PDF Service Manual Hyundai Forklift 15BT-9U 18BT-9U 20BT-9U - 4 MB
This comprehensive service manual covers the Hyundai 9U series electric forklifts, including the 15BT-9U, 18BT-9U, and 20BT-9U models.
It provides detailed instructions for diagnostics, repair, and maintenance.
Filled with technical specifications and schematics, this manual is the ultimate resource for service technicians.
Keep your Hyundai electric forklift fleet running efficiently with this factory guide.
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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 ----------------------------------------------------------------------------------------------- 3-9
Group 3 Disassembly and assembly -------------------------------------------------------------------------- 3-10
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function ----------------------------------------------------------------------------------- 4-1
Group 2 Operational checks and troubleshooting ---------------------------------------------------- 4-5
Group 3 Adjustments ----------------------------------------------------------------------------------------------------- 4-7
SECTION 5 STEERING SYSTEM
Group 1 Structure and function ----------------------------------------------------------------------------------- 5-1
Group 2 Operational checks and troubleshooting ---------------------------------------------------- 5-10
Group 3 Disassembly and assembly -------------------------------------------------------------------------- 5-13
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function ----------------------------------------------------------------------------------- 6-1
Group 2 Operational checks and troubleshooting ---------------------------------------------------- 6-25
Group 3 Disassembly and assembly -------------------------------------------------------------------------- 6-30
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 ------------------------------------------------------------------------------- 8-10
--- 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 and other fire fighting
D50ASF01
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.
Ambient temperature °C (°F)
Service
Kind of fluid Capacity ℓ (U.S. gal)
point -50 -30 -20 -10 0 10 20 30 40
(-58) (-22) (-4) (14) (32) (50) (68) (86) (104)
0.35
Axle Gear oil ATF Dexron Ⅲ
(0.1)
★ISO VG 15
Hydraulic Hydraulic
20 (5.2) ISO VG 46
oil tank oil
ISO VG 68
Brake 0.5
Brake oil DOT 3
system (0.13)
Fitting ★NLGI No.1
0.1
(Grease Grease
(0.03)
nipple) NLGI No.2
·ATF : Automatic Transmission Fluid ★ : Cold region
·API : American Petroleum Institute Russia, CIS, Mongolia
·SAE : Society of Automotive Engineers
·ISO : International Organization for Standardization
·NLGI : National Lubricating Grease Institute
1-11
--- Page 5 ---
② Remove three hexagon bolts holding the
Drive motor
drive motor in place.
③ Carefully remove the drive motor from
the drive unit. Drive unit
USE pm 4010 page DWG Bolt
15BT9USM0216
④ Loosen seven mounting bolts on the
truck frame and carefully take out the
drive unit.
Frame
Drive unit
Mounting bolt
15BT9USM0217
2) INSTALLATION
Installation is the reverse order of removal, Frame
but be careful of the following tightening
torque. Motor
Drive tire
wiring
·Tightening torque
Item kgf·m lbf·ft
Drive motor (1) 5.6 ~ 8.2 40.5 ~ 59.3 2 1
3
Drive unit (2) 12.5 ~ 15 90.4 ~ 109 15BT9USM0218
Wheel nut (3) 12.5 ~ 15.5 90.4 ~ 112
2-8
--- Page 6 ---
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.
15BT9USM0305
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.
3-5
--- Page 7 ---
(11) By levering the spur gear alternately on
both sides, manually remove it from the
housing cover.
※ Be careful not to damage the toothing
when levering.
15BT9USM0323
15BT9USM0323
(12) Remove the grooved ball roller bearing
from the spur gear using tool and the
hand lever press.
※ Risk of accident and injury from crushing.
When pressing out the grooved ball roller
bearing, do not place hands between the
punch and the tool.
15BT9USM0324
15BT9USM0324
3-15
--- Page 8 ---
# Wheel shaft side bearing seat
(5) Clean the wheel shaft side bearing seat
of the taper roller bearing in the housing .
15BT9USM0351
(6) Drive the wheel shaft side bearing cup of
the taper roller bearing into the bearing
seat.
The inside of the bearing cup shall narrow
to a taper towards the bearing seat and
the wide edge of the bearing cup shall be
positioned at the bottom.
15BT9USM0352
15BT9USM0353
(7) Coat the inner lip of the shaft sealing ring
with multipurpose
15BT9USM0354
3-25
--- Page 9 ---
# Protective cap
(33) Fit the protective cap to the wheel shaft
and tap it lightly until it snaps into place.
15BT9USM0381
# Planetary gears
(34) Version with 3 planet gears
Place a planet gear with pre-assembled
cylindrical roller bearing straight onto one
of the pins of the planet carrier.
Do not tilt the planet gear. Face upwards
the identification mark of the planet gear.
15BT9USM0382
(35) Drive in the planet gear including the
cylindrical roller bearing until reaching the
limit stop. Use a hammer and a striking
mandrel. Drive in the remaining two pre-
assembled planet gears by using the same
method. Note the correct meshing of the
teeth of both planet gears and ring gear.
15BT9USM0383
(36) Apply a pining by using tool to lock the
planet gears.
The pining is done correcly as soon as the
axial play of the planet gear's cylindrical
roller bearings on the bolts has
dissappeared completely.
15BT9USM0384
3-35
--- Page 10 ---
3) Motor reassembly
# Motor
(1) Fasten the motor to suitable lifting gear using
approved attachment equipment.
15BT9USM03108
(2) Position the motor in front of the drive unit
and manually mesh the motor pinion with
the spur gear pinion.
When meshing the motor pinion with the
spur gear, make sure that both sets of
teeth are not tilted or damaged.
The motor connections shall be at
the top in the installation position.
15BT9USM03109
(3) Fasten the motor to the drive unit with the
3 Allen bolts.
Screw in the shorter Allen bolt at the top of
the drive unit and each of the two other
bolts into the right hand and left-hand side
of the drive unit.
15BT9USM03110
(4) Firmly tighten the 3 Allen bolts to a
tightening torque of 23Nm.
15BT9USM03111
3-45
--- Page 11 ---
SECTION 5 STEERING SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. LAYOUT
15BT9USM0501
1 Hole (connection to Forklift chassis) 5 Steering controller 8 Angle sensor
2 Helical gear (3 stage) 6 Steering controller connection 9 Axle carrier
3 Motor controller unit 7 Connection for angles-of- 10 Output flange
4 AC Steering motor rotation sensor
The steering operation by rotating the electric motor using the signal values from the steering sensor
installed under the steering handle. EPS(Electronic Power Steering) system uses the electric motor for
steering to achieve advanced functions such as operating force, lock to lock rev adjustment, and the
correct system. Unlike traditional HPS(Hydraulic Power Steering) system, The electric motor only
operates when the steering wheel is turned. And eliminating unnecessary energy consumption and
noise. Without any hydraulic equipment, oil maintenance is unnecessary and environmentally friendly.
5-1
--- Page 12 ---
(6) Slotted nut wrench
(7) Pressure piece
(8) Forcing device
(9) Assembly lever set
(10) Extrator
(11) Counter support
5-11
--- Page 13 ---
⑧ If required, remove fitting key.
# Breather
① For removal on detached housing cover,
drive the breather out of the hole on the
inner side of the housing cover using a pin
punch and remove it.
② For removal on mounted unit, locate pincer
head of the end-cutting pliers beneath the
breather cap.
③ Pull the breather out of the housing cover.
# Wheel hub bearing
① Rotate transmission on the assembly truck
(horizontal position).
Use screw driver to lever out protective cap and
remove it from the output flange.
② Loosen hexagon screw.
5-21
--- Page 14 ---
⑥ Insert locking plate.
⑦ Hand-tighten slotted nut.
Remove lashing strap.
⑧ Position the holding device on the gear shaft
and fix it on the wheel bolt using two wheel
nuts. Tighten slotted nut until the required
rolling torque is obtained. Then force out
bearing by means of slight hits and roll it in.
⑨ Check rolling torque of axle carrier bearing
10~15 Nm.
⑩ Secure slotted nut with locking plate.
(2) Housing
# Angles of rotation sensor
① Insert solenoid into the groove of the axle carrier.
5-31
--- Page 15 ---
2. HYDRAULIC GEAR PUMP
1) STRUCTURE
6
4
9
3 14
13
11
2
7
8
1
5
11
9
6
8
7
10
12
15BT9USM0607
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.
6-7
--- Page 16 ---
2) STRUCTURE (4 Spool)
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
Inlet port 7/8-14UNF P
Outlet port 7/8-14UNF T 15BT9USM0622
Work port 7/8-14UNF 1A
Work port 3/4-16UNF 2A, 2B, 3A, 3B, 4A, 4B
1 Inlet block assy 7 Main relief valve assy
2 Lift block assy 8 Auxiliary relief valve assy
3 Tilt block assy 9 Long bolt
4 Aux 1 block assy 10 Nut
5 Aux 2 block assy 11 Solenoid valve
6 Outlet block assy
6-17
--- Page 17 ---
2. TROUBLE SHOOTING
1) SYSTEM
Problem Cause Remedy
Large fork lowering speed ·Seal inside control valve defective. ·Replace spool or valve body.
·Oil leaks from joint or hose. ·Replace.
·Seal inside cylinder defective. ·Replace packing.
Large spontaneous tilt of mast ·Tilting backward : Check valve defec- ·Clean or replace.
tive.
·Tilting forward : tilt lock valve defect- ·Clean or replace.
ive.
·Oil leaks from joint or hose. ·Replace.
·Seal inside cylinder defective. ·Replace seal.
Slow fork lifting or slow mast ·Lack of hydraulic oil. ·Add oil.
tilting ·Hydraulic oil mixed with air. ·Bleed air.
·Oil leaks from joint or hose. ·Replace.
·Excessive restriction of oil flow on ·Clean filter.
pump suction side.
·Relief valve fails to keep specified ·Adjust relief valve.
pressure.
·Poor sealing inside cylinder. ·Replace packing.
·High hydraulic oil viscosity. ·Change to ISO VG46.
·Mast fails to move smoothly. ·Adjust roll to rail clearance.
·Oil leaks from lift control valve spool. ·Replace spool or valve body.
·Oil leaks from tilt control valve spool. ·Replace spool or valve body.
Hydraulic system makes ·Excessive restriction of oil flow pump ·Clean filter.
abnormal sounds suction side.
·Gear or bearing in hydraulic pump ·Replace gear or bearing.
defective.
Control valve lever is locked ·Foreign matter jammed between sp- ·Clean.
ool and valve body.
·Valve body defective. ·Tighten body mounting bolts uniform-
ly.
High oil temperature ·Lack of hydraulic oil. ·Add oil.
·High oil viscosity. ·Change to ISO VG46.
·Oil filter clogged. ·Clean filter.
6-27
--- Page 18 ---
(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
6-33-4
--- Page 19 ---
(3) S damping screw
※ S damping
Integrated combination of orifice,
check valve, pre-load valve (approx.
25 bar).
※ Tightening torque
1.02 kgf·m (7.4 lbf·ft)
6-42
6-41
--- Page 20 ---
5) ADD SECTION PART
(1) Disassembly
1 2 ※Tightening torque
- Item 1 (2 EA) : 2.3 kgf·m (17.0 lbf·ft)
- Item 2 (1 EA) : 0.97 kgf·m (7.0 lbf·ft)
3 spool tension rod set
※From 4 spool to 3 spool.
※When it needs to disassemble section valve, it’s possible to release tension rod sets.
6-52
6-51
--- Page 22 ---
UL MANUAL TYPE (15BT-9U : ~#89, 18BT-9 : ~#145, 20BT-9U : ~#179)
·UL
21FY-90611
7-2-3
--- Page 23 ---
OHG (15BT-9U : #278~, 18BT-9U : #397~, 20BT-9U : #661~)
·OHG
21FY-90960
7-2-13
--- Page 24 ---
(2) Performance and maintenance of batteries
① Initial charge
Wet-charged battery gradually decreases its capacity during storage. In order to provide
sufficient discharge capacity in the first discharge, the good initial charge is required. The
conditions of initial charging are seen as below at room temperature.
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 (standard)
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 0.1C×5 hour rate nominal
capacity current for 24 hours or more. The charge shall be terminated when one of the following
conditions is identified.
·When a constant value is indicated for more than 1 hour after the battery voltage has
reached the maximum value.
·When more than 1 hour of charge is continued after the electrolyte specific gravity has risen
fully and becomes constant.
② 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 30°C.
That is, the capacity is indicated by AH (ampere hour) being calculated as the product of ampere
(A) and time (H). However, even if it is 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.
③ 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 25°C by the following formula.
S25 = St + 0.0007 (t-25)
Where, S25 : Specific gravity at 25°C
St : Actually measured specific gravity at t°C
t : Electrolyte temperature (°C)
The standard specific gravity for this type of battery is 1.280±0.01(25°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.
7-7
--- Page 25 ---
5. CONTROLLER SYSTEM
1) STRUCTURE
(1) Traction and Pump controller
15BT9USM0708
7-17
--- Page 26 ---
(3) Connection of encoder(Traction and Pump)
ACE2 can handle different types of encoder. To control AC motor, it is necessary to install an
incremental encoder with 2 phases shifted by 90°. The encoder supply can be 5 V or 12 V. For
special applications it is possible to install incremental encoder with zero-position signal.
- A 8 : +5V/+12V : encoder positive power supply.
- A15 : GND : encoder negative supply.
- A 7 : ENC A : encoder phase A.
- A14 : ENC B : encoder phase B.
15BT9USM0713
4) Function configuration
Using the CONFIG MENU of the programming smart console, or using a display, the user can
configure the following functions.
(1) Right traction inverter
① Set option
SET OPTIONS DESCRIPTION
This option specifies the hour counter mode. It can be set one of two:
HOUR COUNTER - RUNNING: The counter registers travel time only
- KEY ON: The counter registers when the "key" switch is closed
This option specifies the management of the low battery charge situation. There are
four levels of intervention:
- 0 : nothing happens; the battery charge level is evaluated but ignored, meaning that
no action is taken when the battery runs out.
- 1 : The BATTERY LOW alarm occurs when the battery level is evaluated to be lower
or equal to 10% of the full charge. With the BATTERY LOW alarm, the control
BATTERY CHECK reduces the maximum speed down and it also reduces the maximum current
down to 50% of the full current.
- 2 : The BATTERY LOW alarm occurs when the battery level is evaluated to be lower
or equal to 10% of the full charge.
- 3 : The BATTERY LOW alarm occurs when the battery level is evaluated to be lower
or equal to 10% of the full charge. With the BATTERY LOW alarm, the control
reduces the maximum speed down.
7-27
--- Page 27 ---
(4) EPS inverter
① Parameter
Parameter DESCRIPTION
From 30 to 90. This setting specifies the number of revolutions of the steering wheel
POTI REVOLUTIONS
for a side to side rotation of the steered axle.
0 to 1000mA. The minimum Force Feedback value is set via SET STEER MIN.
SET STEER MIN. (Please refer to the Force Feedback vs. Traction Speed in the description of SET TFD
HTS)
0 to 1000mA. The maximum Force Feedback value is set via SET STEER MAX.
SET STEER MAN. (Please refer to the Force Feedback vs. Traction Speed in the description of SET TFD
HTS)
0 to 1000mA. This parameter is used to handle the minimum Force Feedback value
SET STEER HTS at HTS (High Traction Speed). (Please refer to the Force Feedback vs. Traction
Speed in the description of SET TFD HTS)
The time delay before switching off the Force Feedback when the steered axle has
reached the limiting
position and the steering wheel has been released is set by this parameter.
PERCUSSION DUTY - LEVEL 0: 16 msec delay.
- LEVEL 1: 32 msec delay.
- LEVEL 2: 48 msec delay.
- LEVEL 9: 160 msec delay.
From 30 to 180 degrees. This parameter sets the maximum steered axle angle in
1ST ANGLE GAIN
the steering direction with FEEDBACK POT 1 value higher than 2.5V.
From 30 to 180 degrees. This parameter sets the maximum steered axle angle in
2ND ANGLE GAIN
the steering direction with FEEDBACK POT 1 value lower than 2.5V.
This parameter is used to handle the minimum Force Feedback value at LTS(Low
SET TFD LTS Traction Speed). (Please refer to the Force Feedback vs. Traction Speed in the
description of SET TFD HTS)
This parameter is used to handle the minimum Force Feedback value at HTS(High
Transation Speed).
SET TFD HTS
7-37
--- Page 28 ---
④ Left traction slave
Monitoring Description
Motor speed measured through the encoder and expressed in the same unit of
MEASURED SPEED
FREQUENCY (Hz).
CNA4 Status of the Brake oil SW Input on A4.
CNA5 Status of the Tilt leveling SW input A5.
CNA6 Status of the Load sensor potentiometer (analog signal) input A6.
CNA19 Status of the SBR SW Input on A19.
A13 TILT LEV 1 Status of the Auto tilt leveling 1 (Decreasing analog signal) input A13.
7-47
--- Page 29 ---
(5) Truck speed
The truck speed is shown in number. The unit can be km/h or mph according to the display setting
(see 7-66 page).
(6) Hour meter
The number shows the hours worked. The letter present beside the hour meter number shows
which hour meter is displayed.
– hK : the Key Hour shows the truck Key ON time;
– hT : the Traction Hour shows the Gate ON (driven) time of the traction motor.
– 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 points 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