Hyundai 100D-7 Operating Manual

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SECTION 1 GENERAL

Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

Group 3 Operational checkout record sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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 Operation and maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-46

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-57

Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-150

SECTION 4 BRAKE SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32

Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-40

Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-43

SECTION 5 STEERING SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9

Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17

Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-21

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-31

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-36

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3

Group 3 Monitoring system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13

Group 4 Cluster indication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19

Group 5 Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24

CONTENTS

Summary of Contents for Hyundai 100D-7

Page 1 CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Operational checkout record sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16 SECTION 2 REMOVAL AND INSTALLATION OF UNIT...
Page 2 Group 6 Electrical component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28 Group 7 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Group 8 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-51 SECTION 8 MAST...
Page 3 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
Page 4 Revised edition mark( Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
Page 7 Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
Page 8 m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 11 SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Operational checkout record sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16...
Page 12 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.
Page 13 Be particularly careful when removing the radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using the machine, there is a danger that boiled oil may spurt out. The procedure for releasing the hydraulic pressure is as follows : lower the fork to the ground, and stop the engine(Motor), move the control levers to each position two or three times.
Page 14 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. D50ASF09 When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
Page 15 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...
Page 16 GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENTS 160D7OM54 Mast Tilt cylinder 13 Bonnet Lift chain Cabin 14 Counterweight Lift cylinder Work lamp-fender 15 Rear wheel Fork positioner cylinder 10 Work lamp-cabin front 16 Front wheel Carriage 11 Work lamp-cabin rear 17 Rear combination lamp Forks 12 Operator's seat...
Page 17 2. SPECIFICATIONS 100D-7/120D-7 C' C 160D7SP01 Model Unit 100D-7 120D-7 Capacity 10000 12000 Load center Weight(Unloaded) 14820 15965 Lifting height 3300 Free lift Lifting speed(Unload/Load) Fork mm/sec 510/440 510/430 Lowering speed(Unload/Load) mm/sec 460/510 L W T L,W,T 1350 200 70...
Page 18 135D-7/160D-7 C' C 160D7SP01 Model Unit 135D-7 160D-7 Capacity 13500 16000 Load center Weight(Unloaded) 17240 18865 Lifting height 3300 Free lift Fork Lifting speed(Unload/Load) 450/360 450/350 mm/sec Lowering speed(Unload/Load) mm/sec 390/430 L W T L,W,T 1350 200 85 1350 200 90 Tilt angle (forward/backward) C/C’...
Page 19 3. SPECIFICATION FOR MAJOR COMPONENTS 100D/120D-7 ENGINE Item Specification Unit Model CUMMINS QSB5.9 Type 4 cycle turbocharged diesel type Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, In-line Firing order 1-5-3-6-2-4 Combustion chamber type Direct injection Cylinder bore X stroke mm(in) 102×120mm(4.02"×4.72") Piston displacement...
Page 20 TEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev 45.4 Rated flow POWER TRAIN DEVICES Item Specification Model F & S 300* OZG 040/18(ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.3 : 1 Type Full auto, power shift...
Page 21 135D/160D-7 ENGINE Item Specification Unit Model CUMMINS QSB5.9 Type 4-cycle turbocharged diesel type Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, in line Firing order 1-5-3-6-2-4 Combustion chamber type Direct injection mm(in) Cylinder bore X stroke 102×120mm(4.02"×4.72") Piston displacement cc(cu in) 5883(359)
Page 22 TEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev 45.4 Rated flow POWER TRAIN DEVICES Item Specification Model F&S 300* OZG 040/18(ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.3 : 1 Type Full auto, Power shift Gear shift(FR/RR)
Page 23 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS 100D/120D-7 kgf m lbf ft Items Size Engine mounting bolt, nut M24 3.0 100 15 723 109 Engine Radiator mounting bolt, nut M12 1.75 12.8 3.0 93 22 Hydraulic pump mounting bolt M12 1.75 9.0 0.5 65 3.6 Hydraulic...
Page 24 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT - Coarse thread Bolt size kgf m lbf ft kgf m lbf ft M 6 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8 1.25 2.0 ~ 3.0 14.5 ~ 21.7...
Page 25 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat mm kgf m lbf ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 130.2 1" 151.9 1-1/4" 253.2 IPE AND HOSE(ORFS TYPE) Width across flat mm kgf m lbf ft Thread size(PF) 28.9 9/16-18 36.2...
Page 26 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. 。 C (。 F) Capacityℓ(U.S.gal) Ambient temperature Service Kind of point fluid 10~12ton 13.5~16ton (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil 14.2 14.2...
Page 27 GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET Owner Date Hours Serial No. Technician U U se this sheet to record operational checkout results. Perform the operational check before installing any test equipment. 100D7GE02 Item Comments 1. Monitor indicator and gauge checks(Engine OFF) Hour meter and gauge check ƒw ƒw...
Page 28 4. Brake system and clutch cut off checks Park brake capacity check ƒw ƒw Park brake transmission lockout check ƒw ƒw Service brake pump flow check ƒw ƒw Service brake capacity check ƒw ƒw Brake accumulator precharge check ƒw ƒw Brake system leakage check ƒw ƒw...
Page 29 7. Steering system checks Steering valve check ƒw ƒw Steering system leakage check ƒw ƒw Priority valve(built in MCV) ƒw ƒw Low check pressure ƒw ƒw High check pressure ƒw ƒw . Accessory checks Operating lights check ƒw ƒw Work light check ƒw ƒw Brake light check...
Page 30 SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
Page 31 GROUP 1 STRUCTURE 160D7OM21 Mast Transmission 17 Counterweight Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder 12 Steering cylinder 20 Cabin Main control valve 13 Hydraulic pump 21 Steering wheel Fork 14 Steering axle 22 Muffler Front wheel 15 Rear wheel...
Page 32 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Fork Carriage Piping Mast FORKS Carriage Hanger bar Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Cover Release fork retainer and remove cover.
Page 33 Pull the chains out of the sheaves and drape them over the front of the carriage. Inner mas Outer mast Work lamp assy Lift chain Block 100D7RE55 Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage to work area and lower the mast.
Page 34 PIPING LIft Remove the bulk hoses and clamps cylinder attached to the cylinder. Bulk hose Remove the return hose from the down control valve. Put blind plugs in the piping immediately after removing hoses. This prevents the hydraulic oil from Return flowing out and also prevents dust and hose...
Page 35 LIFT CYLINDER Loosen and remove hexagon bolts and Inner mast washers securing lift cylinders to inner mast. Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no Over V400 slack or binding. Make sure the lift cylinder be tightened LIft cylinder firmly for safety.
Page 36 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. Inner mast Outer mast 100D7RE59 TILT CYLINDER PIN MAST SUPPORT PIN Attach a crane to the stay at the top of the outer mast, and raise it.
Page 37 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. Installation procedure for each of mast component is the reverse of the removal procedure. MAST SUPPORT PIN Check the mast support pins for wear, then install pins into the mast support bracket and drive axle.
Page 38 2. POWER TRAIN ASSEMBLY REMOVAL Mast Brake piping Drive axle Mounting bolts holding to engine flywheel Inching harness T/M & axle cooling Floor plate piping Flexible plate mount bolt 100D7RE04 Mast Refer to section on mast(Page 2-2)
Page 39 Brake piping Disconnect the brake hydraulic pipes from Brake hose Return the brake housing of drive axle unit. hose Drive axle 100D7RE05 Drive axle Before removing the drive axle unit, drain all of the oil from the axle. Jack up the machine and then put the block under the frame.
Page 40 Transmission and axle cooling piping Disconnect cooling hose and connector from the transmission. Transmission Radiator Make sure that the coolant has been assembly assembly drained from the line. Cooling hose 100D7RE10 Disconnect axle cooling hose and Axle Radiator connector from the axle. cooling assy oil tank...
Page 41 Using a moving truck slowly pull out transmission assembly to the front. Block Transmission Transmission Truck 100D7RE13 2-11...
Page 42 INSTALLATION Installation is the reverse order to removal, but be careful of the following points. Bolt Tightening torque of mounting bolt for Engine torque converter. 3.9~5.1kgf m(28.2~36.9lbf ft) Socket bolt Tightening torque of mounting socket bolts to flywheel housing. Transmission 5.5~8.3kgf m(39.8~60.0lbf ft) 100D7RE12 Tightening torque of mounting bolt for...
Page 43 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL Mounting bolts T/C housing holding to engine cover flywheel Engine hood Engine accessory Shroud Mounting bolts Overhead Radiator guard hose Air cleaner hose 100D7RE25 Engine rood...
Page 44 Engine cover(center) Remove muffler and bellows pipe by License Muffler loosening the mounting bolt. plate Bolt Pull upside the precleaner and seal the Precleaner air intake hole of air cleaner. Remove engine cover upward. Bellows pipe Engine cover Air cleaner hole 100D7RE91 Torque converter housing cover and...
Page 45 Engine mounting bracket Attach a crane to the engine hook and raise, then remove mounting bolts. Raise Bolt the engine slightly, slide towards the radiator, then lift up. When sliding the engine, be careful of the collision of engine and radiator. Bolt Rubber mount 100D7RE93...
Page 46 Hold the counterweight with hoist bars, and raise it with a crane. Remove the mounting bolts, raise slightly and move it slowly to rear side. Weight of counterweight(standard) 100D-7 : 3,800kg(8,378lb) 120D-7 : 5,140kg(11,332lb) 135D-7 : 5,120kg(11,288lb) 160D-7 : 6,240kg(13,757lb)
Page 47 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. 100D7RE31 Hose Steering axle Hose 100D7RE32 Mounting bolt Support Put a block under the steering axle, support on a truck, an raise the frame with a crane.
Page 48 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Operation and maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-46 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-57 Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-150...
Page 49 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION . POWER TRAIN COMPONENT OVERVIEW 100D7PT01 The power train consists of the following components : Torque converter Transmission Propeller shaft Drive axle Engine power is transmitted to the transmission through the torque converter. The transmission is a hydraulically engaged three speed forward, three speed reverse power shift type transmission.
Page 50 ydraulic circuit Pressure Temp reducing sensor valve 9 bar Main pressure valve 16+2.5bar Valve block control circuit Converter Filter Back pressure Con. valve 4.3+3 bar safety valve By pass valve 11+2 bar 5.5 bar Pump 16+2 bar Oil sump Main oil circuit Lubrication D507PT31 Positions...
Page 51 2. TORQUE CONVERTER D503TM01 Turbine Pump Input shaft Stator Transmission pump The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the characteristics, and with it the favorable efficiency of a fluid clutch. The converter will be defined according to the engine power so that the most favorable operating conditions for each installation case are given.
Page 52 If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the turbine moment becomes equal to that of the pump moment. From this point on, the converter is working similar to a fluid clutch. A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the conversion range the moment upon the housing, and is released in the coupling range.
Page 53 3. TRANSMISSION LAYOUT D507TM03 Input gear Engine connection Clutch shaft(KR) Clutch shaft Converter 10 Clutch shaft(K1) Power take-off Input shaft 11 Output flange Clutch shaft(KV) Transmission pump 12 Clutch shaft(K3/output)
Page 54 INSTALLATION VIEW 21 20 11 10 FRONT VIEW REAR VIEW D507PT26 Converter 13 Breather Converter bell 14 Electro - hydraulic control Lifting lugs 15 Temperature sensor behind the converter Inductive transmitter n central gear train 16 Connection to the oil cooler Inductive transmitter n turbine 17 Filter head Gearbox housing - Front section...
Page 55 OPERATION OF TRANSMISSION Gearbox diagram The multi-speed reversing transmission in counter shaft design is power shiftable by hydraulically actuated multi-disk clutches. All gears are constantly meshing and carried on anti-friction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 3-speed reversing transmission is equipped with 5 multi-disk clutches.
Page 56 Forward In forward, forward clutch and 1st, 2nd, 3rd clutch are engaged. Forward clutch and 1st, 2nd, 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston. 1st speed-forward Transmission diagram K3/AB Opinion direction of rotation Legend: AN = Input K3/AB KV = Clutch forward...
Page 57 Reverse In reserve, reserve clutch and 1st, 2nd, 3rd clutch are engaged. Reverse clutch and 1st, 2nd, 3rd are actuated by the hydraulic pressure applied to the clutch piston. 1st speed-reverse Transmission diagram K3/AB Opinion direction of rotation Legend: AN = Input K3/AB KV = Clutch forward KR = Clutch reverse...
Page 58 ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE SECTION A-A SECTION B-B D507PT03 Pressure reducing valve(9bar) Intermediate plate Main pressure valve (16 + 2bar) Duct plate Housing Vibration damper Plug(cable harness) 10 Follow - on slide Cover 11 Pressure regulator Valve block 3-10...
Page 59 Transmission control, see schedule of measuring points, Oil circuit diagram and Electro-hydraulic control unit see page 3-2, 3-10. The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is sitting in the transmission on the engine-dependent input shaft. The feed rate of the pump is Q = 85 /min, at n = 2000 min...
Page 60 GEAR SELECTOR(DW-3) The gear selector is designed for the mounting on the steering column left side. By a rotative motion, the positions(speeds) 1 to 3 are selected by tilting the lever, the driving direction(Forward (F) - Neutral(N) - Reverse(R)). For the protection from unintended start off, a neutral interlock is installed : Position "...
Page 61 Gear selector(DW-3) LEVER FOR MECHANICAL CODING GEAR SELECTOR NEUTRAL INTERLOCK OUTPUT FORWARD REVERSE NEUTRAL SPEED IN POSITION(NEUTRAL), F-R NOT SWITCHABLE CIRCUIT DIAGRAM SELECTOR TYPE PLATE GEAR POSITIONS AD3(B3) AD1(B1) ED1(+/VP) F = FORWARD AD6(N) N = NEUTRAL R = REVERSE AD4(FORWARD) D = MECANICAL NEUTRAL INTERLOCK 1 = 1st SPEED...
Page 62 TRANSMISSION ERROR DISPLAY Function The display can be used with the gear selector. It indicates speed and driving direction as well as the activated inching. When driving in the automatic mode, a bar indicator gives additionally also information about the selected driving range;...
Page 63 isplay during operation Symbol Meaning Remarks Actual gear and direction F, N, R Central side shows actual gear 1, 2, 3 Right side shows actual direction Not neutral, waiting for neutral To engage a gear, first move shift selector to (Central and right side) after power up or a reverse fault neutral position and again to F to R position...
Page 64 Transmission error codes Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Logical error at gear range signal TCU shifts transmission to Check the cables from TCU to neutral shift lever TCU detected a wrong signal combination...
Page 65 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Retarder function is affected Check the cable from TCU to the S.C. to battery voltage at load sensor input TCU uses default load sensor OP mode : Normal...
Page 66 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction, TCU uses default Check the cable from TCU to the S.C. to ground at retarder temperature sensor input temperature sensor OP mode : Normal...
Page 67 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection OP mode : Substitute clutch Logical error at engine speed input Check the cable from TCU to the control TCU measures a engine speed over a sensor threshold and the next moment the...
Page 68 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection OP mode : Substitute clutch Logical error at internal speed input Check the cable from TCU to the control TCU measures a internal speed over a sensor threshold and at the next moment the...
Page 69 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection TCU shifts to neutral Check the cable from TCU to the S.C. to battery voltage at clutch K1 OP mode : Limp home gearbox The measured resistance value of the valve If failure at another clutch is...
Page 70 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection TCU shifts to neutral S.C. to battery voltage at clutch K3 Check the cable from TCU to the OP mode : Limp home The measured resistance value of the gearbox If failure at another clutch is...
Page 71 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction Check the cable from TCU to the O.C. at engine derating device OP mode : Normal engine derating device TCU detected a wrong voltage at the Check the connectors from engine output pin, that looks like a O.C.
Page 72 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection TCU shifts to neutral S.C. to ground at clutch KR Check the cable from TCU to the OP mode : Limp home The measured resistance value of the valve gearbox If failure at another clutch is...
Page 73 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction Check the cable from TCU to the O.C. at relay reverse warning alarm OP mode : Normal backup alarm device TCU detected a wrong voltage at the Check the connectors from...
Page 74 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction S.C. to ground at park brake solenoid Check the cable from TCU to the OP mode : Normal TCU detected a wrong voltage at the park brake solenoid output pin, that looks like a S.C.
Page 75 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction S.C. to battery voltage at converter lock Check the cable from TCU to the up clutch solenoid OP mode : Normal converter clutch solenoid TCU detected a wrong voltage at the...
Page 76 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction S.C. to ground at difflock or axle Check the cable from TCU to the connection solenoid OP mode : Normal difflock solenoid TCU detected a wrong voltage at the Check the connectors from difflock...
Page 77 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection TCU shifts to neutral Check pressure at clutch K1 Slippage at clutch K1 OP mode : Limp home Check main pressure in the TCU calculates a differential speed at If failure at another clutch is system...
Page 78 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection TCU shifts to neutral Slippage at clutch KV Check pressure at clutch KV OP mode : Limp home TCU calculates a differential speed at Check main pressure in the If failure at another clutch is closed clutch KV.
Page 79 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Slippage at converter lockup clutch Check pressure at converter TCU calculates a differential speed at lockup clutch closed converter lockup clutch. If this Check main pressure in the calculated value is out of range, TCU...
Page 80 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction Cool down machine Overtemp converter output OP mode : Normal Check oil level TCU measured a oil temperature at the Check temperature sensor converter output that is the allowed threshold...
Page 81 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection See fault codes No.21 to 2C Check cables and connectors to S.C. to battery voltage at power supply for sensors sensors, which are supplied from TCU measures more than 6V at the pin Check the power supply at the pin...
Page 82 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Not used S.C. battery voltage at speedometer output S.C. to ground or O.C at speedometer Not used output S.C. to battery voltage at display output No reaction Check the cable from TCU to the TCU sends data to the display and...
Page 83 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction Replace TCU General EEPROM fault OP mode : Normal Often shown together with fault TCU can't read non volatile memory code F2 TCU is defective onfiguration lost...
Page 84 Measuring of resistance at actuator/sensor and cable Actuator 76043PT19 Open circuit Short cut to ground = R; R = 0, R = R or R = R, R (For S.C. to ground, G is connected to vehicle ground) Short cut to battery = R;...
Page 85 ELECTRONIC CONTROL FOR POWER TRANSMISSION Description of the basic functions The powershift transmission is equipped with TCU. The system is processing the desire of the driver according to the following criteria : Gear determination depending on gear selector position, driving speed and load condition. Protection from operating error as far as necessary, is possible via electronic protect- tion(programming).
Page 86 Legend 2 = Display 3 = Gear selector DW - 3 4 = Power supply connection 5 = Switch for enable inched(Option) 6 = Switch for driving program manual/Auto 1/Auto 2 9 = TCU(EST-37A) 11 = Wiring 14 = Cable to inductive transmitter speed central gear train 15 = Cable to inductive speed engine 16 = Cable to inductive transmitter speed turbine 17 = Cable to temperature measuring point behind the converter...
Page 87 Inching device This function is especially suitable for lift trucks. It allows to reduce the driving speed infinitely variable without modification of the engine speed in such a way that driving with a very low speed will be possible. In his way, the driver can move the vehicle very exactly to a determined position. At the same time and important part of the engine power for the output of the hydraulic system is at disposal by the high engine speed.
Page 88 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS The measurement have to be carried out with hot transmission(about 80~95 C) D50TM04 3-40...
Page 89 OIL PRESSURE AND TEMPERATURE Port Description Size In front of converter - Opening pressure 11+2 bar M10x1 Behind converter - Opening pressure 4.3 + 3 bar M14x1.5 Clutch Forward 16 + 2 bar M10x1 Clutch reverse 16 + 2 bar M10x1 Clutch 16 + 2 bar...
Page 90 5. DRIVE AXLE STRUCTURE 1 419 528 402 425 538 535 530 529 531 100D7DR02 400 Differential & carrier 412 Bearing bushing 422 Hexagon screw 401 Drive pinion 413 Hexagon screw 423 Hexagon screw 402 Ring gear 414 Hexagon screw 425 Hexagon screw 403 Differential housing 415 Tapered roller bearing...
Page 91 STRUCTURE 2 100D7DR03 250 Inner disk 263 O-ring 280 Bleeder valve 251 Outer disk 266 Hexagon screw 281 Pipe 252 Piston 269 Hex sockets crew 282 Hexagon screw with flange 258 Gasket 271 Face seal 283 Compression spring 259 Gasket 272 Screw plug 260 Brake carrier 273 Sealing ring...
Page 92 STRUCTURE 3 100D7DR04 300 Planetary housing 314 Sun gear 335 Ring gear 304 O-ring 316 Circlip 336 Ring gear carrier 306 Sealing ring 320 Thrust ring 337 Retainer 307 Screw plug 322 Planetary gear 338 Hexagon socket screw 308 Sealing ring 324 Thrust washer 340 O-ring 310 Adjusting screw...
Page 93 6. TIRE AND WHEEL D507AX68 Wheel rim Lock ring Valve assembly Tire Side ring Wheel nut The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with the ground to gain the power which drives the machine. Various types of tires are available to suit the purpose.
Page 94 GROUP 2 OPERATION AND MAINTENANCE 1. OPERATION DRIVING PREPARATION AND MAINTENANCE Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filters as well as the pipes must get filled with oil.
Page 95 - Upshifting in overrunning condition. In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if the speed of the vehicle on a downgrade should not be further increased. - Downshifting in overrunning condition. Downshifting in overrunning mode will be then carried out if the vehicle should be related. If the vehicle will be stopped and is standing with running engine and engaged transmission, the engine cannot be stalled.
Page 96 Now, the temperature must drop quickly(in about 2-3minutes) to normal values. If this is not the case, there is a trouble pending, which must be eliminated prior to continue working. The monitoring of the oil temperature(behind the converter) is additionally on the temperature gauge which is located on the dashboard.
Page 97 2. MAINTENANCE TRANSMISSION Oil level check At the oil level check, the vehicle has to be secured against rolling with blocks. The oil level check must be carried out as follows : - Oil level check(weekly) - At horizontally standing vehicle - Transmission in neutral position "...
Page 98 Oil change and filter replacement intervals First oil change after 100operating hours in service. Every further oil change after 1000operating hours in service, however at least once a year. At every oil change, the fine filter has to be replaced. Oil change and oil filling capacity The oil change has to be carried out as follows.
Page 99 D507PT19 Legend: 1 = Oil filter tube with oil dipstick 2 = Oil drain plug M38 3 = Attachment possibility oil level tube with oil dipstick(converter side) 4 = Filter head 5 = Fine filter Oil dipstick MEASURED AT LOW COLD IDLING-NEUTRAL D507PT20...
Page 100 DRIVE AXLE Important remarks For safety reasons, the operator should verify and service at regular intervals all of the bolted assemblies and all of the important safety locks such as : Wheel nuts Nuts of axle mounting bolts Bolts on the steering components and the brake system parts : if the screws are tightable, the loctite contact breaks loose and remounting is necessary.
Page 101 Lubrication points The binding lubrication points has to be taken from the according installation drawing of the axle. Single drive assembly The position is dependent from the respective axle version. Legend 100D7XL03 1 : Oil fill plug 2 : Oil level control plug 3 : Oil drain plug 3-53...
Page 102 3. TROUBLESHOOTING BRAKE LEAKS ACTUATION FLUID Condition ossible cause Correction Internal leak : Fluid 1. Worn or damaged piston seal. 1. Replace piston seals. bypasses seals into axle 2. Melted or extruded piston seals. 2. Correct cause of overheating and replace and fills axle with fluid seals.
Page 103 BRAKE OVERHEATS Condition Possible cause Correction Overheating due to Inadequate coolant flow or heat 1. Install brake cooling system if not already excessive duty cycle. exchange. installed on vehicle. 2. Re-analyze and re-size brake cooling system if necessary. Inadequate coolant flow Low pump output, blocked filter or Check pump output at different operating coolant lines.
Page 104 BRAKE DOES NOT RELEASE Condition Possible cause Correction Vehicle does not move Damaged hydraulic system. Repair hydraulic system. Brakes dragging 1. More than 1.4bar(20psi) pressure 1. Repair hydraulic system so pressure is less applied when brakes released. than 1.4bar(20psi) when brakes released and while machine is operating in any mode.
Page 105 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY Electro-hydraulic control and filter (exchange filter) Mount the transmission to the assembly truck. (S)Assembly truck 5870 350 000 (S)Holding fixture 5870 350 124 Prior to start the disassembly, drain the D507TM11 Removal of the filter By means of the strap wrench separate the filter(1) from the filter head.
Page 106 Removal of the electric shift system Remove the shift system(1). Loosen the Torx screws(2) and separate the gearshift housing from the intermedi- ate sheet. (S)Socket spanner TX-27 5873 042 002 (S)Adjusting screw M6 5870 204 063 D507TM14 Remove the complete shift system(1) and the intermediate shaft(2).
Page 107 Separate the duct plate(3), and inter- mediate sheet(2) from the valve block(1). D507TM18 Remove the retaining clamp(1). D507TM19 Loosen the cap screws(1) and remove the cover. Remove the opposite cover. (S)Socket spanner TX-27 5873 042 002 D507TM20 Remove the wiring harness(1). Loosen the cap screws(3), remove the fixing plates and the pressure regul- ators(2).
Page 108 Loosen the cap screws, remove the fixing plates and the pressure regulators(1). (S)Socket spanner TX-27 5873 042 002 D507TM22 Loosen two cap screws(1) and fasten the adjusting screws(S) preliminarily (housing is spring-loaded). Following to this loosen the remaining cap screws. (S)Adjusting screws 5870 204 036 (S)Socket spanner...
Page 109 Remove the single parts on the opposite side analogously: 1 = Main pressure valve 2 = Vibration damper 3 = Follow-on slide D507TM26 nductive transmitters, valves, oil filter and oil drain plug, screw plugs Mount the transmission to the assembly truck.
Page 110 Remove the positioned parts. 1 = Inductive transmitter n - Internal speed input 2 = Inductive transmitter n - Turbine 3 = Speed transmitter n - Output 4 = Cover(mounting possibility for oil filler tube) D507TM30 ngine connection, pressure oil pump and removal of the clutches Mount the transmission to the assembly truck.
Page 111 By means of the lifting equipment the converter bell(1) with pressure oil pump(5) are commonly to be separated from the transmission housing rear section(4). Remove the intermediate sheet(3) and the stator hollow shaft(2). (S)Eyebolts assortment 5870 204 002 (S)Lifting chain 5870 281 047 D507TM33 Separate the pressure oil pump(1) from...
Page 112 Remove the tab washer(2) and loosen the hexagon screws(1). D507TM37 Pull off the input shaft(1). Remove the shaft seal. (S)Two-armed puller 5870 970 003 D507TM38 Unsnap the retaining ring(1) from the power take-off and remove the O-ring(2). (S)Set of internal pliers 5870 900 013 D507TM39 Pull the pump shaft (1) out of the housing...
Page 113 By means of the lifting equipment separate the transmission housing rear section(1) from the transmission housing front section(2). (S)Eyebolts 2x(M20) 0636 804 003 (S)Ring nut(M12) 0664 462 774 (S)Lifting chain 5870 281 047 D507TM41 Loosen the cap screws(2) and remove the suction tube(1).
Page 114 Remove the pipes(system pressure from the electro-hydraulic control to the respective clutch). Remove the holding segment(6). The pipes are to disassembled in the following sequence: 1 = Pipe 2 = Pipe 3 = Pipe D507TM45 4 = Pipe 5 = Pipe Remove all bearing outer rings(see arrows).
Page 115 Clutches KV/KR/K1/K2/K3 and Input See figure on the right. D507TM51 Clutch KV Remove the stud(1) and unsnap the piston ring(2). D507TM52 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 001 011 D507TM53...
Page 116 Unsnap the retaining ring(1). (S)Set of external pliers 5870 900 015 D507TM55 Press the clutch shaft(1) out of the idler(2). (S)Parting tool 5870 300 028 D507TM56 Unsnap the retaining ring(2) from the idler(1) and remove the ball bearing(3). (S)Set of internal pliers 5870 900 013 D507TM57 Remove the needle cage(1) from the...
Page 117 Rotate the shaft(2) by 180 and unsnap the piston ring(1). D507TM59 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 011 011 D507TM60 Clutch KR Remove the stud(1) and unsnap the piston ring(2).
Page 118 Pull the clutch(1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM63 Unsnap the retaining ring(1). (S)Set of external pliers 5870 900 015 D507TM64 Press the clutch shaft(1) out of the idler(2). (S)Parting tool 5870 300 028 D507TM65 Disassemble the idler(1). D507TM66 3-70...
Page 119 Unsnap the retaining ring(2) from the idler(1) and remove the ball bearing. (S)Set of internal pliers 5870 900 013 D507TM67 Remove the needle cage(1) from the shaft(2). D507TM68 Shaft(2) and gear(1) cannot be separa- ted(shrink fit). D507TM69 Rotated the shaft(2) by 180 and unsnap the piston ring(1).
Page 120 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 011 011 D507TM71 Clutch K1 Remove the stud(1) and unsnap the piston ring(2). D507TM72 Pull the taper roller bearing(inner ring) from the shaft.
Page 121 Remove the complete axial bearing(1). D507TM75 Take off idler(1), remove the needle cage(2) and the complete axial bea- ring(3). D507TM76 Pull the clutch(1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM77 Rotated the shaft(2) by 180 and unsnap the piston ring(1). D507TM78 3-73...
Page 122 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 011 011 D507TM79 Clutch K1 Remove the stud(1) and unsnap the piston ring(2). D507TM80 Pull the taper roller bearing(inner ring) from the shaft.
Page 123 Remove the complete axial bearing(1). D507TM83 Take off idler(1), remove the needle cage(2) and the complete axial bea- ring(3). D507TM84 Pull the clutch(1), front the shaft. (S)Two-armed puller 5870 970 003 D507TM85 Rotated the shaft(2) by 180 and unsnap the piston ring(1). D507TM86 3-75...
Page 124 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 011 011 D507TM87 Clutch K3 Unsnap the piston ring(1). D507TM88 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert...
Page 125 Take off idler(1), remove the needle cage(2) and the complete axial bea- ring(3). D507TM91 Pull the clutch(1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM92 Rotated the shaft(2) by 180 and unsnap the piston ring(1). D507TM93 Pull the taper roller bearing(inner ring) from the shaft.
Page 126 Input Unsnap the piston ring(1). The turbine wheel shaft(2) and the input gear(3) are attached with a snap ring. The components are destroyed at separ- ation D507TM95 Pull the taper roller bearing(inner ring) from the input gear. (S)Gripping insert 5873 001 058 (S)Back-off insert 5870 026 100 (S)Rapid grip...
Page 127 2. TRANSMISSION ASSEMBLY Clutches KV/KR/K1/K2/K3 and input In the EST-37A(electronic transmission control)the gear change(filling times and pressure level) are controlled via the drive program of the transmission electronics. Additionally, the EST-37A monitors the disc clearance(clearance) of the clutches and if exceeded, a fault message is given in the transmission error display.
Page 128 Put the ball bearing(2) into the idler(1) until contact is obtained and fasten it by means of retaining ring(3). (S)Set of internal pliers D507TM104 Press in preassembled idler(1) until contact. D507TM105 Fasten the idler(1) by means of retaining ring(2). (S)Set of external pliers 5870 900 015 D507TM106 Heat up the inner diameter of the...
Page 129 Mount the clutch(1) until contact is obtained. Wear safety gloves. D507TM108 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM109 Install the piston ring(1). D507TM110 Install the stud(1). Tightening torque - - - - - - - - - - - - - - M =1.7kg m Check closing respective opening of the clutch by means of compressed air at the...
Page 130 Clutch KR Press the taper roller bearing(inner ring)(1) onto the shaft(2) until contact is obtained. D507TM112 Install the piston ring(1). D507TM113 Heat up the inner diameter of the gear(1)(approx. 120 (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 ear safety gloves.
Page 131 Fasten the gear(1) by means of retaining ring(2). (S)Set of internal pliers 5870 900 015 D507TM116 Mount the needle bearing(1) onto the shaft(2). D507TM117 Put the ball bearing(2) into the idler(1) until contact is obtained and fasten it by means of retaining ring(3). (S)Set of internal pliers 5870 900 013 Press in the preassembled idler(1) until...
Page 132 Fasten the idler(1) by means of retaining ring(2). (S)Set of internal pliers 5870 900 015 D507TM120 Heat up the inner diameter of the clutch(1)(approx. 120 (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 D507TM121 Mount the clutch(1) and press it until contact is obtained.
Page 133 Install the piston ring(1). D507TM124 Install the stud(1). Tightening torque - - - - - - - - - - - - - - M =1.7kg Check closing respective opening of the clutch by means of compressed air at the bore(2).
Page 134 Install the sealing cap(1). Wet the contact surface with(Loctite Type No. 262). D507TM128 Heat up the inner diameter of the clutch(1)(approx. 120 (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 D507TM129 Mount the clutch(1) and press it until contact is obtained.
Page 135 Mount the needle cage(1). D507TM132 Install the idler(1). D507TM133 Mount the axial washer(1), axial cage(2) Chamfer and running disc(3). Install chamfer(see arrow) of the running disc(3) showing towards the axial cage D507TM134 Fasten the idler(1) and the single parts by means of the retaining ring(2). (S)Set of external pliers 5870 900 015 D507TM135...
Page 136 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM136 Install the piston ring(1). D507TM137 Install the stud(1). Tightening torque - - - - - - - - - - - - - - M =1.7kg Check closing respective opening of the clutch by means of compressed air at the bore(2).
Page 137 Install the piston ring(1). D507TM140 Heat up the inner diameter of the clutch(1)(approx. 120 (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 D507TM141 Mount the clutch(1) until contact is obtained. Wear safety gloves. D507TM142 Mount the running disc(1), axial cage(2) and axial washer(3).
Page 138 Mount the needle cage(1). D507TM144 Install the idler(1). D507TM145 Mount the axial washer(1), axial cage(2) Chamfer and running disc(3). Install chamfer(see arrow) of the running disc(3) showing towards the axial cage. D507TM146 Fasten the idler(1) and the single parts by means of the retaining ring(2). (S)Set of external pliers 5870 900 015 D507TM147...
Page 139 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM148 Install the piston ring(1). D507TM149 Install the stud(1). Tightening torque - - - - - - - - - - - - - - M =1.7kg Check closing respective opening of the clutch by means of compressed air the bore(2).
Page 140 Install the piston ring(1). D507TM152 Install the sealing cap(1). Wet the contact surface with loctite type No.262. D507TM153 Heat up the inner diameter of the clutch(1)(approx. 120 (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 D507TM154 Mount the clutch(1) until contact is obtained.
Page 141 Mount the running disc(1), axial cage(2) and axial washer(3). Chamfer Install chamfer(see arrow) of the running disc(3) showing toward the axial cage. D507TM156 Mount the needle cage(1). D507TM157 Install the idler(1). D507TM158 Mount the axial washer(1), axial cage(2) Chamfer and running disc(3). Install chamfer(see arrow) of the running disc(3) showing towards the axial cage.
Page 142 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM160 Install the piston ring(1). D507TM161 Install the screw plug(1). (S)Lever riveting tongs 5870 320 016 D507TM162 Check closing respective opening of the clutch by means of compressed air at the bore(1).
Page 143 Input Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM164 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM165 Have the snap ring(1) engaged into the annular groove of the turbine wheel shaft(2). D507TM166 Mount the turbine wheel shaft until the snap ring engages into the recess of the input gear-turbine wheel shaft is axially fixed.
Page 144 ENGINE CONNECTION, PRESSURE OIL PUMP AND INSTALLATION OF THE CLUTCHES Install all bearing outer rings into the bearing bores of both transmission housing sections. Should contrary to the recommendations the taper roller bearing of the clutches as well as of the input not be replaced, the assignment(bearing inner and outer rings) has to be kept at least .
Page 145 Fasten the screen sheet(1) by means of cap screws(2). Tightening torque(M8/8.8) - - - M =2.3kg D507TM174 The clutch is to be put into the transmiss- ion housing front section as described in the legend. 1 = Input shaft 2 = Clutch KV 3 = Clutch KR 4 = Clutch K2 5 = Clutch K1...
Page 146 Install the O-rings(3) and fasten the suction pipe(1) by means of cap scre- ws(2). Tightening torque(M8/8.8) - - - M =2.3kg m D507TM178 Grease the rectangular rings(see arrows) and align them, centrically. Wet the mounting face with sealing com- pound loctite(Type No.574) D507TM179 Cautiously place the transmission housing rear section(1) by means of the...
Page 147 Install the shaft seal(1) with the sealing lip showing to the oil sump. The exact installation position is obtained by using the specified mounting tool(S). Fill the shaft seal between dust lip and sealing lip with grease. Wet the outer diameter with spirit. (S)Mounting tool 5870 048 057 D507TM182...
Page 148 Install the retaining ring(1) and the O- ring(2). Grease the O-ring D507TM186 Install two adjusting screws and mount the stator hollow shaft(1). Observe the radial installation position. (S)Adjusting screws 5870 204 007 D507TM187 Install the converter safety valve(1) until contact. (S)Drive mandrel 5870 705 012 D507TM188...
Page 149 Cautiously place the converter bell(1) by means of the lifting equipment to the tran-smission until contact is obtained. (S)Eyebolts assortment 5870 204 002 (S)Lifting chain 5870 281 047 D507TM190 Pressure oil pump If running-in marks should be found in the pump housing or on the cam disc, the complete pump has to be replaced.
Page 150 Installation of the external and internal rotor Install the external rotor. Chamfer shows to the pump base (cannot be seen in the picture). Install the internal rotor. Gearing(arrow) shows downwards. D507TM194 Put on the cam disc and by means of two cap screws(1) fasten it radially.
Page 151 Fasten the converter bell, pressure oil pump and stator hollow shaft together by means of cap screws. Different bolted connections. 1 = Bolted connection converter bell/tran- smission housing rear section. Tightening torque(M10/8.8) - - M =4.7kg m 2 = Bolted connect. pressure oil pump/ stator hollow shaft transmission hous- D507TM197 ing rear section.
Page 152 Inductive transmitters, valves, oil filters and oil drain plug, screw plugs Install the converter pressure back-up valve. 1 = Piston 2 = Compression spring 3 = O-ring(27x2) 4 = Screw plug(30x1.5) Tightening torque - - - - - - - - - - - - - - - M =10.2kg m D507TM201 Install the differential pressure switch for...
Page 153 Installation of: 1 = Inductive transmitter - n Internal speed input 2 = Inductive transmitter - n Turbine 3 = Breather Tightening torque(1 and 2) - - M =3.1kg m Tightening torque(3) - - - - - - - - - - - M =1.2kg m Fasten the cove replate(4) by means of hexagon screws(5).
Page 154 ELECTRO-HYDRAULIC CONTROL UNIT WITH PROPORTIONAL VALVES Different versions as to the positions of the wiring harness are possible. The following sketches shows the sections of the electro-hydraulic control unit. Pressure reducing valve (9 bar) Main pressure valve Housing (16+2 bar) Wiring harness Cover Cover...
Page 155 Mounting of the electric control unit All single parts are to be checked for damaged and replaced, if required. Prior to installation check the mobile parts in the housing for functionality. Piston can be replaced individually. Oil the single parts prior to installation acc. to the list of lubricants. Place the orifices(1) with the concave side showing upwards, until contact.
Page 156 Install two adjusting screws. Assembly flat gasket(1) and housing cover. Then place the housing cover by means of adjusting screws equally until contact. (S)Adjusting screws 5870 204 036 D507TM217 Preload the pistons with cap screws and remove the cyl. pins(assembly aid)again. D507TM218 Fasten the housing cover by means of cap screws(1).
Page 157 Preassemble the opposite side The figure on the right shows the followi- ng single parts: 1 = Main pressure valve (1x, piston a. compr. spring) 2 = Vibration damper (3x, piston a. compr. spring) 3 = Follow-on slide (3x, piston a. compr. spring) D507TM221 Install the single parts acc to right figure.
Page 158 Mount the pressure regulators(1) and fasten them by means of fixing plates and cap screws. Install the fixing plate with the neck showing downwards Observe radial installation position of the pressure regulators. Tightening torque - - - - - - - - - - - - - M =0.56kg D507TM224 Assemble the wiring harness(1) and...
Page 159 Install two adjusting screws. (S)Adjusting screws 5870 204 063 D507TM228 Screens(1) are to be flush mounted into the bores of the intermediate sheet, see arrows. Observe the installation position-the screens are showing upwards(to the duct plate). D507TM229 Put on the intermediate sheet(1) Screens(2) must show upwards.
Page 160 Provide the screw plugs(1) with new O- rings and install them. Tightening torque - - - - - - - - - - - - - M =0.61kg m D507TM232 Insert the pressure relief valve(1) and lock it with the indented ring(2). (S)Drive mandrel 5870 705 012 D507TM233...
Page 161 Mounting of the filter(pressure filter) Fasten the filter head(1) with new O-rings by means of cap screws(2) to the trans- mission housing. Tightening torque(M8) - - - - - - - M =2.4kg (S)Torque spanner 5870 203 034 (S)Socket spanner TX-40 5870 042 004 D507TM236 The filter is to be installed as follows: - Oil the gasket slightly...
Page 162 Loctite. (16) The bolted or keyed assemblies safeties are to be checked according to instructions ; in case of doubt, consult Hyundai dealer. (17) Refill the oil after assembly. (18) Repair weldment is only allowed after consultation with Hyundai. 3-114...
Page 163 USING OF LOCTITE AND OPERATING SUPPLIES Kind Type Color Application Loctite Blue Lightly locked screws Middle locked screws Green Highly locked screws Green Increased coefficient of friction in contact surfaces Orange Surface gasket White Special gasket Light-green Glueing with big width of slit Epple Grey Surface gasket...
Page 164 UTILIZATION OF LOCTITE AND OPERATING SUPPLIES Hub assembly Safety blocked parts Joint Loctite Operating supplies Spacer ring Contact surface Axle spindle Screws Axle spindle Contact surface Grommet In planetary housing Disk In axle spindle Adjusting screw with nut In planetary housing Support Screw Ring gear retainer...
Page 165 TIGHTENING TORQUES Unit : N ¡⁄ m Metric standard thread Screw Screw Screw Thread 10.9 12.9 1050 1220 1100 1550 1800 1450 2100 2450 Unit : N ¡⁄ m Metric fine thread Screw Screw Screw Thread 10.9 12.9 M 8 1 M10 1 M10 1.25 M12 1.25...
Page 166 Tightening torques of wheel nuts Wheel nut with spring lock Wheel nut with clamp Wheel nut with thrust collar washer (For clamp fixation) (For rims with centering) Wheel nut with spring lock washer Dimensions Phosphorus darkened Galvanized 270Nm 250Nm M18 1.5 450Nm 350Nm M22 1.5...
Page 167 Tightening torques for castle nuts on ball joints for track rods and ram cylinders The tightening torques of the different thread dimensions of the joints are applicable for nuts of quality S6. Cone size Thread Torque d1(mm) d2(mm) (Nm) 200~220 280~300 M24 1.5 290~320...
Page 168 SERVICE TOOLS When ordering service tools please provide order number(Installation drawing no), respective fabrication number identification plate.(The illustrations are not binding for the design) Spanner for wheel safety nut 100D7XL14 100D7XL15 Spanner for splined nut(hub assembly) 100D7XL16 3-120...
Page 169 Seal ring sleeve driver. 100D7XL17 Spanner for thread rings. (Differential bearing) 100D7XL18 Spanner for counter nut. (Planetary gear drive) 100D7XL19 Assembly cone for O-ring. (Differential lock) 100D7XL82 3-121...
Page 170 Centering tool for discs. 100D7XL20 Installation tool for face seal. 100D7XL21 3-122...
Page 171 ASSEMBLY DRIVE ASSEMBLY Adjustment of gear meshing of gleason gears Perfect marking To become a perfect gear meshing is only possible, if the fabrication number of the drive pinion (marked on the end face) and the ring gear(marked on the circumference) are corresponding.
Page 172 Securing of the striking nut The brim of the striking nut has to be sheared only along the slot flank and the corner has to be bent on the slot ground. 100D7XL26 100D7XL25 Using of Loctite and other operating supplies Striking nut at drive flange - In thread : Assembly paste with MoS (exception through drive pinion see point Z).
Page 173 Drive assembly D 51 100D7XL27 3-125...
Page 174 Adjustment drive pinion distance To obtain the proper tooth flank contact, adjust the axial position of the drive pinion with the thickness of the adjustment disk. The necessary thickness of the adjustment disk for first time assembly can be obtained by measurement(see calculation example).
Page 175 Assembly of drive pinion bearing Insert the two outer rings of the taper roller bearings into the differential carrier. Calculate the thickness C of the spacer ring. Place the two inner rings of the taper roller bearings in their outer rings. Measure A.
Page 176 ASSEMBLY OF THE DIFFERENTIAL Before assembly all of the bevel gears and the thrust rings should be well oiled. Place one differential side gear with the side gear thrust washer in the differential case. Install the spider with differential gears and differential pinion thrust washers in the differential case.
Page 177 ASSEMBLY OF DRIVE ASSEMBLY Place the differential with the outer rings of the taper roller bearings on the differ- ential carrier which is in a vertical position, with mounted drive pinion. Mount the differential straps and align them with the thread rings. During this operation be careful of the alignment marks on the differential straps with respect to the differential carrier.(Do...
Page 178 ASSEMBLY OF HUB ASSEMBLY Assembly of the spacer ring Coat the seat of the spacer ring on the steering knuckle respective axle spindle with Loctite 572. Heat the spacer ring to about 100 C and push it by gently striking onto the steering knuckle respective axle spindle.(The steering knuckle respective axle spindle must be free of corrosion) Oil the seal ring tread onto the spacer ring.
Page 179 ASSEMBLY OF THE DRIVE ASSEMBLY ONTO THE AXLE HOUSING 100D7XL39 100D7XL40 Coat the contact surface of the axle housing with Epple 33(at version through drive with Loctite 510), and mount the complete drive assembly. The axle housing being placed in a horizontal position, secure the screws with Loctite 262.
Page 180 Mount wheel hub Push the pre-assembled wheel hub(9) parallel onto the axle spindle respective steering knuckle. Be carefully do not damage the seal rings. 100D7XL41 Adjustment of wheel bearings Tightening torque of the wheel safety nut. Series Adjustment of wheel bearings The temperature of the axle parts should be between 0 and +20 C at the bearing adjustment.
Page 181 Assembly of the face seal 1 Seal ring 2 Rubber toric ring 3 Housing retaining lip 4 Housing ramp 5 Seal ring housing 100D7XL46 Seal rings, torics, and housings must be clean and free of any oil film, dust, or other foreign matter.
Page 182 Put the installation tool(9) onto the seal ring(1) with toric ring(2). Lower the rings into a container with lsopropanol until all surfaces of the toric(2) are wet. 100D7XL50 Toric sliding on retainer ramp. 100D7XL51 Toric caught on housing retainer lip. 100D7XL52 Toric sliding on seal ramp.
Page 183 After dipping the seal assembly in the solvent, shake the excess solvent from the seal assembly and immediately "pop" the seal into the housing with a firm push of the installation tool. Remove the installation tool and check the seal standout height at several places around the circumference of the ring to verify an accurate installation.
Page 184 Be sure there is no visible debris on § either of the seal faces even a small piece of lint can hold the seal faces apart and cause leakage. 100D7XL57 After successful installation, wait one §æ minute for the lsopropanol to dry before assembling the two seal halves in the final loaded position.
Page 185 After the unit to be sealed is assembled, a post-assembly leakage test can be performed to insure the seal is properly installed. A vacuum check is recommended rather than a pressure check as vacuum checks are more sensitive. Many users find this an easy check to combine with a vacuum fill technique for the lubricant.
Page 186 ASSEMBLY OF PLANETARY GEAR DRIVE Prepare the ring gear and the ring gear carrier Heat the taper roller bearing inner ring with cage(1) to about 100 C and install it onto the ring gear carrier(2). Place the ring gear(3) onto the ring gear carrier. Bolt the retainer(5) with the screws(4), secure the screws with Loctite 270.
Page 187 Assembly of planetary gear Prepare planetary gear : Install the needle bearing(10, 11) into the planetary gear(12, 13). 100D7XL63 Insert the preassembled planetary gears (12, 13) with needle bearings (10, 11), rings(16) (if present) and thrust disks (14 , 15) into the planetary housing (22, 23) (planetary housing in horizontal position).
Page 188 Disassembly of planetary gear Knock the locking pin(20, 21) completely to the inner side of the planetary pin. 100D7XL66 Press the planetary pin in direction of arrow out of the planetary housing. Because of the difference of diameter of 0.1mm do not press the planetary pin against the direction of arrow out of the planetary housing, to prevent damaging the bore.
Page 189 Assembly / disassembly cageless needle bearing(planetary gear bearing) 100D7XL39 100D7XL40 Assembly Version 1 Install the needle bearing with mounting bushings into the planetary gear, thereby the outer mounting bushing will be stripping. Insert the planetary gear with thrust disks into the planetary housing.
Page 190 Assembly of the planetary housing Place O-ring(30) into the slot of the planetary housing. Install the planetary housing and bolt it. Adjustment of the axial clearance 100D7XL72 The axial clearance between axle shaft respective universal joint and adjusting screw must be 0.3~0.7mm.
Page 191 Assembly of service brake 100D7XL83 Brake carrier Seal ring 17 Seal ring Brake housing 10 Seal ring 18 Screw plug Piston 11 Connection piece 19 O-ring Inner disk 12 Breather 20 Face seal Outer disk 13 Sealing ring 21 Screw O-ring 14 Sealing ring 22 Tube...
Page 192 Assembly of the piston seals Place piston with the larger diameter downwards. Note succession of the sealing parts at fitting. Install O-rings free of torsion and loops. Assembly of O-ring and supporting ring Install the supporting rings to the averting side of pressure. Pressure 100D7XL73/84 Large supporting ring...
Page 193 Assembly of the piston 100D7XL86 Lubricate cylinder bore, apply the thread holes at wet disk brakes of dimension X270 and X340 with Loctite 243, at wet disk brakes of dimension X460 and X650 with Loctite 262 and install and screw the bushing(if present). Place the piston onto the brake carrier(do not cant it). Wet disk brakes of dimension X270 and X340 Press the piston equal by hand into the brake carrier(do not cant it).
Page 194 Prepare housing and check the air gap 100D7XL87 Lay discs into the housing. Check the air gap Air gap = measure A-measure B(measured without pressure) Rated size about 0.5mm smaller than the air gap pressurized(see table). Install O-ring(brake housing / brake carrier) free of torsion and loops. Air gap and wear dimension Brake type Air gap sL new(Pressurized) (mm)
Page 195 Finish assembly Place the brake carrier onto the brake housing and bolt it. Mount breather with connection piece and seal ring, screw plugs with seal rings. Check brake hydraulic system for leaks(see tightness checking instruction). Install O-ring(Brake carrier / axle spindle respective steering knuckle) free of torsion and loops. Check the air gap(pressurized) Measure through the check hole the distance from brake carrier to the piston end face, while non actuated brake, actuate the brake and repeat the measure operation-the difference of the...
Page 196 Is the measured dimension bigger than the marked dimension and max. wear dimension, unconditional consult Hyundai dealer. 100D7XL76 After working at the brake, bleed the brake hydraulic system and check for tightness. 3-148...
Page 197 Brake disk 100D7XL78 Network - like formation of cracks admissible Radially shaped crack not admissible C Uneven brake surface characteristics below 1.0mm admissible D Continuous cracks not admissible (10) Spring - loaded sliding caliper brakes Safety notes : Warning Before commencing work on the parking brake, ensure that no unintended machine movement can happen when the braking effect is removed.
Page 198 GROUP 4 ADJUSTMENT 1. CHECKING THE RING GEAR BACKFACE RUNOUT Runout specification : 0.20mm(0.008-inch) maximum Attach a dial indicator on the mounting INDICATOR flange of the carrier. Rotate ring gear . Adjust the dial indicator so that the plunger or pointer is against the back surface of the ring gear.
Page 199 2. ADJUSTING THE GEARSET BACKLASH Backlash specification : 0.13~0.18mm (0.005-0.007inch) If the old gearset is installed, adjust the backlash to the setting that was measured before the carrier was disassembled. If a new gearset is installed, adjust the backlash to the correct specification for new gearsets.
Page 200 3. ADJUSTING TOOTH CONTACT PATTERN OF THE GEARSET Always check tooth contact pattern on the drive side of the gear teeth. Apply marking compound to approximately 12 teeth of the ring gear. HEEL BOTTOM DRIVE SIDE (CONVEX) D507AX57 D507AX58 Rotate ring gear forward and backward so that the 12 marked teeth go past the drive pinion six times to get a good contact pattern.
Page 201 LOW PATTERN D507AX61 GOOD PATTERN IN OPERATION (USED GEARS) D507AX62 High pattern : A high contact pattern Move pattern toward indicates that the pinion was installed too bottom shallow into the carrier. To correct, move the pinion toward the ring gear by decreasing the shim pack between pinion spigot and inner bearing cone.
Page 202 4. ADJUSTMENT OF GEAR MESHING OF GLEASON GEARS To become a perfect gear meshing is only possible, if the fabrication number of the drive pinion(marked on the end face) and the ring gear(marked on the circumference) are corresponding. Perfect marking The following figures are showing improper gear meshing marks of the ring gear.
Page 203 5. SECURING OF THE STRIKING NUT The brim of the striking nut has to be sheared only along the slot flank and the corner has to be bent on the slot ground. 100D7XL25 100D7XL26 Using of Loctite and other operating supplies Striking nut at drive flange - In thread : Assembly paste with MoS (Exception through drive pinion see point Z)
Page 204 6. ADJUSTMENT DRIVE PINION DISTANCE To obtain the proper tooth flank contact, adjust the axial position of the drive pinion with the thickness of the adjustment disk. The necessary thickness of the adjustment disk for first time assembly can be obtained by measurement(see calculation example).
Page 205 SECTION 4 BRAKE SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32 Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-40 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-43...
Page 206 ECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE The brakes are operated by a pressure compensated, closed center hydraulic system. Flow is supplied by a fixed displacement, gear type brake pump. BRAKE SYSTEM The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit and park brake circuits.
Page 207 FULL POWER HYDRAULIC BRAKE SYSTEM Response time ADVANTAGES - The full power hydraulic Full power brake actuation VS brake system has several advantages over Air/Hydraulic brake actuation traditional brake actuation systems. These systems are capable of supplying fluid to a 1000 range of very small and large volume service brakes with actuation that is faster...
Page 208 2. HYDRAULIC CIRCUIT 107kgf/cm 173kgf/cm 127~ 153kgf/cm Return Steering line unit 31~41 kgf/cm kgf/cm 178kgf/cm 100D7BS101 Main pump 11 RCV 23 Strainer Brake pump 17 Pressure switch 24 Return filter Cut off valve 18 Pressure switch 31 Hydraulic oil tank Brake valve 20 Accumulator Line filter...
Page 209 SERVICE BRAKE RELEASED 107kgf/cm 173kgf/cm 127~ 153kgf/cm Return Steering line unit 31~41 kgf/cm kgf/cm 178kgf/cm 100D7BS102 When the pedal of brake valve(8) is released, the operating force is eliminated by the force of the spring, and the spool is returned. When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles return to the tank(31).
Page 210 SERVICE BRAKE OPERATED 107kgf/cm 173kgf/cm 127~ 153kgf/cm Return Steering Parking brake line unit solenoid valve 31~41 kgf/cm kgf/cm 178kgf/cm 100D7BS103 When the pedal of brake valve(8) is depressed, the operating force overcomes the force of the spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and at the same time the hydraulic oil controlled the pressure level by the cut-off valve(5) enters the piston in the front and rear axles.
Page 211 PARKING BRAKE RELEASED 107kgf/cm Parking brake switch 173kgf/cm 127~ 153kgf/cm Return Steering Parking brake line unit solenoid valve 31~41 kgf/cm kgf/cm 178kgf/cm 100D7BS104 When the parking brake switch is pressed B position, the solenoid valve is energized and the hydraulic oil controlled the pressure level by the cut-off valve enters the parking brake. It overcomes the force of the spring and pushes the piston rod.
Page 212 PARKING BRAKE OPERATED 107kgf/cm Parking brake switch 173kgf/cm 127~ 153kgf/cm Return Steering Parking brake line unit solenoid valve 31~41 kgf/cm kgf/cm 178kgf/cm 100D7BS105 When the parking brake switch is pressed A position, the solenoid valve is deenergized and the valve open the drain port. At the same time, the hydraulic oil in the parking brake return to the tank through the solenoid valve.
Page 213 3. BRAKE PUMP STRUCTURE 100D7BS106 Body Bushings 17 Tie rods Rear cover 10 Drive gear 18 Washers Flange 11 Driven gear 19 Nuts Seal 12 Coupling sleeve 20 Bracket Bushing seal & back up ring 13 Plate 21 Reference pins Shaft seals 14 Plate 22 Reference pins...
Page 214 PRINCIPLE OF OPERATION Mechanism for delivering oil The drawing at right shows the operational principle of an external gear pump in which two gears are rotating in mesh. The oil entering through the suction port is Suction Discharge trapped in the space between two gear teeth, and is delivered to the discharge port as the gear rotates.
Page 215 Internal oil leakage Oil leaks from a place under higher pressure to a place under lower pressure, provided that a gap or a clearance exists in between. In the gear pump, small clearances are provided between the gear and the case and between the gear and the side plate to allow the oil to leak out and to serve as a lubricant so that the pump will be...
Page 216 Forces acting on the gear The gear, whose outer surface is subjected to oil pressure, receives forces jointing towards its center. Due to the action of the delivery pressure, the oil pressure in higher on the delivery side of the pump, and due to suction pressure, is lower on the suction side.
Page 217 4. PARKING BRAKE SYSTEM STRUCTURE 100D7BS111 Housing Adjust screw Lining pad Pressure ring Bank of cup springs Lining pad Thrust bolt Piston Gliding bolt OPERATION The two identical brake pads and slide freely on the guide bolt, which is fastened in the housing. The guide bolts are guided in an additional brake anchor plate which in turn is screwed onto the vehicle, i.e.
Page 218 MOUNTING AND BASIC SETTING REGULATIONS Basic brake setting is required after mounting new brake lining plates or brake disks, as well as during all repair stages and in the event of insufficient braking performance. 100D7BS112 Thrust bolt Screw cap Even surface Bank of cup springs Lock nut Socket wrench...
Page 219 BASIC SETTING REGULATION Turn the adjusting screw manually clockwise until both brake pads make contact with the brake disk. Then it is not longer possible to turn the adjusting screw without exerting a major amount of force. Turn the adjusting screw anticlockwise in order to set the following rated clearances. Model Adjusting screw Clearance(mm)
Page 220 EMERGENCY RELEASE OF THE PARKING BRAKE After the failure of the pressure release the parking brake by using following manual procedure. 100D7BS117 Thrust bolt Screw cap Even surface Bank of cup springs Lock nut Socket wrench Adjusting screw Piston The vehicle has to be secured against rolling away. Release the screw cap and unscrew Release the lock nut(size 24 or 30) and turn the adjusting screw with socket wrench size 8 or 10 manually counter-clockwise until the brake disc is free.
Page 221 MAINTENANCE AND REPAIR WORK Maintenance and exchange of brake pads The brake pads themselves are maintenance free. All that is required here is a check for damaged parts, as well as inspection to ensure that the brake disk remains easy running. The thickness of the brake lining must be subjected to a visual inspection at regular intervals, which depend on vehicle usage, but every six months at the latest.
Page 222 100D7BS114 Guide bolt Castellated nut Lining pad 6a Safety splint Lining pad 6b Safety clip Permanent magnet Depending on the free space available, release one of the two guide bolts, removing the safety splint, unscrewing the castellated nut and pulling the guide bolt out of the brake anchor plate. Now, the brake lining pads can be removed tangentially to the brake disk.
Page 223 Changing the seal DETAIL A DETAIL B 100D7BS115 Piston Circlip Bank of cup spring Adjusting screw Seal Detail of the seal Lock nut Guide bolt Detail of the seal Housing Thrust bolt Faulty seals must be exchanged in accordance with the instructions below. Stand the vehicle on an even surface and secure against rolling away.
Page 224 General Any discovered defects or damage to parts not listed here must naturally be repaired or replaced using original parts. For any other information not contained in these instructions or for more detailed instructions, please contact Hyundai dealer. 4-19...
Page 225 5. BRAKE VALVE STRUCTURE 15-1 15-3 15-4 15-2 100D7BS107 Body 12 Snap ring 19 Lock pin 1 Spool 13 Du bushing 20 Snap ring Plug 14 Pedal plate 21 Hexagon bolt Holder(piston) 15 Pedal assembly 22 Hexagon nut Lower spring 15-1 Pedal 23 Name plate Main spring...
Page 226 OPERATION Hydraulic circuit Port Port name Port size Main pressure port PF3/8 Drain port PF3/8 Brake cylinder port PF3/8 Pressure switch port PF1/4 100D7BS108 4-21...
Page 227 Purpose The purpose of the brake valve is to sensitively increase and decrease the braking pressure when the brake pedal is actuated. Ready position When the braking system is ready for operation, its accumulator pressure acts directly on ports (P) of the brake valve. A connection is established between ports(BR) and ports(T) so that the wheel brakes ports(BR) are pressureless via the returns ports(T).
Page 228 Repair work When working on the braking system, always make sure that there is absolutely no pressure in the system. Even when the engine is switched off there will be some residual pressure in the system. When doing repair work, make sure your environment is very clean. Immediately close all open ports on the components and on pipes using plugs.
Page 229 6. CUT-OFF VALVE STRUCTURE SECTION A - A SECTION B - B HYDRAULIC SYMBOL SECTION C - C SECTION D - D 7707BS06 Cut-off valve Coil Relief valve Solenoid valve Check valve OPERATION When the pump works, the oil under the pressure flows into P port. The oil in P port is stored in the accumulator on A3 port.
Page 230 7. BRAKE ACCUMULATOR STRUCTURE Item 81L1-0004 Diameter 110mm Mounting height 164mm Nominal volume Priming pressure 50kgf/cm Operating medium Operating pressure Max 150kgf/cm Thread M18 1.5 Priming gas Nitrogen A Fluid portion C Diaphragm B Gas portion D Valve disk (770-3ATM) 4-22 OPERATION Purpose Fluids are practically incompressible and are thus incapable of accumulating pressure energy.
Page 231 Maintenance of the accumulator No special maintenance beyond the legal requirements is necessary. The accumulator should be checked annually. It should be replaced if the initial gas pressure has fallen by more than 30%(Please refer to Performance testing and checking of the accumulator).
Page 232 Repair work When working on the braking system, always make sure that there is absolutely no pressure in the system. Even when the engine in switched off there will be some residual pressure in the system. When doing repair work, make sure your environment is very clean. Immediately close all open ports on the components and on pipes using plugs.
Page 233 8. PRESSURE SWITCHES STRUCTURE Normally closed Normally open (770-3ATM) 4-25 Technical data Adjusting range Adjusting pressure Voltage Item Type Medium kgf/cm kgf/cm 50 ~ 150 Max 48 Parking 1/4" Charging 1/4" 50 ~ 150 Max 48 Max 24 Brake stop 1/4"...
Page 234 OPERATION Purpose The pressure switches are used to visually or audibly warn the driver of the pressure within the system. Make contact / circuit closer The pressure switch can be fitted in the braking system or directly on one of its components. The system pressure acts on an absorption area within the switch, making an electrical contact as the pressure on that area is increased.
Page 235 Adjusting and testing pressure switch The adjusting screw located between the two contact plugs can be set to the desired value within a certain range. For adjusting range, please refer to the table Technical data on the previous page. After making the adjustment, the adjusting screw should be secured using wax or a similar material.
Page 236 9. PARKING BRAKE 100D7BS109 Brake Brake disk Brake carrier Hexagon screw O-ring Hexagon screw 4-31...
Page 237 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS This procedure is designed so the mechanic can make a quick check of the system using a minimum amount of diagnostic equipment. If you need additional information, read structure and function, Group 1.
Page 238 Hydraulic oil must be at operating temperature for these checks. Item Description Service action Parking brake capacity Start engine. check Check completed. Fasten seat belt. Seat belt must be worn NOT OK while doing this check to Release parking brake and put Inspect parking brake.
Page 239 Item Description Service action Service brake pump flow Stop engine. check Check completed. Operate brake pedal approximately 20 Hydraulic oil must be at times. NOT OK operating temperature Start engine and run at low idle. Check for brake circuit for the check. leakage.
Page 240 Item Description Service action Brake accumulator Start and run engine for 30 precharge check seconds. Check completed. The axles and hydraulic Stop engine and turn start switch NOT OK oil must be at operating to ON and wait 5 seconds. Make sure brake pedal is temperature for this not binding and keeping...
Page 241 Item Description Service action Service brake pedal Slowly depress brake pedal. check Check completed. Listen for a hissing noise that indicates oil is flowing to brake NOT OK pistons. Inspect for debris under brake pedal. Inspect LISTEN/FEEL : A hissing noise clutch cut-off linkage.
Page 242 2. TROUBLESHOOTING SERVICE BRAKE Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure(See section 1) Step 2.
Page 243 Problem Cause Remedy Brakes chatter Air in brake system Do brake bleed procedure. Worn brake surface material Inspect brake surface material. Wrong oil in differential Drain. Refill. Hissing noise when Leakage in brake valve, or brake Do brake system leakage test. brake pedal is held with piston engine stopped...
Page 244 PARKING BRAKE MALFUNCTIONS Problem Cause Remedy Brake will not hold Pads not adjusted correctly Adjust parking brake. Malfunctioning parking brake Inspect and replace. solenoid Worn brake disk and / or brake Disassemble, inspect, repair. pads Brake piston hangs up in bore Remove and inspect.
Page 245 GROUP 3 TESTS AND ADJUSTMENTS 1 1 . PARKING BRAKE PERFORMANCE MEASUREMENT CONDITION Tire inflation pressure:Specified pressure Road surface : Flat, dry, paved surface with 1/5(11 20') gradient. Machine : In operating condition gradient 11 20' Item Standard value Parking brake Keep machine on 20 performance (11 20') gradient...
Page 246 BASIC SETTING REGULATION Turn the adjusting screw manually clockwise until both brake pads make contact with the brake disk. Then it is not longer possible to turn the adjusting screw without exerting a major amount of force. Turn the adjusting screw anticlockwise in order to set the following rated clearances. Model Adjusting screw Clearance(mm)
Page 247 3. HYDRAULIC BRAKE BLEEDING PROCEDURE Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Breather vent Search for leaks with a piece of cardboard. Protect hands and body from high Air breather pressure fluids.
Page 248 GROUP 4 DISASSEMBLY AND ASSEMBLY 1. BRAKE PUMP STRUCTURE 100D7BS106 Bushings 17 Tie rods Body Rear cover 10 Drive gear 18 Washers Flange 11 Driven gear 19 Nuts Seal 12 Coupling sleeve 20 Bracket Bushing seal & back up ring 13 Plate 21 Reference pins Shaft seals...
Page 249 GENERAL INSTRUCTION Cleanliness Cleanliness is the primary means of assuring satisfactory hydraulic pump life. Components such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears should be washed in solvent, air dried, and oiled immediately. Certain cleaning solvents are flammable.
Page 250 Now remove the plate(14), then extract the bushings(9), seals(5), drive gear(15), driven gear(16), keeping the body and gears as straight as possible. 100D7BS43 From the plate(14), extract the shaft seals(6) and the washer(8). 100D7BS44 Front section From the front section, remove the flange(3), the reference pins(21) and the body seal(4).
Page 251 From the flange(3), extract the shaft seals(6), the washer(8) and the elastic ring(7). To use internal snap ring pliers 100D7BS47 REASSEMBLY Flange assembly Insert the shaft seals(6) and the washer(8) carefully and fit them inside of flange with proper tool. Fit the elastic ring(7) in pre-arranged position with proper tool.
Page 252 Locate the bushing seals(5) on the Front groove pre-arranged on the bushings(9). section Then locate the back-up rings(5). Smear clean grease on the seals and back-up rings to avoid they drift away. Remember that the seals and back-up rings are the same, but the bushings of the rear section are different from those on the front section.
Page 253 Assemble the front section, insert the complete group, realized on the step inside of the body. Take care to keep it as straight as possible with the body while the assembling. 100D7BS55 Assemble the rear section, the plate(13), the coupling sleeve(12), and the front Front section section.
Page 254 2. BRAKE VALVE STRUCTURE 100D7BS110 Body 12 Snap ring 19 Spring 1 Spool 13 Du bushing 20 Snap ring Plug 14 Pedal plate 21 Hexagon bolt Holden(piston) 15 Pedal assembly 22 Hexagon nut Lower spring 15-1 Pedal 23 Name plate Main spring 15-2 Lock plate 24 Drive screw...
Page 255 REASSEMBLY Body assembly 1 Plug 2 Spring 3 Spool 4 Body 5 Oil seal 6 Plain washer 7 Stop ring 8 DU bushing 100D7BS08 9 Spring retainer(Lower) Main spring Spring retainer(Upper) Pipe Holder Rubber cover Install oil seal(5), plain washer(6), stop ring(7), DU bushing(8).
Page 256 Tighten plug(1) - Tool : 19mm spanner - Tightening torque : 14.0~16.5kgf m ress-in the DU bushing(8) with a exclusive jig. Be careful of dust and scrap after washing the parts. 100D7BS11 Spring retainer(lower)(9), main spring(10), spring retainer(upper)(11), pipe(12) and holder(13).
Page 257 Pedal plate assembly 1 Pedal cover 2 Lock plate 3 Pedal 4 Stop ring 5 Hexagon bolt 6 Pedal plate 7 Torsion spring 8 Lock pin(pedal) 100D7BS15 Pedal plate(6) assembly - Tool : 6mm torque wrench - Tightening torque : 2.5~3.0kgf 100D7BS16 Pre-assemble pedal assembly(2)(3) and torsion spring(7) on the pedal plate(6)
Page 258 Rubber cover(1) 100D7BS19 100D7BS20 Hexagon bolt(5) - Tool : 13mm spanner - Tightening torque : 2.0kgf 100D7BS21 Never remove the hexagon bolt. (Pressure setting valve deviation occurs) 4-53...
Page 259 SECTION 5 STEERING SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9 Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-17 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-21...
Page 260 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE OUTLET 1 Main control vavle 2 Main pump 3 Steering unit 4 Steering cylinder Hydraulic oil tank 100D7SS00 The steering system for this machine is composed of steering wheel assembly, steering unit(3), steering cylinder(4), steering axle and piping.
Page 261 2. HYDRAULIC CIRCUIT 230kgf/cm Cut off valve TO THE AXLE 178kgf/cm FROM THE AXLE Return line Return line 100D7SS01...
Page 262 NEUTRAL 230kgf/cm Cut off valve TO THE AXLE FROM THE 178kgf/cm AXLE Return line Return line 100D7SS02 The steering wheel is not being operated so control spool(G) does not move. The oil from the main pump(1) enters port P of steering unit(4) and the inlet pressure oil moves the spool(D) to the left.
Page 263 LEFT TURN 230kgf/cm Cut off valve TO THE Priority valve AXLE FROM THE 178kgf/cm AXLE Return line Return line 100D7SS03 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 the main pump(1) flows into the spool(G) the steering unit through the spool(D) of priority valve built in main pump(1) and flows the gerotor(H).
Page 264 RIGHT TURN 230kgf/cm Cut off valve TO THE Priority valve AXLE FROM THE 178kgf/cm AXLE Return line Return line 100D7SS04 When the steering wheel is turned to the right, the spool(G) within the steering unit(4) connected with steering column turns in right hand direction. At this time, the oil discharged from the main pump(1) flows into the spool(G) the steering unit through the spool(D) of priority valve built in main pump(1) and flows the gerotor(H).
Page 265 3. STEERING UNIT STRUCTURE 26 34 32 35 33 25 16 17 51 52 13 10 11 12 8 7 23 SECTION E-E 44 45 46 47 48 43 41 42 SECTION E-E SECTION D-D ‚c ‚c DETAIL B 100D7SS05 Cap screw 12 Spool 23 O-ring...
Page 266 OPERATION The steering unit consists of a rotary valve and a rotary meter. Via a steering column the steering unit is connected to the steering wheel of the machine. When the steering wheel is turned, oil is directed from the steering system pump via the rotary valve (spool and sleeve) and rotary meter(gear wheel set) to the cylinder ports L or R, depending on the direction of turn.
Page 267 4. STEERING CYLINDER STRUCTURE 100D7SS06 Tube assembly Rod seal 11 Back up ring Rod assembly Back up ring 12 O-ring Piston seal Dust wiper 13 Ping bushing Gland Snap ring Du bushing 10 O-ring OPERATION This machine use to cross connected cylinder for steering operation. The steering cylinder use a gland(4) to remove piston and sealed seals.
Page 268 G G ROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS This procedure is designed so the service man can make a quick check of the steering system using a minimum amount of diagnostic equipment. If you need additional information, refer to structure and function in group 1.
Page 269 Hydraulic oil must be at operating temperature for these checks. Item Description Service action Steering unit check Run engine at low idle. Check completed. Turn steering wheel until frames are at maximum right(A) and then NOT OK left(B) positions. Go to next check. LOOK : Frames must move smoothly in both directions.
Page 270 2. TROUBLESHOOTING Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure(See group 3 in section 1) Step 2.
Page 271 Problem Cause Remedy Slow or hard steering Too much friction in the mechanical parts of Lubricate bearings and joints of steering the machine column or repair if necessary. Check steering column installation. Cold oil Warm the hydraulic oil. Low priority valve pressure setting Do priority valve pressure test.
Page 272 Problem Cause Remedy Erratic steering Air in oil Check for foamy oil. Low oil level Add recommended oil. Sticking priority valve spool Remove and inspect spool. Loose cylinder piston Remove rod to inspect piston. Damaged steering unit Remove and inspect. Spongy or soft steering Air in oil Check for foamy oil.
Page 273 Problem Cause Remedy "Motoring" effect. Leaf springs are stuck or broken and have Replace leaf springs. The steering wheel can therefore reduced spring force turn on its own. Inner and outer spools pinch, possibly due Clean steering unit or contact the nearest to dirt service shop.
Page 274 Problem Cause Remedy Backlash Cardan shaft fork worn or broken Replace cardan shaft. Leaf springs without spring force or broken Replace leaf springs. Worn splines on the steering column Replace steering column. "Shimmy" effect. The Air in the steering cylinder Bleed cylinder.
Page 275 Problem Cause Remedy Heavy kick-back Wrong setting of cardan shaft and gear- Correct setting as shown in service manual. steering wheel in both wheel set directions. Turning the steering Hydraulic hoses for the steering cylinders Connect lines to correct ports. wheel activates have been switched around...
Page 276 GROUP 3 TESTS AND ADJUSTMENTS 1 1 . HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY Service equipment and tool. Portable filter caddy Two 3658mm(12ft) 1" I.D. 100R1 hoses with 3/4 M NPT ends Quick disconnect fittings Discharge wand Various size fittings and hoses Brake system uses oil from hydraulic oil tank.
Page 277 Start the filter caddy. Check to be sure oil is flowing through the filters. Operate filter caddy approximately 10 minutes so oil in hydraulic oil tank is circulated through filter a minimum of four times. Hydraulic oil tank capacity 115 (30.4U.S. gal).
Page 278 2. TEST TOOLS CLAMP-ON ELECTRONIC TACHOMET- ER INSTALLATION Service equipment and tools Tachometer A : Clamp on tachometer. Remove paint using emery cloth and connect to a straight section of injection line within 100mm(4in) of pump. Finger tighten only-do not over tighten.
Page 279 3. STEERING UNIT LEAKAGE TEST SPECIFICATION Oil temperature 45 5 C(113 9 F) Engine speed High idle Cap fitting Maximum leakage 7.5 /min(2gpm) AUGE AND TOOL Temperature reader Measuring container(Approx. 20 ) Stop watch Install temperature reader. (See temperature reader installation procedure in this group).
Page 280 GROUP 4 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 14 13 100D7SS10 Cap screw 17 Needle bearing 35 Spring Retainer screw 18 O-ring 41 Retainer plug Cap end 19 Seal 42 Spring Gerotor 20 Dust seal 43 Ball Spacer plate 21 Retaining ring 44 seat Spacer plate...
Page 281 TOOLS Holding tool + Guide ring 7607SE08 Assembly tool for O-ring and kin-ring. 7607SE09 Assembly tool for lip seal. (780-3A) 5-69(3) Assembly tool for cardan shaft. (780-3A) 5-69(4) 5-22...
Page 282 Assembly tool for dust seal. (780-3A) 5-70(1) Torque wrench 0~7.1kgf m (0~54.4lbf ft) 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 (780-3A) 5-70(2) Tweezers 5-23...
Page 283 TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS Hydraulic connections L : Left port R : Right port T : Tank T L P R P : Pump (780-3A) 5-71 Tightening torque Max. tightening torque [ kgf m(lbf ft) ] Screwed With cutting With copper With aluminum connection...
Page 284 When repairing orbitrol, refer to parts manual. We cannot assure any troubles of orbitrol repaired by customers, so we commend sending back to our Hyundai dealer when repairing. Cleanliness is extremely important for repairing. Work in a clean area. Before disconnecting the lines, clean port area of orbitrol thoroughly.
Page 285 Remove drive(8). Remove spacer plate(7). Replace O-ring(24) in housing(10). Be careful that O-ring size(23) and (24) is different. 100D7SS14 Put spacer plate(7) on housing(10). Align bolt holes in spacer plate(7) with tapped holes in housing(10). Pich dia. of bolt holes and oil holes in spacer plate(7) is different.(Larger pitch dia.
Page 286 Install spacer(s)(5) in gerotor(4). Anti-cavi check assy Install end cap(3) on gerotor(4) aligning positions holes. Install cap screw(1) and retainer screw assy(2) in end cap(3). Tighten screws to 15Nm(1.5kgf m) in advance. Retainer screw assy Then tighten screws to tightening torque position in sequence shown right figure.
Page 287 Remove seal gland bushing(22) from housing(10). 100D7SS19 Replace O-ring(18) with new one. Remove oil seal(19) from seal gland Screw driver bushing(22) and replace oil seal(19) with new one. When installing oil seal(19) in seal gland bushing(22), be careful not to twist and deform oil seal.
Page 288 Tools required for repair - Torque wrench(50Nm capacity) - 5/12" socket - Screw driver - Plastic hammer or rubber hammer - Grease - Vice - Marker pen 5-29...
Page 289 2. STEERING CYLINDER STRUCTURE 100D7SS06 Tube assembly Rod seal 11 Back up ring Rod assembly Back up ring 12 O-ring Piston seal Dust wiper 13 Ping bushing Gland Snap ring DU bushing 10 O-ring 5-30...
Page 290 DISASSEMBLY Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in & vice. Remove the cover by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube. Check wear condition of the sealing parts(O-ring, oil seal, dust seal, U-packing, bush).
Page 291 Install the dust wiper(8) to the gland(4) using a special installing tool. Coat the dust wiper with grease slightly before installing. Using a special tool, install gland assembly into the cylinder tube(1). Special tool D507SE29 Using a hook spanner, install the gland(4) ass- Hook spanner embly, and tighten it with torque 60 6kgf m (434 43lbf ft).
Page 292 3. STEERING AXLE STRUCTURE Do not remove the stopper bolt unless necessary. 1-40 1-41 1-43 1-43 1-43 1-38 1-15 1-16 1-14 1-33 1-46 1-32 1-34 1-31 1-27 1-27 1-44 1-26 1-38 1-42 1-29 1-43 1-41 1-30 1-39 1-45 1-36 1-13 1-35 1-37 1-12...
Page 293 CHECK AND INSPECTION A1, A2 100D7SS22 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 95(3.74) 94(3.70) Shaft ID of bushing 95(3.74) 94(3.70) 80(3.2) 79.5(3.1) OD of king pin Replace 22(0.9) 21.9(0.9) OD of steering cylinder pin 22(0.9) 21.9(0.9) OD of pin...
Page 294 DISASSEMBLY Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the balance weight part of the truck. Hub nut Loosen the hub nut and take off the steering wheel tire.
Page 295 ASSEMBLY In reassembling, have all parts washed, grease 1-15 1-16 applied to lubricating parts, and all expendable 1-14 1-46 1-27 items such as oil seal and spring washers replaced by new ones. 1-26 Perform the disassembly in reverse order. 1-29 1-30 Tighten the set screw(1-8) of king pin(1-6).
Page 296 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-31 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-36...
Page 297 ECTION 6 WORK EQUIPMENT GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC SYSTEM OUTLINE The hydraulic system is a pilot operated, open center system which is supplied with flow from the fixed displacement main hydraulic pump. The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow from the first(Steering) pump.
Page 298 2. HYDRAULIC CIRCUIT 230kgf/cm BL BR 107kgf/cm 214kgf/cm 173kgf/cm From RCV From RCV 127~ 153kgf/cm 31~41 kgf/cm 168kgf/cm kgf/cm 168kgf/cm 168kgf/cm 168kgf/cm 122kgf/cm Tilting Cabin Hyd Circuit 214kgf/cm TO THE AXLE TILT POSITIONER LIFT 178kgf/cm FROM THE AXLE 100D7HS01 Main pump 23 Strainer 12 Steering cylinder Auxiliary pump...
Page 299 3. WORK EQUIPMENT HYDRAULIC CIRCUIT Steering system 214kgf/cm From RCV From RCV 168kgf/cm 168kgf/cm 168kgf/cm 168kgf/cm Cut off valve TO THE AXLE 214kgf/cm LIFT TILT POSITIONER FROM THE AXLE 178kgf/cm Brake valve 100D7HS02 Main pump 13 Lift cylinder 24 Return filter Auxiliary pump 14 Tilt cylinder 25 Down control valve...
Page 300 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION Load check valve Steering system 214kgf/cm LIFT From RCV From RCV Load check valve 168kgf/cm 168kgf/cm 168kgf/cm 168kgf/cm Cut off valve TO THE AXLE 214kgf/cm LIFT TILT POSITIONER FROM THE AXLE 178kgf/cm Brake valve...
Page 301 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION Steering system 214kgf/cm LOWER From RCV From RCV 168kgf/cm 168kgf/cm 168kgf/cm 168kgf/cm Cut off valve TO THE AXLE 214kgf/cm TILT POSITIONER LIFT FROM THE AXLE 178kgf/cm Brake valve 100D7HS04 When the lift control is pushed forward, the spool on the first block is moved to lower position by the pilot oil pressure from the remote control valve(11).
Page 302 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION Steering system 214kgf/cm TILT From RCV From RCV Load 168kgf/cm check valve 168kgf/cm 168kgf/cm 168kgf/cm Cut off valve TO THE AXLE 214kgf/cm LIFT TILT POSITIONER FROM THE AXLE 178kgf/cm Brake valve 100D7HS05 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position by the pilot oil pressure from the remote control valve(11).
Page 303 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION Steering system 214kgf/cm TILT From RCV From RCV Load 168kgf/cm check valve 168kgf/cm 168kgf/cm 168kgf/cm Cut off valve TO THE AXLE 214kgf/cm LIFT TILT POSITIONER FROM THE AXLE 178kgf/cm Brake valve 100D7HS06 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position by the pilot oil pressure from the remote control valve(11).
Page 304 WHEN THE FORK POSITIONER LEVER IS IN THE SPREAD-OUT POSITION(OPTION) Steering system 214kgf/cm 168kgf/cm FORK 168kgf/cm POSITIONER From RCV From RCV 168kgf/cm 168kgf/cm Cut off valve TO THE AXLE 214kgf/cm TILT POSITIONER LIFT FROM THE AXLE 178kgf/cm Brake valve 100D7HS07 When the fork positioner lever is pulled back, the spool on the third block is moved to fork spread- out position by the pilot oil pressure from the remote control valve(11).
Page 305 WHEN THE FORK POSITIONER LEVER IS IN THE CLOSE POSITION(OPTION) Steering system 214kgf/cm 168kgf/cm FORK 168kgf/cm POSITIONER From RCV From RCV 168kgf/cm 168kgf/cm Cut off valve TO THE AXLE 214kgf/cm TILT POSITIONER LIFT FROM THE AXLE 178kgf/cm Brake valve 100D7HS08 When the fork positioner lever is pushed forward, the spool on the third block is moved to fork close position by the pilot oil pressure from the remote control valve(11).
Page 306 4. MAIN PUMP STRUCTURE 25 26 100D7PMP00 Snap ring 10 Drive gear 19 Plug Shaft seal 11 Driven gear 20 Priority valve body Assembling bolt 12 Steel bushing 21 Compensation spool Assembling washer 13 Square ring 22 Cap Mounting flange 14 Front working section 23 LS port connector Copper bushing...
Page 307 INSTRUCTION Hydraulic pumps used for the work equipment hydraulic units on construction machinery are pressure loaded type gear pumps. This gear pump could run under 300kgf/§†(4,350psi) maximum. The pressure loaded type gear pump is designed so that the clearance between the gear and the side plate can be automatically adjusted according to the delivery pressure.
Page 308 PRINCIPLE OF OPERATION Mechanism for delivering oil The below drawing shows the operational principle of an external gear pump on which two gears are rotation in mach. The oil entering through the suction port is Suction Discharge trapped in the space between two gear teeth, and is delivered to the discharge port as the gear rotates.
Page 309 If there is no resistance in the oil passage into which the discharged oil flows, the oil merely flows through the passage, producing no increase in pressure. If however, the oil passage is blocked with Discharge Suction something like a hydraulic cylinder, there will be no other place for the oil to flow, so the oil pressure will rise.
Page 310 Forces acting on the gear The gear, whose outer surface is subjected to oil Drive gear pressure, receives force jointing towards its center. Due to the action of the delivery pressure, the oil pressure in higher on the Suction Discharge delivery side of the pump, and due to suction side side...
Page 311 GENERAL REFERENCE Installation The direction of rotation of single-rotation pumps must be the same as that of the drive shaft. Check that the coupling flange correctly aligns the transmission shaft and the pump shaft. Flexible couplings should be used (never rigid fittings) which will not generate an axial or radial load on the pump shaft.
Page 312 5. REMOTE CONTROL VALVE STRUCTURE UT 1,2,3,4,5,6 100D7RCV00 Metering spring 14 O-ring Lever Seeger ring 15 Kit 3 Plug Seeger ring 16 Clamp Body 10 Docking rod 17 Rubber bellow Kit 1 11 Spring 18 Screw Plunger kit 12 Kit 2 19 Support kit Spring guide 13 Tie rod with nut...
Page 313 OPERATION HYDRAULIC CIRCUIT Hydraulic functional principle Pilot devices with end position locks operate as direct operated pressure reducing valves. They basically comprise of control lever(A), two pressure reducing valves, body(3) and locks. Each pressure reducing valve comprises of a plunger kit(5), a metering spring(7) and a spring(11).
Page 314 6. MAIN CONTROL VALVE STRUCTURE 32-4 32-3 30-5 26-3 26-1 30-3 30-6 30-4 32-6 30-2 30-1 32-5 32-2 31-1 32-1 31-2 31-4 28-3 28-1 28-2 30-2 30-4 31-3 30-1 31-5 30-3 30-6 30-5 30-5 30-3 30-6 30-1 30-4 30-2 28-5 28-3 29-4 28-1...
Page 315 STRUCTURE A1 B1 A2 B2 A3 B3 168 bar 168 bar 168 bar 168 bar 214 bar 214 bar HYDRAULIC CIRCUIT 100D7WE12 Size Port Port Port name Port name Size P1, P2 From main pump 1 5/16" - 12UNF V1, V2 To aux port (4-spool) 9/16"...
Page 316 LIFT SECTION OPERATION Neutral position of lift spool Cout Cout 100D7MCV31 Inlet from hydraulic pump Return passage to tank Outlet to tank Lift spool Pilot passage (Hydraulic pressure from joystick) Closed passage(Not used) PV (Hydraulic pressure from joystick) Passage to head end of lift cylinders(lift upward) Working actuation T Closed with through line(Lc) open.
Page 317 Upward position for lift spool Cout Cout 100D7MCV32 Inlet from hydraulic pump Return passage to tank Outlet to tank Lift spool Pilot passage PV (Hydraulic pressure from joystick) Plugged passage PV (Hydraulic pressure from joystick) Passage to head end of lift cylinders(lift upward) Working actuation B open...
Page 318 Downward position for lift spool Cout Cout 100D7MCV33 Inlet from hydraulic pump Return passage to tank Outlet to tank Lift spool Pilot passage PV (Hydraulic pressure from joystick) Plugged passage PV (Hydraulic pressure from joystick) Passage to head end of lift cylinders(lift upward) Working actuation T open...
Page 319 TILT & AUXILIARY SECTION OPERATION Neutral position of auxiliary spool Cout Cout 100D7MCV34 Inlet from hydraulic pump Return passage to tank Outlet to tank Master spool Pilot passage PV (Hydraulic pressure from joystick) Passage to head end of cylinders PV (Hydraulic pressure from joystick) Passage to rod end of cylinders Working actuation T Closed with through line(Lc) open.
Page 320 Forward position for auxiliary spool Cout Cout 100D7MCV35 Inlet from hydraulic pump Return passage to tank Outlet to tank Master spool Pilot passage PV (Hydraulic pressure from joystick) Passage to head end of cylinders PV (Hydraulic pressure from joystick) Passage to rod end of cylinders Working actuation A, B T open.
Page 321 Backward position for auxiliary spool Cout Cout 100D7MCV36 Inlet from hydraulic pump Return passage to tank Outlet to tank Master spool Pilot passage PV (Hydraulic pressure from joystick) Passage to head end of cylinders PV (Hydraulic pressure from joystick) Passage to rod end of cylinders Working actuation B, A T open.
Page 322 7. LIFT CYLINDER 14 10 100D7CYL01 Tube assembly Stop ring 13 Back up ring Rod assembly Rod cover 14 O-ring Piston DU-bushing 15 Spacer U-packing 10 U-packing 16 O-ring Rod seal 11 Dust wiper Back up ring 12 O-ring 8. TILT CYLINDER 14 15 100D7CYL02 Tube assembly...
Page 323 9. FREE CYLINDER 100D7CYL03 Tube assembly Orifice 15 Back up ring Rod assembly Rod cover 16 Plug Piston 10 U-packing 17 O-ring Check valve 11 Back up ring 18 Dust cap Retaining ring 12 Dust wiper 19 O-ring 20 O-ring Seal slipper 13 Retaining ring Wear ring...
Page 324 10. HYDRAULIC OIL TANK STRUCTURE The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders. In the return circuit, the oil from various parts merges. A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the hydraulic tank.
Page 325 AIR BREATHER The air breather is equipped with the capacity to perform two functions simultaneously-as an air filter and as a breathing valve. Preventing negative pressure inside the tank The tank is a pressurized sealed type, so negative pressure is formed inside the Bolt Element hydraulic tank when the oil level drops...
Page 326 11. ACCUMULATOR The accumulator is installed at the pilot oil supply unit. When the boom is left the raised position, and the control levers are operated with the engine stopped the pressure of the compressed nitrogen gas inside the accumulator sends pilot pressure to the control valve to actuate it and allow the boom and bucket to come down under their own weight.
Page 327 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1m from ground. Wait for 10 minutes and measure hydraulic drift(amount forks move down and amount mast tilts forward). Check condition 100D7HS16 - Hydraulic oil : Normal operating temp...
Page 328 . TROUBLESHOOTING SYSTEM Problem ause 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 Tilting backward : Check valve defec- Clean or replace.
Page 329 Problem Cause Remedy Actuator(cylinder or motor) Shortage of oil in oil tank. Check the oil level in the oil tank. works slowly or does not Decrease of relief valve pressure. Install pressure gauge on the circuit, operate. and check the pressure with it by handling the lever.
Page 330 HYDRAULIC GEAR PUMP Problem ause Remedy Pump does not develop full System relief valve set too low or Check system relief valve for proper pressure. leaking. setting. Oil viscosity too low. Change to proper viscosity oil. Pump is worn out. Repair or replace pump.
Page 331 CYLINDER Problem ause Remedy Oil leaks out from gland Foreign matters on packing. Replace packing. through rod. Unallowable score on rod. Smooth rod surface with an oil stone. Unusual distortion of dust seal. Replace dust seal. Chrome plating is striped. Replace rod.
Page 332 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP STRUCTURE 25 26 100D7PMP00 Snap ring 10 Drive gear 19 Plug Shaft seal 11 Driven gear 20 Priority valve body Assembling bolt 12 Steel bushing 21 Compensation spool Assembling washer 13 Square ring 22 Cap Mounting flange 14 Front working section...
Page 333 GENERAL INSTRUCTIONS Check immediately that any spare parts you receive have not been damaged in shipment. Always work in a clean environment. Wash all components in solvent and blow dry with compressed air before refitting. Take care not to damage rubber seals. Avoid damaging precision machined surfaces.
Page 334 DISASSEMBLY MOUNTING FLANGE SECTION Loosen and remove the assembling bolts(3) with washers(4) from the mounting flange. Remove the square-ring(13) from the mounting flange(5). Replace the square-ring if damaged. 100D7PMP01 Remove the snap-ring(1) with proper tool(Only when it is needed to replace shaft seal.) Remove the shaft seals(2) taking care not to give any damage on the surface of...
Page 335 Remove the assembling bolts(3) with washers(4) from the working section(14). Remove the square-ring(13) from the working section. 100D7PMP05 Remove the through shaft(15) from the drive gear(16). Remove the pressure plate(9) with related parts(7, 8) from the working section and examine it carefully. 100D7PMP06 Remove the drive gear(16) and driven gear(11) from the rear working section,...
Page 336 REAR WORKING SECTION Loosen and remove the assembling bolts(3) with washers(4) from the priority valve body. Loosen and remove the LS port connector(23) from the priority valve body(20). Remove the O-ring(18) from the mounting flange(17). 100D7PMP08 Replace the square-ring if damaged. Loosen and remove the upper cap(22), O- ring(18) and compensator spool(21) from the priority valve body(20).
Page 337 ASSEMBLY IMPORTANT It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior with a proper cleaning solvent before continuing. New seals should be installed upon reassembly. REAR WORKING SECTION Tighten the lower cap(22) after putting the spring with related parts into the priority valve body.
Page 338 FRONT WORKING SECTION Locate the drive gear(10) and driven gear(11) into the rear working section(17) after fitting the parts of the pressure plate into the drive gear. Locate the pressure plate(9+8+7) with care for the direction. Fit the through shaft(15) into the drive gear(10).
Page 339 MOUNTING FLANGE SECTION Insert the shaft seal(2) carefully and fit it inside of the mounting flange(5) Fit the snap ring(1) in pre-arranged position with proper. 100D7PMP02 Insert the square ring(13) into the mounting flange(5). Smear clean grease on the square ring to avoid drifting away of square ring from the body.
Page 340 2. MAIN CONTROL VALVE STRUCTURE 32-4 32-3 30-5 26-3 26-1 30-3 30-6 30-4 32-6 30-2 30-1 32-5 32-2 31-1 32-1 31-2 31-4 28-3 28-1 28-2 30-2 30-4 31-3 30-1 31-5 30-3 30-6 30-5 30-5 30-3 30-6 30-1 30-4 30-2 28-5 28-3 29-4 28-1...
Page 341 GENERAL PRECAUTIONS In the system, all of the pipes must be carefully cleaned before installation in order to remove dirt, rust, and deposits. The following cleaning procedures are recommended: Sanding, brushing, pickling, and flushing with a solvent to remove contaminating particles. The use of Teflon tape, hemp, or other "fillers"...
Page 342 INSTRUCTION FOR DISASSEMBLY AND REASSEMBLY Before disassembly, visually inspect for leakage of oil and for part that have damage and clean the valve up. Preparation for assembly put the tag on each part to prevent wrong assembly and clean the parts completely. Inspect the parts if there is any scratch or dent, and check the movement. In assembly process, follow the tightening torque specification.
Page 343 DISASSEMBLY & ASSEMBLY Replacing complete working section Loosen tightening two bolts with 17mm spanner. 100D7MCV01 Taking out working section one by one. 100D7MCV02 Remove O-rings on the surface of working section properly. Pay special attention not to give any scratch on the surface. 100D7MCV03 Prepare two sizes of O-rings.
Page 344 Locate new or repaired working section in right position according to the order of functions. 100D7MCV05 Tighten four nuts (M17) in a crisscross pattern with proper assembling torque of 4.3kgf m(31lbf ft). 100D7MCV06 Replacing spool & control kit Loosen 4 screws holding aluminum kits to the body with 5mm wrench.
Page 345 Take out the spool, as straight as possible. Even very little force on the spool while disassembling & assembling could make deformation on the spool. 100D7MCV09 Prepare all components before starting reassembling spool control kit. 100D7MCV10 Fit aluminum kit to the body with 5mm wrench by 1.0kgf m(7.2lbf ft).
Page 346 Replace old relief valve with new one. Relief valve should be fitted with proper tool, 36mm spanner, with 4.3kgf m(31lbf ft) torque. 100D7MCV13 6-50...
Page 347 3. REMOTE CONTROL VALVE STRUCTURE UT 1,2,3,4,5,6 100D7RCV00 Lever Metering spring 14 O-ring Seeger ring 15 Kit 3 Plug Seeger ring 16 Clamp Body 10 Docking rod 17 Rubber bellow Kit 1 11 Spring 18 Screw Plunger kit 12 Kit 2 19 Support kit Spring guide 13 Tie rod with nut...
Page 348 GENERAL PRECAUTIONS In the system, all of the pipes must be carefully cleaned before installation in order to remove dirt, rust, and deposits. The following cleaning procedures are recommended: Sanding, brushing, pickling, and flushing with a solvent to remove contaminating particles. The use of Teflon tape, hemp, or other "fillers"...
Page 349 DISASSEMBLY & ASSEMBLY Replacing complete working section Loosen two tightening bolts with 13mm spanner. 100D7RCV02 Taking out the damaged section and insert new one. Pay attention 2 O-rings on the internal passage to be in right position. 100D7RCV03 Tight M13 nut with proper torque 3.06kgf m(22.1lbf ft).
Page 350 Take off the fulcrum and mounting flange very carefully keeping all components in their own positions. 100D7RCV06 Take out the spool, return spring from the body. And replace any component if it is needed. 100D7RCV07 Reassemble the spool in opposite order mentioned above.
Page 351 Hold tightly mounting flange and lay fulcrum on the flange and screw in clamp bolts in a crisscross pattern. Clamp torque is 0.67kgf m(4.9lbf ft). 100D7RCV10 6-55...
Page 352 SECTION 7 ELECTRICAL SYSTEM Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Group 4 Cluster indication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19...
Page 353 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Cabin ceiling Rear Front Cabin roof 100D7EL01 Aircon & heater switch 10 Operator seat 19 Rear wiper washer switch Remote control lever 11 Inc/Dec switch 20 Parking brake switch Multi function switch 12 Work lamp switch 21 Hydraulic safety lever...
Page 354 2. LOCATION 2 18 19 100D7EL02 Switch panel 12 Travel cut relay 23 Heater relay Multi function switch 13 Int-wiper relay 24 Rear combination lamp Wiper assembly 14 Flasher 25 Travel alarm buzzer Wiper motor 15 Wiper relay 26 Work lamp-cabin rear Head lamp 16 Washer pump relay 27 Radio and cassette...
Page 355 GROUP 2 ELECTRICAL CIRCUIT S/W MULTI FUNCTION S/W GEAR SELECTOR R O L F *HARNESS CABIN BEACON I ^Z LAMP I ^Z O SPEAKER R/WORK R/WORK CN-98 CN-21 RESISTER TO:MAIN HARNESS CN-27 CN-10 CASSETTE TO:CABIN HARNESS FRONT WIPER FUSE BOX (ACC) RADIO CN-14 RELAY ILL.
Page 356 MEMORANDUM...
Page 357 1. POWER CIRCUIT The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the off position, the current flows from the positive battery terminal. OPERATING FLOW Start relay[CR-23] Battery(+) Fusible link[CN-60] I/conn[CN-1(1)] Master switch[CS-62] Start motor[CN-45(B+)] Fusible link[CN-95]...
Page 358 POWER CIRCUIT ^Z O CN-27 CN-37 CS-2 PARKING SOL. BEACON AIRCON/HEATER AIRCON/HEATER CR-11 CASSETTE RADIO START RELAY TURN LAMP CL-1 RADIO/ROOM LAMP FLASHER ROOM LAMP CS-41 BRAKE LAMP START KEY CL-30 TCU(B+) CLUSTER/OPSS CN-1 CD-4 ROOM LAMP CN-10 STOP SWITCH S/W HAZARD F/LINK CN-3...
Page 359 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Master Switch[CS-62] Start motor[CN-45(B+)] Fusible link[CN-95] I/conn[CN-1(2)] Start Switch[CS-2(1)] Start relay[CR-23] he engine can be started only when the gearshift is in neutral position. When start key switch is in ON position Start switch ON [CS-2(2)] Fuse box[CN-36(1 7)] I/conn[CN-2(14)] ECU[CN-92]...
Page 360 STARTING CIRCUIT S/W GEAR SELECTOR CR-5 CN-36 ILLUMINATION WORK LAMP-FENDER CS-2 BACK-UP CN-8 SAFETY RELAY CLUSTER CASSETTE-RADIO OPSS SYSTEM CIGAR LIGHTER PREHEATER WORK LAMP-CABIN F/R WIPER/HORN START KEY CS-14 CN-37 PARKING SOL. BEACON AIRCON/HEATER AIRCON/HEATER START RELAY CS-15 TURN LAMP RADIO/ROOM LAMP CN-1 BRAKE LAMP...
Page 361 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator release the start switch to the ON position. Charging current generated by operating alternator flows into the battery. The current also flows from alternator to each electrical component through the fusible link(CN-60) and the fuse box.
Page 362 CHARGING CIRCUIT FUSE BOX CN-60 CN-45 CN-1 START MOTOR CS-62 38SQ MASTER SWITCH CN-74 15SQ 3 FI E/G EARTH 4 NC CLUSTER ALTERNATOR 38SQ 38SQ CN-3 BATTERY 12VX2 BATTEY EARTH CN-8 100D7EL06 7-10...
Page 363 4. PREHEATING CIRCUIT Combustion chamber glow plugs are used in order to give satisfactory starting of low ambient temperatures. OPERATING FLOW Battery(+) terminal Master Switch[CS-62] Alternator[CN-74(B+)] Start motor[CN-45(B+)] Pre-heater relay[CR-24] I/conn[CN-3(2)] Safety relay[CR-42(4 Fuse box[CN-36(10)] When you turn the start switch to the ON position, the glow relay makes the glow plugs operated and the glow lamp of the cluster turned ON.
Page 364 PREHEATING CIRCUIT CR-42 CN-36 ILLUMINATION WORK LAMP-FENDER BACK-UP CS-2 CLUSTER SAFETY RELAY CASSETTE-RADIO OPSS SYSTEM CIGAR LIGHTER PREHEATER WORK LAMP-CABIN F/R WIPER/HORN FUSE BOX START KEY CN-1 CN-2 CN-93 FUSIBLE LINK STOP LAMP WIF LAMP DIAGNOSTIC LAMP WAIT TO START LAMP THROTTLE POSITION RETURN REMOTE THROTTLE RETURN OFF IDLE S/W...
Page 365 GROUP 3 MONITORING SYSTEM The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of abnormal truck operation or conditions for the appropriate operation and inspection. Gauges : Indicate operating status of the truck. Warning lamp : Indicate abnormality of the truck.
Page 366 FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank. Fill the fuel when the indicator moves E point, refuel as soon as possible to avoid running out of fuel. If the gauge indicates below E point even though the truck is on the normal condition, check the electric device as that can be caused by the poor connection of electricity or sensor.
Page 367 DIRECTION PILOT LAMP This lamp flashes when the signal indicator lever is moved. 77073CD10 WORK LAMP PILOT LAMP(FRONT / REAR) This lamp lights ON when cabin work lamp switch is pressed. 77073CD11 HEAD LIGHT PILOT LAMP This lamp comes ON when the main light switch is operated to 2nd step.
Page 368 Immediately pull the truck to a convenient stop. Stop the engine. Investigate the cause. Consult a HYUNDAI dealer to investigate the cause. 77073CD19 Do not operate until the cause has been corrected.
Page 369 AIR CLEANER WARNING LAMP This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged. Check the filter and clean or replace it when the lamp is ON. 77073CD20 BATTERY CHARGING WARNING LAMP This lamp is ON after key switch is turned ON. Check the battery charging circuit when this lamp comes ON during engine operation.
Page 370 T/M ERROR, HOUR METER, ENGINE RPM INDICATOR FND and LED displaying T/M error, engine RPM and hour meter. T/M MESSAGE It displays T/M error codes through CAN (Controller Area Network) calibrator, messages from inching or AEB operation, total work hours and engine rpm. HOURMETER ⋅...
Page 371 GROUP 4 CLUSTER INDICATION INCHING Inching sensor initializing Synchronize inching pedal & linkage with inching sensor. Initializing inching sensor. Symbol Meaning Remark Prepare for initialization(1) - Place the truck on the level floor, release parking brake and set the gear to neutral. (Before releasing parking brake, install block under the wheels for safety.) Prepare for initialization(2) - With the truck stopped, turn the start key...
Page 372 Symbol Meaning Remark - Truck is not stopped. (After stopping the truck, restart initialization) - Gear not on the neutral. (After putting gear to neutral, restart initializat- ion) - Narrow gap between angle and pedal - Wide gap between angle and pedal - Voltage of inching sensor(AU1) is out of standard.(Need adjustment) - Signals of sensor No 1 and No 2 are different.
Page 373 AEB(Initializing transmission efficiency) AEB(Automatische Ermittlung der Berfullparameter) To minimize gear shift impact by manufacture tolerance of each transmission, measure the play of disc inside the clutch assembly and compensate it to keep optimal performance. AEB(Initializing transmission efficiency) operation principle TCU(T/M Control Unit) sensing the signals from speed sensor calculates each of clutch discs, whenever oil is charged into clutch, and compensates the oil charging pressure and time.
Page 374 Symbol Description Remark - Initializing 3rd gear clutch. - Completion of initialization. T/M MESSAGE - Restart in 1~3 seconds after key OFF. - Low engine rpm. T/M MESSAGE - Slowly step on the accelerator pedal. - High engine rpm. T/M MESSAGE - Slowly step off the accelerator pedal.
Page 375 Normal sequence of AEB operation. In normal operation, it indicates in the order of "ST > KR > KV > K1 > K2 > K3" and takes 3~5 minutes. After AEB is completed successfully, it displays "OK". After completing AEB, turn ON the start switch again after turning OFF the switch. In case of error, rerun AEB.
Page 376 GROUP 5 SWITCHES Work light switch Inc/Dec switch Hazard switch Inching switch Diagnostic switch Main light switch Auto/Manual select switch Rear wiper/washer switch Start switch Parking brake switch Horn button Multi function switch Cabin tilt switch DETAIL A Cover(LH) STOP DOWN Cabin tilt switch location 160D7CD05...
Page 377 HAZARD SWITCH Use for parking, or loading truck. If the switch is left ON for a long time, the battery may be discharged. 160D7CD42 INCHING SWITCH If this switch is pressed, inching operation is applied to inching pedal. Also, inching lamp on the cluster is illuminated. 160D7CD43 PARKING BRAKE SWITCH If this switch is pressed, the parking brake is applied and the gauge...
Page 378 REAR WIPER AND WASHER SWITCH This switch is used to operate the rear wiper and washer by two steps. First step : The rear wiper operates. Second step : The washer liquid is sprayed and the rear wiper is operated only while pressing. If release the switch, return to the first step position.
Page 379 CABIN TILT SWITCH Tilting UP cabin Press the top of the switch fully to tilt the cabin upward. STOP DOWN STOP the tilting operation(Default) Release the switch to stop the tilting operation. Tilting DOWN cabin 160D7CD74 Press the bottom of the switch fully to tilt the cabin downward. Refer to operator's manual for cabin tilting procedure.
Page 380 GROUP 6 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check Check specific gravity 200Ah 1.280 over : Over charged Battery (2EA) 1.280 ~ 1.250 : Normal 1.250 below : Recharging Check disconnection Normal : 0 CN-60 : 24V 27A Fusible link (Connect ring terminal and CN-95 : 24V 45A check resistance between...
Page 381 Part name Symbol Specifications Check Pressure : Check contact Air cleaner 635mmH pressure switch Normal : (N.O TYPE) CD-10 Check resistance Reed switch : Fuel sender Full : About 50 Magnetic type Low level : About 700 CD-2 Check resistance Normal : About 200 Relay 24V 20A...
Page 382 Part name Symbol Specifications Check Check resistance PRE-HEATER Normal : 10 (For terminal coil) 24V 200A Preheat relay (Between ring term) CR-24 Check disconnection Work lamp, 24V 65W Head lamp Normal : A few H3 bulb CL-5 CL-22 CL-3 CL-4 CL-6 CL-23 AVS(R)
Page 383 Part name Symbol Specifications Check Check resistance License lamp 24V 10W Normal : A few CL-12 Check contact CS-17 CS-34 OFF : CS-41 Switch 24V 8A (For terminal 1-5, 2-6) CS-42 (Locking type) (For terminal 5-7, 6-8) CS-3 CS-21 Check contact CS-39 Switch 24V 8A...
Page 384 Part name Symbol Specifications Check Check voltage Delco Remy 24SI Alternator Normal : 24~28V 24V 70A 3 FI 4 NC CN-74 DENSO Start motor Operating or not 24V 3.7kW CN-45 Check resistance Cassette radio 24V 20W+20W Power ON : 4 + 4 (For terminal 1-6, 4-8) CN-27 24V 0.5A...
Page 385 Part name Symbol Specifications Check Check resistance Speaker Normal : 50 CN-23(LH) CN-23 CN-24(RH) CN-24 Air conditioner Check contact 24V 79W compressor Normal : 13.4 CN-28 Cigar lighter 24V 5A CL-2 Flasher 85~190 C/M 50dB CR-11 Pf 2 24V 1.5A Wiper motor 2-speed Auto parking...
Page 386 Part name Symbol Specifications Check 24V 200mA Warning buzzer 5dB( m) CN-26 7-34...
Page 387 GROUP 7 CONNECTORS 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Main harness-Engine harness) S813-030200 S813-130200 CN-2 I/conn(Main harness-Engine harness) 368047-1 368050-1 CN-3 I/conn(Main harness-Engine harness) 368047-1 368050-1 CN-4 I/conn(Main harness-Engine harness) 2-85262-1 368301-1 CN-5 I/conn(Main harness-Engine harness)
Page 388 Connector part No. Connector No. of Type Destination number Female Male CN-71 DEUTSCH Parking sol DT06-2S CN-74 PACKARD Alternator 12186568 CN-92 DEUTSCH ECU connector(A) HD36-24-23SN S813-130200 CN-93 DEUTSCH ECU connector(B) DRC26-50S-05 DT06-3P-EP10 CN-95 Fusible link 21N4-01310 CN-98 DEUTSCH I/conn DT06-3S-EP06 CN-102 Sumitomo Wiper-rear...
Page 389 Connector part No. Connector No. of Type Destination number Female Male DEUTSCH CL-6 Mast lamp LH DT04-2P CL-7 Beacon lamp S822-014000 S822-114000 CL-15 Rear combi LH S814-006100 CL-16 Rear combi RH S814-006100 CL-21 License lamp S822-014000 S822-114000 DEUTSCH CL-22 R/work RH DT04-2P CL-23 R/work LH...
Page 390 2. CONNECTION TABLE FOR CONNECTORS 58-L TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S813-030100 S813-130100 S813-030200 S813-130200 7-38...
Page 391 PA TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 S811-109002 S811-011002 S811-111002 7-39...
Page 392 No. of Receptacle connector(Female) Plug connector(Male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 7-40...
Page 393 J TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S816-002001 S816-102001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 7-41...
Page 394 SWP TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S814-001000 S814-101000 S814-002000 S814-102000 S814-003000 S814-103000 S814-004000 S814-104000 7-42...
Page 395 No. of Receptacle connector(Female) Plug connector(Male) S814-106000 S814-006000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 7-43...
Page 396 CN TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S810-001202 S810-101202 S810-002202 S810-102202 S810-003202 S810-103202 S810-004202 S810-104202 7-44...
Page 397 No. of Receptacle connector(Female) Plug connector(Male) S810-006202 S810-106202 S810-008202 S810-108202 7-45...
Page 398 ITT SWF CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) SWF593757 HW090 SEALED CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 6189-0133 MWP02F-B CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) PH805-02028 7-46...
Page 399 AMP ECONOSEAL CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 344111-1 344108-1 344111-1 344108-1 AMP TIMER CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 85202-1 AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 174045-2 7-47...
Page 400 KET 090 WP CONNECTORS No. of Receptacle connector(Female) Plug connector(Male) MG640795 ITT SWF CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) SWF593757 MWP NMWP CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) NMWP01F-B 7-48...
Page 401 DEUTSCH DT CONNECTORS DT 06 - 3S - Modifications(See below) Number of contacts(P : Pin, S : Socket) 04 : Receptacle, 06 : Plug Deutsch connectors Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
Page 402 No. of Receptacle connector(Female) Plug connector(Male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 7-50...
Page 403 GROUP 8 TROUBLESHOOTING Trouble symptom robable cause Remedy Lamps dimming even at maxi- Faulty wiring. Check for loose terminal and discon- mum engine speed. nected wire. Lamps flicker during engine Improper belt tension. Adjust belt tension. operation. Charge lamp does not light Charge lamp defective.
Page 404 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 405 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) Lift cylinder Lift cylinder Frame Carriage 100D7MS01 Outer mast Lift chain Chain sheave bearing Roller bearing Anchor bolt 10 Anchor bolt Tilt cylinder pin Side roller bearing 11 Roller bearing Mast mounting pin Inner mast 12 Side roller bearing...
Page 406 2. 3 STAGE MAST(MAST) Middle master Outer master Inner master Tilt cylinder Lift cylinder Lift cylinder Free Lift cylinder D507MS011 Outer mast Mast mounting pin 11 Chain Shim Wear plug 12 Sheave bracket Roller bearing Middle mast 13 Inner mast Side roller bearing Sheave Tilt cylinder pin...
Page 407 3. CARRIAGE, BACKREST AND FORK(SHAFT TYPE) Shaft type fork Extension fork 100D7MS02 Carriage & backrest Side roller Hanger bar Fork Fork retaining Extension fork Roller...
Page 408 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. EX : =1200mm(47in) mm(in) STD Fork assy Applicable model Standard Limit Thickness 61FT-70322 100D/120D-7 75(3.0) 68(2.7) 61FT-70122 135D/160D-7...
Page 409 2. TROUBLESHOOTING MAST Problem ause Remedy Forks fail to lower. Deformed mast or carriage. Disassemble, repair or replace. Fork fails to elevate. Faulty hydraulic equipment. See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. Deformed mast assembly. Disassemble mast and replace damaged parts or replace complete mast assembly.
Page 410 FORKS Problem ause Remedy 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. Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...
Page 411 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm(19in). 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 following value by adjust bolt.
Page 412 CARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100mm from the top of the inner mast. 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...
Page 413 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS(SHAFT TYPE) Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Release fork anchor pins and slide one fork Fork retainer at a time toward the center of the carriage Hanger bar where a notch has been cut in the bottom Cover...
Page 414 Pull the chains out of the sheaves and Inner mast drape them over the front of the carriage. Disconnect connector from the work lamp Outer mast assy. Work lamp assy Lift chain Block 100D7RE96 Slowly raise inner mast upright until mast clears top of fork carriage.
Page 415 SIDE ROLLER Remove carriage as outlined in the Side roller carriage removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side plate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assem- bly.
Page 416 4. MAST LOAD ROLLER 2 STAGE MAST(V MAST) Remove the carriage assembly and move them to one side. Loosen and remove hexagon nuts and screws securing lift cylinders to inner mast. Chain Loosen and remove hexagon bolts and nuts securing lift cylinders to outer mast. Hexagon nut Attach chains or sling to the inner mast section at top crossmember.
Page 417 3 STAGE MAST(TF MAST) Remove the carriage assembly and move Lift chain it to one side. Loosen and remove hexagon bolt secur- ing bottom cylinder from outer mast. Loosen and remove set screws and nuts securing lift cylinders to middle mast. Inner Attach chains or sling to the inner and mast...
Page 418 5. CHAIN CHAIN SHEAVE Place a sling around carriage and attach to an overhead hoist. Lift carriage high Chain enough so that the tension on the chain over sheaves is relieved after the carriage Sheave is blocked. Position wooden blocks under the carriage and lower it.
Page 419 SHEAVE SUPPORT(TF MAST) A, B Remove the carriage assembly and move to one side. Sheave Sheave support After removing bolt to securing sheave support assembly to free lift cylinder. Attach a sling to the sheave support Middle mast assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
Page 420 CARRIAGE CHAIN Place a sling around carriage front plate Inner mast and attach to an overhead hoist. Lift and secure carriage high enough so that split Outer mast and chain anchor pins on carriage can be Work lamp assy easily be removed. Remove chain anchor pins from carriage and drape chains out over carriage.
Page 421 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.
Page 422 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.
Page 423 Adjustment Chain adjustments are important for the following reasons : Equal loading of chain. Proper sequencing of mast. Prevent over-stretching of chains. Prevent chains from jumping off sheaves if they are too loose. djustment procedure With mast in its fully collapsed and vertical position, lower the fork to the floor. Adjust the chain length by loosening or tightening nut on the chain anchor.

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Hyundai 100D-7 Operating Manual

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