Hyundai 60L-7A Manual
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Hyundai 60L-7A Manual

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Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Inspection and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-14
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-22
Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-58
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20
Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
CONTENTS

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Summary of Contents for Hyundai 60L-7A

  • Page 1: Table Of Contents

    CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13 SECTION 2 REMOVAL AND INSTALLATION OF UNIT...
  • Page 2 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...
  • Page 3 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 When a manual is revised, an edition mark is Any additions, amendments or other changes recorded on the bottom outside corner of the will be sent to HYUNDAI distributors. pages. Get the most up-to-date information before you start any work.
  • 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

    SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13...

  • Page 12: Group 1 Safety Hints

    GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. · Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
  • Page 13 Be particularly careful when removing the radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using the machine, there is a danger that boiled oil may spurt out. · The procedure for releasing the hydraulic pressure is as follows : lower the fork to the ground, and stop the engine(Motor), move the control levers to each position two or three times.
  • Page 14 · Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. D50ASF09 · When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
  • Page 15 Way to use dipstick Push the dipstick fully into the guide, and then pull out. Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request the HYUNDAI Forklift distributor to carry out...

  • Page 16: Group 2 Specifications

    GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENTS 60L7AOM57 Steering wheel Forks 15 LPG tank Mast Tilt cylinder 16 Clamp Lift chain 10 Front wheel 17 Overhead guard Lift cylinder 11 Bonnet 18 Rear combination lamp Cluster 12 Rear wheel 19 Turn signal lamp Backrest 13 Counterweight 20 Head lamp...
  • Page 17 2. SPECIFICATIONS 60L7ASP01 Model Unit 60L-7A 70L-7A Capacity 6000 7000 Load center ← Weight(Unloaded) 8990 9670 Lifting height ← 3000 Free lift ← Lifting speed(Unload/Load) ← Fork mm/sec Lowering speed(Unload/Load) ← 450/500 mm/sec L×W×T L,W,T ← 1200×150×64 Tilt angle(Forward/Backward) ←...
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item Specification Unit Model GM, 4.3L V6 Type 4-cycle, in-line, Vertical OHV Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, V6 Valve configuration Push rod actuated overhead valve Cylinder bore X stroke mm(in) 101.6×88.39(4×3.48) cc(cu in)
  • Page 19 POWER TRAIN DEVICES Item Specification Model DE 280 (KAPEC) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.25 : 1 Type Power shift Gear shift(FR/RR) Transmission Control Electrical single lever type 1 : 2.550 2 : 1.29 Overhaul ratio 1 : 2.550 2 : 1.29...
  • Page 20 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Item Size kgf·m lbf·ft 13.5 97.6 M16×2.0 Engine mounting bolt, nut 4±0.5 28.9±3.6 M10×1.5 Engine Radiator mounting bolt, nut 54.2 M16×2.0 Transmission mounting bolt 10±1 72.3±7.2 M12×1.75 MCV mounting bolt, nut Hydraulic system 4±0.5 28.9±3.6 M10×1.5 Steering unit mounting bolt...
  • Page 21 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT Coarse thread Bolt size kgf·m lbf·ft kgf·m lbf·ft × 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 2.73 ~ 4.12 19.7 ~ 29.8...
  • Page 22 PIPE AND HOSE(FLARE TYPE) Thread size Width across flat(mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" PIPE AND HOSE(ORFS TYPE) Thread size Width across flat(mm) kgf·m lbf·ft 9/16-18 28.9 11/16-16 36.2 13/16-16 68.7 1-3/16-12 1-7/16-12 1-11/16-12 FITTING Thread size Width across...
  • Page 23 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. 。 C (。 F) Ambient temperature Service Kind of Capacityℓ(U.S.gal) point fluid (-4) (14) (32) (50) (68) (86) (104) Engine oil Engine oil SAE 10W-30(API SL class or better) (1.1) Torque 15ℓ...

  • Page 24: Group 3 Periodic Replacement

    GROUP 3 PERIODIC REPLACEMENT For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time of periodic maintenance;...

  • Page 25: Section 2 Removal And Installation Of Unit

    SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...

  • Page 26: Group 1 Structure

    GROUP 1 STRUCTURE 24 25 9 10 11 12 13 14 15 16 17 60L7AOM23 Mast 10 Transmission 19 Radiator Lift cylinder 11 Torque converter 20 Muffler Steering unit 12 Engine 21 LPG tank Tilt cylinder 13 Air cleaner 22 Overhead guard Control valve 14 Exhaust pipe 23 Seat...

  • Page 27: Group 2 Removal And Installation Of Unit

    GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Forks ① Knob Backrest Lower the fork carriage until the forks are Roll pin approximately 25mm(1in) from the floor. ②...
  • Page 28 ② While supporting lift chains, remove the Chain split pin and nuts from the anchor bolt. Anchor bolt Outer mast Split pin 60L7ARE06 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain...
  • Page 29 Piping ① Remove the return hoses and clamps attached to the cylinder. ② Remove the return hose from the tee. ③ Remove hose assembly, tee and down Hose clamp safety valve(1). ※ Put blind plugs in the piping immediately Return hose after removing hoses.
  • Page 30 Inner mast ① Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Inner Be careful the mast not to swing or mast fall. Outer mast 60L7ARE11 Tilt cylinder pin Mast mounting pin ①...
  • Page 31 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 mounting pin ① Check the mast mounting pins for wear, then install pins into the mast support bracket. ②...
  • Page 32 2. POWER TRAIN ASSEMBLY REMOVAL D503RE04 Mast Refer to section on mast(Page 2-2)
  • Page 33 Brake piping Brake valve Disconnect the brake piping from the brake housing of drive axle unit. Brake valve Drive axle 60L7ARE13 Parking brake cable Parking Disconnect parking brake cable from the brake lever brake housing of drive axle unit. Parking brake cable Drive axle...
  • Page 34 Inching linkage Remove the bolt fixing the linkage Inching pedal assembly to T/M control valve. T / M Bolt n t r l v e 60L7ARE16 Transmission cooling piping ① Disconnect cooling oil hose and Radiator assy connector from the transmission. Hose ※...
  • Page 35 Mounting bolts holding to flywheel housing ① Remove the transmission assembly from the engine flywheel by loosening the Mounting bolt mounting bolts. 60L7ARE19 ② Using a moving truck slowly, pull out transmission assembly to the front. Frame Block Truck 60L7ARE20 INSTALLATION Installation is the reverse order to removal, but be careful of the following points.
  • Page 36 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL D503RE25 Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and flasher lamp on the stay of the overhead guard and then raise it together with the bonnet.
  • Page 37 Remove the torque converter housing cover, mounting bolts installed to flywheel housing. For details, see page 2-9. Engine Engine accessory Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. ① Wiring harness to alternator and starter. ②...
  • Page 38 Radiator hoses ·Distance to insert hose : 45mm(1.77in) Air cleaner hose Engine ① Insert the air cleaner hose securely and fit a clamp. ② Distance to insert hose Air cleaner ·Air cleaner hose : 45mm(1.77in) Muffler Tail pipe ·Engine end : 60mm(2.36in) Loctite #243 Engine Exhaust...
  • Page 39 Counterweight 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) 60L-7A 2690kg (5930lb) 70L-7A 3250kg (7165lb) ·Tightening torque : 199±30 kgf·m (1440±216lbf·ft)
  • Page 40 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. 35DS7RE28 Hose Drain hydraulic oil in the hoses and cylinders before removing them. Steering axle Remove the fitting and then disconnect the hoses.

  • Page 41: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Inspection and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-14 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-22 Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-58...

  • Page 42: Group 1 Structure And Operation

    GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN COMPONENT OVERVIEW STRUCTURE Engine 60L7ATA01 Torque converter T/M control valve Drive wheel T/M oil level gauge Differential Disk brake Transmission Drive shaft 11 Drive axle T/M oil pump OPERATION Power train system consists of engine , torque converter(1) , transmission(3) , drive shaft(7) , drive axle(11) and drive wheel(8).
  • Page 43 SPECIFICATION Item Unit Specification Type 3 elements 2 phase 1 stage Torque converter Power transmit Torque converter Type/Gear shift POWER SHIFT / F2 : R2 4.97 FR/RR 1 stage Gear ratio 1.55 FR/RR 2 stage Transmission P.T.O system Included T/M oil DEXRON 3 ℓ...
  • Page 44 2. TORQUE CONVERTER STRUCTURE Turbine Input plate Impeller Torque converter Stator Pump gear Engine side Transmission side D357TA02 Item Specification Torque converter input plate 4.5±0.3kg·m (32.5±2.2lbf·ft) Torque converter pump gear 2.0±0.3kg·m (14.5±2.2lbf·ft) Pilot boss outer diameter 19.009 ~ 19.030mm(0.748 ~ 0.749in) Oil seal outer diameter 134.9 ~ 135.0mm(5.311 ~ 5.315in) Needle bearing outer diameter...
  • Page 45 The touque converter has four main parts : housing, impeller (pump), turbine and stator. The housing is connected to the engine flywheel through flex plate. Impeller and housing are connected and turn with the engine flywheel at engine speed. Turbine turns the transmission input shaft. Stator is installed stationary on stator support.
  • Page 46 3. TRANSMISSION STRUCTURE 50DF7TA03 Torque converter Clutch piston 15 Clutch drum (RR) Input shaft Valve assembly 16 Clutch (RR, 2 stage) 3 P.T.O gears 10 Clutch (FR, 1 stage) 17 Gear (RR, 2 stage) Pump assembly 11 Gear (FR, 1 stage) 18 Gear (Output, 2 stage) Gear (FR, 2 stage) 12 Gear (RR, 1 stage)
  • Page 47 TRANSMISSION GEAR ARRAY T/C input T/C input relief T/C output (to cooler) T/C output relief INPUT COUNTER INTERMEDIATE OUTPUT 50DF7TA04 Cylinder clutch (FR) Cylinder clutch(RR) Gear(Output, 1st stage) Gear(FR, 2nd stage) Gear(RR, 2nd stage) Gear(Output, 2nd stage) Gear(FR, 1st stage) Gear(RR, 1st stage) 10 Output gear ※...
  • Page 48 TRANSMISSION INPUT PORT 50DF7TA05 T/C input port pressure FR 1st stage pressure Main line pressure FR 2nd stage pressure RR 2nd stage pressure T/C output port pressure RR 1st stage pressure ± ·Transmission pressure( 50± 10。 C) Engine Main line T/Converter FR 1,2 stage RR 1,2 stage...
  • Page 49 4. DIFFERENTIAL CARRIER ASSEMBLY STRUCTURE 50D7EAX02 Item Unit Specification Differential pinion gear inner diameter mm(in) 20.000 - 20.021(0.787~0.788) Spider outer diameter mm(in) 19.959 - 19.980(0.786~0.787) Pinion gear washer mm(in) 1.92 - 2.08(0.076~0.082) Side gear washer mm(in) 1.95 - 2.05(0.077~0.081) Side gear OPERATION Differential transmits the power from the transmission to drive wheel.
  • Page 50 5. DRIVE AXLE STRUCTURE 50D7EAX01 Differential carrier ass'y Drive wheel Parking brake Drive shaft Disc brake OPERATION The drive axle is composed of differential carrier assy (1), drive shaft (2), and drive wheel (3). The power is transmitted from the engine fly wheel to the transmission. The power of transmission is transmitted to the spiral bevel gear through the output gear of the transmission.
  • Page 51 DRIVE AXLE 50D7EAX03 Sun gear Hub assy 11 Pinion shaft Planetary gear Disk brake 12 Spider Inner gear Drive shaft 13 Differential pinion gear Inner gear carrier Differential carrier assy 14 Differential side gear Tapered bearing 10 Ring gear OPERATION Drive axle which consists of differential carrier assembly (9), drive shaft (8) and hub assembly (6) transmits the drive force from transmission to the wheels.
  • Page 52 DRIVE AXLE TIGHTENING TORQUE 50D7EAX04 Item Specification Inner carrier 2.2±0.3kgf·m (15.9±2.2lbf·ft) Spindle 12±0.5kgf·m (86.8±3.6lbf·ft) Service piston 1.5±0.1kgf·m (10.8±0.7lbf·ft) Adjuster nut 1.0±0.2kgf·m (7.2±1.4lbf·ft) Differential cap 16±0.5kgf·m (116±3.6lbf·ft) Differential case 6.0±0.5kgf·m (43.4±3.6lbf·ft) Ring gear 13.5±0.5kgf·m (97.6±3.6lbf·ft) Differential carrier assembly 18.0±0.5kgf·m (130±3.6lbf·ft) Wheel hub rolling resistant 3.0±0.3kgf·m (21.7±2.2lbf·ft) Parking brake 20.0±0.9kgf·m (144.7±6.5lbf·ft)
  • Page 53 DISK BRAKE View "A" 50D7EAX05 Spindle Service piston Drive shaft Steel plate Service collar Parking brake Disk plate Service piston adjust bolt OPERATION Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the high humid or dusty area. Because it is possible to use the brake semi-permanently, there is no need to maintain its lining as drum type brake do.
  • Page 54 6. TIRE AND WHEEL B507AX68 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 55: Group 2 Inspection And Troubleshooting

    GROUP 2 INSPECTION AND TROUBLESHOOTING 1. INSPECTION To check the problems of transmission, operate the machine and test its performance. Check and record the abnormal noise and if the machine doesn't operate perfectly, refer to problem and possible cause in the troubleshooting table. VISUAL CHECK Start engine and check T/M oil level at the neutral gear shift.
  • Page 56 2. TROUBLESHOOTING TRANSMISSION Check list during operation list Condition Possible causes Correction Transmission does not Low oil pressure or no oil Check to oil level. operate in any speed or pressure caused by : Check to mix another oil. does not engage(slips) in Low oil, no oil, or thick oil.
  • Page 57 Condition Possible causes Correction Clutch engagement is Low oil pressure. Check to oil level. slow or loss of power Low converter pressure. Check touque converter assy. during engagement. Air mixed in the oil. Check to transmission inside cover. Air leaks on suction side of pump. Air mixed in the oil air on the intake side of the pump.
  • Page 58 Condition Possible causes Correction High stall speed in one There is a leak in that clutch circuit. Check to clutch assy and then speed or one direction. replace to relate with other comonent. There is a failure if the clutch in that Replace the clutch assy.
  • Page 59 Check list from operation noises Condition Possible causes Correction Noise in NEUTRAL only. Worn bushing pump Changing is related with other assembly. componrent of charging. Worn one-way clutch in torque Charging to torque converter converter. assy. Oil level low. Check to oil level. Converter housing or converter Should be alignment with engine tangs not in alignment with...
  • Page 60 Check list from pressure test Condition Possible causes Correction Low pressure to FORWARD Inching valve linkage adjustment Adjust to inching valve. and REVERSE clutches. is not correct. Inching valve spool held(stuck) Change to inching spool. open. Clutch piston seals cause Change to clutch and piston leakages.
  • Page 61 DRIVE AXLE Condition Possible causes Correction · Constant noise in differential. Oil is not enough(Replace Refueling lubricating oil interval : 50 hrs first, then every 500hrs ). · Wrong kind of oil. Exchange lubricating oil · Wheel bearings Exchange bearing adjustment or have a defect.
  • Page 62 Condition Possible causes Correction Drive wheels do not rotate Broken axle shaft. · Loose wheel bearings. Re-assemble wheel bearings. · Axle shaft too short. Replace drive shaft · Loose flange studs or nuts. Tighten studs or nuts · Drive gear teeth have been Exchange damaged drive gear damaged.

  • Page 63: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF TRANSMISSION Pull torque converter(1) straight forward and remove from the converter housing. Remove six bolts(3) and flexible plate(1), plate(2) from the torque converter. 35L7ADA22 Remove six socket bolts (3) and then gear P.T.O input from the the torque converter.
  • Page 64 Remove plug (16) and O-ring, spring (18) and ball (17) from the bearing plate. Remove plug (13) and spring (12), Valve(14). Remove plug (11). 35L7ADA24 ※ Bearing cups and their shims will be in cover or on the shafts in transmission case. Put identification on each of bearing cups and shims as to their location on transmission cover or shaft in transmission...
  • Page 65 Remove four socket bolts (29), flange pump (28) from bearing plate (21). Remove a bolt.soc(32) and four socket bolt (33) from flange pump. Remove charging pump(31) and pump gasket(30), then seperate to gear-P.T.O output(25) and ball bearing, 90° elbow(27). D357TM07 Separate to two thrust washers(34), needle bearing(35), gear- P.T.O Idle(36) from front cover.
  • Page 66 Remove nut(43), yoke(44), washer(76), cork(79) from transmission assy. 50DFTM04 Use plastic hammer when removing tube(45) from transmission case. Untighten bolt(46), oil collector(47) then remove output shaft assembly(48) from transmission case. Remove input shaft assembly(50), counter shaft assembly(51), intermediate shaft assembly(49) from transmission case. 50DFTM05 For high speed forward clutch assembly, remove bearing cone (52) with gear pulley...
  • Page 67 Remove two thrust washes (53) and gear (54). Remove needle bearings and thrust washer from the forward shaft of high speed clutch side. 50DFTM07 Use a tool and remove snap ring(55) from the cylinder. Remove a five clutch discs and three 4T clutch plates(56), six 2T clutch plates(57), one bending plate(59) from the cylinder.
  • Page 68 For low speed forward clutch assembly, remove seal rings (66) from shaft. Remove bearing (63), thrust washer (64), gear (65), needle bearing, spacer and sealing (66). 50DFTM10 Remove snap ring (55), then remove a seven clutch discs (58) and three 4T clutch plates (56) and six 2T clutch plates (57), one bending plate (59) from the cylinder.
  • Page 69 Remove bearing(67) and gear(68). 50DFTM13 3-28...
  • Page 70 Remove bearing(69) from output shaft assembly(48). 50DFTM14 Remove bearing cups (70) from the transmission case. ※ Put identification on bearing cups to use at assembly. 50DFTM15 Remove plug(71) from the transmission case. 50DFTM16 3-29...
  • Page 71 Remove oil seal(72) from the transmission case. 50DFTM17 3-30...
  • Page 72 2. ASSEMBLY OF TRANSMISSION Thoroughly clean all the parts of the transmission. Put clean transmission oil on all of the inner parts. Put lip type oil seal (72) in position on the case with the spring loaded lip of the inside seal toward the inside of the transmission case.
  • Page 73 Install bearing(69) to output shaft assembly(48). 50DFTM18 Install bearing(67) and gear(68) to intermediate shaft assembly. 50DFTM13 Install seal ring on the piston(62). Put clean transmission oil on the seal ring. Install piston with seal ring in cylinder. Put spring assembly and retainer(60) in position in the cylinder.
  • Page 74 Put clean transmission oil on each side of the clutch plates and clutch discs. Install six 2T clutch plates(57), three 4T clutch plates(56), seven clutch discs(58) and one bending plate(59) in the cylinder with the following procedure. Install a clutch plate first, that has guide shape on its outside diameter.
  • Page 75 For the other side of the counter shaft assembly, follow the procedure in steps 5 through 8. Put clean transmission oil on each side of the clutch plates and clutch discs. Install four 2T clutch plates, three 4T clutch plates, five clutch discs and one bending plate in the cylinder with the following procedure.
  • Page 76 When new parts are used, required shim thickness should be calculated as follows . Assemble shaft assembly (including taper Shim bearing cone and cup). gage Insert shaft assembly into transmission case. ※ Use depth gage and block gage because the height of bearing cup is higher than surface of transmission case.
  • Page 77 Assemble input shaft assembly with the same procedure as counter shaft assembly. Install the gear assembly into transmission case. Carefully put the counter shaft assembly (51) in position in the transmission case. Carefully put the input shaft assembly (50) in position in the transmission case. Install output shaft assembly (48) into output gear assembly.
  • Page 78 Install a two thrust washer(34), a needle bearing(35), gear-P.T.O idle(36) in the bearing plate(21). 50DFTM32 Install a gear-P.T.O output(25), two ball bearings on the flange pump(28) by using the jig then, install four bolts(29) on the bearing plate. Then, charging pump(31) and gasket(30) on the flange pump by install a bolt(32) and four bolts(33).
  • Page 79 Install plug (11) and O-ring, elbow (11-1) rubber hose (11-2) in the bearing plate. Install valve (14), spring (12), plug (13) and O-ring in the bearing plate. Install plug (15) in the bearing plate. Install ball (17), spring (18), plug (16) and O-ring in the bearing plate.
  • Page 80 Install yoke(44), washer(76), cork(77), nut(43) in a output shaft assembly. 50DFTM22 Install torque converter housing in position. Install four bolts (9) and washes, oil seal (10), four bolts (8) that hold torque converter housing to the transmission. 35L7ADA43 Install gear P.T.O input(5) to torque converter, then tighten six socket bolts(6) in postion.
  • Page 81 3. DISASSEMBLY OF DRIVE AXLE 1) REMOVAL AND DISASSEMBLY OF WHEEL HUB Loosen drain plug with a torque wrench(1) in axle housing and drain oil. 50D7EDA01 Loosen oil drain plug in planetary housing and drain oil. 50D7EDA02 Loosen 4 socket head bolts and remove the planetary carrier.
  • Page 82 Remove 3 pins(6) with a plastic hammer. 50D7EDA05 Remove needle bearing(8), planet gear(7) and thrust washer(9). 50D7EDA06 Remove sun gear(10) and drive shaft(11). 50D7EDA07 Remove snap ring(12) and then remove sun gear(10) from the shaft(11). 50D7EDA08 3-41...
  • Page 83 After removing bolt(13), remove ring gear(14) and torque plate assembly(14) from the spindle. ※ Must measure the rolling resistance of tapered roller bearing. 50D7EDA09 (10) Remove C-ring (14) from the ring gear and pull the spindle (15) out of the ring gear. 50D7EDA10 (11) Pull out bearing inner race on flange using...
  • Page 84 (13) Disassemble drive shaft and disc & plate assembly. 50D7EDA13 50D7EDA14 (14) After loosing 4 bolt-self adjust (18), disassemble spring-self adjust (20) form bushing-self adjust (19). Then disassemble piston (17) from axle housing (16). After checking 3 pins (23), then finally remove square ring (21, 22).
  • Page 85 DISASSEMBLY OF THE DIFFEREN- TIAL CARRIER ASSEMBLY Loosen 12 bolts(1) and then remove carrier from the housing by using a lifting machine. 50D7EDA17 For the reassembly, check rolling resistance and record it. After loosen 2 bolts(2) and then remove backing plate (3).
  • Page 86 After removing 12 mounting bolts(8) from the housing and then disassemble the ring gear. 50D7EDA21 Check the mark on the housing and separate the housing from the differential. If there is no mark, be sure to mark on the housing. When reassembling, it must be placed at the same position as before.
  • Page 87 (11) After removing lock nut(11) and then remove the yoke(12). (12) Loosen 4 bolts (13) and then remove parking brake (14) from the carrier housing. (13) Remove the drive bevel pinion shaft (15) carefully busing a plastic hammer. ※ Be careful not to damage bevel pinion shaft.
  • Page 88 4. REASSEMBLY OF DRIVE AXLE Clean every parts with cleaner and then remove remained loctite. ※ Be careful not to spill cleaner on your body. Avoid drinking cleaner or breathing its fumes. Wear protective clothing, glasses and gloves. If spilled on the skin, flush your skin with water immediately. If swallowed, get medical attention immediately.
  • Page 89 Using different kinds of shims, adjust shim thickness as measured by previous equation. Place shims at the bearing place. Using a jig, assemble drive bearing so that the outer race contact with the bearing place. 50D7EDA31 Heat inner race of bearing to max 100。...
  • Page 90 ADJUSTMENT OF PINION SHAFT Assemble bearing cup. Assemble spacer to the pinion shaft and then install measured shims onto the spacer. 50D7EDA35 Insert pinion shaft into the carrier. Assemble bearing cone and lock nut. Apply grease on the outer bearing. Apply loctite #271 or #277 on the thread of pinion and then tighten lock nut.
  • Page 91 ASSEMBLY DIFFERENTIAL ASSEMBLY Assemble thrust washer, side gear and spider with gears and then install them to the differential housing. Apply grease on the bevel gear and thrust washer. 50D7EDA37 Assemble differential housing. ※ Check marks on the housing. Match two marks at the same position.
  • Page 92 Install differential assembly into the carrier. Place the bearing cup and screw into the housing. At this moment, using a screw adjust rotation backlash. Install the dial gauge on the gear tooth and measure the backlash while rotating bevel gear. ·Rotation backlash : 0.18~0.23 (0.007~0.009 50D7EDA41...
  • Page 93 ASSEMBLING CARRIER Assemble carrier assembly into the axle housing. Fix the carrier assembly with hexagon bolt (1). Apply loctite #271 or #277 to thread of bolt and then assemble it with tightening torque of 11~13 (79.6~94.0 kgf·m lbf·ft 50D7EDA42 Assemble brake drum to yoke with tighting 4 bolts (2).
  • Page 94 ASSEMBLING WHEEL HUB ASS'Y Insert bearing into wheel hub. ※ Apply grease or oil to shaft seal and then assemble it with proper direction (outer side of wheel hub). 50D7EDA45 Install wheel hub assembly to the spindle completely. 50D7EDA46 Insert the spindle into ring gear and secure with circlip.
  • Page 95 Install the torque plate to fix the spindle. Apply loctite #5127 to axle housing surface which contact to the spindle. 50D7EDA49 50D7EDA50 Assemble square ring(2), (3) to the axle housing(1) then apply the oil (Mobilfluid #424). Assemble bushing(5) to piston (2) and then assemble piston (2) to axle housing after applying oil sufficiently and then assemble the spring (6) to the...
  • Page 96 Assembling plate and inspection ① Assemble 5 plates(9) and 4 disks(10) with spline collar(11) and then lock with snap ring (12). - Disc must be assembled after the oil immersion during 12 hours. (Mobilfluid #424) ② Install assembled spline collar to the axle housing with the drive shaft.
  • Page 97 After assemble sun gear to axle shaft and fix it with a snap ring. Apply grease on the shaft where bushing contacts. Apply grease on teeth of the planetary gear. 50D7EDA57 (10) Assemble internal components of planetary carrier with the reverse order of disassembly.
  • Page 98 (12) Assemble wheel hub and tighten plug(14). ·Tightening torque : 35~60 kgf·m (253.2~434.0 lbf·ft 50D7EDA61 3-57...

  • Page 99: Group 4 Adjustment

    GROUP 4 ADJUSTMENT CHECKING RING GEAR BACKFACE RUNOUT Runout specification : 0.20mm(0.008-inch) maximum INDICATOR Attach a dial indicator on the mounting Rotate ring gear . flange of the carrier. Adjust the dial indicator so that the plunger or pointer is against the back surface of the ring gear.
  • Page 100 ADJUSTING 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 gear sets.
  • Page 101 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 102 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 103 Heel pattern : Decrease the gearset Move pattern toward toe Move pattern toward toe backlash(within specified range) to move contact pattern toward toe and away from heel. Loosen adjusting ring this side Refer to "Adjusting the gearset backlash". Decrease backlash Tighten adjusting ring this side D507AX65 Toe pattern : Increase the gearset back-...

  • Page 104: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8 Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10...

  • Page 105: Group 1 Structure And Function

    SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE There are two brake systems, the foot brake system and the hand brake system. In the foot brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
  • Page 106 3. BRAKE PEDAL AND PIPING STRUCTURE T / M n t r l v e Drive axle 60L7ABS03 Brake pedal & bracket assembly Reservoir tank assembly Parking lever assembly Brake valve...
  • Page 107 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the front axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force. By treading the pedal further, the brake is applied. 115mm(4.52in) T/M control valve Inching spool...
  • Page 108 5. WET DISK BRAKE STRUCTURE View "A" 50D7EAX05 Spindle Service piston Drive shaft Steel plate Service piston adjust bolt Parking brake Disk plate Spline collar Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 109 6. BRAKE VALVE STRUCTURE 18 17 16 35D7EBV00 Front housing 11 U-cup seal 21 O-ring Rear housing 12 U-cup seal 22 Spring Push rod 13 U-cup seal 23 Gauge Bellows 14 U-cup seal 24 Air bent Master piston 15 Relief piston 25 Plug Lock washer 16 Relief spring...
  • Page 110 DISASSEMBLY 28 27 Remove push rod (3), bellows (4), air vent (24), bolt (27) and washer (28). 35D7EBV01 Remove front housing (1), rear housing (2), servo spring (10), servo piston (9) and master piston (5). 35D7EBV02 Remove relief plug (17) with O-ring (18), relief spring (16) and relief piston (15).
  • Page 111 INSPECTION AND ASSEMBLY Clean all parts thoroughly and lubricate the parts either with mineral or with hydraulic oil, according to their use destination. All single parts are to be checked for damage and replaced, if required. Assembly is in opposite order to disassembly. Seal kit : XKAU-00176 Use only brake fluid (Azola ZS10) into the compensation reservoirs.

  • Page 112: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS BRAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. PARKING BRAKE Operating force of parking lever is 35 - 40 ·...
  • Page 113 2. TROUBLESHOOTING Problem cause Remedy Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil. ·Hydraulic system leaks air. ·Bleed air. ·Disc worn. ·Replace. ·Brake valve malfunctioning. ·Repair or replace. ·Hydraulic system clogged. ·Clean. Brake acting unevenly. ·Tires unequally inflated. ·Adjust tire pressure.

  • Page 114: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS 1. AIR BLEEDING OF BRAKE SYSTEM Air bleeding should be performed by two persons : One rides on truck for depressing and releasing brake pedal : the other person is Disk brake on the ground and removes cap from air Vinyl tube vent plug on wheel cylinder.
  • Page 115 Micro switch for parking brake (if equipped) ① After assembling parking brake and parking cable, put the parking brake lever P/lever stroke released. Knob ② Loosen the nut for parking brake plate to play up and down. ③ Move up the plate so that the stopper can be contacted with the pin and then reassemble nut.

  • Page 116: Section 5 Steering System

    SECTION 5 STEERING SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13...

  • Page 117: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Steering unit Priority valve Steering axle Steering cylinder pump Hydraulic tank 60L7ASE01 The steering system for this machine is composed of steering wheel assembly, steering unit, priority valve steering cylinder, steering axle and piping.
  • Page 118 2. HYDRAULIC CIRCUIT 13.5MPa Brake valve To Axle From Axle 60L7ASE02 Hydraulic gear pump Steering cylinder Steering unit Suction filter Priority valve 14 Hydraulic tank...
  • Page 119 NEUTRAL 13.5MPa Brake valve To Axle From Axle 60L7ASE03 The steering wheel is not being operated, so control spool(G) does not move. The oil from hydraulic gear pump(1) enters the port P of priority valve(4) and the inlet pressure oil moves the spool(D) to the left.
  • Page 120 LEFT TURN 13.5MPa Brake valve To Axle From Axle 60L7ASE04 When the steering wheel is turned to the left, the spool(G) within the steering unit(3) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through the spool(D) of priority valve(4) and flows the gerotor(H).
  • Page 121 RIGHT TURN 13.5MPa Brake valve To Axle From Axle 60L7ASE05 When the steering wheel is turned to the right, the spool(G) within the steering unit(3) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through the spool(D) of priority valve(4) and flows the gerotor(H).
  • Page 122 3. STEERING UNIT STRUCTURE Hydraulic circuit 26-4 26-3 26-1 26-2 SECTION B-B 25-6 25-5 25-4 25-3 25-2 25-1 SECTION A - A D507SE32 Dust seal 10 O-ring 19 Plate 25-3 Spring seat Retaining ring 11 O-ring 20 Cap screw 25-4 Spring Cap seal 12 Rolled screw 21 Housing...
  • Page 123 4. PRIORITY VALVE STRUCTURE 1-1/16-12UNF HYDRAULIC CIRCUIT 7/16-20UNF 3/4-16UNF 1-1/16-12UNF 50DS7ESE06 Body 4 End plug 7 Orifice Spool 5 Spring Spring plug 6 O-ring OPERATION The oil from the hydraulic gear pump flows to the priority valve. The priority valve supplies a flow of oil to the steering system and lift, tilt system. The steering flow is controlled by the steering unit to operate the steering cylinder.
  • Page 124 OPERATION The steering unit is composed of the control valve(rotary valve) and the metering device. The control valve controls the flow of oil from the pump in the interior of the unit depending on the condition of the steering wheel. The metering device is a kind of hydraulic motor composed of a stator and a rotor. It meters the required oil volume, feeds the metered oil to the power cylinder and detects cylinder’s motion value, that is, cylinder’s motion rate.
  • Page 125 5. STEERING AXLE STRUCTURE 50DS7ESE24 Steering axle 12 Gasket 23 Grease nipple 35 Cover Knuckle 13 Cover 24 Hub 36 Hexagon bolt Thrust bearing 14 Bolt w/washer 25 Hub bolt 38 Support Needle bearing 15 Grease nipple 26 Taper roller bearing 39 Bushing Oil seal 16 Hexagon bolt...
  • Page 126 TIGHTENING TORQUE AND SPECIFICATION Stroke 150mm Hub nut 61.2 kgf.m(443 lbf.ft) 35.1 ~ 47.5 kgf.m (253 ~ 343 lbf.ft) 50DS7ESE07 Center pin support Type Unit single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of degree...

  • Page 127: Group 2 Operational Checks And Troubleshooting

    · If minimum turning radius is not within±100mm (±4in)of specified value, adjust turning angle stopper bolt. Min turning radius(Outside) 60L-7A 3315mm(131in) 70L-7A 3360mm(132in) Hydraulic pressure of Remove screw coupling from CF port of priority valve and install oil pressure gauge.
  • Page 128 Problem cause Remedy Steering wheel turns unstea- ·Lockout loosening. ·Retighten. dily. ·Metal spring deteriorated. ·Replace. Steering system makes abn- ·Gear backlash out of adjustment. ·Adjust. ormal sound or vibration. ·Lockout loosening. ·Retighten. ·Air in oil circuit. ·Bleed air. Abnormal sound heard when Valve ·Faulty.

  • Page 129: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 50DS7ESE05 Dust seal 10 O-ring 19 Plate Retaining ring 11 O-ring 20 Cap screw Cap seal 12 Rolled screw 21 Housing Thrust bearing 13 Gerotor set 22 Spool Ball 14 Bearing race 23 Sleeve 15 Bore screw 24 Plate spring...
  • Page 130 TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-14...
  • Page 131 Assembly tool for dust seal. 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 Tweezers 5-70(2) TIGHTENING TORQUE L : Left port R : Right port T : Tank P : Pump...
  • Page 132 DISASSEMBLY Disassemble steering column from steering unit and place the steering unit in the holding tool. Screw out the screws in the end cover(6- off plus one special screw). 5-72(1) Remove the end cover, sideways. 5-72(2) Lift the gearwheel set(With spacer if fitted) off the unit.
  • Page 133 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball and suction valve pins and balls. D353SE09 5-17...
  • Page 134 Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and thrust bearing will be pushed out of the housing together.
  • Page 135 (12) Carefully press the spool out of the sleeve. 5-74(4) (13) Press the neutral position springs out of their slots in the spool. 5-75(1) (14) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (15) Screw out the plug using an 8mm hexagon socket spanner.
  • Page 136 (16) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (17) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (18) The pressure relief valve is now disassembled. D353SE13 5-20...
  • Page 137 ASSEMBLY Assemble spool and sleeve. ※ When assembling spool and sleeve only one of two possible ways of positioning the spring slots is correct. There are three slots in the spool and three holes in the sleeve in the end of the spool / sleeve opposite to the end with spring slots.
  • Page 138 Press the springs together and push the neutral position springs into place in the sleeve. 5-77(2) Line up the springs and center them. 5-77(3) Guide the ring down over the sleeve. ※ The ring should be able to rotate free of the springs.
  • Page 139 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) ※ Assembly pattern for standard bearings Outer bearing race Thrust bearing Inner bearing race Spool Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 140 (11) Grease O-ring with hydraulic oil and place them on the tool. 5-79(1) 5-79(2) (12) Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.
  • Page 141 (14) Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore. 5-80(1) Installation instructions for lip seal (15) Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 142 (17) Press and turn the lip seal into place in the housing. 5-81(1) (18) With a light turning movement, guide the spool and sleeve into the bore. ※ Fit the spool set holding the cross pin horizontal. 5-81(2) (19) The spool set will push out the assembly tool guide.
  • Page 143 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20° C. 5-82(2) (23) Place the distributor plate so that the...
  • Page 144 (25) Place the cardan shaft as shown - so that it is held in position by the mounting fork. 5-83(1) (26) Grease the two O-rings with mineral oil approx. viscosity 500 cSt at 20° C and place them in the two grooves in the gear rim.
  • Page 145 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ·Tightening torque : 4.0 ±...
  • Page 146 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. ※ Do not use a hammer! 5-85(2) 5-30...
  • Page 147 2. PRIORITY VALVE STRUCTURE 50DS7ESE08 Body End plug Orifice Spool Spring Spring plug O-ring 5-31...
  • Page 148 3. STEERING CYLINDER STRUCTURE ※ Specifications ·Cylinder bore : 80mm ·Outer diameter : 94mm ·Stroke(half) : 180mm ·Rod diameter : 55mm D357SE21 1 Tube assy DU bushing 11 O-ring 2 Rod assy Rod seal 12 Back up ring 3 Piston seal Back up ring 13 O-ring 4 Wear ring...
  • Page 149 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 150 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 151 4. STEERING AXLE STRUCTURE 50DS7ESE24 Steering axle 12 Gasket 23 Grease nipple 35 Cover Knuckle 13 Cover 24 Hub 36 Hexagon bolt Thrust bearing 14 Bolt w/washer 25 Hub bolt 38 Support Needle bearing 15 Grease nipple 26 Taper roller bearing 39 Bushing Oil seal 16 Hexagon bolt...
  • Page 152 CHECK AND INSPECTION A1, A2 50DS7ESE25 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 60(2.4) 59.5(2.3) Shaft ID of bushing 60(2.4) 59.5(2.3) 50(2.0) 49.8(2.0) 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 153 DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the balance Hub nut weight part of the truck. Loosen the hub nut and take off the steering wheel tire.
  • Page 154 ASSEMBLY ※ In reassembling, have all parts washed, grease applied to lubricating parts, and all expendable items such as oil seal and spring washers replaced by new ones. Perform the disassembly in reverse order. Notch Tighten the set screw(10) of king pin(6). There is a notch in the middle of the king pin(6), make sure that this notch is on the set screw side.

  • Page 155: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20...

  • Page 156: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 1A 1B 2A 2B 3A 3B 4A 4B 18.5MPa 13.5MPa 15MPa GAGE PORT To Axle 4.5MPa TO BRAKE From Axle 60L7AHS01 Main pump Suction filter Priority valve 10 Return filter Main control valve 11 Down control valve Steering unit...
  • Page 157 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 1B 1A 2B 2A 3A 4B 18.5MPa 15MPa Lift GAGE PORT Load check valve Steering system Steering return line Brake system Brake return line 50DS7EHS02 When the lift control lever is pulled back, the spool on the first block is moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large chamber of lift cylinder(8) by pushing the load check valve of the spool.
  • Page 158 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 1B 1A 2B 2A 3A 4B 18.5MPa Lower 15MPa GAGE PORT Steering system Steering return line Brake system Brake return line 50DS7EHS03 When the lift control is pushed forward, the spool on the first block is moved to lower position. The work port(1B) and the small chamber and the large chamber are connected to the return passage, so the lift will be lowered due to its own weight.
  • Page 159 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 1B 1A 2B 2A 3A 4B 18.5MPa Tilt forward 15MPa GAGE PORT Load check valve Steering system Steering return line Brake system Brake return line 50DS7EHS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
  • Page 160 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 1B 1A 2B 2A 3A 4B 18.5MPa 15MPa Tilt Backward GAGE PORT Load check valve Steering system Steering return line Brake system Brake return line 50DS7EHS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
  • Page 161 2. HYDRAULIC GEAR PUMP STRUCTURE 60L7AHS06 Cover Connecting shaft 15 Stud bolt Gear housing Thrust plate 16 Washer Bearing carrier 10 Lip seal 17 Hex nut Gear housing 11 Rubber seal 18 Name plate Cover 12 Back up seal 19 Screw Shaft gear set 13 Square seal Drive gear set...
  • Page 162 3. MAIN CONTROL VALVE STRUCTURE(4 Spool) Inlet SECTION B - B Outlet 3 Work ports Gauge port VIEW D - D Port name Size SECTION A - A Inlet port 1-5/16-12UNF Outlet port 1-5/16-12UNF Gauge port PF1/4 Work port 1-1/16-12UNF 50DS7EHS07 Solenoid valve 13 Wiper...
  • Page 163 LIFT SECTION OPERATION Lift position D353HS08 When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flow into lift cylinder port(B1). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 164 Lower position D353HS09 When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (B1)→T. In lift lower position the fork drops due to its own weight.
  • Page 165 TILT SECTION OPERATION Tilt forward position D353HS10 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flow into tilt cylinder port(A2). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage.
  • Page 166 Tilt backward position D353HS11 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flows into tilt cylinder port(B2).
  • Page 167 MAIN RELIEF VALVE Pressure setting A good pressure gauge must be installed in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit.
  • Page 168 The loss of oil behind poppet C, effected by the opening of pilot poppet E, causes poppet C to move back and seat against pilot puppet E. This shuts off the oil flow to the area behind relief valve poppet D, and causes a low pressure area internally.
  • Page 169 4. LIFT CYLINDER 13 10 6 4,5 3 60L7AHS12A Tube assy Retaining ring 13 O-ring Gland 14 Spacer Piston DU busing 15 O-ring Piston seal 10 Rod seal Back up ring 11 Dust wiper Wear ring 12 O-ring 5. TILT CYLINDER 21,20,19 3 11 12 5,6 4 9,10 2 23,24,25...

  • Page 170: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Load maximum load, set mast vertical and raise 1m from ground. Wait for 10 minutes measure hydraulic drift(amount forks move down and amount mast tilts forward).
  • Page 171 2. TROUBLESHOOTING SYSTEM Problem Cause Remedy Large fork lowering speed. ·Seal inside control valve defective. ·Replace spool or valve body. ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. Large spontaneous tilt of ·Tilting backward : Check valve defec- ·Clean or replace.
  • Page 172 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 173 HYDRAULIC GEAR PUMP Problem Cause Remedy Pump does not develop full ·System relief valve set too low or ·Check system relief valve for proper pressure. leaking. setting. ·Oil viscosity too low. ·Change to proper viscosity oil. ·Pump is worn out. ·Repair or replace pump.
  • Page 174 LIFT CYLINDER Problem Cause Remedy Oil leaks out from gland ·Foreign matters on packing. ·Replace packing. through rod. ·Unallowable score on rod. ·Smooth rod surface with an oil stone. ·Unusual distortion of dust seal. ·Replace dust seal. ·Chrome plating is striped. ·Replace rod.

  • Page 175: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP STRUCTURE 60L7AHS06 Cover Connecting shaft 15 Stud bolt Gear housing Thrust plate 16 Washer Bearing carrier 10 Lip seal 17 Hex nut Gear housing 11 Rubber seal 18 Name plate Cover 12 Back up seal 19 Screw Shaft gear set 13 Square seal...
  • Page 176 GENERAL INSTRUCTION Cleanliness ① Cleanliness is the primary means of assuring satisfactory hydraulic pump life. Components such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears should be washed in solvent, air dried, and oiled immediately. Certain cleaning solvents are flammable.
  • Page 177 ② Remove the rear end cover along with dowel pin to facilitate removal of the thrust plate. 50D7EMP22 ③ Carefully disassemble gear housing assembly which is composed of thrust plate, drive gear set(drive gear and driven gear) and gear housing. Disassemble the thrust plate, drive gear set and gear housing.
  • Page 178 ⑤ Remove the drive gear set and disassemble the gear housing from end cover. ⑥ Clean and dry all parts throughly prior to inspection. Check all parts where are happened damage deformation, crack, broken or severe wear or not. 50D7EMP27 ASSEMBLY Assembly procedure of the pump is the reverse order of the removal procedure.
  • Page 179 2. MAIN CONTROL VALVE Lay out valve components on a clean, flat working surface. The inlet assembly will include an O-ring, and the spool section(s) include an O-ring, a load check poppet and a load check spring. Tools required for basic valve assembly include 3/4 and 11/16 open or box end wrenches and a torque wrench with thin wall sockets.
  • Page 180 Position valve assembly with the mounting pads of the end sections on a flat surface. To obtain proper alignment of end sections relative to the spool sections apply downward pressure to the end sections ; Snug tie rod nuts to about 10lbf·ft.
  • Page 181 4. LIFT CYLINDER STRUCTURE · I.D×O.D×stroke(standard) 85×98×1335mm (3.3×3.8×52.6in) · Rod O.D : 60mm(2.4in) 60L7AHS19 Tube assy DU busing 10 Rod seal Piston 11 Dust wiper Piston seal 12 O-ring Back up ring 13 O-ring Wear ring 14 Spacer Retaining ring 15 O-ring Gland 6-26...
  • Page 182 DISASSEMBLY Hold the cylinder tube in a vice, loosen the cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn. Lever up the edge of the guide, then turn the guide in again and the guide can be removed.
  • Page 183 5. TILT CYLINDER STRUCTURE · I.D×O.D×stroke : 110×124×338mm (4.3×4.9×13.3in) · Rod O.D : 50mm(1.97in) 60L7AHS16 Tube assy 10 Back up ring 19 Hexagon bolt 11 O-ring 20 Hexagon nut Rod cover 12 Washer 21 Spring washer Rod bush 13 Piston 22 Spherical bearing U-packing 14 O-ring...
  • Page 184 DISASSEMBLY Hold the parallel parts of the cylinder tube bottom in a vice and mark the rod head end to show how much it is screwed in, then remove the rod head. Next, hook a wrench into the notch at the cylinder head and remove the cylinder head from cylinder tube.

  • Page 185: Section 7 Electrical System

    SECTION 7 ELECTRICAL SYSTEM Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2 Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10...

  • Page 186: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 12 13 HYUNDAI 60L7AEL02 Work lamp Beacon lamp 13 Horn button Battery License lamp 14 Start switch Master switch 10 Forward-reverse lever 15 OPSS unit Tilt alarm 11 Operating panel 16 Buzzer...

  • Page 187: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT 60L7AEL01...
  • Page 188 ELECTRIC CIRCUIT FOR LPG FUE KIT 10MM RING 35L7AEL07...
  • Page 189 MEMORANDUM...
  • Page 190 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(+) Start motor [CN-45(B+)] I/conn [CN-1(2)] Start switch [CS-2(3)] Fuse box [CN-36] (No.1)
  • Page 191 POWER CIRCUIT START KEY S/W BR R1 R2 C ACC 9 10 11 12 ALTERNATOR CN-74 FUEL SYSTEM HARNESS START MOTOR CN-45 OPTION(CABIN) 35SQ(R) 35SQ(B) 35SQ(B) BATTERY MASTER SW CN-17 FLASHER UNIT CN-1 OPSS BUZZER CR-11 CN-113 SEAT S/W REV S/W GEAR SELECTOR FWD S/W TRAVEL CUT...
  • Page 192 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Start motor [CN-45(B+)] I/conn [CN-1(2)] Start switch [CS-2(3)] ※ The 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(4)] Fuse box [No.5] Combination switch [CS-12(5)] Illumination relay [CR-40(30)]...
  • Page 193 STARTING CIRCUIT START KEY S/W BR R1 R2 C ACC 9 10 11 12 ALTERNATOR CN-74 FUEL SYSTEM HARNESS START MOTOR CN-1 CLUSTER CN-45 E/G TEMP GAUGE 35SQ(R) 35SQ(B) 35SQ(B) FUEL GAUGE MAIN ANTI-RESTART EARTH BATTERY EARTH(GAUGE) MASTER SW CN-57 FUEL SYSTEM INTERFACE IG(VSW) CHARGE WARNING LAMP...

  • Page 194: Group 3 Component Specification

    GROUP 3 COMPONENT SPECIFICATION Specification Remark Part name 12V, 58AH, RC : 130min, CCA : 630 Battery 12V, 16A Working lamp 12V, 10W License lamp 12V, 21/5W (Tail/Stop) Combination lamp 12V, 21W (Turn signal) 12V, 21W (Back up) 12V, 55W Head lamp 12V, 23/8W Flasher lamp...

  • Page 195: Group 4 Connector Destination

    GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Frame harness-dashboard harness) 2-85262-1 368301-1 CN-2 I/conn(Dashboard harness-frame harness) 368047-1 368050-1 CN-4 LH support harness S810-004201 CN-5 RH support harness S810-004201 CN-6 PACKARD 15326868 Engine interface CN-7 S814-104002...
  • Page 196 Connector part No. Connector No. of Type Destination number Female Male CL-7 S822-114000 Beacon lamp S822-014000 CL-15 Combination lamp-LH S814-006100 CL-16 Combination lamp-RH S814-006100 CL-21 S822-114000 License lamp S822-014000 CL-23 S822-114000 Work lamp S822-014000 CR-5 Neutral relay MG640927 CR-11 Flasher unit relay S810-003702 CR-13 Head lamp relay...

  • Page 197: Group 5 Troubleshooting

    GROUP 5 TROUBLESHOOTING Trouble symptom Probable 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 d- ·Charge lamp defective.
  • Page 198 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...

  • Page 199: Group 1 Structure

    SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) Lift cylinder Carriage Lift cylinder Drive axle 60L7AMS01 Outer mast Bearing 10 Chain sheave bearing Roller bearing Inner mast 11 Roller bearing Tilt cylinder pin Lift chain 12 Wear plug Mast mounting pin Anchor bolt...
  • Page 200 2. 3 STAGE MAST(TF MAST) Middle master Outer master Inner master Tilt cylinder Lift cylinder Lift cylinder Free Lift cylinder Drive axle Carriage 60L7AMS03 Outer mast Mast mounting pin 11 Chain Shim(0.5, 1.0t) Bearing 12 Sheave bracket Roller bearing Middle mast 13 Inner mast Side roller Chain sheave bearing...
  • Page 201 3. CARRIAGE, BACKREST AND FORK 60L7AMS04 Backrest Fork Carriage Extension fork Roller Wear plug Side roller Knob...

  • Page 202: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. ℓ=1200mm(47in) EX : mm(in) STD Fork assy Applicable model Standard Limit Thickness F14710111 60/70L-7A 65(2.6) 59(2.3) D507FK01 Set forks in middle and measure out of...
  • Page 203 2. TROUBLESHOOTING MAST Problem cause Remedy Forks fail to lower. ·Deformed mast or carriage. ·Disassemble, repair or replace. Fork fails to elevate ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. ·Deformed mast assembly. ·Disassemble mast and replace damaged parts or replace complete mast assembly.
  • Page 204 FORKS Problem cause Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear wear and reduces the thickness of the limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...

  • Page 205: Group 3 Adjustment

    GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V, VF MAST) INNER/OUTER MAST ROLLER CLEAR-ANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. 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...
  • Page 206 2. MAST LOAD ROLLER(TF MAST) INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast and the middle mast, and adjust the clearance between the roller side face and mast at the closest position on the L15C3MS06...
  • Page 207 CARRIAGE LOAD ROLLER Outer mast Adjust Bring into Measure the clearance when the center of screw contact the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, middle Side and lower rollers after loosen the adjust roller Carriage screws from the side rollers.

  • Page 208: Group 4 Removal And Installation

    GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Release fork anchor pins and slide forks, one by one, toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 209 SIDE ROLLER Remove carriage as outlined in the carriage Side roller assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. ※...
  • Page 210 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Chain ① Remove the carriage assembly and Hexagon nut move them to one side. ② Loosen and remove hexagon bolts and nuts securing lift cylinders to outer mast. Set screw ③...
  • Page 211 3 stage mast(TF mast) ① Remove the carriage assembly and move to one side. ② Loosen and remove hexagon bolt and nut securing bottom cylinder from outer Mast load roller mast. ③ Loosen and remove hexagon nuts and set screw securing lift cylinders to middle mast.
  • Page 212 ELEVATING MAST Inner mast (V mast) ① After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. ② Lift inner mast upright straight up and out of outer mast section. ③...
  • Page 213 CHAIN Chain sheave(V mast) ① Place a sling around carriage and attach Outer mast Chain to an overhead hoist. Lift carriage high enough so that the tension on the chain Sheave over sheaves is relieved after the carriage Inner mast is blocked.
  • Page 214 Chain wheel bearing support(TF mast) ① Remove the carriage assembly and move to one side. ② After removing bolt to securing chain wheel bearing support assembly to free lift cylinder. After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 215 ② ② 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 216 ⑧ ⑧ 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 217 ③ ③ 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. ④ Adjustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor. ·Adjust the chain length by loosening or tightening nut on the chain anchor.

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70l-7a

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