Hyundai 110D-7E Operating Manual

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SECTION 1 GENERAL

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

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

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

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Operation and maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-46

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

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

SECTION 4 BRAKE SYSTEM

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

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

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

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

SECTION 5 STEERING SYSTEM

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

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

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

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

SECTION 6 HYDRAULIC SYSTEM

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

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

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

SECTION 7 ELECTRICAL SYSTEM

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

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

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

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

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

CONTENTS

Summary of Contents for Hyundai 110D-7E

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-36 Group 7 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-42 Group 8 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-58 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16...
Page 12 GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. · Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
Page 13 Be particularly careful when removing the radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using the machine, there is a danger that boiled oil may spurt out. · The procedure for releasing the hydraulic pressure is as follows : lower the fork to the ground, and stop the engine(Motor), move the control levers to each position two or three times.
Page 14 · Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. D50ASF09 · When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
Page 15 160D7ESP01 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 160D7EOM54 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 110D/130D-7E C' C 160D7ESP011 Model Unit 110D-7E 130D-7E Capacity 11,000 13,000 Load center Weight(Unloaded) 15797 16503 Lifting height 3300 Free lift Lifting speed(Unload/Load) Fork mm/sec 510/440 510/430 Lowering speed(Unload/Load) mm/sec 460/510 L W T L,W,T 1350 200 75...
Page 18 140D/160D-7E C' C Model Unit 140D-7E 160D-7E Capacity 14,000 16,000 Load center Weight(Unloaded) 18378 19235 Lifting height 3300 Free lift Fork Lifting speed(Unload/Load) 450/360 450/350 mm/sec Lowering speed(Unload/Load) mm/sec 390/430 L W T L,W,T 1350 200 85 1350 200 90 Tilt angle (forward/backward) 15/12 degree...
Page 19 3. SPECIFICATION FOR MAJOR COMPONENTS 110D/130D-7E ENGINE Specification Item Unit CUMMINS QSB6.7 Model 4 cycle turbocharged diesel type Type Water cooling Cooling Method 6 cylinders, In-line Number of cylinders and arrangement 1-5-3-6-2-4 Firing order Direct injection Combustion chamber type mm(in) 107 124mm(4.21"...
Page 20 TEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev 45.4 Rated flow POWER TRAIN DEVICES Item Specification Model F & S 300* OZG 040/18(ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.3 : 1 Type Full auto, power shift...
Page 21 140D/160D-7E ENGINE Item Specification Unit Model CUMMINS QSB6.7 Type 4 cycle turbocharged diesel type Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, In-line Firing order 1-5-3-6-2-4 Combustion chamber type Direct injection Cylinder bore X stroke mm(in) 107×124mm(4.21"×4.88") Piston displacement cc(cu in) 6700(410)
Page 22 TEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev 45.4 Rated flow POWER TRAIN DEVICES Item Specification Model F&S 300* OZG 040/18(ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.3 : 1 Type Full auto, Power shift Gear shift(FR/RR)
Page 23 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS 110D/130D-7E Item 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 93 ± 22 Hydraulic pump mounting bolt M12 ×...
Page 24 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT - Coarse thread Bolt size kgf·m lbf·ft kgf·m lbf·ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7...
Page 25 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat(mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 130.2 1" 151.9 1-1/4" 253.2 IPE AND HOSE(ORFS TYPE) Width across flat(mm) kgf·m lbf·ft Thread size(PF) 28.9 9/16-18 36.2 11/16-16 68.7 13/16-16 130.2 1-3/16-12 151.9...
Page 26 If any engine oil of API service class CF is used instead of class CH4 engine oil, the frequency of oil change must be doubled. Cold region : Russia, CIS, Mongolia Ultra low sulfur diesel : sulfur content 15 ppm Machine serial No. 110D-7E : -#0365 130D-7E : -#0145 140D-7E : -#0031 160D-7E : -#1169 110D-7E : #0366-...
Page 27 GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET ·Owner ·Date ·Hours ·Serial No. ·Technician ※ U U se this sheet to record operational checkout results. Perform the operational check before installing any test equipment. 100D7GE02 Item Comments 1. Monitor indicator and gauge checks(Engine OFF) ·...
Page 28 4. Brake system and clutch cut off checks · Park brake capacity check ƒw ƒw · Park brake transmission lockout check ƒw ƒw · Service brake pump flow check ƒw ƒw · Service brake capacity check ƒw ƒw · Brake accumulator precharge check ƒw ƒw ·...
Page 29 7. Steering system checks ·Steering valve check ƒw ƒw ·Steering system leakage check ƒw ƒw ·Priority valve(built in MCV) ƒw ƒw Low check pressure ƒw ƒw High check pressure ƒw ƒw . Accessory checks ·Operating lights check ƒw ƒw ·Work light check ƒw ƒw ·Brake light check...
Page 30 SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
Page 31 GROUP 1 STRUCTURE 160D7EOM21 Mast Transmission 17 Counterweight Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder 12 Steering cylinder 20 Cabin Main control valve 13 Hydraulic pump 21 Steering wheel Fork 14 Steering axle 22 Muffler Front wheel 15 Rear wheel...
Page 32 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Fork Carriage Piping Mast FORKS ① Lower the fork carriage until the forks are Cover Carriage approximately 25mm(1in) from the floor. ②...
Page 33 ③ 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 ④ Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage to work area and lower the mast.
Page 34 PIPING ① 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...
Page 35 LIFT CYLINDER 110/130D-7E V400~V700 140/160D-7E V350~V700 ① Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast. ② 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...
Page 36 INNER MAST ① Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. Inner mast Outer mast 100D7RE59 TILT CYLINDER PIN MAST SUPPORT PIN Attach a crane to the stay at the top of the outer mast, and raise it.
Page 37 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. ※ Installation procedure for each of mast component is the reverse of the removal procedure. MAST SUPPORT PIN Check the mast support pins for wear, then install pins into the mast support bracket and drive axle.
Page 38 2. POWER TRAIN ASSEMBLY REMOVAL Mast Brake piping Drive axle Mounting bolts holding to engine flywheel Inching harness T/M & axle cooling Floor plate piping Flexible plate mount bolt 100D7RE04 Mast Refer to section on mast(Page 2-2)
Page 39 Brake piping Disconnect the brake hydraulic pipes from Brake hose Return the brake housing of drive axle unit. hose Drive axle 100D7RE05 Drive axle ※ Before removing the drive axle unit, drain all of the oil from the axle. ① Jack up the machine and then put the block under the frame.
Page 40 Transmission and axle cooling piping Radiator assembly ① Disconnect cooling hose and connector from the transmission. Transmission ※ Make sure that the coolant has been assembly Cooling drained from the line. hose 110D7ERE10 ② Disconnect axle cooling hose and Radiator assy Axle connector from the axle.
Page 41 ② Using a moving truck slowly pull out transmission assembly to the front. Block Transmission Truck 110D7ERE13 2-11...
Page 42 INSTALLATION Installation is the reverse order to removal, but be careful of the following points. Bolt 1 ① to Tightening torque of mounting bolts Engine flywheel housing. ① : 5.5~8.3kgf·m (39.8~60.0lbf·ft) Socket bolt Tightening torque of mounting socket bolts ② for torque converter. Transmission ②...
Page 43 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL Mounting bolts T/C housing holding to engine cover flywheel Engine hood Engine accessory Shroud Mounting bolts Overhead Radiator guard hose Air cleaner hose 100D7RE25 Engine hood...
Page 44 ② ② 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 110D7ERE18 Torque converter housing cover and mounting bolts.
Page 45 Engine mounting bracket Attach a crane to the engine hook and raise, then remove mounting bolts. Raise Bolt the engine slightly, slide towards the radiator, then lift up. ※ When sliding the engine, be careful of the collision of engine and radiator. Bolt Rubber mount 110D7ERE93...
Page 46 Hold the counterweight with hoist bars, and raise it with a crane. Remove the mounting bolts, raise slightly and move it slowly to rear side. ·Weight of counterweight (standard) 110D-7E : 4,140kg (9,130lb) 130D-7E : 5,270kg (11,620lb) 140D-7E : 4,990kg (11,000lb) 160D-7E : 6,100kg (13,450lb) ·Tightening torque : 199±29.9kgf·m (1440±216lbf·ft)
Page 47 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. 100D7RE31 Hose Steering axle Hose 100D7RE32 Mounting bolt Support Put a block under the steering axle, support on a truck, an raise the frame with a crane.
Page 48 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Operation and maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-46 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-57 Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-150...
Page 49 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION . POWER TRAIN COMPONENT OVERVIEW Drive axle Transmission Steering axle Propeller shaft Torque converter Engine 110D7EPT01 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 50 ·H ydraulic circuit Pressure Temp reducing sensor valve 9 bar Main pressure valve 16+2.5bar Valve block control circuit Converter Filter Back pressure Con. valve 4.3+3 bar safety valve By pass valve 11+2 bar 5.5 bar Pump 16+2 bar Oil sump Main oil circuit Lubrication D507PT31...
Page 51 2. TORQUE CONVERTER D503TM01 Turbine Pump Input shaft Stator Transmission pump The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the characteristics, and with it the favorable efficiency of a fluid clutch. The converter will be defined according to the engine power so that the most favorable operating conditions for each installation case are given.
Page 52 If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the turbine moment becomes equal to that of the pump moment. From this point on, the converter is working similar to a fluid clutch. A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the conversion range the moment upon the housing, and is released in the coupling range.
Page 53 3. TRANSMISSION LAYOUT D507TM03 Input gear Engine connection Clutch shaft(KR) Clutch shaft Converter 10 Clutch shaft(K1) Power take-off Input shaft 11 Output flange Clutch shaft(KV) Transmission pump 12 Clutch shaft(K3/output)
Page 54 INSTALLATION VIEW 21 20 11 10 FRONT VIEW REAR VIEW D507PT26 Converter 13 Breather Converter bell 14 Electro - hydraulic control Lifting lugs 15 Temperature sensor behind the converter Inductive transmitter n central gear train 16 Connection to the oil cooler Inductive transmitter n turbine 17 Filter head Gearbox housing - Front section...
Page 55 OPERATION OF TRANSMISSION Gearbox diagram The multi-speed reversing transmission in counter shaft design is power shiftable by hydraulically actuated multi-disk clutches. All gears are constantly meshing and carried on anti-friction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 3-speed reversing transmission is equipped with 5 multi-disk clutches.
Page 56 Forward In forward, forward clutch and 1st, 2nd, 3rd clutch are engaged. Forward clutch and 1st, 2nd, 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston. 1st speed-forward Transmission diagram K3/AB Opinion direction of rotation Legend: AN = Input K3/AB KV = Clutch forward...
Page 57 Reverse In reserve, reserve clutch and 1st, 2nd, 3rd clutch are engaged. Reverse clutch and 1st, 2nd, 3rd are actuated by the hydraulic pressure applied to the clutch piston. 1st speed-reverse Transmission diagram K3/AB Opinion direction of rotation Legend: AN = Input K3/AB KV = Clutch forward KR = Clutch reverse...
Page 58 ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE SECTION A-A SECTION B-B D507PT03 Pressure reducing valve(9bar) Intermediate plate Main pressure valve (16 + 2bar) Duct plate Housing Vibration damper Plug(cable harness) 10 Follow - on slide Cover 11 Pressure regulator Valve block 3-10...
Page 59 Transmission control, see schedule of measuring points, Oil circuit diagram and Electro-hydraulic control unit see page 3-2, 3-10. The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is sitting in the transmission on the engine-dependent input shaft. The feed rate of the pump is Q = 85ℓ/min, at n = 2000 min...
Page 60 GEAR SELECTOR(DW-3) The gear selector is designed for the mounting on the steering column left side. By a rotative motion, the positions(speeds) 1 to 3 are selected by tilting the lever, the driving direction(Forward (F) - Neutral(N) - Reverse(R)). For the protection from unintended start off, a neutral interlock is installed : Position "...
Page 61 Gear selector(DW-3) LEVER FOR MECHANICAL CODING GEAR SELECTOR NEUTRAL INTERLOCK OUTPUT FORWARD REVERSE NEUTRAL SPEED ● ● ● ● ● ● ● ● ● ● ● ● IN POSITION(NEUTRAL), ● ● ● F-R NOT SWITCHABLE ● ● ● CIRCUIT DIAGRAM SELECTOR TYPE PLATE GEAR POSITIONS AD3(B3)
Page 62 TRANSMISSION ERROR DISPLAY Function The display can be used with the gear selector. It indicates speed and driving direction as well as the activated inching. When driving in the automatic mode, a bar indicator gives additionally also information about the selected driving range;...
Page 63 isplay during operation Symbol Meaning Remarks Actual gear and direction F, N, R Central side shows actual gear 1, 2, 3 Right side shows actual direction Not neutral, waiting for neutral To engage a gear, first move shift selector to (Central and right side) after power up or a reverse fault neutral position and again to F to R position...
Page 64 Transmission error codes Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Logical error at gear range signal TCU shifts transmission to Check the cables from TCU to neutral shift lever TCU detected a wrong signal combination...
Page 65 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Retarder function is affected Check the cable from TCU to the S.C. to battery voltage at load sensor input TCU uses default load sensor...
Page 66 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction, TCU uses default Check the cable from TCU to the S.C. to ground at retarder temperature sensor input temperature sensor...
Page 67 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · OP mode : Substitute clutch Logical error at engine speed input Check the cable from TCU to the control TCU measures a engine speed over a sensor...
Page 68 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · OP mode : Substitute clutch Logical error at internal speed input Check the cable from TCU to the control TCU measures a internal speed over a sensor...
Page 69 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · TCU shifts to neutral Check the cable from TCU to the S.C. to battery voltage at clutch K1 OP mode : Limp home gearbox The measured resistance value of the valve...
Page 70 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · TCU shifts to neutral S.C. to battery voltage at clutch K3 Check the cable from TCU to the OP mode : Limp home The measured resistance value of the gearbox...
Page 71 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction Check the cable from TCU to the O.C. at engine derating device OP mode : Normal engine derating device TCU detected a wrong voltage at the ·...
Page 72 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · TCU shifts to neutral S.C. to ground at clutch KR Check the cable from TCU to the OP mode : Limp home The measured resistance value of the valve gearbox ·...
Page 73 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction Check the cable from TCU to the O.C. at relay reverse warning alarm OP mode : Normal backup alarm device TCU detected a wrong voltage at the ·...
Page 74 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction S.C. to ground at park brake solenoid Check the cable from TCU to the OP mode : Normal TCU detected a wrong voltage at the park brake solenoid ·...
Page 75 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction S.C. to battery voltage at converter lock Check the cable from TCU to the up clutch solenoid OP mode : Normal converter clutch solenoid ·...
Page 76 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction S.C. to ground at difflock or axle Check the cable from TCU to the connection solenoid OP mode : Normal difflock solenoid ·...
Page 77 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · TCU shifts to neutral Check pressure at clutch K1 Slippage at clutch K1 · OP mode : Limp home Check main pressure in the TCU calculates a differential speed at If failure at another clutch is...
Page 78 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · TCU shifts to neutral Slippage at clutch KV Check pressure at clutch KV · OP mode : Limp home TCU calculates a differential speed at Check main pressure in the If failure at another clutch is...
Page 79 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Slippage at converter lockup clutch Check pressure at converter TCU calculates a differential speed at lockup clutch · closed converter lockup clutch.
Page 80 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction Cool down machine Overtemp converter output · OP mode : Normal Check oil level TCU measured a oil temperature at the ·...
Page 81 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · See fault codes No.21 to 2C Check cables and connectors to S.C. to battery voltage at power supply for sensors sensors, which are supplied from TCU measures more than 6V at the pin...
Page 82 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection ※ Not used S.C. battery voltage at speedometer output ※ S.C. to ground or O.C at speedometer Not used output ·...
Page 83 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction Replace TCU General EEPROM fault ※ OP mode : Normal Often shown together with fault TCU can't read non volatile memory ·TCU is defective code F2 ·...
Page 84 Measuring of resistance at actuator/sensor and cable ① ① Actuator 76043PT19 = ∞ Open circuit Short cut to ground = R; R = 0, R = R or R = R, R (For S.C. to ground, G is connected to vehicle ground) Short cut to battery = R;...
Page 85 ELECTRONIC CONTROL FOR POWER TRANSMISSION Description of the basic functions The powershift transmission is equipped with TCU. ·The system is processing the desire of the driver according to the following criteria : ·Gear determination depending on gear selector position, driving speed and load condition. ·Protection from operating error as far as necessary, is possible via electronic protect- tion(programming).
Page 86 Legend 2 = Display 3 = Gear selector DW - 3 4 = Power supply connection 5 = Switch for enable inched(Option) 6 = Switch for driving program manual/Auto 1/Auto 2 9 = TCU(EST-37A) 11 = Wiring 14 = Cable to inductive transmitter speed central gear train 15 = Cable to inductive speed engine 16 = Cable to inductive transmitter speed turbine 17 = Cable to temperature measuring point behind the converter...
Page 87 Inching device This function is especially suitable for lift trucks. It allows to reduce the driving speed infinitely variable without modification of the engine speed in such a way that driving with a very low speed will be possible. In his way, the driver can move the vehicle very exactly to a determined position. At the same time and important part of the engine power for the output of the hydraulic system is at disposal by the high engine speed.
Page 88 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS The measurement have to be carried out with hot transmission(about 80~95。 C) D50TM04 3-40...
Page 89 OIL PRESSURE AND TEMPERATURE Port Description Size In front of converter - Opening pressure 11+2 bar M10x1 Behind converter - Opening pressure 4.3 + 3 bar M14x1.5 Clutch Forward 16 + 2 bar M10x1 Clutch reverse 16 + 2 bar M10x1 Clutch 16 + 2 bar...
Page 90 5. DRIVE AXLE STRUCTURE 1 419 528 402 425 538 535 530 529 531 100D7DR02 400 Differential & carrier 412 Bearing bushing 422 Hexagon screw 401 Drive pinion 413 Hexagon screw 423 Hexagon screw 402 Ring gear 414 Hexagon screw 425 Hexagon screw 403 Differential housing 415 Tapered roller bearing...
Page 91 STRUCTURE 2 100D7DR03 250 Inner disk 263 O-ring 280 Bleeder valve 251 Outer disk 266 Hexagon screw 281 Pipe 252 Piston 269 Hex sockets crew 282 Hexagon screw with flange 258 Gasket 271 Face seal 283 Compression spring 259 Gasket 272 Screw plug 260 Brake carrier 273 Sealing ring...
Page 92 STRUCTURE 3 100D7DR04 300 Planetary housing 314 Sun gear 335 Ring gear 304 O-ring 316 Circlip 336 Ring gear carrier 306 Sealing ring 320 Thrust ring 337 Retainer 307 Screw plug 322 Planetary gear 338 Hexagon socket screw 308 Sealing ring 324 Thrust washer 340 O-ring 310 Adjusting screw...
Page 93 6. TIRE AND WHEEL D507AX68 Wheel rim Lock ring Valve assembly Tire Side ring Wheel nut The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with the ground to gain the power which drives the machine. Various types of tires are available to suit the purpose.
Page 94 GROUP 2 OPERATION AND MAINTENANCE 1. OPERATION DRIVING PREPARATION AND MAINTENANCE Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filters as well as the pipes must get filled with oil.
Page 95 - Upshifting in overrunning condition. In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if the speed of the vehicle on a downgrade should not be further increased. - Downshifting in overrunning condition. Downshifting in overrunning mode will be then carried out if the vehicle should be related. If the vehicle will be stopped and is standing with running engine and engaged transmission, the engine cannot be stalled.
Page 96 Now, the temperature must drop quickly(in about 2-3minutes) to normal values. If this is not the case, there is a trouble pending, which must be eliminated prior to continue working. The monitoring of the oil temperature(behind the converter) is additionally on the temperature gauge which is located on the dashboard.
Page 97 2. MAINTENANCE TRANSMISSION Oil level check At the oil level check, the vehicle has to be secured against rolling with blocks. The oil level check must be carried out as follows : - Oil level check(weekly) - At horizontally standing vehicle - Transmission in neutral position "...
Page 98 Oil change and filter replacement intervals ※ First oil change after 100operating hours in service. Every further oil change after 1000operating hours in service, however at least once a year. At every oil change, the fine filter has to be replaced. ①...
Page 99 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 100 DRIVE AXLE Important remarks ① For safety reasons, the operator should verify and service at regular intervals all of the bolted assemblies and all of the important safety locks such as : Wheel nuts Nuts of axle mounting bolts Bolts on the steering components and the brake system parts : if the screws are tightable, the loctite contact breaks loose and remounting is necessary.
Page 101 Lubrication points The binding lubrication points has to be taken from the according installation drawing of the axle. ① Single drive assembly ※ The position is dependent from the respective axle version. ※ Legend 100D7XL03 1 : Oil fill plug 2 : Oil level control plug 3 : Oil drain plug 3-53...
Page 102 3. TROUBLESHOOTING BRAKE LEAKS ACTUATION FLUID Condition ossible cause Correction Internal leak : Fluid 1. Worn or damaged piston seal. 1. Replace piston seals. bypasses seals into axle 2. Melted or extruded piston seals. 2. Correct cause of overheating and replace and fills axle with fluid seals.
Page 103 BRAKE OVERHEATS Condition Possible cause Correction Overheating due to Inadequate coolant flow or heat 1. Install brake cooling system if not already excessive duty cycle. exchange. installed on vehicle. 2. Re-analyze and re-size brake cooling system if necessary. Inadequate coolant flow Low pump output, blocked filter or Check pump output at different operating coolant lines.
Page 104 BRAKE DOES NOT RELEASE Condition Possible cause Correction Vehicle does not move Damaged hydraulic system. Repair hydraulic system. Brakes dragging 1. More than 1.4bar(20psi) pressure 1. Repair hydraulic system so pressure is less applied when brakes released. than 1.4bar(20psi) when brakes released and while machine is operating in any mode.
Page 105 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY Electro-hydraulic control and filter (exchange filter) ① 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 ①...
Page 106 Removal of the electric shift system ① 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 ② Remove the complete shift system(1) and the intermediate shaft(2).
Page 107 ⑤ Separate the duct plate(3), and inter- mediate sheet(2) from the valve block(1). D507TM18 ⑥ Remove the retaining clamp(1). D507TM19 ⑦ Loosen the cap screws(1) and remove the cover. Remove the opposite cover. (S)Socket spanner TX-27 5873 042 002 D507TM20 ⑧...
Page 108 ⑨ Loosen the cap screws, remove the fixing plates and the pressure regulators(1). (S)Socket spanner TX-27 5873 042 002 D507TM22 ⑩ Loosen two cap screws(1) and fasten the adjusting screws(S) preliminarily (housing is spring-loaded). Following to this loosen the remaining cap screws. (S)Adjusting screws 5870 204 036 (S)Socket spanner...
Page 109 ⑬ Remove the single parts on the opposite side analogously: 1 = Main pressure valve 2 = Vibration damper 3 = Follow-on slide D507TM26 nductive transmitters, valves, oil filter and oil drain plug, screw plugs ① Mount the transmission to the assembly truck.
Page 110 ④ Remove the positioned parts. 1 = Inductive transmitter n - Internal speed input 2 = Inductive transmitter n - Turbine 3 = Speed transmitter n - Output 4 = Cover(mounting possibility for oil filler tube) D507TM30 ngine connection, pressure oil pump and removal of the clutches ①...
Page 111 ③ 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 ④...
Page 112 ⑦ Remove the tab washer(2) and loosen the hexagon screws(1). D507TM37 ⑧ Pull off the input shaft(1). Remove the shaft seal. (S)Two-armed puller 5870 970 003 D507TM38 ⑨ 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...
Page 113 ⑪ 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 ⑫ Loosen the cap screws(2) and remove the suction tube(1).
Page 114 ⑮ Remove the pipes(system pressure from the electro-hydraulic control to the respective clutch). Remove the holding segment(6). The pipes are to disassembled in the following sequence: 1 = Pipe 2 = Pipe 3 = Pipe D507TM45 4 = Pipe 5 = Pipe Remove all bearing outer rings(see arrows).
Page 115 Clutches KV/KR/K1/K2/K3 and Input See figure on the right. D507TM51 Clutch KV ① Remove the stud(1) and unsnap the piston ring(2). D507TM52 ② Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 001 011 D507TM53...
Page 116 ④ Unsnap the retaining ring(1). (S)Set of external pliers 5870 900 015 D507TM55 ⑤ Press the clutch shaft(1) out of the idler(2). (S)Parting tool 5870 300 028 D507TM56 ⑥ Unsnap the retaining ring(2) from the idler(1) and remove the ball bearing(3). (S)Set of internal pliers 5870 900 013 D507TM57...
Page 117 ⑧ Rotate the shaft(2) by 180°and unsnap the piston ring(1). D507TM59 ⑨ 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 ① Remove the stud(1) and unsnap the piston ring(2).
Page 118 ③ Pull the clutch(1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM63 ④ Unsnap the retaining ring(1). (S)Set of external pliers 5870 900 015 D507TM64 ⑤ Press the clutch shaft(1) out of the idler(2). (S)Parting tool 5870 300 028 D507TM65 ⑥...
Page 119 ⑦ Unsnap the retaining ring(2) from the idler(1) and remove the ball bearing. (S)Set of internal pliers 5870 900 013 D507TM67 ⑧ Remove the needle cage(1) from the shaft(2). D507TM68 Shaft(2) and gear(1) cannot be separa- ted(shrink fit). D507TM69 ⑨ Rotated the shaft(2) by 180°...
Page 120 ⑩ 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 ① Remove the stud(1) and unsnap the piston ring(2). D507TM72 ② Pull the taper roller bearing(inner ring) from the shaft.
Page 121 ④ Remove the complete axial bearing(1). D507TM75 ⑤ Take off idler(1), remove the needle cage(2) and the complete axial bea- ring(3). D507TM76 ⑥ Pull the clutch(1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM77 ⑦ Rotated the shaft(2) by 180° and unsnap the piston ring(1).
Page 122 ⑧ 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 ① Remove the stud(1) and unsnap the piston ring(2). D507TM80 ② Pull the taper roller bearing(inner ring) from the shaft.
Page 123 ④ Remove the complete axial bearing(1). D507TM83 ⑤ Take off idler(1), remove the needle cage(2) and the complete axial bea- ring(3). D507TM84 ⑥ Pull the clutch(1), front the shaft. (S)Two-armed puller 5870 970 003 D507TM85 ⑦ ° and unsnap ° Rotated the shaft(2) by 180 the piston ring(1).
Page 124 ⑧ 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 ① Unsnap the piston ring(1). D507TM88 ② Pull the taper roller bearing(inner ring) from the shaft.
Page 125 ④ Take off idler(1), remove the needle cage(2) and the complete axial bea- ring(3). D507TM91 ⑤ Pull the clutch(1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM92 ⑥ Rotated the shaft(2) by 180°and unsnap the piston ring(1). D507TM93 ⑦ Pull the taper roller bearing(inner ring) from the shaft.
Page 126 Input ① 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 ② Pull the taper roller bearing(inner ring) from the input gear. (S)Gripping insert 5873 001 058 (S)Back-off insert...
Page 127 2. TRANSMISSION ASSEMBLY Clutches KV/KR/K1/K2/K3 and input ※ In the EST-37A(electronic transmission control)the gear change(filling times and pressure level) are controlled via the drive program of the transmission electronics. Additionally, the EST-37A monitors the disc clearance(clearance) of the clutches and if exceeded, a fault message is given in the transmission error display.
Page 128 ④ 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 ⑤ Press in preassembled idler(1) until contact. D507TM105 ⑥ Fasten the idler(1) by means of retaining ring(2).
Page 129 ⑧ Mount the clutch(1) until contact is obtained. Wear safety gloves. D507TM108 ⑨ Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM109 ⑩ Install the piston ring(1). D507TM110 ⑪ Install the stud(1). =1.7kg · m Tightening torque - - - - - - - - - - - - - - M ※...
Page 130 Clutch KR ① Press the taper roller bearing(inner ring)(1) onto the shaft(2) until contact is obtained. D507TM112 ② Install the piston ring(1). D507TM113 ③ 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 ear safety gloves.
Page 131 ⑤ Fasten the gear(1) by means of retaining ring(2). (S)Set of internal pliers 5870 900 015 D507TM116 ⑥ Mount the needle bearing(1) onto the shaft(2). D507TM117 ⑦ Put the ball bearing(2) into the idler(1) until contact is obtained and fasten it by means of retaining ring(3).
Page 132 ⑨ Fasten the idler(1) by means of retaining ring(2). (S)Set of internal pliers 5870 900 015 D507TM120 ⑩ 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 ⑪...
Page 133 ⑬ Install the piston ring(1). D507TM124 ⑭ Install the stud(1). · m Tightening torque - - - - - - - - - - - - - - M =1.7kg ※ Check closing respective opening of the clutch by means of compressed air at the bore(2).
Page 134 ③ Install the sealing cap(1). ※ Wet the contact surface with(Loctite Type No. 262). D507TM128 ④ 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 ⑤...
Page 135 ⑦ Mount the needle cage(1). D507TM132 ⑧ Install the idler(1). D507TM133 ⑨ 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 ⑩ Fasten the idler(1) and the single parts by means of the retaining ring(2).
Page 136 ⑪ Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM136 ⑫ Install the piston ring(1). D507TM137 ⑬ Install the stud(1). · m Tightening torque - - - - - - - - - - - - - - M =1.7kg ※...
Page 137 ② Install the piston ring(1). D507TM140 ③ 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 ④ Mount the clutch(1) until contact is obtained. Wear safety gloves.
Page 138 ⑥ Mount the needle cage(1). D507TM144 ⑦ Install the idler(1). D507TM145 ⑧ 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 ⑨ Fasten the idler(1) and the single parts by means of the retaining ring(2).
Page 139 ⑩ Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM148 ⑪ Install the piston ring(1). D507TM149 ⑫ Install the stud(1). · m Tightening torque - - - - - - - - - - - - - - M =1.7kg ※...
Page 140 ② Install the piston ring(1). D507TM152 ③ Install the sealing cap(1). Wet the contact surface with loctite type No.262. D507TM153 ④ 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 ⑤...
Page 141 ⑥ 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 ⑦ Mount the needle cage(1). D507TM157 ⑧ Install the idler(1). D507TM158 ⑨ Mount the axial washer(1), axial cage(2) Chamfer and running disc(3).
Page 142 ⑩ Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM160 ⑪ Install the piston ring(1). D507TM161 ⑫ Install the screw plug(1). (S)Lever riveting tongs 5870 320 016 D507TM162 ※ Check closing respective opening of the clutch by means of compressed air at the bore(1).
Page 143 Input ① Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM164 ② Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM165 ③ Have the snap ring(1) engaged into the annular groove of the turbine wheel shaft(2). D507TM166 ④...
Page 144 ENGINE CONNECTION, PRESSURE OIL PUMP AND INSTALLATION OF THE CLUTCHES Install all bearing outer rings into the bearing bores of both transmission housing sections. ※ Should contrary to the recommendations the taper roller bearing of the clutches as well as of the input not be replaced, the assignment(bearing inner and outer rings) has to be kept at least .
Page 145 ② Fasten the screen sheet(1) by means of cap screws(2). Tightening torque(M8/8.8) - - - M =2.3kg·m D507TM174 ③ 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 146 ⑥ Install the O-rings(3) and fasten the suction pipe(1) by means of cap scre- ws(2). =2.3kg · m Tightening torque(M8/8.8) - - - M D507TM178 ⑦ Grease the rectangular rings(see arrows) and align them, centrically. ※ Wet the mounting face with sealing com- pound loctite(Type No.574) D507TM179 ⑧...
Page 147 ⑩ 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.
Page 148 ⑭ Install the retaining ring(1) and the O- ring(2). ※ Grease the O-ring D507TM186 ⑮ 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.
Page 149 Cautiously place the converter bell(1) by means of the lifting equipment to the tran-smission until contact is obtained. (S)Eyebolts assortment 5870 204 002 (S)Lifting chain 5870 281 047 D507TM190 Pressure oil pump ※ If running-in marks should be found in the pump housing or on the cam disc, the complete pump has to be replaced.
Page 150 Installation of the external and internal rotor ※ Install the external rotor. Chamfer shows to the pump base (cannot be seen in the picture). ※ Install the internal rotor. Gearing(arrow) shows downwards. D507TM194 ① Put on the cam disc and by means of two cap screws(1) fasten it radially.
Page 151 ③ 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. =4.7kg · m Tightening torque(M10/8.8) - - M 2 = Bolted connect.
Page 152 Inductive transmitters, valves, oil filters and oil drain plug, screw plugs ① Install the converter pressure back-up valve. 1 = Piston 2 = Compression spring 3 = O-ring(27x2) 4 = Screw plug(30x1.5) ※ =10.2kg · m Tightening torque - - - - - - - - - - - - - - - M D507TM201 ②...
Page 153 ④ Installation of: 1 = Inductive transmitter - n Internal speed input 2 = Inductive transmitter - n Turbine 3 = Breather ※ =3.1kg · m Tightening torque(1 and 2) - - M =1.2kg · m Tightening torque(3) - - - - - - - - - - - M Fasten the cove replate(4) by means of hexagon screws(5).
Page 154 ELECTRO-HYDRAULIC CONTROL UNIT WITH PROPORTIONAL VALVES ※ Different versions as to the positions of the wiring harness are possible. · The following sketches shows the sections of the electro-hydraulic control unit. Pressure reducing valve (9 bar) Main pressure valve Housing (16+2 bar) Wiring harness Cover...
Page 155 Mounting of the electric control unit ※ All single parts are to be checked for damaged and replaced, if required. Prior to installation check the mobile parts in the housing for functionality. Piston can be replaced individually. Oil the single parts prior to installation acc. to the list of lubricants. ①...
Page 156 ④ 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 ⑤ Preload the pistons with cap screws and remove the cyl. pins(assembly aid)again. D507TM218 ⑥...
Page 157 · Preassemble the opposite side ⑧ 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.
Page 158 ⑪ 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. · m Tightening torque - - - - - - - - - - - - - M =0.56kg D507TM224 ⑫...
Page 159 ⑮ 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) ※...
Page 160 Provide the screw plugs(1) with new O- rings and install them. ※ =0.61kg · m Tightening torque - - - - - - - - - - - - - M D507TM232 Insert the pressure relief valve(1) and lock it with the indented ring(2). (S)Drive mandrel 5870 705 012 D507TM233...
Page 161 Mounting of the filter(pressure filter) Fasten the filter head(1) with new O-rings ① by means of cap screws(2) to the trans- mission housing. · m Tightening torque(M8) - - - - - - - M =2.4kg (S)Torque spanner 5870 203 034 (S)Socket spanner TX-40 5870 042 004 D507TM236 The filter is to be installed as follows:...
Page 162 Loctite. (16) The bolted or keyed assemblies safeties are to be checked according to instructions ; in case of doubt, consult Hyundai dealer. (17) Refill the oil after assembly. (18) Repair weldment is only allowed after consultation with Hyundai. 3-114...
Page 163 USING OF LOCTITE AND OPERATING SUPPLIES Kind Type Color Application Loctite Blue Lightly locked screws Middle locked screws Green Highly locked screws Green Increased coefficient of friction in contact surfaces Orange Surface gasket White Special gasket Light-green Glueing with big width of slit Epple Grey Surface gasket...
Page 164 UTILIZATION OF LOCTITE AND OPERATING SUPPLIES Hub assembly Safety blocked parts Joint Loctite Operating supplies Spacer ring Contact surface Axle spindle Screws Axle spindle Contact surface Grommet In planetary housing Disk In axle spindle Adjusting screw with nut In planetary housing Support Screw Ring gear retainer...
Page 165 TIGHTENING TORQUES Unit : N ¡⁄ m Metric standard thread Screw Screw Screw Thread 10.9 12.9 1050 1220 1100 1550 1800 1450 2100 2450 Unit : N ¡⁄ m Metric fine thread Screw Screw Screw Thread 10.9 12.9 M 8×1 M10×1 M10×1.25 M12×1.25...
Page 166 Tightening torques of wheel nuts Wheel nut with spring lock Wheel nut with clamp Wheel nut with thrust collar washer (For clamp fixation) (For rims with centering) ① Wheel nut with spring lock washer Dimensions Phosphorus darkened Galvanized 270Nm 250Nm M18×1.5 450Nm 350Nm...
Page 167 Tightening torques for castle nuts on ball joints for track rods and ram cylinders The tightening torques of the different thread dimensions of the joints are applicable for nuts of quality S6. Cone size Thread Torque d1(mm) d2(mm) (Nm) 200~220 M20×1.5 280~300 M24×1.5...
Page 168 SERVICE TOOLS When ordering service tools please provide order number(Installation drawing no), respective fabrication number→ see identification plate.(The illustrations are not binding for the design) Spanner for wheel safety nut 100D7XL14 100D7XL15 Spanner for splined nut(hub assembly) 100D7XL16 3-120...
Page 169 Seal ring sleeve driver. 100D7XL17 Spanner for thread rings. (Differential bearing) 100D7XL18 Spanner for counter nut. (Planetary gear drive) 100D7XL19 Assembly cone for O-ring. (Differential lock) 100D7XL82 3-121...
Page 170 Centering tool for discs. 100D7XL20 Installation tool for face seal. 100D7XL21 3-122...
Page 171 ASSEMBLY DRIVE ASSEMBLY Adjustment of gear meshing of gleason gears ① ① Perfect marking To become a perfect gear meshing is only possible, if the fabrication number of the drive pinion (marked on the end face) and the ring gear(marked on the circumference) are corresponding.
Page 172 Securing of the striking nut The brim of the striking nut has to be sheared only along the slot flank and the corner has to be bent on the slot ground. 100D7XL26 100D7XL25 ① Using of Loctite and other operating supplies Striking nut at drive flange - In thread : Assembly paste with MoS (exception through drive pinion see point Z).
Page 173 ③ ③ Drive assembly D 51 100D7XL27 3-125...
Page 174 Adjustment drive pinion distance To obtain the proper tooth flank contact, adjust the axial position of the drive pinion with the thickness of the adjustment disk. The necessary thickness of the adjustment disk for first time assembly can be obtained by measurement(see calculation example).
Page 175 Assembly of drive pinion bearing ① Insert the two outer rings of the taper roller bearings into the differential carrier. ② Calculate the thickness C of the spacer ring. Place the two inner rings of the taper roller bearings in their outer rings. Measure A.
Page 176 ASSEMBLY OF THE DIFFERENTIAL Before assembly all of the bevel gears and the thrust rings should be well oiled. Place one differential side gear with the side gear thrust washer in the differential case. Install the spider with differential gears and differential pinion thrust washers in the differential case.
Page 177 ASSEMBLY OF DRIVE ASSEMBLY Place the differential with the outer rings of the taper roller bearings on the differ- ential carrier which is in a vertical position, with mounted drive pinion. Mount the differential straps and align them with the thread rings. During this operation be careful of the alignment marks on the differential straps with respect to the differential carrier.(Do...
Page 178 ASSEMBLY OF HUB ASSEMBLY Assembly of the spacer ring Coat the seat of the spacer ring on the steering knuckle respective axle spindle with Loctite 572. Heat the spacer ring to about 100 C and push it by gently striking onto the steering knuckle respective axle spindle.(The steering knuckle respective axle spindle must be free of corrosion) Oil the seal ring tread onto the spacer ring.
Page 179 ASSEMBLY OF THE DRIVE ASSEMBLY ONTO THE AXLE HOUSING 100D7XL39 100D7XL40 Coat the contact surface of the axle housing with Epple 33(at version through drive with Loctite 510), and mount the complete drive assembly. The axle housing being placed in a horizontal position, secure the screws with Loctite 262.
Page 180 Mount wheel hub ① Push the pre-assembled wheel hub(9) parallel onto the axle spindle respective steering knuckle. ※ Be carefully do not damage the seal rings. 100D7XL41 Adjustment of wheel bearings ① ① Tightening torque of the wheel safety nut. Series ②...
Page 181 Assembly of the face seal 1 Seal ring 2 Rubber toric ring 3 Housing retaining lip 4 Housing ramp 5 Seal ring housing 100D7XL46 ① Seal rings, torics, and housings must be clean and free of any oil film, dust, or other foreign matter.
Page 182 ⑦ Put the installation tool(9) onto the seal ring(1) with toric ring(2). Lower the rings into a container with lsopropanol until all surfaces of the toric(2) are wet. 100D7XL50 ⑧ Toric sliding on retainer ramp. 100D7XL51 ⑨ Toric caught on housing retainer lip. 100D7XL52 ⑩...
Page 183 ⑪ After dipping the seal assembly in the solvent, shake the excess solvent from the seal assembly and immediately "pop" the seal into the housing with a firm push of the installation tool. Remove the installation tool and check the seal standout height at several places around the circumference of the ring to verify an accurate installation.
Page 184 Be sure there is no visible debris on § either of the seal faces even a small piece of lint can hold the seal faces apart and cause leakage. 100D7XL57 After successful installation, wait one §æ minute for the lsopropanol to dry before assembling the two seal halves in the final loaded position.
Page 185 After the unit to be sealed is assembled, a post-assembly leakage test can be performed to insure the seal is properly installed. A vacuum check is recommended rather than a pressure check as vacuum checks are more sensitive. Many users find this an easy check to combine with a vacuum fill technique for the lubricant.
Page 186 ASSEMBLY OF PLANETARY GEAR DRIVE Prepare the ring gear and the ring gear carrier Heat the taper roller bearing inner ring with cage(1) to about 100。 C and install it onto the ring gear carrier(2). Place the ring gear(3) onto the ring gear carrier. Bolt the retainer(5) with the screws(4), secure the screws with Loctite 270.
Page 187 Assembly of planetary gear ① Prepare planetary gear : Install the needle bearing(10, 11) into the planetary gear(12, 13). 100D7XL63 ② Insert the preassembled planetary gears (12, 13) with needle bearings (10, 11), rings(16) (if present) and thrust disks (14 , 15) into the planetary housing (22, 23) (planetary housing in horizontal position).
Page 188 Disassembly of planetary gear ① Knock the locking pin(20, 21) completely to the inner side of the planetary pin. 100D7XL66 ② Press the planetary pin in direction of arrow out of the planetary housing. ※ Because of the difference of diameter of 0.1mm do not press the planetary pin against the direction of arrow out of the planetary housing, to prevent damaging...
Page 189 Assembly / disassembly cageless needle bearing(planetary gear bearing) 100D7XL39 100D7XL40 Assembly ① Version 1 Install the needle bearing with mounting bushings into the planetary gear, thereby the outer mounting bushing will be stripping. Insert the planetary gear with thrust disks into the planetary housing.
Page 190 Assembly of the planetary housing Place O-ring(30) into the slot of the planetary housing. Install the planetary housing and bolt it. Adjustment of the axial clearance 100D7XL72 The axial clearance between axle shaft respective universal joint and adjusting screw must be 0.3~0.7mm.
Page 191 Assembly of service brake 100D7XL83 Brake carrier Seal ring 17 Seal ring Brake housing 10 Seal ring 18 Screw plug Piston 11 Connection piece 19 O-ring Inner disk 12 Breather 20 Face seal Outer disk 13 Sealing ring 21 Screw O-ring 14 Sealing ring 22 Tube...
Page 192 Assembly of the piston seals Place piston with the larger diameter downwards. Note succession of the sealing parts at fitting. Install O-rings free of torsion and loops. Assembly of O-ring and supporting ring Install the supporting rings to the averting side of pressure. ⇒...
Page 193 Assembly of the piston 100D7XL86 Lubricate cylinder bore, apply the thread holes at wet disk brakes of dimension X270 and X340 with Loctite 243, at wet disk brakes of dimension X460 and X650 with Loctite 262 and install and screw the bushing(if present). Place the piston onto the brake carrier(do not cant it). ※...
Page 194 ① ① Prepare housing and check the air gap 100D7XL87 Lay discs into the housing. ② ② Check the air gap Air gap = measure A-measure B(measured without pressure) Rated size about 0.5mm smaller than the air gap pressurized(see table). Install O-ring(brake housing / brake carrier) free of torsion and loops.
Page 195 Finish assembly Place the brake carrier onto the brake housing and bolt it. Mount breather with connection piece and seal ring, screw plugs with seal rings. Check brake hydraulic system for leaks(see tightness checking instruction). Install O-ring(Brake carrier / axle spindle respective steering knuckle) free of torsion and loops. ①...
Page 196 Is the measured dimension bigger than the marked dimension and max. wear dimension, unconditional consult Hyundai dealer. 100D7XL76 After working at the brake, bleed the brake hydraulic system and check for tightness. 3-148...
Page 197 Brake disk 100D7XL78 Network - like formation of cracks admissible Radially shaped crack not admissible C Uneven brake surface characteristics below 1.0mm admissible D Continuous cracks not admissible (10) Spring - loaded sliding caliper brakes Safety notes : ·Warning Before commencing work on the parking brake, ensure that no unintended machine movement can happen when the braking effect is removed.
Page 198 GROUP 4 ADJUSTMENT 1. CHECKING THE RING GEAR BACKFACE RUNOUT Runout specification : 0.20mm(0.008-inch) maximum Attach a dial indicator on the mounting INDICATOR flange of the carrier. Rotate ring gear . Adjust the dial indicator so that the plunger or pointer is against the back surface of the ring gear.
Page 199 2. ADJUSTING THE GEARSET BACKLASH Backlash specification : 0.13~0.18mm (0.005-0.007inch) If the old gearset is installed, adjust the backlash to the setting that was measured before the carrier was disassembled. If a new gearset is installed, adjust the backlash to the correct specification for new gearsets.
Page 200 3. ADJUSTING TOOTH CONTACT PATTERN OF THE GEARSET Always check tooth contact pattern on the drive side of the gear teeth. Apply marking compound to approximately 12 teeth of the ring gear. HEEL BOTTOM DRIVE SIDE (CONVEX) D507AX57 D507AX58 Rotate ring gear forward and backward so that the 12 marked teeth go past the drive pinion six times to get a good contact pattern.
Page 201 LOW PATTERN D507AX61 GOOD PATTERN IN OPERATION (USED GEARS) D507AX62 High pattern : A high contact pattern Move pattern toward indicates that the pinion was installed too bottom shallow into the carrier. To correct, move the pinion toward the ring gear by decreasing the shim pack between pinion spigot and inner bearing cone.
Page 202 4. ADJUSTMENT OF GEAR MESHING OF GLEASON GEARS To become a perfect gear meshing is only possible, if the fabrication number of the drive pinion(marked on the end face) and the ring gear(marked on the circumference) are corresponding. Perfect marking The following figures are showing improper gear meshing marks of the ring gear.
Page 203 5. SECURING OF THE STRIKING NUT The brim of the striking nut has to be sheared only along the slot flank and the corner has to be bent on the slot ground. 100D7XL25 100D7XL26 Using of Loctite and other operating supplies Striking nut at drive flange - In thread : Assembly paste with MoS (Exception through drive pinion see point Z)
Page 204 6. ADJUSTMENT DRIVE PINION DISTANCE To obtain the proper tooth flank contact, adjust the axial position of the drive pinion with the thickness of the adjustment disk. The necessary thickness of the adjustment disk for first time assembly can be obtained by measurement(see calculation example).
Page 205 SECTION 4 BRAKE SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32 Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-40 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-43...
Page 206 ECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE ※ The brakes are operated by a pressure compensated, closed center hydraulic system. Flow is supplied by a fixed displacement, gear type brake pump. BRAKE SYSTEM The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit and park brake circuits.
Page 207 FULL POWER HYDRAULIC BRAKE SYSTEM Response time ADVANTAGES - The full power hydraulic Full power brake actuation VS brake system has several advantages over Air/Hydraulic brake actuation traditional brake actuation systems. These systems are capable of supplying fluid to a 1000 range of very small and large volume service brakes with actuation that is faster...
Page 208 2. HYDRAULIC CIRCUIT Drive axle Return Steering line unit EF CF TO THE AXLE POSITIONER LIFT TILT FROM THE AXLE V4 V1 110D7EBS01 Main pump 11 RCV 23 Strainer Brake pump 17 Pressure switch 24 Return filter Cut off valve 18 Pressure switch 31 Fan drive motor Brake valve...
Page 209 SERVICE BRAKE RELEASED Drive axle Return Steering line unit EF CF TO THE AXLE LIFT TILT POSITIONER FROM THE AXLE V4 V1 110D7EBS02 When the pedal of brake valve(8) is released, the operating force is eliminated by the force of the spring, and the spool is returned.
Page 210 SERVICE BRAKE OPERATED Drive axle Return Steering line unit EF CF TO THE AXLE LIFT TILT POSITIONER FROM THE AXLE V4 V1 110D7EBS03 When the pedal of brake valve(8) is depressed, the operating force overcomes the force of the spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and at the same time the hydraulic oil controlled the pressure level by the cut-off valve(5) enters the piston in the front and rear axles.
Page 211 PARKING BRAKE RELEASED Drive axle Parking brake switch Return Steering Parking brake line unit solenoid valve EF CF TO THE AXLE LIFT TILT POSITIONER FROM THE AXLE V4 V1 110D7EBS04 When the parking brake switch is pressed B position, the solenoid valve is energized and the hydraulic oil controlled the pressure level by the cut-off valve enters the parking brake.
Page 212 PARKING BRAKE OPERATED Drive axle Parking brake switch Return Steering Parking brake line unit solenoid valve EF CF TO THE AXLE LIFT POSITIONER TILT FROM THE AXLE V4 V1 110D7EBS05 When the parking brake switch is pressed A position, the solenoid valve is deenergized and the valve open the drain port.
Page 213 3. BRAKE PUMP STRUCTURE 110D7EBS06 Body 10 Driven gear 19 Snap ring Body 11 Driven gear 20 Back up ring Body 12 Driven gear 21 Middle flange Mounting flange 13 Nut 22 Middle flange Rear cover 14 Washer 23 Middle flange Pressure plate 15 Square ring 24 Through shaft...
Page 214 PRINCIPLE OF OPERATION Mechanism for delivering oil The drawing at right shows the operational principle of an external gear pump in which two gears are rotating in mesh. The oil entering through the suction port is Suction Discharge trapped in the space between two gear teeth, and is delivered to the discharge port as the gear rotates.
Page 215 Internal oil leakage Oil leaks from a place under higher pressure to a place under lower pressure, provided that a gap or a clearance exists in between. In the gear pump, small clearances are provided between the gear and the case and between the gear and the side plate to allow the oil to leak out and to serve as a lubricant so that the pump will be...
Page 216 Forces acting on the gear The gear, whose outer surface is subjected to oil pressure, receives forces jointing towards its center. Due to the action of the delivery pressure, the oil pressure in higher on the delivery side of the pump, and due to suction pressure, is lower on the suction side.
Page 217 4. PARKING BRAKE SYSTEM STRUCTURE 100D7BS111 Housing Adjust screw Lining pad Pressure ring Bank of cup springs Lining pad Thrust bolt Piston Gliding bolt OPERATION The two identical brake pads and slide freely on the guide bolt, which is fastened in the housing. The guide bolts are guided in an additional brake anchor plate which in turn is screwed onto the vehicle, i.e.
Page 218 MOUNTING AND BASIC SETTING REGULATIONS Basic brake setting is required after mounting new brake lining plates or brake disks, as well as during all repair stages and in the event of insufficient braking performance. 100D7BS112 Thrust bolt Screw cap Even surface Bank of cup springs Lock nut Socket wrench...
Page 219 BASIC SETTING REGULATION ① Turn the adjusting screw manually clockwise until both brake pads make contact with the brake disk. Then it is not longer possible to turn the adjusting screw without exerting a major amount of force. ② Turn the adjusting screw anticlockwise in order to set the following rated clearances. Model Adjusting screw Clearance(mm)
Page 220 EMERGENCY RELEASE OF THE PARKING BRAKE After the failure of the pressure release the parking brake by using following manual procedure. 100D7BS117 Thrust bolt Screw cap Even surface Bank of cup springs Lock nut Socket wrench Adjusting screw Piston The vehicle has to be secured against rolling away. Release the screw cap and unscrew Release the lock nut(size 24 or 30) and turn the adjusting screw with socket wrench size 8 or 10 manually counter-clockwise until the brake disc is free.
Page 221 MAINTENANCE AND REPAIR WORK Maintenance and exchange of brake pads The brake pads themselves are maintenance free. All that is required here is a check for damaged parts, as well as inspection to ensure that the brake disk remains easy running. The thickness of the brake lining must be subjected to a visual inspection at regular intervals, which depend on vehicle usage, but every six months at the latest.
Page 222 100D7BS114 Guide bolt Castellated nut Lining pad 6a Safety splint Lining pad 6b Safety clip Permanent magnet ⑥ Depending on the free space available, release one of the two guide bolts, removing the safety splint, unscrewing the castellated nut and pulling the guide bolt out of the brake anchor plate. Now, the brake lining pads can be removed tangentially to the brake disk.
Page 223 Changing the seal DETAIL A DETAIL B 100D7BS115 Piston Circlip Bank of cup spring Adjusting screw Seal Detail of the seal Lock nut Guide bolt Detail of the seal Housing Thrust bolt ※ Faulty seals must be exchanged in accordance with the instructions below. ①...
Page 224 General Any discovered defects or damage to parts not listed here must naturally be repaired or replaced using original parts. For any other information not contained in these instructions or for more detailed instructions, please contact Hyundai dealer. 4-19...
Page 225 5. BRAKE VALVE STRUCTURE 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 226 OPERATION Hydraulic circuit Port Port name Port size PF3/8 Main pressure port Drain port PF3/8 Brake cylinder port PF3/8 Pressure switch port PF1/4 110D7EBS08 4-21...
Page 227 Purpose The purpose of the brake valve is to sensitively increase and decrease the braking pressure when the brake pedal is actuated. Ready position 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 228 Repair work When working on the braking system, always make sure that there is absolutely no pressure in the system. Even when the engine is switched off there will be some residual pressure in the system. ※ When doing repair work, make sure your environment is very clean. Immediately close all open ports on the components and on pipes using plugs.
Page 229 6. CUT-OFF VALVE STRUCTURE 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 230 7. BRAKE ACCUMULATOR STRUCTURE Item 81L1-0004 Diameter 110mm Mounting height 164mm Nominal volume 0.7ℓ Priming pressure 50kgf/cm Operating medium Operating pressure Max 150kgf/cm Thread M18×1.5 Priming gas Nitrogen A Fluid portion C Diaphragm B Gas portion D Valve disk (770-3ATM) 4-22 OPERATION Purpose Fluids are practically incompressible and are thus incapable of accumulating pressure energy.
Page 231 Maintenance of the accumulator No special maintenance beyond the legal requirements is necessary. The accumulator should be checked annually. It should be replaced if the initial gas pressure has fallen by more than 30%(Please refer to Performance testing and checking of the accumulator).
Page 232 Repair work When working on the braking system, always make sure that there is absolutely no pressure in the system. Even when the engine in switched off there will be some residual pressure in the system. ※ When doing repair work, make sure your environment is very clean. Immediately close all open ports on the components and on pipes using plugs.
Page 233 8. PRESSURE SWITCHES STRUCTURE - Normally closed - Normally open 7407ABS20 ·Technical data Adjusting range Adjusting pressure Voltage Item Type Medium kgf/cm kgf/cm 95 ± 5 50 ~ 150 Max 42 Parking M12×1.5 95 ± 5 Charging M12×1.5 50 ~ 150 Max 42 5 ±...
Page 234 OPERATION Purpose The pressure switches are used to visually or audibly warn the driver of the pressure within the system. Make contact / circuit closer The pressure switch can be fitted in the braking system or directly on one of its components. The system pressure acts on an absorption area within the switch, making an electrical contact as the pressure on that area is increased.
Page 235 Adjusting and testing pressure switch The adjusting screw located between the two contact plugs can be set to the desired value within a certain range. For adjusting range, please refer to the table Technical data on the previous page. After making the adjustment, the adjusting screw should be secured using wax or a similar material.
Page 236 9. PARKING BRAKE 100D7BS109 Brake Brake disk Brake carrier Hexagon screw O-ring Hexagon screw 4-31...
Page 237 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS This procedure is designed so the mechanic can make a quick check of the system using a minimum amount of diagnostic equipment. If you need additional information, read structure and function, Group 1.
Page 238 ※Hydraulic oil must be at operating temperature for these checks. Item Description Service action Parking brake capacity Start engine. check Check completed. Fasten seat belt. Seat belt must be worn NOT OK while doing this check to Release parking brake and put Inspect parking brake.
Page 239 Item Description Service action Service brake pump flow Stop engine. check Check completed. Operate brake pedal approximately 20 ※ Hydraulic oil must be at times. NOT OK operating temperature Start engine and run at low idle. Check for brake circuit for the check.
Page 240 Item Description Service action Brake accumulator Start and run engine for 30 precharge check seconds. Check completed. ※The axles and hydraulic Stop engine and turn start switch NOT OK oil must be at operating to ON and wait 5 seconds. Make sure brake pedal is temperature for this not binding and keeping...
Page 241 Item Description Service action Service brake pedal Slowly depress brake pedal. check Check completed. Listen for a hissing noise that indicates oil is flowing to brake NOT OK pistons. Inspect for debris under brake pedal. Inspect LISTEN/FEEL : A hissing noise clutch cut-off linkage.
Page 242 2. TROUBLESHOOTING SERVICE BRAKE Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure(See section 1) Step 2.
Page 243 Problem Cause Remedy Brakes chatter Air in brake system Do brake bleed procedure. Worn brake surface material Inspect brake surface material. Wrong oil in differential Drain. Refill. Hissing noise when Leakage in brake valve, or brake Do brake system leakage test. brake pedal is held with piston engine stopped...
Page 244 PARKING BRAKE MALFUNCTIONS Problem Cause Remedy Brake will not hold Pads not adjusted correctly Adjust parking brake. Malfunctioning parking brake Inspect and replace. solenoid Worn brake disk and / or brake Disassemble, inspect, repair. pads Brake piston hangs up in bore Remove and inspect.
Page 245 GROUP 3 TESTS AND ADJUSTMENTS 1 1 . PARKING BRAKE PERFORMANCE MEASUREMENT CONDITION Tire inflation pressure:Specified pressure Road surface : Flat, dry, paved surface with 1/5(11° 20') gradient. Machine : In operating condition gradient Item Standard value 11 20' Parking brake Keep machine on 20% performance (11°...
Page 246 BASIC SETTING REGULATION Turn the adjusting screw manually clockwise until both brake pads make contact with the brake disk. Then it is not longer possible to turn the adjusting screw without exerting a major amount of force. Turn the adjusting screw anticlockwise in order to set the following rated clearances. Model Adjusting screw Clearance(mm)
Page 247 3. HYDRAULIC BRAKE BLEEDING PROCEDURE Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
Page 248 GROUP 4 DISASSEMBLY AND ASSEMBLY 1. BRAKE PUMP STRUCTURE 110D7EBS06 Body 10 Driven gear 19 Snap ring Body 11 Driven gear 20 Back up ring Body 12 Driven gear 21 Middle flange Mounting flange 13 Nut 22 Middle flange Rear cover 14 Washer 23 Middle flange Pressure plate...
Page 249 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 250 1st working section ① Remove the pressure plate(1) with prearranged parts, O-ring(2) and back up ring(3) from the working section and examnine it carefully. ② Remove square ring(6) posited on the groove of body. ③ Pull out driving gear(5) and driven gear(4) keeping gears as straight as 110D7EBS12 possible.
Page 251 Separation intermediate section ① Remove the through shaft and intermediate section as well as guard pins. ② Remove snap ring(1) and shaft seal(2) with proper tool. 110D7EBS16 rd working section ① Do same job as for 1st and 2nd sections. 110D7EBS17 ASSEMBLY Preassemble...
Page 252 Mounting flange ⑤ Locate shaft seal(1) inside shaft hole to the end. ⑥ Insert snap ring(2) and locate it into the groove prearranged. 110D7EBS20 Separation intermediate section ⑦ Insert shaft seal(1) and snap ring(2) with same way as for mounting flange(3). ⑧...
Page 253 ⑦ Locate 2nd body on the semi assembled parts. ⑧ Insert all components inside of working body with same way as for 3rd section. 110D7EBS24 ⑨ Assemble standard intermediate cover(1) to the semi assembled part. 110D7EBS25 ⑩ Assemble 1st working section with same way as for 2nd and 3rd section.
Page 254 ⑪ Assemble preassembled mounting flange(1) to the body. ※ It is recommended to smear clean grease to the shaft seal before assembling to avoid any damage to the shaft seal by edge of shaft. ⑫ Tighten the bolts(2) with in a crisscross pattern to a torque value of 4.59kgf·...
Page 255 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 256 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 ① Install oil seal(9), plain washer(23), stop ring(24), DU bushing(11).
Page 257 ③ Tighten plug(3) - Tool : 19mm spanner - Tightening torque : 14.0~16.5kgf·m ress-in the DU bushing(11) with a exclusive jig. Be careful of dust and scrap after washing the parts. 110D7EBS53 ④ Spring retainer(7), main spring(6) and holder(4). 110D7EBS54 ⑤...
Page 258 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 ① Pedal plate(12) assembly - Tool : 6mm torque wrench - Tightening torque : 2.5~3.0kgf·m 110D7EBS58 ②...
Page 259 ④ Rubber cover(13-2) 13-2 110D7EBS61 100D7BS20 ⑤ Hexagon bolt(19) - Tool : 13mm spanner - Tightening torque : 2.0kgf·m 110D7EBS62 Never remove the hexagon bolt. (Pressure setting valve deviation occurs) 4-54...
Page 260 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 261 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering cylinder Main pump OUTLET Main Steering wheel control valve Steering unit 110D7ESS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and piping. The steering force given to the steering wheel enters the steering unit through the steering column.
Page 262 2. HYDRAULIC CIRCUIT Cut off valve Fan drive motor EF CF To the axle From the axle Return line 110D7ESS02 Main pump 23 Suction strainer Auxiliary pump 24 Return filter Steering unit 34 Hydraulic tank 12 Steering cylinder...
Page 263 NEUTRAL Cut off valve Fan drive motor EF CF To the axle From the axle Return line 110D7ESS03 · The steering wheel is not being operated so control spool(G) does not move. · The oil from the main pump(1) enters port P of steering unit(4) and the inlet pressure oil moves the spool(D) to the left.
Page 264 LEFT TURN Cut off valve Fan drive motor EF CF To the axle Priority valve From the axle Return line 110D7ESS04 · When the steering wheel is turned to the left, the spool(G) within the steering unit(4) connected with steering column turns in left hand direction. ·...
Page 265 RIGHT TURN Cut off valve Fan drive motor EF CF To the axle Priority valve From the axle Return line 110D7ESS05 · When the steering wheel is turned to the right, the spool(G) within the steering unit(4) connected with steering column turns in right hand direction. ·...
Page 266 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 267 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 268 4. STEERING CYLINDER STRUCTURE 100D7SS06 Tube assembly Rod seal 11 Back up ring Rod assembly Back up ring 12 O-ring Piston seal Dust wiper 13 Ping bushing Gland Snap ring Du bushing 10 O-ring OPERATION This machine use to cross connected cylinder for steering operation. The steering cylinder use a gland(4) to remove piston and sealed seals.
Page 269 G G ROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS This procedure is designed so the service man can make a quick check of the steering system using a minimum amount of diagnostic equipment. If you need additional information, refer to structure and function in group 1.
Page 270 ※ 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.
Page 271 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 272 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 273 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 274 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 275 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 276 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 277 GROUP 3 TESTS AND ADJUSTMENTS 1 1 . HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY ※ Service equipment and tool. ·Portable filter caddy ·Two 3658mm(12ft) × 1" I.D. 100R1 hoses with 3/4 M NPT ends ·Quick disconnect fittings ·Discharge wand ·Various size fittings and hoses ※...
Page 278 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 115ℓ(30.4U.S. gal).
Page 279 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 280 3. STEERING UNIT LEAKAGE TEST · · SPECIFICATION Oil temperature 45±5。 C(113±9。 F) Engine speed High idle Cap fitting Maximum leakage 7.5ℓ/min(2gpm) · AUGE AND TOOL Temperature reader Measuring container(Approx. 20ℓ) Stop watch Install temperature reader. (See temperature reader installation procedure in this group).
Page 281 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 282 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 283 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 284 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 With O - ring...
Page 285 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 286 ⑦ Remove drive(8). ⑧ Remove spacer plate(7). ⑨ Replace O-ring(24) in housing(10). ※ Be careful that O-ring size(23) and (24) is different. 100D7SS14 ⑩ Put spacer plate(7) on housing(10). Align bolt holes in spacer plate(7) with tapped holes in housing(10). ※...
Page 287 ⑭ Install spacer(s)(5) in gerotor(4). ⑮ 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 288 ② Remove seal gland bushing(22) from housing(10). 100D7SS19 ③ Replace O-ring(18) with new one. ④ 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 289 · · 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 290 2. STEERING CYLINDER STRUCTURE 100D7SS06 Tube assembly Rod seal 11 Back up ring Rod assembly Back up ring 12 O-ring Piston seal Dust wiper 13 Ping bushing Gland Snap ring DU bushing 10 O-ring 5-30...
Page 291 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.
Page 292 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 293 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...
Page 294 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 295 DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the balance weight part of the truck. Hub nut Loosen the hub nut and take off the steering wheel tire.
Page 296 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 297 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 298 ECTION 6 WORK EQUIPMENT GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC SYSTEM OUTLINE The hydraulic system is a pilot operated, open center system which is supplied with flow from the fixed displacement main hydraulic pump. The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow from the first(Steering) pump.
Page 299 2. HYDRAULIC CIRCUIT Drive axle S1 S2 L1 L2 21MPa From RCV From RCV From RCV From RCV 12MPa 16.5 16.5 Tilting Cabin Hyd Circuit 21MPa TO THE AXLE LIFT TILT POSITIONER FROM THE AXLE V4 V1 110D7EHS01 Main pump 24 Return filter 13 Lift cylinder Auxiliary pump...
Page 300 3. WORK EQUIPMENT HYDRAULIC CIRCUIT S1 S2 L1 L2 Steering system 21MPa From RCV From RCV From RCV From RCV 16.5 16.5 Return line Cut off valve EF CF 21MPa AXLE LIFT TILT POSITIONER V4 V1 110D7EHS02 Main pump 13 Lift cylinder 23 Strainer Auxiliary pump 14 Tilt cylinder...
Page 301 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION L1 L2 S1 S2 Load check valve Steering system 21MPa LIFT From RCV From RCV From RCV From RCV Load check valve 16.5 16.5 Return line Cut off valve EF CF 21MPa AXLE LIFT...
Page 302 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION S1 S2 L1 L2 Steering system 21MPa LOWER From RCV From RCV From RCV From RCV 16.5 16.5 Return line Cut off valve 21MPa AXLE LIFT TILT POSITIONER V4 V1 110D7EHS04 When the lift control is pushed forward, the spool is moved to lower position by the pilot oil pressure from the remote control valve(11).
Page 303 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION L1 L2 S1 S2 Steering system 21MPa From RCV From RCV From RCV From RCV TILT 16.5 Load check valve 16.5 Return line Cut off valve EF CF 21MPa AXLE LIFT TILT POSITIONER...
Page 304 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION L1 L2 S1 S2 Steering system 21MPa From RCV From RCV From RCV From RCV TILT 16.5 Load check valve 16.5 Return line Cut off valve EF CF 21MPa AXLE LIFT TILT POSITIONER...
Page 305 WHEN THE FORK POSITIONER LEVER IS IN THE SPREAD-OUT POSITION(OPTION) S1 S2 L1 L2 Steering system 21MPa From RCV From RCV From RCV From RCV 16.5 16.5 From RCV From RCV Return line Cut off valve EF CF 21MPa AXLE LIFT TILT POSITIONER...
Page 306 WHEN THE FORK POSITIONER LEVER IS IN THE CLOSE POSITION(OPTION) S1 S2 L1 L2 21MPa From RCV From RCV From RCV From RCV 16.5 16.5 From RCV From RCV EF CF 21MPa AXLE LIFT TILT POSITIONER V4 V1 110D7EHS08 When the fork positioner lever is pushed forward, the spool is moved to fork close position by the pilot oil pressure from the remote control valve(11).
Page 307 4. MAIN PUMP STRUCTURE 25 26 100D7PMP00 Snap ring 10 Drive gear 19 Plug Shaft seal 11 Driven gear 20 Priority valve body Assembling bolt 12 Steel bushing 21 Compensation spool Assembling washer 13 Square ring 22 Cap Mounting flange 14 Front working section 23 LS port connector Copper bushing...
Page 308 INSTRUCTION Hydraulic pumps used for the work equipment hydraulic units on construction machinery are pressure loaded type gear pumps. This gear pump could run under 300kgf/§†(4,350psi) maximum. The pressure loaded type gear pump is designed so that the clearance between the gear and the side plate can be automatically adjusted according to the delivery pressure.
Page 309 PRINCIPLE OF OPERATION Mechanism for delivering oil The below drawing shows the operational principle of an external gear pump on which two gears are rotation in mach. The oil entering through the suction port is Suction Discharge trapped in the space between two gear teeth, and is delivered to the discharge port as the gear rotates.
Page 310 If there is no resistance in the oil passage into which the discharged oil flows, the oil merely flows through the passage, producing no increase in pressure. If however, the oil passage is blocked with Discharge Suction something like a hydraulic cylinder, there will be no other place for the oil to flow, so the oil pressure will rise.
Page 311 Forces acting on the gear The gear, whose outer surface is subjected to oil Drive gear pressure, receives force jointing towards its center. Due to the action of the delivery pressure, the oil pressure in higher on the Suction Discharge delivery side of the pump, and due to suction side side...
Page 312 GENERAL REFERENCE Installation The direction of rotation of single-rotation pumps must be the same as that of the drive shaft. Check that the coupling flange correctly aligns the transmission shaft and the pump shaft. Flexible couplings should be used (never rigid fittings) which will not generate an axial or radial load on the pump shaft.
Page 313 5. REMOTE CONTROL VALVE STRUCTURE UT 1,2,3,4,5,6 100D7RCV00 Metering spring 14 O-ring Lever Seeger ring 15 Kit 3 Plug Seeger ring 16 Clamp Body 10 Docking rod 17 Rubber bellows Kit 1 11 Spring 18 Screw Plunger kit 12 Kit 2 19 Support kit Spring guide 13 Tie rod with nut...
Page 314 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 315 6. MAIN CONTROL VALVE STRUCTURE 30-6 30-5 30-4 30-3 33-4 30-2 30-1 33-3 31-1 31-2 33-2 31-3 34-4 31-4 34-3 31-5 31-6 33-1 30-1 34-2 31-7 30-2 31-6 30-3 30-4 30-5 30-6 34-1 35-2 31-6 31-9 31-4 35-1 35-3 31-3 31-2 31-8 33-4...
Page 316 STRUCTURE A4 B4 A6 B6 A5 B5 A2 B2 16.5 16.5 110D7EHS10 Size Port Port Port name Port name Size P1, P2 From main pump 1 5/16" - 12UNF A6, B6 To aux port(4-spool) 1 1/16" - 12UNF To hydraulic tank 1 5/16"...
Page 317 LIFT SECTION OPERATION Neutral position of lift spool Cout Cout 100D7MCV31 Inlet from hydraulic pump Return passage to tank Outlet to tank Lift spool Pilot passage PV₁ (Hydraulic pressure from joystick) Closed passage(Not used) PV₂ (Hydraulic pressure from joystick) Passage to head end of lift cylinders(lift upward) Working actuation ※...
Page 318 Upward position for lift spool Cout Cout 100D7MCV32 Inlet from hydraulic pump Return passage to tank Outlet to tank Lift spool Pilot passage PV₁ (Hydraulic pressure from joystick) Plugged passage PV₂ (Hydraulic pressure from joystick) Passage to head end of lift cylinders(lift upward) Working actuation ※...
Page 319 Downward position for lift spool Cout Cout 100D7MCV33 Inlet from hydraulic pump Return passage to tank Outlet to tank Lift spool Pilot passage PV₁ (Hydraulic pressure from joystick) Plugged passage PV₂ (Hydraulic pressure from joystick) Passage to head end of lift cylinders(lift upward) Working actuation ※...
Page 320 TILT & AUXILIARY SECTION OPERATION Neutral position of auxiliary spool Cout Cout 100D7MCV34 Inlet from hydraulic pump Return passage to tank Outlet to tank Master spool Pilot passage (Hydraulic pressure from joystick) ７ Passage to head end of cylinders (Hydraulic pressure from joystick) ８...
Page 321 Forward position for auxiliary spool Cout Cout 100D7MCV35 Inlet from hydraulic pump Return passage to tank Outlet to tank Master spool Pilot passage (Hydraulic pressure from joystick) ７ Passage to head end of cylinders (Hydraulic pressure from joystick) ８ Passage to rod end of cylinders Working actuation ※...
Page 322 Backward position for auxiliary spool Cout Cout 100D7MCV36 Inlet from hydraulic pump Return passage to tank Outlet to tank Master spool Pilot passage (Hydraulic pressure from joystick) ７ Passage to head end of cylinders (Hydraulic pressure from joystick) ８ Passage to rod end of cylinders Working actuation ※...
Page 323 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 324 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 325 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 326 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 327 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 328 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 329 . TROUBLESHOOTING SYSTEM Problem ause Remedy Large fork lowering speed. ·Seal inside control valve defective. ·Replace spool or valve body. ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. Large spontaneous tilt of ·Tilting backward : Check valve defec- ·Clean or replace.
Page 330 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.
Page 331 HYDRAULIC GEAR PUMP Problem ause Remedy Pump does not develop full ·System relief valve set too low or ·Check system relief valve for proper pressure. leaking. setting. ·Oil viscosity too low. ·Change to proper viscosity oil. ·Pump is worn out. ·Repair or replace pump.
Page 332 CYLINDER Problem ause Remedy Oil leaks out from gland ·Foreign matters on packing. ·Replace packing. through rod. ·Unallowable score on rod. ·Smooth rod surface with an oil stone. ·Unusual distortion of dust seal. ·Replace dust seal. ·Chrome plating is striped. ·Replace rod.
Page 333 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP STRUCTURE 25 26 100D7PMP00 Snap ring 10 Drive gear 19 Plug Shaft seal 11 Driven gear 20 Priority valve body Assembling bolt 12 Steel bushing 21 Compensation spool Assembling washer 13 Square ring 22 Cap Mounting flange 14 Front working section...
Page 334 GENERAL INSTRUCTIONS Check immediately that any spare parts you receive have not been damaged in shipment. Always work in a clean environment. Wash all components in solvent and blow dry with compressed air before refitting. Take care not to damage rubber seals. Avoid damaging precision machined surfaces.
Page 335 DISASSEMBLY MOUNTING FLANGE SECTION Loosen and remove the assembling bolts(3) with washers(4) from the mounting flange. Remove the square-ring(13) from the mounting flange(5). ※ Replace the square-ring if damaged. 100D7PMP01 Remove the snap-ring(1) with proper tool(Only when it is needed to replace shaft seal.) Remove the shaft seals(2) taking care not to give any damage on the surface of...
Page 336 Remove the assembling bolts(3) with washers(4) from the working section(14). Remove the square-ring(13) from the working section. 100D7PMP05 Remove the through shaft(15) from the drive gear(16). Remove the pressure plate(9) with related parts(7, 8) from the working section and examine it carefully. 100D7PMP06 Remove the drive gear(16) and driven gear(11) from the rear working section,...
Page 337 REAR WORKING SECTION Loosen and remove the assembling bolts(3) with washers(4) from the priority valve body. Loosen and remove the LS port connector(23) from the priority valve body(20). Remove the O-ring(18) from the mounting flange(17). 100D7PMP08 ※ Replace the square-ring if damaged. Loosen and remove the upper cap(22), O- ring(18) and compensator spool(21) from the priority valve body(20).
Page 338 ASSEMBLY IMPORTANT ※ It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior with a proper cleaning solvent before continuing. ※ New seals should be installed upon reassembly. REAR WORKING SECTION Tighten the lower cap(22) after putting the spring with related parts into the priority valve body.
Page 339 FRONT WORKING SECTION Locate the drive gear(10) and driven gear(11) into the rear working section(17) after fitting the parts of the pressure plate into the drive gear. ※ Locate the pressure plate(9+8+7) with care for the direction. Fit the through shaft(15) into the drive gear(10).
Page 340 MOUNTING FLANGE SECTION Insert the shaft seal(2) carefully and fit it inside of the mounting flange(5) Fit the snap ring(1) in pre-arranged position with proper. 100D7PMP02 Insert the square ring(13) into the mounting flange(5). ※ Smear clean grease on the square ring to avoid drifting away of square ring from the body.
Page 341 2. MAIN CONTROL VALVE STRUCTURE 30-6 30-5 30-4 30-3 33-4 30-2 30-1 33-3 31-1 31-2 33-2 34-4 31-3 31-4 31-5 34-3 31-6 33-1 30-1 34-2 31-7 30-2 31-6 30-3 30-4 30-5 30-6 34-1 35-2 31-6 31-9 31-4 35-1 35-3 31-3 31-2 31-8 33-4...
Page 342 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 343 INSTRUCTION FOR DISASSEMBLY AND REASSEMBLY Before disassembly, visually inspect for leakage of oil and for part that have damage and clean the valve up. Preparation for assembly put the tag on each part to prevent wrong assembly and clean the parts completely. Inspect the parts if there is any scratch or dent, and check the movement. In assembly process, follow the tightening torque specification.
Page 344 DISASSEMBLY & ASSEMBLY Replacing complete working section Loosen tightening two bolts with 17mm spanner. 100D7MCV01 Taking out working section one by one. 100D7MCV02 Remove O-rings on the surface of working section properly. Pay special attention not to give any scratch on the surface. 100D7MCV03 Prepare two sizes of O-rings.
Page 345 Locate new or repaired working section in right position according to the order of functions. 100D7MCV05 Tighten four nuts (M17) in a crisscross pattern with proper assembling torque of 4.3kgf·m(31lbf·ft). 100D7MCV06 Replacing spool & control kit Loosen 4 screws holding aluminum kits to the body with 5mm wrench.
Page 346 Take out the spool, as straight as possible. Even very little force on the spool while disassembling & assembling could make deformation on the spool. 100D7MCV09 Prepare all components before starting reassembling spool control kit. 100D7MCV10 Fit aluminum kit to the body with 5mm wrench by 1.0kgf·m(7.2lbf·ft).
Page 347 Replace old relief valve with new one. Relief valve should be fitted with proper tool, 36mm spanner, with 4.3kgf·m(31lbf· ft) torque. 100D7MCV13 6-50...
Page 348 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 349 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 350 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 351 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 352 Hold tightly mounting flange and lay fulcrum on the flange and screw in clamp bolts in a crisscross pattern. Clamp torque is 0.67kgf·m(4.9lbf·ft). 100D7RCV10 6-55...
Page 353 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 354 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Front Rear Switch panel 110D7EEL01 Cluster 11 Starting switch 21 Hazard switch Multi function switch 12 Aircon & heater switch 22 Rear wiper/washer switch Gear selector lever 13 Handsfree(opt) 23 Aircon switch Inching pedal 14 Cigar lighter...
Page 355 2. LOCATION 2 110D7EEL02 Switch panel 14 Head lamp 27 License lamp Remote controller 15 Horn 28 Rear camera kit USB & socket assembly 16 Tilt switch 29 Start key Start switch 17 Int wiper relay 30 Heater relay Cigar lighter 18 Alarm 31 Travel alarm buzzer Monitor assembly...
Page 356 GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT 110D7EEL03-1...
Page 357 110D7EEL04-1...
Page 358 110D7EEL03-2 7-4-1...
Page 359 110D7EEL04-2 7-4-2...
Page 360 110D7EEL03-3 7-4-3...
Page 361 110D7EEL04-3 7-4-4...
Page 362 110D7EEL03-4 7-4-5...
Page 363 110D7EEL04-4 7-4-6...
Page 364 101 AWG10 TRANSMISSION CONTROL UNIT(TCU) CDMP3-RADIO 103 AWG10 TCU(EST-37) ECU SERVICE TOOL CONNECTOR TO:RMCU(CN-125) FUSE BOX #1 FUSE BOX #2 FUSE BOX #3 TO:RMCU(CN-125) TO:S/W E/G MODE(CS-79) CN-246 START KEY USB(+5V) CN-59 BR ACC USB(D+) E/G MODE SWITCH USB(D-) TO:HARNESS AIRCON USB(GND) 236 AWG18 0, I...
Page 365 HEAD LAMP HEAD LAMP CN-95 103 AWG10 102 AWG10 F/LINK CN-60 101 AWG10 100 AWG10 F/LINK DO-1 203 AWG18 TO:PUMP RELAY 204 AWG18 CR-1 204 AWG18 DO-2 CN-19 G AWG18B G AWG18B 424 AWG18 DISCONNECT 204 AWG18 438 AWG18 BATT.RY SWITCH CHECK TO:START MOTOR...
Page 366 101 AWG10 TRANSMISSION CONTROL UNIT(TCU) CDMP3-RADIO 103 AWG10 TCU(EST-37) ECU SERVICE TOOL CONNECTOR TO:RMCU(CN-125) FUSE BOX #1 FUSE BOX #2 FUSE BOX #3 TO:RMCU(CN-125) TO:S/W E/G MODE(CS-79) CN-246 START KEY USB(+5V) CN-59 BR ACC USB(D+) E/G MODE SWITCH USB(D-) TO:HARNESS AIRCON USB(GND) 236 AWG18 0, I...
Page 367 110D7EEL05-2 7-4-10...
Page 368 CABIN 7-4-11...
Page 369 CABIN 7-4-12...
Page 370 WITHOUT CABIN 7-4-13...
Page 371 WITHOUT CABIN 7-4-14...
Page 372 MEMORANDUM...
Page 373 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] Fusible link[CN-60] I/conn[CN-1(3)] Fuse box #1[CN-36(1)] Fusible link[CN-95]...
Page 374 POWER CIRCUIT FUSE BOX #1 FUSE BOX #2 FUSE BOX #3 CS-2 START SWITCH CN-95 F/LINK CN-60 F/LINK DO-1 CR-1 DO-2 DISCONNECT SWITCH BATT RELAY TO START MOTOR MAIN EARTH 110D7EEL05...
Page 375 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Master Switch Battery relay[CR-1] I/conn[CN-1(1)] Start switch[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(87→30)] Fuse box #3[CN-38(12)]...
Page 376 STARTING CIRCUIT FUSE BOX #1 FUSE BOX #2 FUSE BOX #3 CN-93(J2) OFF IDLE S/W BRAKE SWITCH THROTTLE POSITION SIG. ON IDLE S/W THROTTLE +5V DC THROTTLE POSITION RETURN IDLE INCREMENT INPUT CN-2 IDLE DECREMENT INPUT COOLANT LEVEL ALTERNATE TORQUE COOLANT LEVEL RETURN STARTER LOCKOUT RETURN REMOTE THROTTLE S/W RETURN...
Page 377 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 378 CHARGING CIRCUIT FUSE BOX #2 CN-54 ALT LEVEL FAN MOTOR(-) FAN MOTOR(+) CAN-L CAN-H IG 24V CN-56 CAN LOW(-) CS-2 CRUISE RESUME/INC CR-42 RS232C RX INCHING SPEED GAUGE(CAN) CRUISE SET/DEC E/G TEMP GAUGE(CAN) BATT(+) RELAY START SWITCH CAN HIGH(+) PREHEAT CRUISE ENABLE DOWNLOAD RX232C TX...
Page 379 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 380 PREHEATING CIRCUIT FUSE BOX #1 FUSE BOX #2 FUSE BOX #3 CN-93(J2) OFF IDLE S/W BRAKE SWITCH THROTTLE POSITION SIG. ON IDLE S/W THROTTLE +5V DC THROTTLE POSITION RETURN IDLE INCREMENT INPUT IDLE DECREMENT INPUT COOLANT LEVEL ALTERNATE TORQUE CN-2 COOLANT LEVEL RETURN STARTER LOCKOUT RETURN CR-42...
Page 381 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 382 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 383 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 384 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 385 (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 386 (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 387 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 388 (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 389 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 390 (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 391 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 392 LCD has the functions to display start mode, standby mode, cruise function, 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 393 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 394 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 395 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 396 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 397 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 398 GROUP 5 SWITCHES Cabin tilt switch DETAIL A STOP DOWN Cruise set-resume switch Cruise switch Main light switch Work lamp switch Hazard switch Cover(LH) Rear wiper/washer switch Aircon switch Seat heat switch Parking brake switch Cabin tilt switch Lock lever Auto/Manual select switch Inching switch DETAIL A...
Page 399 HAZARD SWITCH Use for parking, or loading truck. ※ If the switch is left ON for a long time, the battery may be discharged. 160D7CD42 INCHING SWITCH If this switch is pressed, inching operation is applied to inching pedal. Also, inching lamp on the cluster is illuminated. 160D7CD43 PARKING BRAKE SWITCH If this switch is pressed, the parking brake is applied and the gauge...
Page 400 REAR WIPER AND WASHER SWITCH This switch is used to operate the rear wiper and washer by two steps. ·First step : The rear wiper operates. ·Second step : The washer liquid is sprayed and the rear wiper is operated only while pressing. If release the switch, return to the first step position.
Page 401 HORN BUTTON If you press the button on the top of the multifunction switch and the Horn button center of the steering wheel, the horn will sound. 160D7ECD28 CAB LAMP SWITCH This switch turns ON the cab room lamp. 73033CD24 ULTI FUNCTION SWITCH Front wiper and washer switch Ⅰ...
Page 402 RUISE SET/RESUME SWITCH Auto cruise function is used to travel at constant engine speed with RESUME a desired engine rpm. CRUISE This function is activated only when the CRUISE SWITCH is turned ON. If you want to travel the truck at constant speed, you raise the engine rpm and then press the CRUISE SET switch.
Page 403 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 404 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 405 Part name Symbol Specifications Check ※ Check disconnection Work lamp, 24V 65W Head lamp Normal : A fewΩ H3 bulb CL-5 CL-22 CL-3 CL-4 CL-6 CL-23 AVS(R) ※ Check disconnection 24V 15W AVS(B) Beacon lamp (Strobe type) Normal : A fewΩ CL-7 ※...
Page 406 Part name Symbol Specifications Check CS-17 ※ Check contact CS-17 CS-18 CS-34 OFF : ∞Ω CS-34 Switch CS-41 CS-41 24V 8A (For terminal 1-5, 2-6) CS-42 (Locking type) CS-42 : ∞Ω CS-54 (For terminal 5-7, 6-8) CS-79 CS-3 CS-3 CS-21 CS-19 ※...
Page 407 Part name Symbol Specifications Check DENSO ※ Operating or not Start motor 24V 3.7kW CN-45 ※ Check resistance Cassette radio 24V 20W+20W Power ON : 4Ω+ 4Ω (For terminal 1-6, 4-8) CN-27 24V 0.5A ※ Operating or not Back up buzzer 115dB CN-65 ※...
Page 408 Part name Symbol Specifications Check ※ Check contact Air conditioner 24V 79W compressor Normal : 13.4Ω CN-30 CN-28 Cigar lighter 24V 5A CL-2 Flasher 85~190 C/M 50dB CR-11 Pf 2 24V 1.5A Wiper motor 2-speed Auto parking CN-102 ※ Check contact Washer pump 24V 2.5A Normal : 26.4Ω...
Page 409 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) MG613245 MG643241 CN-2 I/conn(Main harness-Engine harness) MG613245 MG643241 CN-3 DEUTSCH Seat switch DT04-4P CN-6 I/conn(Frame harness-Engine harness) 368047-1 368050-1 CN-7 I/conn(Cabin harness-Main harness) 368047-1...
Page 410 Connector part No. Connector No. of Type Destination number Female Male CN-92 DEUTSCH ECU connector(J3) DT06-4S-EP06 CN-93 DEUTSCH ECU connector(J2) DRC26-50S01 CN-95 Fusible link 21N4-01310 CN-98 DEUTSCH I/conn DT06-3S-EP06 CN-102 Rear wiper motor 180900 CN-103 Rear washer MG610320 CN-112 Gear box 21L7-60290 CN-124 Accel pedal...
Page 411 Connector part No. Connector No. of Type Destination number Female Male DEUTSCH CL-6 Mast lamp LH DT04-2P CL-7 Beacon lamp S822-014000 S822-114000 CL-15 Rear combi LH MG610335 CL-16 Rear combi RH MG610335 CL-21 License lamp S822-014000 S822-114000 DEUTSCH CL-22 R/work RH DT04-2P DEUTSCH CL-23...
Page 412 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 7-45...
Page 413 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 7-46...
Page 414 No. of Receptacle connector(Female) Plug connector(Male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 7-47...
Page 415 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 7-48...
Page 416 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 7-49...
Page 417 No. of Receptacle connector(Female) Plug connector(Male) S814-106000 S814-006000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 7-50...
Page 418 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 7-51...
Page 419 No. of Receptacle connector(Female) Plug connector(Male) S810-006202 S810-106202 S810-008202 S810-108202 7-52...
Page 420 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 7-53...
Page 421 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 7-54...
Page 422 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 7-55...
Page 423 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 424 No. of Receptacle connector(Female) Plug connector(Male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 7-57...
Page 425 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 426 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 427 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 428 2. 3 STAGE MAST(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 429 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 430 FORKS Measure thickness of root of forks and check that it is more than specified value. ℓ=1800mm(71in) EX : mm(in) STD Fork assy Applicable model Standard Limit Thickness 61FT-70342 110D-7E 75(3.0) 68(2.7) 61FT-71440 130D-7E 90(3.5) 80(3.2) D507FK01 95(3.7) 85(3.3) 140D-7E 61FT-70143 85(3.3)
Page 431 2. TROUBLESHOOTING MAST Problem ause Remedy Forks fail to lower. ·Deformed mast or carriage. ·Disassemble, repair or replace. Fork fails to elevate. ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. ·Deformed mast assembly. ·Disassemble mast and replace damaged parts or replace complete mast assembly.
Page 432 FORKS Problem ause Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear wear and reduces the thickness of the limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...
Page 433 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 434 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 435 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 436 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 437 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 438 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 439 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 440 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 441 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 442 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 443 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 444 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 445 Adjustment Chain adjustments are important for the following reasons : ·Equal loading of chain. ·Proper sequencing of mast. ·Prevent over-stretching of chains. ·Prevent chains from jumping off sheaves if they are too loose. djustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor. ·Adjust the chain length by loosening or tightening nut on the chain anchor.

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Hyundai 110D-7E Operating Manual

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