Hyundai 15BT-9, 18BT-9, 20BT-9 Forklift Truck Factory Service Repair Manual INSTANT

2-2 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Forks Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. 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 easy removal. Remove only one fork at a time. On larger forks it may be necessary to use a block of wood. 1. MAST REMOVAL 1) (1) Remove and install following units as explained in the flow chart. Backrest Carriage Center notch Fork Knob Rolled pin Spring Pin Backrest(If necessary) Remove bolts securing backrest to fork carriage. Disassemble the backrest from the carriage. (2) Carriage Backrest Bolt 15BT9RE04 15BT9RE03 Carriage With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor. Make sure the carriage is level, this will prevent any binding when the mast is raised. (3) Block Crane 15BT9RE10

2-3 While supporting lift chains, remove the split pins and slide out chain anchor pins from the chain anchors of stationary upright. Nut Outer mast Lift chain Split pin 20B7RE05 Pull the chains out of the sheaves and drape them over the front of the carriage. Block Lift chain Carriage Mast 20B7RE06 Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage to work area and lower the mast. Make sure that carriage remains on floor and does not bind while mast is being raised. Inspect all parts for wear or damage. Replace all worn or damaged parts. Inner mast Lift chain Carriage 15BT9RE07

2-4 1 Outer mast Lift cylinder 2 Inner mast Bolt 15BT9RE08 Lift cylinder Loosen hexagonal bolts and remove washers securing the lift cylinders to outer mast. Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no slack or binding. Make sure that the lift cylinder be tightened firmly for safety. Loosen and remove hexagon bolts and clamp securing the lift cylinder to outer mast. Using an overhead hoist, slowly raise the inner mast high enough to clear lift cylinder. Using an overhead hoist, draw out lift cylinder carefully and put down on the work floor. (5) Clamp Stud bolt Inner mast Outer mast Lift cylinder Bolt Bolt 15BT9RE09 Piping Loosen the bolts (2EA) of the weld- connector (2) from low crossmember of the outer mast. Disconnect the connectors from the lift cylinders. Disassemble the velocity fuse valve (1), hoses, and weld-connector (2). (4)

2-5 Inner mast Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. (6) Inner mast Outer mast 15BT9RE12 Tilt cylinder pin Attach a crane to the stay at the top of the outer mast, and raise enough to sustain jacked up machine. This operation is carried out from under the machine, so use a pit, or if there is no pit, jack up the machine and loosen with on impact wrench. Remove the socket bolts, washers from the mast mounting pins and take out the mast mounting pins, and then slowly raise up the outer mast (7) Outer mast Pin Tilt cylinder Bushing Mast mounting pin Washer Socket bolt 15BT9RE11

2-6 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. Assemble the cylinder rod to the inner mast, and check the left-to-right play of the mast at the maximum lifting height. If play is to LEFT, install adjustment shim to LEFT cylinder. If play is to RIGHT, install adjustment shim to RIGHT cylinder. Shim thickness : 1.0mm(0.04in) INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. Installation procedure for each of mast component is the reverse of the removal procedure. Brone bushings Check the inside of the bronze bushings for wear which are the contact area with the mast mounting pins. Jack up the machine so that the front is raised and then using an overhead hoist assemble outer mast to drive axle unit. Tilt cylinder pin Hold the mast with a crane, operate the tilt control lever and align the holes, then knock the pin. Lift cylinder installation and adjustment 2) (1) (2) (3) L15C3RE12

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Hyundai 15BT-9, 18BT-9, 20BT-9 Forklift Truck Factory Service Repair Manual INSTANT

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