage between hous-ing ÂSeal faces not sealed or uneven. ÂApply LOCTITE 574 onto seal faces.
and top section Touch up seal faces with oil rubber.
ÂBurrs on cylinder pin. ÂUse a new cylinder pin.
ÂBolts not tightened according to ÂTighten bolts with the specified
the specified tightening torque. tightening torque.
Oil leakage on top section ÂToo much oil in transmission. ÂCheck oil level.
within helical gear stage / input ÂO-ring on cover defective. ÂInstall new O-ring.
ÂBreather valve defective. ÂReplace breather valve.
Beating noise at helical gear ÂTeeth on input pinion and/or helical ÂCheck tooth flanks for damage and
stage gear damaged by false installation. touch up damaged spots with oil
rubber.
Ringing noise ÂHelical gear stage running without ÂCheck oil level.
oil. Refill oil.
Grinding noise ÂBearing preload or backlash not ÂChecking and new adjustment.
correctly adjusted.
Bearing damage on input ÂNo axial play. ÂInstall new bearing and adjust axial
pinion play.
Pivoting bearing is difficult to ÂCover disc loosened and dirt enter- ÂReplace pivoting bearing.
rotate or backlash recog- ed into the bearing.
nizable ÂCage segments are damaged. ÂReplace pivoting bearing.
ÂPlastic deformation of balls or ball ÂReplace pivoting bearing.
race.
ÂBearing not relubricated. ÂRelubricate pivoting bearing.
ÂGrease not distributed. ÂRotate pivoting bearing several times
by hand.
3-5
--- Page 8 ---
4. BRAKE SYSTEM
1) STRUCTURE
14
15
2
21
20 4 7
19
6
5
17 1
11 4
16
14 10
13 9
12 40
18
19
20
8 21
3
41
15BR9EBS03
1 Brake drum 9 B/cam bracket 17 Hex nut
2 Low castle nut 10 Spring washer 18 Brake rod
3 Brake shoe pin 11 Hex bolt 19 Spring
4 Lining brake shoe 12 Brake cam 20 Plain washer
5 Lock plate 13 Plain washer 21 Hex nut
6 Plain washer 14 Split pin 40 Du-bushing
7 Hex nut 15 Grease nipple 41 Traction motor
8 Cable bracket 16 Cam bolt
4-4
--- Page 9 ---
2. SPECIFICATIONS AND SERVICE STANDARD
1st stage Chain
Type Unit
2st stage Gear
Steering wheel diameter (mm) ͚300
Steering wheel free play (mm) 25~50
Steering chain slack (mm) 3~5
Right turn 79Á
Steering angle
Left turn 101Á
Minimum
15BR-9E 1605
turning radius (mm)
3. TROUBLE SHOOTING
Problem Cause Remedy
Heavy At traveling  Damage of bearing at steering  Replace bearing
steering pinion
 Damage of bearing of steering  Replace bearing
shaft of drive unit
 Lack of grease of bearing  Lubricate grease
At releasing joint at  Damage of bearing in steering  Replace bearing
spline racket
 Over tension of roller chain  Adjust the tension
Steering play is large  Looseness of roller chain  Adjust the tension
(STD : 25~50 mm)  Extension of roller chain  Adjust the tension or replace the
chain
 Looseness of rubber coupling is  Replace coupling
large
 Looseness of spline and joint is  Replace
large
 Backlash of steering pinion and  Replace
gear is large
Steering wheel is robbed in one  Eccentric wear of tire  Replace
way during traveling  Transformation of drive unit-rear  Repair or replace
axle
 Transformation of frame  Repair or replace
5-2
--- Page 10 ---
6) WHEN THE REACH CONTROL LEVER IS IN THE BACK
BACKWARD
WARD POSITION
3
8
130k
B4
A4
7
B3
A3
B2
A2
5
A1 6
4
190k
2 9
M
1
15BR9EHS07
When the reach control lever is pulled backward, the spool on the third block is moved to reach
backward position.
The oil from hydraulic gear pump (2) flows into main control valve (3) and then goes to the small
chamber of reach cylinder (8) by pushing the load check valve of spool.
The oil at the large chamber of reach cylinder (8) returns to hydraulic tank (1) at the same time.
When this happens, the mast reaches backward.
6-7
--- Page 11 ---
9) 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 130 kgf/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
2
2
2
2
15BR9EHS20A
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
6-17
--- Page 12 ---
(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
6-27
--- Page 14 ---
(7) 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.
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 1.0~1.5 kgfÂm (7.2~10.8
lbfÂft) 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 1.0~1.5 kgfÂm (7.2~10.8
lbfÂft) is reached on both bolts.
Κ The load check assembly is inserted into the top center cavity.
Torque to 3.5~4.0 kgfÂm (25.3~30lbfÂft).
(8) Outlet section
Η Install the secondary main relief valve into the cavity on the clevis end of the housing.
Torque to 4.5~5.0 kgfÂm (32.5~36.2 lbfÂft)
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.
6-37
--- Page 15 ---
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.
7-3
--- Page 16 ---
2) SPECIFICATION
Item Unit 15BR-9E
Type - AMDU4004A
Rated voltage Vac 30
Rated output kW 4.5
Insulation - Class F
3) MAINTENANCE
AINTENANCE INSTRUCTION
(1) Inspection
ΗRotor assembly inspection
Rotor should always be cleaned with
compressed air.
If the dirt will not come off lightly wipe off
with piece of cotton or soft cloth wetted
with gasoline.
Rotor out diameter : ͚123.1Ü 0.05
Tool : Vernier calipers and standard tool
18BR9EL41
ΘStator assembly inspection
Stator should always be cleaned with
compressed air.
If the dirt will not come off lightly wipe off
with piece of cotton or soft cloth wetted
with gasoline, using care not to damage
the coil insulation.
Use mmɮ tester and check for two power
line of stator repeatedly (U-V, V-W, W-U).
At that time resistance is around 6.3 18BR9EL42
mmɮ
Insulation test
Use insulation tester (1000 Vac, Min. 10
Mɮ) and measure as a picture.
If the insulation is defective, replace with
new parts.
18BR9EL43
7-13
--- Page 17 ---
2) OPERATIONAL FEATURES
(1) Features
Η Speed control.
Θ Optimum behavior an a slope due to the speed feedback:
ÂThe motors speed follows the accelerator, starting a regenerative braking if the speed
overtakes the speed set-point.
ÂThe system can perform an electrical stop on a ramp (the machine is electrically hold on a
slope) for a programmable time.
Ι Electronic differential feature with torque balance between external and internal wheel.
Κ Regenerative release braking based upon deceleration ramps.
Λ Regenerative braking when the accelerator pedal is partially released (deceleration).
Μ Direction inversion with regenerative braking based upon deceleration ramp.
Ν Regenerative braking and direction inversion without contactors: only the main contactor is
present.
Ξ Optimum sensitivity at low speeds.
Ο Voltage boost at the start and with overload to obtain more torque (with current control).
Π Electronic steering function:
Ρ Backing forward and reverse options are available, with the tune and the speed of the function
programmable with Zapi console or buttons on a display.
High efficiency of motor and battery due to high frequency commutations.
Σ Modification of parameters through the programming console or buttons on a display.
Τ Internal hour-meter with values that can be displayed on the console.
Υ Memory of the last five alarms with relative hour-meter and temperature displayed on the
console.
Diagnostic function with Zapi console for checking main parameters.
Built in BDI feature.
Flash memory, software downloadable via serial link and via CANBUS.
(2) Diagnosis
The microcontrollers continually monitor the inverter and carry out a diagnostic procedure on the
main functions. The diagnosis is made in 4 points.
Η Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging,
phase's voltages, contactor drivers, can-bus interface, if the switch sequence for operation is
correct and if the output of accelerator unit is correct, correct synchronization of the two ʂCS,
integrity of safety related inputs hardware.
Θ Standby diagnosis in standby that checks: Watchdog circuit, phase's voltages, contactor driver,
current sensor, can-bus interface.
Ι Diagnosis during operation that checks: Watchdog circuits, contactor driver, current sensors, can-
bus interface.
Κ Continuous diagnosis that checks: Temperature of the inverter, motor temperature.
Diagnosis is provided in two ways. The digital console can be used, which gives a detailed
information about the failure; the failure code is also sent on the Can-Bus.
7-23
--- Page 18 ---
ÿ PUMP CONTROLLER
Using the config menu of the programming console, the user can configure the following functions.
(1) Submenu "SET OPTIONS"
Η Load sensor
- ON : Load sensing function is activated.
- OFF : Load sensing function is disactivated.
Θ Hour counter
This option specifies the hour counter mode. It can be set one of two :
- RUNNING : The counter registers travel time only.
- KEY ON : The counter registers when the “key” switch is closed.
Ι Set motor temperature
It can be set:
1. ANALOG : An analogue sensor for the control of the motor temperature is connected to
CNA#22. Typically the temperature sensor is a PTC (positive thermal coefficient
resistance), providing the sensor characteristic to Zapi the correct table can be
loaded in the controller software (analog temperature sensor).
2. DIGITAL : A digital (on/off) sensor for the motor temperature monitoring is connected to
CNA#22 input (digital temperature sensor).
3. NONE : No temperature sensor is connected.
Κ Cooling fan work
Cooling fans installed on nearby motors and controllers will work as follows;
- None : fans don't work.
- Option #1 : fans work always.
- Option #2 : fans work in case a temperature of controller or motor exceeds a temperature set in
START TEMP. FAN menu
- Option #3 : fans work when motors work.
Λ Digital lift
- OFF : The lift sensor includes a lift switch and an analogue lift sensor. Lift speed can be
controlled proportionally with lever position.
- ON : The lift sensor includes a lift switch only. Lift speed cannot be controlled proportionally.
Μ A-16 diag active
- ON : Pump inverter check A16 port (Fan relay coil).
- OFF : Pump inverter doesn't check A16 port (Fan relay coil).
Ν Model truck
This display model setting from traction inverter . Threre are 2 models.
- 10/13BR
- 15BR-9E (Model setting is only avalible at the traction inverter side.)
- This parameter must be set "15BR-9E" for 15BR-9E truck.
7-33
--- Page 19 ---
7) GENERAL SUGGESTION FOR SAFETY
For a proper installation take care of the following recommendations:
After operation, even with the key switch open, the internal capacitors may remain charged for
some time. For safe operation, we recommend that the battery is disconnected, and a short circuit
is made between battery positive and battery negative power terminals of the inverter using a
resister between 10 ohm and 100 ohm.
Do not connect the inverter to a battery with a nominal value different from the value indicated on
the controller plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit
does not "power up"
During battery charge, disconnect the controller from the battery.
Do not connect the controller to a battery with a nominal voltage different than the value indicated
on the controller label. A higher battery voltage may cause power section failure. A lower voltage
may prevent the logic operating.
Before doing 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.
7-43
--- Page 20 ---
6) DESCRIPTION OF THE TRUCK MENU
(1) Access to truck menu
If this button is pressed long, the PASSWORD dialog appears.
Enter correct PASSWORD, then on MAIN SCREEN, Press button to access the controller
“TRUCK MENU”
(2) How to change detail menus
The detail items of menu can be changed as follows ;
758&.0(18
6(77,1* 0$67(5
6(77,1* 0$67(5 6(7237,216
021,725,1* 6/$9( $'-8670(176
$/$50+,6725< 3803 3$5$0(7(5&+$1*(
9$66
0$67(5 0$67(5
0$67(5
3$5$0(7(5&+$1*( $&&(/'(/$< $&&(/'(/$<
$&&(/'(/$< $5(<28685("
6(& 6HF
<(6 (17(512 (6&
22B9EL24
Selection can be made in 4 methods as follows ;
- ON/OFF Selection
0$67(5
%$77(5<&+(&.
21
2))
22B9EL25
Select a desired value with , button, then save with button or press button to escape
without saving.
- Type Selection
0$67(5
&22/,1*)$1:25.
237,21
237,21
237,21
22B9EL30
Select a desired value with , button, then save with button or press button to escape
without saving.
7-53
--- Page 21 ---
7. ALARM CODE
1) TRACTION CONTROLLER
Description
No Code Alarm name Traction Pump
(T) (P) Cause Troubleshooting
1 D EEPROM KO ○ ○ It’s due to a Hardware or - Try to execute a CLEAR EEPROM operation
Software defect of the non- (Please ask to the engineer).
volatile embedded memory Switch the key off and on to check the