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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-53

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-65

Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-147

SECTION 4 BRAKE SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-24

Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32

Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-28

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-33

SECTION 7 ELECTRICAL SYSTEM

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

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

Group 3 Cluster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-14

Group 4 Transmission message indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27

Group 5 Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31

CONTENTS

Summary of Contents for Hyundai 110DF-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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Group 7 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43 Group 8 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60 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(①②③…) 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 1ℓ = 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...
Page 8 kgf·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 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15...
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 110DEOM54 Mast Tilt cylinder 13 Bonnet Lift chain Cabin 14 Counterweight Lift cylinder Head light-fender 15 Rear wheel Fork positioner cylinder 10 Work lamp-mast 16 Front wheel Carriage 11 Work lamp-cabin rear 17 Rear combination lamp Forks 12 Operator's seat...
Page 17 2. SPECIFICATIONS C' C 160DF7SP011 Model Unit 110DF-7 130DF-7 160DF-7 Capacity kg(lb) 11,000(25000) 13,000(29000) 16,000(36000) Load center ← ← mm(in) 600(24") Weight(Unloaded) kg(lb) 16454(36270) 17592(38780) 19765(43570) ← ← Lifting height mm(ft-in) 3000(9' 10") ← ← Free lift mm(in) Lifting speed(Unload/Load)
Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS 110/130DF-7 ENGINE Item Specification Unit Model HMC D6GA Type 4 cycle turbocharged, Intercooler 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) 103 118mm(4.06"...
Page 19 STEERING 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 2.066 : 1 Type Full auto, power shift...
Page 20 160DF-7 ENGINE Item Specification Unit Model HMC D6GA 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 103 118mm(4.06" 4.65") cc(cu in) Piston displacement 5899(360)
Page 21 STEERING UNIT Item Unit Specification Type Load sensing/Non load reaction/Dynamic signal Capacity cc/rev Rated flow 45.4 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 2.066 : 1 Type Full auto, Power shift Gear shift(FR/RR)
Page 22 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Items Size kgf·m lbf·ft Engine mounting bolt, nut M24×3.0 100±15 723±109 Engine Radiator mounting bolt, nut M12×1.75 12.8±3.0 92±21.7 Hydraulic pump mounting bolt M12×1.75 9.0±0.5 65.1±3.6 Hydraulic MCV mounting bolt, nut M10×1.5 6.9±1.4 49.9±10.1 system Steering unit mounting bolt M10×1.5...
Page 23 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 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1...
Page 24 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 PIPE AND HOSE(ORFS TYPE) Width across flat mm kgf m lbf ft Thread size(PF) 28.9 9/16-18 36.2...
Page 25 6. RECOMMENDED LUBRICANTS 。 C (。 F) Capacityℓ(U.S.gal) Ambient temperature Service Kind of 110DF-7 point fluid 160DF-7 130DF-7 (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil 24.5 24.5 Engine oil (6.5) (6.5) SAE 10W-30 SAE 15W-40...
Page 26 GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET Owner Date Hours Serial No. Technician Use 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 Battery check Monitor indicator circuit check Monitor turn signals and warning indicator check...
Page 27 4. Brake system and clutch cut off checks Park brake capacity check Park brake transmission lockout check Service brake pump flow check Service brake capacity check Brake accumulator precharge check Brake system leakage check Service brake pedal check Service and park brake system drag check Clutch cut off check 5.
Page 28 7. Steering system checks Steering valve check Steering system leakage check Priority valve(built in MCV) Low check pressure High check pressure 8. Accessory checks Operating lights check Work light check Brake light check Cab light check Horn circuit check Windshield washer and wiper check Heater/Air conditioner blower check Heater functional check Air conditioner functional check...
Page 29 SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
Page 30 GROUP 1 STRUCTURE 110DEOM21 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 31 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL FORKS Lower the fork carriage until the forks are Cover Carriage approximately 25mm(1in) from the floor. Release fork retainer and remove cover. Slide one hanger bar at a time out of carriage assembly.
Page 32 Pull the chains out of the sheaves and Inner mast drape them over the front of the carriage. Outer mast Work lamp assy Lift chain Block 110D7ERE55 Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage to work area and lower the mast.
Page 33 PIPING Remove the hoses and clamps attached to the cylinder. Put blind plugs in the piping immediately after removing hoses. This prevents the hydraulic oil from Inner mast flowing out and also prevents dust and dirt from getting in. LIft cylinder 110D7ERE57 Remove the lubrication pipes and...
Page 34 LIFT CYLINDER 110/130DF-7 160DF-7 Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast. Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no slack or binding. Inner mast Make sure the lift cylinder be tightened firmly for safety.
Page 35 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 36 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 37 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 38 Brake piping Brake hose Brake hose Disconnect the brake hydraulic pipes from the brake housing of drive axle assy. Drive axle 110DERE05 Drive axle Before removing the drive axle assy, drain all of the oil from the axle. Jack up the machine and then put the block under the frame.
Page 39 Transmission and axle cooling piping Radiator assembly Disconnect cooling hose and connector from the transmission. Transmission Make sure that the coolant has been assembly Cooling hose drained from the line. 110DERE10 Disconnect axle cooling hose and Radiator assy Axle connector from the axle. cooling oil tank Make sure that the axle cooling oil has...
Page 40 Using a moving truck slowly pull out transmission assembly to the front. Block Transmission Truck 110DERE13 2-11...
Page 41 INSTALLATION Installation is the reverse order to removal, Bolt but be careful of the following points. Engine Tightening torque of mounting bolts flywheel housing. 5.5~8.3kgf m (39.8~60.0lbf ft) Socket bolt Tightening torque of mounting socket Transmission bolts for torque converter. 3.9~5.1kgf m (28.2~36.9lbf ft) 110DERE12 Tightening torque of mounting bolts...
Page 42 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 hood...
Page 43 Engine cover(center) Radiator cover Pull upside the precleaner by loosening Precleaner the clamp and seal in the air intake hole Clamp of air cleaner. Remove engine cover and radiator cover upward. Engine cover 110DERE18 Torque converter housing cover and mounting bolts. See page 2-12. Cover Transmission Engine...
Page 44 Engine mounting bracket Attach a crane to the engine hook and Bolt raise, then remove mounting bolts. Raise 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 110DERE33...
Page 45 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) Mode Counter weight (1) Counter weight (2) 110DF-7 2750kg(6010lb) 1390kg(3065lb) 130DF-7 3505kg(7730lb) 1390kg(3065lb)
Page 46 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 47 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Operation and maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-53 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-65 Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-147...
Page 48 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN COMPONENT OVERVIEW Drive axle Transmission Steering axle Propeller shaft Torque converter Engine 160DF7PT01 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.
Page 49 Hydraulic 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 Bypass valve 11+2 bar 5.5 bar Pump 16+2 bar Main oil circuit Oil sump Lubrication D507PT31 Positions...
Page 50 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 51 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 52 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 53 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 54 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 55 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 56 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 57 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 58 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 59 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 60 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 61 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 62 Display 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 63 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 64 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to battery voltage at load sensor Retarder function is affected Check the cable from TCU to the TCU uses default load sensor input OP mode : Normal...
Page 65 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to ground at retarder temperature No reaction, TCU uses default Check the cable from TCU to the temperature sensor sensor input 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 Logical error at engine speed input OP mode : Substitute clutch Check the cable from TCU to the control TCU measures a engine speed over a sensor threshold and the next moment the...
Page 67 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Logical error at internal speed input OP mode : Substitute clutch Check the cable from TCU to the control TCU measures a internal speed over a sensor threshold and at 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 S.C. to battery voltage at clutch K1 TCU shifts to neutral Check the cable from TCU to the OP mode : Limp home gearbox The measured resistance value of the valve If failure at another clutch is...
Page 69 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to battery voltage at clutch K3 TCU shifts to neutral 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 70 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection O.C. at engine derating device No reaction Check the cable from TCU to the 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 71 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to ground at clutch KR TCU shifts to neutral 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 72 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection O.C. at relay reverse warning alarm No reaction Check the cable from TCU to the OP mode : Normal backup alarm device TCU detected a wrong voltage at the Check the connectors from...
Page 73 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to ground at park brake solenoid No reaction 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 74 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to battery voltage at converter lock No reaction Check the cable from TCU to the OP mode : Normal up clutch solenoid converter clutch solenoid TCU detected a wrong voltage at the...
Page 75 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to ground at difflock or axle No reaction Check the cable from TCU to the OP mode : Normal connection solenoid difflock 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 Slippage at clutch K1 TCU shifts to neutral Check pressure 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 77 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Slippage at clutch KV TCU shifts to neutral 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 78 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 79 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Overtemp converter output No reaction Cool down machine OP mode : Normal Check oil level TCU measured a oil temperature at the Check temperature sensor converter output that is the allowed threshold...
Page 80 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to battery voltage at power supply See fault codes No.21 to 2C Check cables and connectors to sensors, which are supplied from for sensors TCU measures more than 6V at the pin Check the power supply at the pin...
Page 81 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. battery voltage at speedometer Not used output Not used S.C. to ground or O.C at speedometer output Check the cable from TCU to the S.C.
Page 82 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection General EEPROM fault No reaction Replace TCU OP mode : Normal Often shown together with fault TCU can't read non volatile memory code F2 TCU is defective Configuration lost...
Page 83 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 84 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 85 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 86 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 87 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS The measurement have to be carried out with hot transmission(about 80~95 C) D50TM04 3-40...
Page 88 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 89 5. DRIVE AXLE STRUCTURE 1 21-1 21-2 110DEDR02 Taper roller bearing 15 Oil seal 29 Hexagon bolt Spacer 16 Differential flange 30 Differential case-RH Taper roller bearing 17 Hexagon bolt 31 Differential case-LH Bevel gear assy 18 Spring washer 32 Side gear Ring gear 19 Hexagon bolt 33 Thrust washer...
Page 90 STRUCTURE 2 38 39 110DEDR03 Brake disc 14 Snap ring 27 Sun gear Brake plate 15 O-ring 28 Snap ring 16 Taper roller bearing 29 Stopper Brake cover Wheel hub 30 Snap ring Magnetic plug 18 O-ring 31 Thrust washer O-ring 19 C-ring 32 Needle bearing...
Page 91 STRUCTURE 3 27 28 10 11 16 17 110DEDR04 Dowel pin 11 O-ring 22 Adjust bolt Axle housing 12 Spacer 23 Piston Gasket 13 O-ring 24 Quad ring Air breather 15 Axle tube 25 Quad ring Plug 16 Magnetic plug 26 Bushing O-ring 17 O-ring...
Page 92 SYSTEM OPERATION General specification 110DEDA01 Differential Service brake Drive shaft Parking brake Drive wheel OPERATION The drive axle is composed of differential carrier assy (1), drive shaft (2), and drive wheel (3). The power is transmitted from the engine fly wheel to the transmission. The power of transmission is transmitted to the spiral bevel gear through the output gear of the transmission.
Page 93 Powertrain specification Classify 110/130DF-7 160DF-7 Reduction Drive shaft Differential 2.93(41/11) 3.73(41/11) gear ratio Plenatary gear 3.60(52/20) 10.548 13.428 Axle oil Differential Cooling oil Differential Cooling oil SAE 80W/90 Mobil 424 SAE 80W/90 Mobil 424 Oil capacity Circulating type Circulating type Brake Service brake Wet disc brake...
Page 94 DIFFERENTIAL 110DEDA02 Differential pinion gear inner diameter 27.110 ~ 27.131 Spider out diameter 26.980 ~ 26.959 Pinion gear washer thickness 1.52 ~ 1.68mm Side gear washer thickness 2.94 ~ 3.06mm Side gear (Inner diameter) 50.00 ~ 50.04 OPERATION Differential transmits the power from the transmission to drive wheel. When the vehicle is running one side wheel rotates slower than the other side wheel.
Page 95 DRIVE SHAFT General standards 110DEDA03 Sun gear Hub assembly 11 Pinion shaft Plenatary gear Disc brake 12 Spider Internal gear Drive shaft 13 Pinion gear Internal gear carrier Differential carrier 14 Side gear Taper roller bearing 10 Ring gear OPERATION Drive axle which consists of differential carrier assembly (9), drive shaft (8) and hub assembly (6) transmits the drive force from transmission to the wheels.
Page 96 Driving axle tightening torque specifications 110DEDA04 Wheel hub pre-load 330~400kg cm Plenatary housing tightening torque 250~400kg cm Spline hub tightening torque 3200 50kg cm Brake cover tightening torque 2100 50kg cm Self-adjust bolt tightening torque 300~350kg cm Axle tube tightening torque 3200 50kg cm Diff carrier cap tightening torque 5500 100kg cm...
Page 97 Disc brake (110/130DF-7) 110DEDA05 Collar spline hub Brake housing Self adjust bolt Wheel hub Service brake piston Drive shaft Disc brake Brake plate Brake cover 10 Parking brake OPERATION Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the high humid or dusty area.
Page 98 Disc brake (160DF-7) 110DEDA06 Collar spline hub Brake housing Self adjust bolt Wheel hub Service brake piston Drive shaft Disc brake Brake plate Brake cover 10 Parking brake OPERATION Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the high humid or dusty area.
Page 99 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 100 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 101 - 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 102 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 103 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 104 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 105 D507PT19 Legend: 1 = Oil filter tube with oil dipstick 2 = Oil drain plug M38 1.5 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 106 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 107 Lubrication points 1 2 , 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 110DEXL03 1 : Oil fill plug 2 : Oil level check plug 3 : Oil drain plug 3-60...
Page 108 3. TROUBLESHOOTING BRAKE LEAKS ACTUATION FLUID Condition Possible 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 109 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 110 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 111 DIFFERENTIAL Condition Possible causes Correction Constant noise in differential. Oil is not enough(Replace Refueling lubricating oil interval : 50 hrs first, then every 500hrs ). Wrong kind of oil. Exchange lubricating oil Wheel bearings Exchange bearing adjustment or have a defect. Drive gear and pinion not in Re-assemble adjustment for correct tooth...
Page 112 Condition Possible causes Correction Drive wheels do not rotate Broken axle shaft. Loose wheel bearings. Re-assemble wheel bearings. Axle shaft too short. Replace drive shaft Loose flange studs or nuts. Tighten studs or nuts Drive gear teeth have been Exchange damaged drive gear damaged.
Page 113 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 114 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 115 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 116 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 117 Remove the single parts on the opposite side analogously: 1 = Main pressure valve 2 = Vibration damper 3 = Follow-on slide D507TM26 Inductive transmitters, valves, oil filter and oil drain plug, screw plugs Mount the transmission to the assembly truck.
Page 118 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 Engine connection, pressure oil pump and removal of the clutches Mount the transmission to the assembly truck.
Page 119 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 120 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 121 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 122 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 123 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 124 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 125 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 126 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 3-78...
Page 127 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 128 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 129 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 3-81...
Page 130 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 131 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 3-83...
Page 132 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 133 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 134 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 135 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 136 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 137 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 138 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 C). (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 Wear safety gloves.
Page 139 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 140 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 C). (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 141 Install the piston ring(1). D507TM124 Install the stud(1). Tightening torque - - - - - - - - - - - - - - M =1.7kg m Check closing respective opening of the clutch by means of compressed air at the bore(2).
Page 142 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 C). (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 143 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 144 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 m Check closing respective opening of the clutch by means of compressed air at the bore(2).
Page 145 Install the piston ring(1). D507TM140 Heat up the inner diameter of the clutch(1)(approx. 120 C). (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 146 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 147 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 m Check closing respective opening of the clutch by means of compressed air the bore(2).
Page 148 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 C). (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 149 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 150 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 151 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 152 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 153 Fasten the screen sheet(1) by means of cap screws(2). Tightening torque(M8/8.8) - - - M =2.3kg m 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...
Page 154 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 155 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 156 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 157 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 158 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 159 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 160 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 161 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 162 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 163 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 164 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 165 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 166 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 m D507TM224 Assemble the wiring harness(1) and...
Page 167 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 168 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 169 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 m (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 170 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. 3-122...
Page 171 REMOVAL AND DISASSEMBLE THE WHEEL HUB Loosen the drain plug of the axle housing by using a torque wrench, and drain the oil. 110DEDA10 Loosen the drain plug of planetary housing, then drain the oil. 110DEDA11 Loosen the four bolts (1) and disassemble the planetary housing.
Page 172 Disassemble four planetary pin (3) using the tool. 110DEDA14 Disassemble planetary gear (4), needle bearing (5) and thrust washers (6). 110DEDA15 Disassemble drive shaft assembly (8) with sun gear (7). 110DEDA16 Disassemble retaining ring (9) by using tool and disassemble sun gear (10) from drive shaft (8).
Page 173 Loosen the bolts (11) and nut (12). (11) (13) Disassemble the internal gear carrier (12) assembly (13) from spindle (A). Mark the installation position of the nut (12) and the internal gear carrier before disassembling. Check for position during assembly. 110DEDA18 (10) Disassemble the gear (15) from ring gear...
Page 174 (12) Slowly disassemble the wheel hub assy and the internal gear carrier by using the extraction tab of the brake housing as loosen the nut. A strong shock may be damaged the oil seal. 110DEDA22 110DEDA23 110DEDA24 (13) Disassemble bearing of the carrier internal gear using two M8 bolts.
Page 175 (14) Disassemble disk (17) and plate (18) and (18) then disassemble six brake pin (19) from the disassembled wheel hub assembly. Disassemble the brake cover (20) and wheel hub assembly (21). (19) (17) 110DEDA26 (20) (21) 110DEDA27 (15) Disassemble hub spline (23) and wheel hub (24) (24) after untightening tweenty bolts (25).
Page 176 (16) Disassemble bearing (26) and O-ring (27) (26) from wheel hub. (27) 110DEDA30 (17) Disassemble brake housing assembly (28), (28) (30), (31) axle tube (29), after untightening tweenty bolts that connect axle housing (30) and tweenty washers (31). Detach O-ring (32) on both joints sides of tube after disassemble brake housing and tube.
Page 177 (33) (34, 35) 110DEDA34 REMOVAL AND DISASSEMBLE THE CARRIER HOUSING ASSY Disassemble parking disc (3) and brake assembly (4) after untightening six bolts (1) and four bolts (2). 110DEDA35 Loosen thirteen bolts (5) that connect the axle housing and the carrier housing and then disassemble the carrier from the axle housing.
Page 178 Check and record the rotational torque measurements of the carrier assy and then disassemble cotter pin (6). Disassemble two nuts (8) and two differential caps (9), after untightening four bolts (7). Check and record the direction of the cap before removing bearing cup. 110DEDA38 110DEDA39 Disassembly ring gear assy (10) from carrier...
Page 179 Loosen sixteen bolt (13) then disassemble differential assembly. (13) 110DEDA42 Disassemble side gear (14), pinion gear (15), thrust washers (16), (17) and spider (18) from (18) differential assembly. (14) (16) (15) (17) 110DEDA43 Disassemble differential flange assembly (21) and shim (22) from carrier housing after loosen snap ring (19) and ten bolts (20).
Page 180 (22) 110DEDA46 Loosen nut (23) and disassemble the york (24) from differential flange assembly. (23) (24) 110DEDA47 (10) Disassemble the pinion shaft (25) from the differential flange (29) by using tools. Be careful imprints on the pinion shaft and oil seal damage. 110DEDA48 3-132...
Page 181 (25) 110DEDA49 (11) Disassemble shim (26) and spacer (27) from (29) pinion shaft (25). Disassemble both of tapered roller bearings (28) from the pinion shaft by using a bearing puller. Do not reuse shim. 110DEDA50 (25) (28) (27) (26) 110DEDA51 3-133...
Page 182 4. REASSEMBLY OF THE DRIVE AXLE Clean every parts with cleaner and then remove remained loctite. Be careful not to spill cleaner on your body. Avoid drinking cleaner or breathing its fumes. Wear protective clothing, glasses and gloves. If spilled on the skin, flush your skin with water immediately. If swallowed, get medical attention immediately.
Page 183 How to adjust the shim between differential carrier and the differential flange Measurements(A) Measurements(B) Pinion Shaft PMD Value Defeat vaule Taper Roller Bearing depth variation Carrier depth variation Shim thickness Flange depth variation 110DEDA53 If gear is damaged, replace a set of the bevel gear shaft and bevel gear. Do not reuse deformed shim or damaged bearing.
Page 184 ASSEMBLY THE PINION SHAFT Inner ring of bearings should be heated up to 100 C by a preheater. Assemble the bevel pinion shaft and set the preload with the ring and the shim. 110DEDA54 110DEDA55 110DEDA56 3-136...
Page 185 Adjust the shim thickness by combinations of the different shims. Add the shims between the differential flange and differential carrier. Apply loctite on them and assemble the differential flange and differential carrier. The bolt tighten torque, see below. Short bolts (4ea) : 10.0~10.5kgf m Long bolts (6ea) : 12.0~12.5kgf m 110DEDA57 110DEDA58...
Page 186 ASSEMBLE THE DIFFERENTIAL ASSY Assemble the thrust washer, side gear and spider with gears and then install them to the differential housing. Assemble the differential housing. Check marks on the differential assembly and housing. Match to marks at the same positions. 110DEDA59 Tighten 12 bolts to the differential housing.
Page 187 Assemble the bearing cap. Fix the bearing cap with hex bolt. Tightening torque : 50.0~65.0kgf cm Measure the rolling resistance of the taper roller bearing. The following table shows the relation between the preload of the bevel pinion shaft(measured at the adjustment, page 3-130) and the rolling resistance.
Page 188 ASSEMBLE CARRIER TO AXLE HOUSING Assemble the carrier assy into axle housing. Fix the carrier assy to axle housing with the hex bolt. Tightening torque : 28.0~32.0kgf cm. 110DEDA64 Assemble brake disc to yoke (1) with hex bolt. Apply loctite #271 or #277 on the thread of the bolt and tighten them.
Page 189 110DEDA68 Assemble the oil seal into the brake cover. 110DEDA69 Assemble the internal gear carrier into the ring gear and fit the C-ring. Heat the bearing and assemble it into the carrier. Cool down the bearing sufficiently and then assemble them into wheel hub. 110DEDA70 110DEDA71 3-141...
Page 190 Assemble the preassembled wheel hub and spline collar with the brake cover assy. Assemble the disc, plate and 6 brake pins and apply loctite #5217 on the assemble surface. Disc 4 piece 110/130DF-7 Plate 7 piece Disc 5 piece 160DF-7 Plate 6 piece 110DEDA72...
Page 191 Fit the square ring (large, 36), square ring (36) (36, 37) (small, 38), backup ring (large, 37) and (38, 39) backup ring (small, 39) into the brake housing and apply oil (MOBIL #424) on them. Assemble the bushing (35) into the piston (36) and assemble the piston into brake housing.
Page 192 Mount the axle tube into the axle housing and assemble the brake housing to axle housing. Tighten the 20 bolts. Tightening torque : 31.5~32.5kgf cm Be careful not to damage the O-ring of the axle tube when assembling the brake housing.
Page 193 110DEDA82 Place the wheel hub to the axle tube until seated completely and tighten the nut. Tighten the nut to the marks that marked when disassembling. 110DEDA83 (10) Apply loctite #271 or #277 on the bolts and tighten them. Tightening torque : 1.8~2.0kgf cm Assemble the ring gear and fix it with the C-ring.
Page 194 (12) Assemble the internal components of the planetary carrier with the reverse order of disassembling. 110DEDA86 110DEDA87 (13) Assemble the planetary carrier assy to the wheel hub. Tighten the bolts. Tightening torque : 2.5~4.0kgf cm 110DEDA88 (14) Assemble the wheel hub and tighten the plug (1).
Page 195 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 196 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 197 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 198 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 199 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 200 SECTION 4 BRAKE SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-24 Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35...
Page 201 SECTION 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 202 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 203 2. HYDRAULIC CIRCUIT FRONT AXLE 5bar 120bar Steering unit 170bar 95bar 125bar~ TILT LIFT 150bar 95bar 10bar DOWN BWD FWD b1 a2 b2 a3 b3 a4 35bar~ 50bar 70bar HYD. COOLER 22 bar 29 bar 280bar 300bar 20cc/rev 74cc/rev 160bar 63cc/rev L5 L4 L3 8.3cc/rev...
Page 204 SERVICE BRAKE RELEASED FRONT AXLE 5bar 120bar Steering unit 170bar 95bar 125bar~ TILT LIFT 150bar 95bar 10bar DOWN BWD FWD b1 a2 b2 a3 b3 a4 35bar~ 50bar 70bar HYD. COOLER 22 bar 29 bar 280bar 300bar 20cc/rev 74cc/rev 160bar 63cc/rev L5 L4 L3 8.3cc/rev...
Page 205 SERVICE BRAKE OPERATED FRONT AXLE 5bar 120bar Steering unit 170bar 95bar 125bar~ TILT LIFT 150bar 95bar 10bar DOWN BWD FWD b1 a2 b2 a3 b3 a4 35bar~ 50bar 70bar HYD. COOLER 22 bar 29 bar 280bar 300bar 20cc/rev 74cc/rev 160bar 63cc/rev L5 L4 L3 8.3cc/rev...
Page 206 PARKING BRAKE RELEASED FRONT AXLE 5bar 120bar Steering unit 170bar Parking brake switch 95bar 125bar~ TILT LIFT 150bar 95bar Parking brake solenoid valve 10bar DOWN BWD FWD b1 a2 b2 a3 b3 a4 35bar~ 50bar 70bar HYD. COOLER 22 bar 29 bar 280bar 300bar...
Page 207 PARKING BRAKE OPERATED FRONT AXLE 5bar 120bar Steering unit 170bar Parking brake switch 95bar 125bar~ TILT LIFT 150bar 95bar Parking brake solenoid valve 10bar DOWN BWD FWD b1 a2 b2 a3 b3 a4 35bar~ 50bar 70bar HYD. COOLER 22 bar 29 bar 280bar 300bar...
Page 208 3. AUXILIARY PUMP (BRAKE) STRUCTURE 180D7EBS06 Shaft gear Bush block 11 Snap ring Driven gear Bush 12 O-ring Front cover Seal 13 Bolt Gear housing Back up seal 14 Spring washer Rear cover 10 Retainer seal This gear pump have a maximum delivery pressure of 170kgf/cm The pressure loaded type gear pump is designed so that the clearance between the gear and the bushing can be automatically adjusted according to the delivery pressure.
Page 209 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 210 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 211 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 212 4. BRAKE VALVE STRUCTURE 13-1 13-2 13-5 13-4 13-3 110D7EBS07 Body 11 Du bushing 17 Torsion spring Spool 12 Pedal plate 18 Snap ring Plug 13 Pedal assembly 19 Hexagon bolt Holder(piston) 13-1 Pedal 20 Hexagon nut Lower spring 13-2 Rubber 23 Plain washer Main spring 13-3 Lock plate...
Page 213 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 110D7EBS08 4-13...
Page 214 Purpose The purpose of the brake valve is to sensitively increase and decrease the braking pressure when the brake pedal is actuated. Ready position A connection is established between ports(BR) and ports(T) so that the wheel brakes ports(BR) are pressureless via the returns ports(T). Partial braking When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot force applied.
Page 215 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 216 5. CUT-OFF VALVE STRUCTURE Hydraulic circuit 110D7EBS35 Manifold Check valve Solenoid valve Cut-off valve Coil Relief 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. As the pressure on P line rises to 150bar, the cut off valve(1) starts cut-offing and the oil in the P port is unloaded.
Page 217 6. 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 218 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 219 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 220 7. PRESSURE SWITCHES STRUCTURE - Normally closed - Normally open 7407ABS20 Technical data Adjusting range Adjusting pressure Voltage Item Type Medium kgf/cm kgf/cm Parking M12 1.5 50 ~ 150 Max 42 Charging M12 1.5 50 ~ 150 Max 42 Brake stop M12 1.5 1~10 Max 42...
Page 221 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 222 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 223 8. PARKING BRAKE 100D7BS109 Brake Brake disk Brake carrier Hexagon screw O-ring Hexagon screw 4-23...
Page 224 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 225 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 226 Item Description Service action Service brake pump flow Stop engine. check Check completed. Operate brake pedal approximately 20 Hydraulic oil must be at NOT OK times. operating temperature Start engine and run at low idle. Check for brake circuit for the check. leakage.
Page 227 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 228 Item Description Service action Service brake pedal Slowly depress brake pedal. check Check completed. Listen for a hissing noise that NOT OK indicates oil is flowing to brake pistons. Inspect for debris under brake pedal. Inspect LISTEN/FEEL : A hissing noise clutch cut-off linkage.
Page 229 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 230 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 231 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 232 GROUP 3 TESTS AND ADJUSTMENTS 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 Item Standard value 11 20' Parking brake Keep machine on 20 performance (11 20') gradient 110D7EBS33...
Page 233 Turn the adjusting screw anticlockwise in order to set the following rated clearances. Model Adjusting screw Clearance(mm) Turns Min. 110DF-7 130DF-7 M16(SW 8) Clearance 160DF-7 Max. Hold the adjusting screw in position with a hexagonal socket wrench and lock with lock nut.
Page 234 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 Breather vent applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high Air breather pressure fluids.
Page 235 GROUP 4 DISASSEMBLY AND ASSEMBLY 1. AUXILIARY PUMP (BRAKE) STRUCTURE 180D7EBP00 Housing Front cover Bush block Retainer seal Backup seal 10 Snap ring Channel seal 11 Rear cover Shaft gear 12 Washer Driven gear 13 Bolt O-ring 4-35...
Page 236 GENERAL INSTRUCTION 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. Components should fit into their housings without excessive force. If force is necessary, this normally means that the component does not have the correct dimensional tolerances of is aligned incorrectly.
Page 237 After removing the snap ring (10), take out the shaft gear (5) and the drive gear (6) from the housing (1). For the gear face of the shaft gear (5) and the driven gear (6), inspect for excessive wear, scoring or crack. 180D7EBP51 Remove bush block (2), back up seal (3), channel seal (4) and O-ring (7) from the...
Page 238 2. BRAKE VALVE STRUCTURE 13-1 13-2 13-5 13-4 13-3 110D7EBS07 Body 11 Du bushing 17 Torsion spring Spool 12 Pedal plate 18 Snap ring Plug 13 Pedal assembly 19 Hexagon bolt Holder(piston) 13-1 Pedal 20 Hexagon nut Lower spring 13-2 Rubber 23 Plain washer Main spring 13-3 Lock plate...
Page 239 REASSEMBLY 9 23 24 Body assembly 1 Body 2 Spool 3 Plug 4 Holder 5 Spring 6 Main spring 7 Spring retainer 9 Oil seal 110D7EBS50 DU bushing Rubber cover Plain washer Stop ring Install oil seal(9), plain washer(23), stop ring(24), DU bushing(11).
Page 240 Tighten plug(3) - Tool : 19mm spanner - Tightening torque : 14.0~16.5kgf m Press-in the DU bushing(11) with a exclusive jig. Be careful of dust and scrap after washing the parts. 110D7EBS53 Spring retainer(7), main spring(6) and holder(4). 110D7EBS54 Holder(4) Body(1) 110D7EBS55 Rubber cover(15) 110D7EBS56...
Page 241 Pedal plate assembly 13-2 13-1 Pedal plate 13-1 Pedal 13-2 Pedal cover 13-3 13-3 Lock plate Lock pin(pedal) Torsion spring Stop ring Hexagon bolt 110D7EBS57 Pedal plate(12) assembly - Tool : 6mm torque wrench - Tightening torque : 2.5~3.0kgf m 110D7EBS58 Pre-assemble pedal assembly(13-1, 13- 3) and torsion spring(17) on the pedal...
Page 242 Rubber cover(13-2) 13-2 110D7EBS61 100D7BS20 Hexagon bolt(19) - Tool : 13mm spanner - Tightening torque : 2.0kgf m 110D7EBS62 Never remove the hexagon bolt. (Pressure setting valve deviation occurs) 4-42...
Page 243 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 244 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Main pump Steering cylinder Main control valve Steering wheel Steering unit " V " 110DESS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and piping.
Page 245 2. HYDRAULIC CIRCUIT STEERING CYLINDER Tilt cylinder Lift cylinder 230bar 165bar Brake system 22 bar 29 bar 280bar 300bar 185bar 166bar 20cc/rev 74cc/rev 63cc/rev L5 L4 L3 110DESS02 Main pump Suction strainer Steering unit 11 Auxiliary pump Main control valve 23 Check valve Return filter 34 Hydraulic tank...
Page 246 NEUTRAL STEERING CYLINDER Tilt cylinder Lift cylinder 230bar 165bar Brake system 22 bar 29 bar 280bar 300bar 185bar 166bar 20cc/rev 74cc/rev 63cc/rev L5 L4 L3 Spool(D) 110DESS03 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(3) and the inlet pressure oil moves the spool(D) to the left.
Page 247 LEFT TURN STEERING CYLINDER Tilt cylinder Lift cylinder 230bar 165bar Brake system 22 bar 29 bar 280bar 300bar 185bar 166bar 20cc/rev 74cc/rev 63cc/rev L5 L4 L3 Spool(D) 110DESS04 When the steering wheel is turned to the left, the spool(G) within the steering unit(3) connected with steering column turns in left hand direction.
Page 248 RIGHT TURN STEERING CYLINDER Tilt cylinder Lift cylinder 230bar 165bar Brake system 22 bar 29 bar 280bar 300bar 185bar 166bar 20cc/rev 74cc/rev 63cc/rev L5 L4 L3 Spool(D) 110DESS05 When the steering wheel is turned to the right, the spool(G) within the steering unit(3) connected with steering column turns in right hand direction.
Page 249 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 250 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 251 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 Pin 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 252 GROUP 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 253 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 254 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 255 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 256 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 257 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 258 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 259 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 260 GROUP 3 TESTS AND ADJUSTMENTS 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 261 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 262 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 263 3. STEERING UNIT LEAKAGE TEST SPECIFICATION Oil temperature 45 5 C(113 9 F) Engine speed High idle Maximum leakage 7.5 /min(2gpm) Cap fitting GAUGE AND TOOL Temperature reader Measuring container(Approx. 20 ) Stop watch Install temperature reader. (See temperature reader installation procedure in this group).
Page 264 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 265 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 266 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 267 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 268 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 269 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 270 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 271 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 272 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 273 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 Pin bushing Gland Snap ring DU bushing 10 O-ring 5-30...
Page 274 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 275 Install the dust wiper to the gland 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. D353SE29 Using a hook spanner, install the gland ass- embly, and tighten it with torque 60 6kgf m (434 43lbf ft).
Page 276 3. STEERING AXLE STRUCTURE Do not remove the stopper bolt unless necessary. 1-39 1-41 1-43 1-43 1-42 1-15 1-16 1-14 1-33 1-46 1-32 1-34 1-31 1-27 1-27 1-42 1-26 1-38 1-44 1-29 1-43 1-41 1-30 1-45 1-40 1-36 1-13 1-35 1-12 1-37 1-11...
Page 277 CHECK AND INSPECTION A1, A2 100D7SS22 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 100(3.94) 99(3.90) Shaft ID of bushing 100(3.94) 99(3.90) 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 278 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 Hub nut weight part of the truck. Loosen the hub nut and take off the steering wheel tire.
Page 279 ASSEMBLY In reassembling, have all parts washed, grease 1-15 1-16 1-14 applied to lubricating parts, and all expendable 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 280 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 281 SECTION 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 282 2. HYDRAULIC CIRCUIT STEERING CYLINDER FREE LIFT CYLINDER FRONT AXLE TILT CYLINDER LIFT CYLINDER 230bar 5bar 120bar PUSH PULL 320bar 170bar 320bar 165bar 95bar Tilting Cabin Hyd. Circuit 125bar~ TILT LIFT 150bar 95bar Main pump Steering unit 10bar Main control valve DOWN BWD FWD b1 a2...
Page 283 3. WORK EQUIPMENT HYDRAULIC CIRCUIT FREE LIFT CYLINDER TILT CYLINDER LIFT CYLINDER Steering system 165bar LIFT TILT DOWN BWD FWD b1 a2 b2 a3 b3 a4 Cut off valve Return line Cut off valve 22 bar 29 bar 280bar 300bar 185bar 166bar 20cc/rev...
Page 284 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION FREE LIFT CYLINDER TILT CYLINDER LIFT CYLINDER 165bar Steering system TILT LIFT DOWN BWD FWD b1 a2 b2 a3 b3 a4 Cut off valve Return line Cut off valve 22 bar 29 bar 280bar 300bar...
Page 285 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION FREE LIFT CYLINDER TILT CYLINDER LIFT CYLINDER 165bar Steering system LIFT TILT DOWN BWD FWD b1 a2 b2 a3 b3 a4 Cut off valve Return line Cut off valve 22 bar 29 bar 280bar 300bar...
Page 286 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION FREE LIFT CYLINDER TILT CYLINDER LIFT CYLINDER 165bar Steering system LIFT TILT DOWN BWD FWD b1 a2 b2 a3 b3 a4 Cut off valve Return line Cut off valve 22 bar 29 bar 280bar 300bar...
Page 287 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION FREE LIFT CYLINDER TILT CYLINDER LIFT CYLINDER 165bar Steering system LIFT TILT DOWN BWD FWD b1 a2 b2 a3 b3 a4 Cut off valve Return line Cut off valve 22 bar 29 bar 280bar 300bar...
Page 288 4. MAIN PUMP STRUCTURE (1/2) This variable displacement piston pump consists of steering pump and working pump. L5 L4 L3 110DEMP04 Size Port Port name Pressure port SAE 1" Pressure port SAE 1" Suction port SAE 2" Suction port SAE 2" L1, L2 Case drain port 7/8-14UNF-28...
Page 289 FRONT PUMP 20 14 15 5 17 51 50 52 1-1 12 22 6, 31 110DEMP01 1-1 Rotary group 14 Stop ring 31 Double break off Pin 1-2 Control plate 15 Taper roller bearing 33 Cylinder pin Adjusting piece 16 Taper roller bearing 41 Plug Pump housing 17 Bearing liner...
Page 290 REAR PUMP VIEW C VIEW D A - A B - B 20 15 110DEMP02 Rotary group 12 Shim 21 O-ring Pressure spring 14 Stop ring 24 Seal ring Stop 15 Taper roller bearing 25 Retaining ring Pump housing 16 Taper roller bearing 27 Socket screw Port plate 17 Bearing liner...
Page 291 FUNCTION LS pressure 75796WE33 Drive shaft Counter spring 11 Control plate Swash plate Pressure & flow compensator valve 12 Pressure compensator spool Shoe plate Piston shoe 13 Flow compensator spool Counter piston Cylinder Piston 10 Control piston The steering pump and attachment pump are variable displacement piston pump. The steering pump and attachment pump are flow controlled by LS signal.
Page 292 Control piston (10) diameter is larger than counter piston (4) diameter, the oil pressure that is acting against control piston (10) overcomes the force of counter spring (6). The oil pressure than causes the pump to destoke. Pressure and flow compensator valve (7) also controls the maximum output of pump pressure. When steering and loader pressure rises above pressure compensator setting, pressure compensator spool (12) overrides flow compensator spool (13).
Page 293 Upstroking LS pressure LS pressure oil System pressure oil Return oil 75796WE35 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage 22 Passage 10 Control piston...
Page 294 Destroking LS pressure LS pressure oil System pressure oil Return oil 75796WE34 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage 22 Passage 10 Control piston...
Page 295 Low pressure standby LS pressure LS pressure oil System pressure oil Return oil 23 13 75796WE36 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage...
Page 296 Cross-drilled hole (24) limits the maximum travel of control piston (10) to the left. The pump supplies a sufficient amount of flow that compensates for system leakage. The pump also supplies a sufficient of flow that compensates for leakage to the pump case. The leakage to the pump case is a result of the cross-drilled hole.
Page 297 High pressure stall LS pressure LS pressure oil System pressure oil Return oil 23 13 75796WE36 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage...
Page 298 Adjustment of flow control Flow compensator setting must be carried out following procedures and conditions. Conditions Engine is running (at high or low idle). RCV is operated slowly (example : Boom up). Pressure gauges are installed. Discharge pump flow should be less than max pump flow. Procedures Loosening the hexagon nut (2).
Page 299 5. 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 bellows Kit 1 11 Spring 18 Screw Plunger kit 12 Kit 2 19 Support kit Spring guide 13 Tie rod with nut...
Page 300 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 301 6. MAIN CONTROL VALVE STRUCTURE Load sensing port 9/16" Outlet port 1-5/16" Inlet port 1-5/16" Steering load Steering supply sensing port 9/16" port 7/8" Outlet gauge port 9/16" OPT inlet port 7/8" Inlet port 1-5/16" Load sensing port 9/16" Outlet port 1-5/16" Intlet gauge port 9/16"...
Page 302 STRUCTURE 165bar 185bar 166bar 110DEHS10 Size Port Port Port name Port name Size P1, P2 Inlet port 1 5/16" - 12UNF 6A, 6B To aux port 1 1/16" - 12UNF Outlet port 1 5/16" - 12UNF a1, b1 To lift pilot prot 9/16"...
Page 303 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 110D7EHS11 Tube assembly...
Page 304 9. FREE CYLINDER 110D7EHS12 Tube assembly Rod cover 16 Plug Rod assembly 10 U-packing 17 O-ring Piston 11 Back up ring 18 Dust cap Check valve 12 Dust wiper 19 O-ring Retaining ring 13 Retaining ring 20 O-ring Seal slipper 14 O-ring Wear ring 15 Back up ring...
Page 305 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 306 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 307 11. ACCUMULATOR The accumulator is installed at the cut off valve. When the mast 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 308 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 110D7EHS14 - Hydraulic oil : Normal operating temp...
Page 309 2. TROUBLESHOOTING SYSTEM Problem Cause Remedy Large fork lowering speed. Seal inside control valve defective. Replace spool or valve body. Oil leaks from joint or hose. Replace. Seal inside cylinder defective. Replace packing. Large spontaneous tilt of Tilting backward : Check valve defec- Clean or replace.
Page 310 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 311 HYDRAULIC GEAR PUMP Problem Cause 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 312 CYLINDER Problem Cause 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 313 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP STRUCTURE (front) 20 14 15 5 17 51 50 52 1-1 12 22 6, 31 110DEMP01 1-1 Rotary group 14 Stop ring 31 Double break off Pin 1-2 Control plate 15 Taper roller bearing 33 Cylinder pin Adjusting piece 16 Taper roller bearing...
Page 314 VIEW C VIEW D A - A B - B 20 15 110DEMP02 Rotary group 12 Shim 21 O-ring Pressure spring 14 Stop ring 24 Seal ring Stop 15 Taper roller bearing 25 Retaining ring Pump housing 16 Taper roller bearing 27 Socket screw Port plate 17 Bearing liner...
Page 315 GENERAL REPAIR GUIDE LINES Observe the following guidelines when carrying out repairs on hydraulic pumps. Close off all openings of the hydraulic unit. Replace all of the seals. Use only original spare parts. Check all sealing and sliding surfaces for wear.
Page 316 SEALING / CLEANING THE CONTROL VALVE Disassemble the control valve. Measure dimension A and note down. Check sealing surface (1). 75796WE62 DISASSEMBLE THE PUMP Remove the control valve. 75796WE63 Mark the location of the connection plate on the housing. 75796WE64 6-36...
Page 317 Remove the connection plate fixing bolts and the connection plate. Distributor plate and adjustment piston can drop down. 75796WE65 Remove distributor plate. Take note of the orientation. Remove bearing with withdrawal tool. Do not damage the sealing surface. 75796WE66 Remove the rotary group in a horizontal position.
Page 318 Remove swash plate and bearing shells. 75796WE68 Remove the circlip and the shaft seal. 75796WE69 Remove the drive shaft through rear side. 75796WE70 Pre-tension the spring (1) using a suitable device. Remove circlip (2). Remove spring (1) and pressure pins (3). 75796WE72 6-38...
Page 319 (10) Use bearing puller to remove outer bearing race of front bearing out of housing press seat. 75796WE74 (11) Remove the control plate. 75796WE75 (12) Use bearing puller to remove outer bearing race of rear bearing - press seat. 75796WE76 (13) Disassemble the guide of control piston (Mounting position: pilot valve side).
Page 320 (14) Disassemble the guide of the opposite piston. 75796WE78 INSPECT HINTS Renew all bearings. 75796WE79 Check : Wear on splines, rust Drive shaft seal wear grooves Bearing seat Splines for cylinder drive Bearing seat 75796WE80 Check : Sliding surface free of grooves. 75796WE81 6-40...
Page 321 Check : Bearing surfaces. 75796WE82 Check : That the retaining plate is free of grooves and that there is no wear in the slipper pad area. 75796WE83 Check : Check to see that there are no scratches or metal deposits on the sliding surface (1) and that there is no axial play (2) (Pistons must only be replaced as a set).
Page 322 Free of grooves, no signs of wear. 75796WE86 Check : Cylinder sliding surface free of grooves, no wear, no embedded foreign particles. That there are no scratches on the control plate. (Only replace them as a set). 75796WE87 (10) Check : Mounting surface - control plate undamaged.
Page 323 (12) Check : Check running conditions of the opposite piston. 75796WE90 ADJUSTMENT OF TAPER ROLLER 0~0.05mm BEARING SET Cast iron housing must have initial tension of the bearings : 0~0,05 mm, grind position A if necessary. Position A 75796WE91 PUMP ASSEMBLY Fit the seal into the housing.
Page 324 Fit pressure pins using an assembly aid. 75796WE94 Pre-tension the spring using a suitable device. 75796WE95 Assemble piston with retaining plate. Oil piston and slipper pad. 75796WE97 6-44...
Page 325 Fit rotary group. Hold the piston by using an O-ring. Fit O-ring (1). 75796WE98 Fit bearing (1) in connection plate. Fit cyilindrical pin (2). Fit O-rings (3) 4 pieces. Fit adjustment spool (4) and guide piston (4a). Fit distributor plate (5) (direction of rotation dependent) Assembly.
Page 326 Fit distributor plate. Assembly aid : Grease 75796WE100 For clockwise rotation pumps the distributor plate is off-set by 4 to the right from the centre position. (Clockwise and anti-clockwise rotation distributor plates are not identical). 75796WE101 (10) Fit connection plate and control valve. 75796WE63 6-46...
Page 327 2. MAIN CONTROL VALVE VALVE SECTION DISASSEMBLY / REASSEMBLY INSTRUCTIONS Clean valve assembly thoroughly to remove any dirt and debris. Remove nuts (10) and tie rods (9) from control valve ( see Figure #4 ). Separate sections being careful not to lose section O-rings ( A and B , Figure #1-3 ). Keep all components for each section together as a set.
Page 328 SPOOL SECTION FIGURE #1 - SPOOL SECTION VIEW FIGURE #2 - SPOOL SECTION VIEW A - Large O-ring A - Large O-ring B - Small O-ring B - Seat assy (CV Valve) C - Small O-ring FIGURE #3 - SPOOL SECTION VIEW A - Large O-ring B - Small O-ring 110DEMCV01...
Page 329 VALVE ASSEMBLY FIGURE #4 - VALVE ASSEMBLY 110DEMCV02 Inlet section Aux section 13 LSRV Lift section Outlet section 14 Plug Lift section Tie rod(3) 15 Plug Tilt section 10 Special nut(6) 16 Check valve Aux section 11 Relief valve 17 Relief valve Aux section 12 Plug 6-49...
Page 330 INLET SECTION (0.98 0.14 kgf m) (0.98 0.14 kgf m) (10.2 1.1 kgf m) 110DEMCV03 Inlet housing Spool 11 Adjust screw O-ring 12 O-ring O-ring Spring 13 Special nut O-ring Poppet 14 Special nut Plug 10 Spring 6-50...
Page 331 LIFT SECTION (10.2 (2.5 1.1 kgf m) 0.3 kgf m) (6.6 0.7 kgf m) 110DEMCV04 Lift spool housing Spring 11 O-ring Spool Plug 12 Poppet End cap Plug 13 Plug Spool O-ring 14 Washer Lockout valve poppet 10 Spring 6-51...
Page 332 TILT SECTION (6.6 0.7 kgf m) 110DEMCV05 Tilt spool housing Spool O-ring Spool Plug Poppet End cap O-ring Spring 6-52...
Page 333 AUX SECTION (6.6 0.7 kgf m) 110DEMCV06 Aux spool housing Spool Spring Spool Plug O-ring End cap Poppet O-ring 6-53...
Page 334 OUTLET SECTION 110DEMCV07 Outlet housing RELIEF VALVE (2.5 0.3 kgf m) (2.5 0.3 kgf m) 110DEMCV08 Special seal Adjust screw Special nut O-ring Jam nut 6-54...
Page 335 DRAIN REGULATOR 110DEMCV09 Body Special nut 11 Filter Poppet O-ring 12 Retaining ring Spring Spring 13 Backup ring Adjust screw Piston 14 O-ring O-ring 10 Washer 6-55...
Page 336 END CAP (0.98 0.14 kgf m) 110DEMCV10 Spool cap Spring Cap screw O-ring Spring seat 6-56...
Page 337 CHECK VALVE 110DEMCV11 Body Filter Flow control O-ring RELIEF VALVE 110DEMCV12 O-ring 6-57...
Page 338 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 339 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 340 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 341 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 342 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 6-62...
Page 343 SECTION 7 ELECTRICAL SYSTEM Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 Group 3 Cluster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-14 Group 4 Transmission message indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27...
Page 344 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Front Rear Switch panel 110DEEL01 Cluster 11 Starting switch 21 Main light switch Multi function switch 12 Aircon & heater switch 22 Work lamp swich Gear selector lever 13 USB socket 23 Hazard switch Inching pedal 14 Cigar lighter...
Page 345 2. LOCATION 2 110DEEL02 Switch panel 14 Head lamp 27 License lamp Remote controller 15 Horn 28 Rear camera kit USB & socket assembly 16 Tilt switch 29 Heater relay Start switch 17 Int wiper relay 30 Travel alarm buzzer Cigar lighter 18 Alarm 31 Beacon lamp...
Page 346 GROUP 2 ELECTRICAL CIRCUIT 110DEEL03...
Page 347 CN-29 R/DRYER CN-154 FAN EPPR V/V 110DEEL04...
Page 348 MEMORANDUM...
Page 349 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 Battery(+) Master switch Battery relay[CR-1] I/conn[CN-1(1)] Start key(BR)[CS-1(1)] Fusible link[CN-60] I/conn[CN-1(3)]...
Page 350 POWER CIRCUIT START SWITCH CS-2 F/LINK CN-95 F/LINK CN-60 BATT RELAY DO-1 DISCONNECT SWITCH CR-1 DO-2 TO START MOTOR MAIN EARTH 110DEEL05...
Page 351 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Master Switch Battery relay[CR-1] I/conn[CN-1(1)] Start key(BR)[CS-2(1)] Start motor[CN-45(B+)] Start relay[CR-23(1)] ※ T 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(3)] ECM Relay[CR-45(86→30)] Fuse box #3[CN-38(12)]...
Page 352 STARTING CIRCUIT CN-2 CN-57 START SWITCH ECM RELAY CR-45 NEUTRAL RELAY CS-2 CR-5 START RELAY CN-100 F/LINK CR-23 CN-95 F/LINK START MOTOR CN-60 DO-1 CN-45 BATT MAIN RELAY EARTH ALTERNATOR DO-2 CR-1 CN-74 GEAR SELECTOR DISCONNECT SWITCH CN-50 CS-14 TRANSMISSION CONTROL UNIT(TCU) CS-15 110DEEL06...
Page 353 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 354 CHARGING CIRCUIT CLUSTER START SWITCH CAN LOW(-) CRUISE RESUME/INC RELAY PREHEAT RS232C RX INCHING SPEED GAUGE(CAN) CRUISE SET/DEC E/G TEMP GAUGE(CAN) CS-2 BATT(+) CR-42 CAN HIGH(+) CRUISE ENABLE DOWNLOAD RX232C TX ILLUMINATION CHARGING T/M TEMP GAUGE(CAN) FUEL GAUGE KEY ON POWER CN-56 F/LINK 3W/300...
Page 355 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 Battery relay[CR-1] Fusible link[CN-95] I/conn[CN-1(2)] Fuse box #2[CN-37(1)] ※ 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 356 PREHEATING CIRCUIT FUSE BOX #1 FUSE BOX #3 FUSE BOX #2 CN-93 (ECU) MAIN RELAY 1,21,18,38,58,78 3,23 START RELAY(-) NEUTRAL S/W START RELAY(+) 13,33 KEY S/W CAN1_LO(Diagnosis) CAN_HI CAN1_LO 2 CAN_HI 2 CN-2 BATT DIRECT HEATER RELAY PREHEAT RELAY ACCEL SENSOR GND 45,65 ACCEL POSITION SENSOR 47,67...
Page 357 3. CLUSTER 3. CLUSTER 1) 1) STRUCTURE STRUCTURE 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. ·...
Page 358 2) 2) GAUGE GAUGE Speed meter Speed meter ① The speedmeter displays the speed of truck in mph and km/h. 7807A3CD03 (2) (2) Fuel gauge Fuel gauge ① This gauge indicates the amount of fuel in the fuel tank. ② Fill the fuel when the indicator moves E point, refuel as soon as possible to avoid running out of fuel.
Page 359 3) 3) WARNING LAMPS WARNING LAMPS Transmission oil temperature warning lamp Brake fail warning lamp T/M error warning lamp Engine coolant temp warning lamp Parking brake warning lamp Seat belt warning lamp OPSS warning lamp Engine oil pressure warning lamp Battery charging warning lamp Water in fuel...
Page 360 ② Immediately pull the truck to a convenient stop. Stop the engine. Investigate the cause. ※ Consult a HYUNDAI dealer to investigate the cause. Consult a HYUNDAI dealer to investigate the cause. 160D7ECD19 ※ Do not operate until the cause has been corrected.
Page 361 (8) (8) Water in fuel warning lamp Water in fuel warning lamp ① This lamp lights up when the water separators full of water or malfunctioning. ※ When this lamp lights up, stop the truck and spill water out of When this lamp lights up, stop the truck and spill water out of the separator.
Page 362 (13) (13) OPSS warning lamp (option) OPSS warning lamp (option) ① This signal lamp lights ON when the operator leaves the seat. ② Powered travel movement of the truck shall be possible only if the operator is in the normal operating position. Transmission will automatically shift to neutral upon the exiting of the operator.
Page 363 4) 4) PILOT LAMPS PILOT LAMPS Head light pilot lamp Right turning pilot lamp Left turning pilot lamp Work lamp pilot lamp Fuel heater pilot lamp Preheater pilot lamp Inching pilot lamp 160D7ECD02-2 (1) (1) Direction pilot lamp Direction pilot lamp ①...
Page 364 (3) (3) Head light pilot lamp Head light pilot lamp ① This lamp comes ON when the main light switch is operated to 2nd step. 160D7CD07 (4) (4) Preheater pilot lamp Preheater pilot lamp ① This lamp lights ON when start switch is turned clockwise to the ON position.
Page 365 4) 4) CLUSTER BUTTON CLUSTER BUTTON Each button has the following function. Buzzer stop button MENU button Next button 160D7ECD121E (1) (1) Buzzer stop button Buzzer stop button ① This button is used to stop the buzzer sound. ② If another alarm condition occurs after this button has been pressed, the alarm buzzer will re-sound.
Page 366 (4) (4) Menu and next buttons Menu and next buttons ※ These buttons are used to select the model select mode. These buttons are used to select the model select mode. ※ The initial model is selected at the factory, so don't change The initial model is selected at the factory, so don't change the different model.
Page 367 Display Description ⑤ To Change another model, press (Equipment model screen) ⑥ To set the ton, press . Model select is completed. ※ If you want to return to the previous state, press If you want to return to the previous state, press 7-24...
Page 368 LCD has the functions to display start mode, standby mode, engine error display, model select mode etc. Name and display Description Start mode - Displays initialization state with HYUNDAI logo and program version. Standby mode Displays on the idle state. Displays engine speed, odometer and hourmeter.
Page 369 Name and display Description Model select mode (Ton) On ton select mode, displays like this image. See page 7-23. Model select mode (Model) On model select mode, displays like this ① ② image. (If you choose the 50~70, displays like ① If you choose the 80, displays like ②...
Page 370 GROUP 4 TRANSMISSION MESSAGE INDICATOR 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 371 DO AEB WORK Start engine after parking the machine on flat floor and blocking wheels. Release parking brake. With stepping on the service brake, operate T/M STALL(3 stage). (To avoid defect of clutch pack, repeat 10 sec of operation and 10 sec of placing neutral) When the T/M oil temperature reaches 75~80°...
Page 372 ISPLAY DURING AEB-MODE Symbol Meaning Remarks AEB-starter is plugged at the diagnostic plug AEB-Starter-button is pressed K1..K3 Calibrating clutch K1...K3, KV or KV, KR KR resp. _and Kx Wait for start, initialization of clutch Kx, x : 1, 2, 3, V, R ≡and Kx Fast fill time determination of clutch Kx =and Kx...
Page 373 4 4 ) INITIALIZING THE INCHING SENSOR Start engine after parking the machine on flat floor and blocking wheels. Release parking brake and keep neutral gear shift. Adjust the inching sensor linkage so that the regular voltage is supplied to inching sensor when operating the pedal.
Page 374 GROUP 5 SWITCHES Cover Parking brake switch Auto/Manual select switch Inching switch Main light switch Work lamp switch Hazard switch Cover(LH) Rear wiper/washer switch Aircon switch Seat heat switch Lock lever Inc/Dec switch Air compressor switch Fuel heater switch STOP DOWN Cover Cabin tilt switch...
Page 375 START SWITCH There are three positions, OFF, ON and START. · (OFF) : None of electrical circuits activate. · (ON) : All the systems of truck operate. · (START) : Use when starting the engine. Release key immediately after starting. 77073CD41 HAZARD SWITCH Use for parking, or loading truck.
Page 376 WORK LAMP SWITCH This switch is used to operate the front and rear work lamps by two steps. ·First step : Front work lamp comes ON. ·Second step : Rear work lamp comes ON. 160D7CD46 REAR WIPER AND WASHER SWITCH This switch is used to operate the rear wiper and washer by two steps.
Page 377 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. Titilting DOWN cabin 160D7CD74 Press the bottom of the switch fully to tilt the cabin downward. ※...
Page 378 MASTER SWITCH This switch is used to shut off the entire electrical system. I : The battery remains connected to the electrical system. O : The battery is disconnected to the electrical system. ※ Never turn the master switch to O(OFF) with the engine running.
Page 379 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 : 0Ω CN-60 : 24V 27A Fusible link (Connect ring terminal and CN-95 : 24V 45A...
Page 380 Part name Symbol Specifications Check Pressure : ※ Check contact Air cleaner 635mmH pressure switch Normal : ∞Ω (N.O TYPE) CD-10 ※ Check resistance Reed switch : Fuel sender Full : About 50Ω Magnetic type Low level : About 700Ω CD-2 ※...
Page 381 Part name Symbol Specifications Check ※ Check disconnection Work lamp, 24V 65W Head lamp Normal : A fewΩ H3 bulb CL-3 CL-4 ※ Check disconnection 24V 15W Beacon lamp (Strobe type) Normal : A fewΩ CL-7 ※ Check disconnection 24V 10W(tail) Combination Normal : A fewΩ...
Page 382 Part name Symbol Specifications Check CS-10 ※ Check contact CS-17 CS-17 CS-34 CS-18 OFF : ∞Ω CS-41 Switch CS-34 24V 8A (For terminal 1-5, 2-6) CS-42 (Locking type) CS-41 : ∞Ω CS-42 CS-54 (For terminal 5-7, 6-8) CS-79 CS-3 CS-3 CS-21 CS-19 ※...
Page 383 Part name Symbol Specifications Check Seat heater CN-170 ※ Check voltage Delco Remy 24SI Alternator 24V 70A Normal : 24~28V CN-74 DENSO ※ Operating or not Start motor 24V 3.7kW CN-45 ※ Check resistance Radio/USB Power ON : 4Ω+ 4Ω 18W×2 player (For terminal 1-6, 4-8)
Page 384 Part name Symbol Specifications Check ※ Check resistance Speaker 4Ω 20W Normal : 50Ω CN-23(LH) CN-23 CN-24(RH) CN-24 ※ Check resistance Receiver Normal : Ω driver CN-29 ※ Check contact Air conditioner 24V 79W compressor Normal : 13.4Ω CN-30 Cigar lighter 24V 5A CN-139 12V socket...
Page 385 Part name Symbol Specifications Check 24V 1.5A Wiper motor 2-speed Auto parking CN-102 ※ Check contact 24V 2.5A Motor Normal : 26.4Ω (For terminal 1-2) CN-103 24V 200mA Warning buzzer 90±5dB(ℓm) CN-26 Camera CN-249 CN-250 7-42...
Page 386 GROUP 7 CONNECTORS 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Engine harness-Main harness) MG643241 MG613245 CN-2 I/conn(Main harness-Engine harness) MG643241 MG613245 CN-3 DEUTSCH Seat switch DT04-4P CN-4 DEUTSCH Work lamp switch DT06-2S DT04-2P CN-5 DEUTSCH...
Page 387 Connector part No. Connector No. of Type Destination number Female Male CN-45 Ring term Start motor S820-308000 926682-3 CN-46 Air compressor harness MG650943-5 CN-50 Transmission control unit 963598-1 CN-51 T/M diagnostic 480704-0 926682-3 CN-55 OPSS unit MG610350 CN-56 Cluster 174047-2 CN-57 Cluster 175967-2...
Page 388 Connector part No. Connector No. of Type Destination number Female Male Switch CS-2 Start key MG610047 CS-3 DAEDONG Rear wiper washer switch 250-10PRG MG610335 CS-6 Center horn MG640322 CS-10 DAEDONG Fuel preheat switch 250-10PRG CS-11 Multifunction switch MG610339 CS-12 Multifunction switch MG610335 CS-14 PACKARD...
Page 389 Connector part No. Connector No. of Type Destination number Female Male Relay CR-3 HELLA Work lamp relay 8JA003526-001 CR-5 Netural relay VCFM-1002 CR-6 Internal wiper relay S810-006202 CR-11 HELLA Flasher unit 8JA003526-001 8JA003526-001 CR-26 Wiper low speed relay VCFM-1002 CR-38 Water pump relay VCFM-1002 CR-39...
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 7-47...
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 7-48...
Page 392 No. of Receptacle connector(Female) Plug connector(Male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 7-49...
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 7-50...
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 7-51...
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 7-52...
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 7-53...
Page 397 No. of Receptacle connector(Female) Plug connector(Male) S810-006202 S810-106202 S810-008202 S810-108202 7-54...
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 7-55...
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 7-56...
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 7-57...
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 7-59...
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 110D7EMS01 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...
Page 406 2. 3 STAGE MAST(TF MAST) Lift cylinder Lift cylinder Free lift cylinder 110D7EMS05 Outer mast Tilt cylinder pin Sheave Shim Mast mounting pin 10 Anchor bolt Roller bearing Inner mast Chain Side roller bearing Middle mast 12 Sheave bracket...
Page 407 3. CARRIAGE, BACKREST AND FORK(SHAFT TYPE) Shaft type fork Extension fork 110D7EMS02 Carriage & backrest Side roller Hanger bar Fork Fork retaining Extension fork Roller...
Page 408 Measure thickness of root of forks and check that it is more than specified value. EX : =1800mm(71in) mm(in) STD Fork assy Applicable model Standard Limit Thickness 61FT-70342 110DF-7 75(3.0) 68(2.7) 61FT-71440 130DF-7 90(3.5) 80(3.2) D507FK01 95(3.7) 85(3.3) 61FT-70143 160DF-7...
Page 409 2. TROUBLESHOOTING MAST Problem cause 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 cause 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 assy. Outer mast Work lamp assy Lift chain Block 110D7ERE55 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 Inner mast Place a sling around carriage front plate 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. Adjustment 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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