Hyundai 20L-7 Service Manual
  1. Manuals
  2. Brands
  3. Hyundai Manuals
  4. Forklifts
  5. 20L-7
  6. Service manual

Hyundai 20L-7 Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for Hyundai 20L-7

Summary of Contents for Hyundai 20L-7

  • Page 4 https://www.facebook.com/groups/ManualesDigitalesJC/ e- mail: manualesdigitalesjc@ gmail.com Tlfs ( Whatsapp ): (+58) 424 858 47 28...
  • Page 5 The following contains the Service Manual for the current Hyundai Construction Equipment Forklift. In order to effectively access and view this manual, please use Adobe Acrobat 7.0 or later software. The latest version of Adobe Reader can be found and downloaded at no cost at http://get.adobe.com/reader/.
  • Page 7 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 8 Revised edition mark( Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 9 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 10 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 11 Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
  • Page 12 m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 13 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 14 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 15: Table Of Contents

    CONTENTS SECTION 1 GENERAL Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14 SECTION 2 REMOVAL AND INSTALLATION OF UNIT...
  • Page 16 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11...

  • Page 17: Section 1 General

    SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14...

  • Page 18: 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 19 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 20 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 21 · 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 22 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 23: Group 2 Specifications

    GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS 25L7OM57 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 24 2 2 . SPECIFICATIONS 20L/25L/30L-7, 20G/25G/30G-7 25L7SP01 Model Unit 20L-7, 20G-7 25L-7, 25G-7 30L-7, 30G-7 Capacity 2000 2500 3000 Load center Weight(Unloaded) 3476 3766 4268 Lifting height 3300 Free lift Fork Lifting speed(Unload/Load) mm/sec 610/580 610/550 610/500 Lowering speed(Unload/Load) mm/sec...
  • Page 25 20LC/25LC/30LC-7, 20GC/25GC/30GC-7 25L7SP01 Model Unit 20LC-7, 20GC-7 25LC-7, 25GC-7 30LC-7, 30GC-7 Capacity 2000 2500 3000 Load center Weight(Unloaded) 3413 3753 4214 Lifting height 3300 Free lift Lifting speed(Unload/Load) Fork mm/sec 610/580 610/550 610/500 Lowering speed(Unload/Load) mm/sec 450/500 L W T L,W,T 1050 100 45 1050 125 45...
  • Page 26 3. SPECIFICATION FOR MAJOR COMPONENTS E E NGINE Item Specification Unit Model HYUNDAI beta Type 4-cycle, vertical Cooling Method Water cooled Number of cylinders and arrangement 4 cylinders, In line Firing order 1-3-4-2 Cylinder bore X stroke mm(in) 82 93.5(3.2 3.7)
  • Page 27 S S TEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev 22.7 Rated flow POWER TRAIN DEVICES Item Specification Model ZF 280 27 613/G7 Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.8 : 1 Type Full auto, Power shift Gear shift(FR/RR)
  • Page 28 4. TIGHTENING TORQUE OF MAJOR COMPONENTS 20L/25L/30L-7, 20G/25G/30G-7 kgf·m lbf·ft Item Size 1.25 12.3 2.4 8.9 17.4 Engine mounting bolt, nut Engine M 8 1.25 2.5 0.5 18.1 3.6 Radiator mounting bolt, nut Torque converter mounting bolt M10 1.25 6.9 1.4 50 10 M10 1.5 6.9 1.4...
  • Page 29 5. TORQUE CHART Use following table for unspecified torque. B B OLT AND NUT Coarse thread Bolt size kgf·m lbf·ft kgf·m lbf·ft 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8 1.25...
  • Page 30 2 2 ) PIPE AND HOSE(FLARE TYPE) Thread size Width across flat kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" P P IPE AND HOSE(ORFS TYPE) Thread size Width across flat kgf·m lbf·ft 9/16-18 28.9 11/16-16 36.2 13/16-16 68.7 1-3/16-12...
  • Page 31 6 6 . RECOMMENDED LUBRICANTS 。 C 。 F Ambient temperature Service Kind of Capacity (U.S.gal) point fluid (-4) (14) (32) (50) (68) (86) (104) Engine oil Engine oil SAE 10W-30(API SL class or better) (1.0) Torque 8.5 (2.2) ATF DEXRON III converter Engine oil transmission...

  • Page 32: 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 33: Section 2 Removal And Installation Of Unit

    SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...

  • Page 34: Group 1 Structure

    SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE 25L7OM23 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 Fork...
  • Page 35 SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE 9 10 11 13 14 15 16 17 25L7OM23 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...

  • Page 36: 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 Backrest Lower the fork carriage until the forks are approximately 25mm (1in) from the floor. Turn knob up and slide one fork at a time toward the center of the carriage where a Knob notch has been cut in the bottom plate for...
  • Page 37 While supporting lift chains, remove nuts and split pin from the anchor bolt. Lift chain Outer mast Split pin 20D7RE05 Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain Block 20D7RE06 Slowly raise inner mast upright until mast...
  • Page 38 Piping Remove the return hoses and clamps attached to the cylinder. Remove hose assembly, valve and tee from the lift cylinder. Band clamp Put blind plugs in the piping immediately Hose clamp after removing hoses. Return hose This prevents the hydraulic oil from flowing out and also prevents dust and dirt from getting in.
  • Page 39 Inner mast Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. Inner mast Outer mast 20D7RE10 Tilt cylinder pin Mast support cap Attach a crane to the stay at the top of the outer mast, and raise enough to sustain jacked up machine.
  • Page 40 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 cap Check the mast support cap and spring pin for wear. Jack up the machine so that the front is raised and then using an overhead hoist assemble outer mast to drive axle unit.
  • Page 41 2. POWER TRAIN ASSEMBLY REMOVAL D503RE04 Mast Refer to the chapter 1. MAST (Page 2-2)
  • Page 42 Brake piping Disconnect the brake piping from the Brake valve brake housing of drive axle. Brake pipe Drive axle 20D7RE12 Parking brake cable Disconnect parking brake cable from the transmission. Transmission Parking brake cable 20D7RE13...
  • Page 43 D D rive axle Attach a crane to the tilt cylinder notches Crane on the dashboard and raise the machine. Loosen hexagonal bolts (1) connection drive axle to the transmission. Put the block under the drive axle and support under the drive axle with a truck. Remove drive axle mount bolts (2) from Tilt cylinder notch...
  • Page 44 Torque converter Remove the cover on top face of the torque converter housing then remove Cover the 8 mounting bolts installed on the engine flywheel. To rotate the flywheel, remove 1 mounting bolt, then insert a turning tool in the mounting hole. One man must turn the engine fan by hand while the other turns the flywheel.
  • Page 45 2 2 ) INSTALLATION Installation is the reverse order to removal, Bolt(1) but be careful of the following points. Tightening torque ·Bolt (1) : 5.5~8.3kgf·m (39.8~60lbf·ft) Bolt(2) ·Bolt (2) : 2.7~4.1kgf·m (19.5~29.7lbf·ft) ·Bolt (3) : 5.5~8.3kgf·m (39.8~60lbf·ft) ·Bolt (4) : 53~72kgf·m (383~521lbf·ft) Bolt(5) ·Bolt (5) : 7.5kgf·m (54.2lbf·ft) Bolt(4)
  • Page 46 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 47 Remove the torque converter housing cover, mounting bolts installed to flywheel housing. For details, see page 2-10. Engine Engine accessory Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. Wiring harness to alternator and starter. Wiring harness for oil pressure and engine water temperature gauges.
  • Page 48 2 2 ) I I NSTALLATION Installation is the reverse order of removal, but be careful of the following points. Tighten the engine mounting bolts and nuts. Tighten the engine mounting bracket bolts. Do not remove the bolts unless necessary. Loctite is coated over the threads of bolt.
  • Page 49 20L7RE27 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) 20L-7, 20G-7 1100kg (2430lb) 20LC-7, 20GC-7 1030kg (2270lb) 25L-7, 25G-7...
  • Page 50 Rear wheel - 20L/25L/30L-7, 20G/25G/30G-7 20L/25L/30L-7, 20G/25G/30G-7 Mounting bolt Remove mounting bolt and hub nut with Tire assy socket wrench and then carefully take out the tire assembly. 20LC/25LC/30LC-7, 20GC/25GC/30GC-7 Hub nut Remove cap, split pin and then loosen castle nut. Take out rear wheel assembly with taper Hub cap roller bearing and oil seal.

  • Page 51: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-21 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-25...

  • Page 52: Group 1 Structure And Operation

    SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN DIAGRAM STRUCTURE 20L7PT26 Engine Drive shaft Brake Transmission Drive axle...
  • Page 53 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN DIAGRAM STRUCTURE 20L7PT26 Engine Drive shaft Brake Transmission Drive axle...
  • Page 54 SPECIFICATION Item Specification Model ZF 280 27 613/G7 Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.8 : 1 Type Full auto, Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick down system 2.444 : 1 Gear ratio 2.538 : 1 Type...
  • Page 55 2. TORQUE CONVERTER STRUCTURE 20D7PT03 Bolt Bolt Plate Torque converter housing cover Flexible plate Temperature sensor Torque converter assembly Inner oil strainer Bolt Oil strainer spring O-ring O-ring Oil level gauge Oil strainer plug Torque converter housing Oil level gauge guide...
  • Page 56 OPERATION The torque converter is connected with a flywheel by a flexible plate, engine output is delivered from the flywheel to the flexible plate. The exterior of the torque converter is protected by the torque converter housing. The torque converter housing forms the oil path for the oil pump, it includes the oil strainer filtering sucked oil through this oil path and the oil level gauge measuring oil level of the transmission inside.
  • Page 57 3. TRANSMISSION STRUCTURE 20D7PT28 Control valve Output gear Torque converter Temperature sensor Turbine shaft Oil input path Impeller shaft Parking drum Stator Forward clutch Forward clutch gear Input shaft Oil pump Reverse clutch Reverse clutch gear...
  • Page 58 INSTALLATION VIEW 20D7PT05 1 Torque converter 5 Oil level pipe and dipstick 2 Temperature sensor 6 Air breather 3 Control valve 7 Transmission oil filter 4 Parking brake link lever 8 Transmission output (Universal joint link part) OPERATION The flywheel of engine transmits a power to torque converter through flexible plate. The torque converter consists of an impeller wheel connected to the input side, a turbine connected to the output side and a stator wheel.
  • Page 59 OPERATING MODES Forward Reverse INPUT INPUT OUTPUT OUTPUT 20D7PT29 20D7PT30...
  • Page 60 OIL PUMP AND SPACER Structure T/C output pressure check port T/C output pressure T/C input pressure control valve check port T/C input pressure control valve 20D7PT06 1 Oil seal Lock bolt 2 Oil pump case bush O-ring 3 Bolt Bolt 4 Plug Plug 5 Oil pump case...
  • Page 61 TRANSMISSION CASE, CONTROL VALVE, OIL PUMP AND PARKING BRAKE Structure 20D7PT07 Parking bracket Oil filter 10 Parking brake connector (Small) Oil filter bolt 11 Band brake Bolt Bolt Bolt 12 Air breather Snap ring Pipe 13 O-ring Parking lever Washer 14 Nut Oil seal Control valve...
  • Page 62 Operation The transmission case includes the function of a control valve, an oil filter and a parking brake. The oil filter is charge of filtering sucked oil by an oil pump before transmitting sucked oil to a control valve and a torque converter. Oil transmitted through an oil filter delivers oil pressure to the piston of the forward and reverse clutch through the solenoid valve.
  • Page 63 CONTROL VALVE Structure Main relief function charge Modulation function charge Main valve pressure detecting port Forward clutch pressure detecting port Inching valve pressure detecting port Reverse clutch pressure detecting port To cooler From cooler Inching function charge Change of direction function charge 20D7PT08 1 Stoper 10 O-ring...
  • Page 64 Operation The control valve mainly consists of the main relief valve, inching valve, accumulator valve and directional valve. The discharged oil from the gear pump enters main relief valve of the control valve and its pressure is adjusted 10.8~14.9 (154~212psi). kgf/cm The oil adjusted pressure by the main relief valve is decided on the direction of forward or reverse by the solenoid valve.
  • Page 65 FORWARD CLUTCH Operation Clutch pack plugging Clutch pack lubrication line pressure delivery line (From control valve) (From control valve) 20D7PT31 Drum gear Friction plate and plate Forward shaft Clutch piston Clutch gear When forward mode is selected through the solenoid valve of control valve, the flux flowed by the oil pump flows into forward clutch pack in 9~14.2 (128~202psi) of pressure through the oil kgf/cm...
  • Page 66 Structure 20D7PT11 21 Forward drum gear 1 Forward clutch gear 11 Thrust needle bearing 2 Forward shaft 12 Thrust washer 22 Snap ring 23 Thrust washer 3 Piston 13 Spring 24 O-ring 4 Piston ring 14 Snap ring 25 Parking drum 5 Friction plate 15 Seal ring 6 Plate...
  • Page 67 REVERSE CLUTCH Operation Clutch pack plugging Clutch pack lubrication line pressure delivery line (From control valve) (From control valve) 20D7PT32 Reverse drum gear Friction plate and plate Reverse shaft Clutch piston Clutch gear When reverse mode is selected through the solenoid valve of control valve, the flux flowed by the oil pump flows into the oil path of reverse shaft in 9~14.2 (128~202psi) of pressure through kgf/cm...
  • Page 68 Structure 8 19 20D7PT13 19 Taper roller bearing 1 Reverse clutch gear 10 O-ring 2 Reverse shaft 11 Snap ring 20 Taper roller bearing 21 Reverse drum gear 3 Piston 12 Needle bearing 22 Snap ring 4 Piston ring 13 Thrust needle bearing 23 Thrust washer 5 Friction plate 14 Thrust washer...
  • Page 69 OUTPUT GEAR Operation The output gear is engaging the forward clutch gear and reverse clutch gear together. If a driver selects forward, the forward clutch gets plugging, the forward clutch gear revolves and the power of forward clutch gear is delivered to output gear. If a driver selects reverse, the reverse clutch gets plugging, the reverse clutch gear revolves and the power of reverse clutch gear is delivered to output gear.
  • Page 70 4. DRIVE AXLE INSTALLATION VIEW 20D7PT15 Carrier assembly Traveling brake Oil level gage Drive axle housing STRUCTURE 20D7PT16 Piston shaft Differential device Ring gear Axle shaft Traveling brake The drive axle is connected with the transmission output gear and universal joint. The power transferred by the universal joint is connected to the pinion shaft of drive axle, the pinion shaft delivers the power to the differential device through the ring gear.
  • Page 71 CARRIER ASSEMBLY Operation The pinion shaft is supported by the taper roller bearing in the carrier case and the bolt at the end of a pinion shaft and transfers the power which is delivered from the universal joint to the ring gear assembled from bolts at a differential device.
  • Page 72 DIFFERENTIAL DEVICE Operation Since the ring gear is linked with the right of the differential case and the bolt, the power transferred to the ring gear makes the differential device revolve. And also, the left and right of the differential case are connected with the left and right of the axle shaft and the spline respectively, it delivers the power to the final drive.

  • Page 73: Group 2 Troubleshooting

    GROUP 2 TROUBLESHOOTING T T rouble symptom P P robable cause Remedy 1. Excessive oil temperature rise ·Improper oil level. ·Check oil level. Add or drain oil as 1) Torque converter necessary. ·Impeller interfering with surroundings. ·After draining oil from oil tank and tra- nsmission, check and replace interfe- ring parts.
  • Page 74 Trouble symptom P P robable cause Remedy 3. Low output power 1) Torque converter ·Insufficient hydraulic pressure : Low oil level. Check oil level and add oil. Air sucked in. Check joints and pipes. If necessary, retighten joint or repla- ce packing.
  • Page 75 Trouble symptom P P robable cause Remedy 4. Unusual oil pressure 1) Oil pressure is high ·Control valve malfunctioning. (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair.
  • Page 76 Trouble symptom P P robable cause Remedy 6. Power is not transmitted ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. 7. Oil leakage ·Oil leaks from oil seal. ·Disassemble and check for wear of (Transmission and torque seal lips and mating sliding surfaces...

  • Page 77: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1.TRANSMISSION DISASSEMBLY Transmission assembly set. 20D7TM001 Disconnect torque converter. 20D7TM002 Extract PTO shaft. 20D7TM003 Remove control valve bolt. 20D7TM004 3-25...
  • Page 78 Extract control valve. 20D7TM005 20D7TM006 Extract oil filter. 20D7TM007 Remove snap ring. 20D7TM008 Remove parking lever. 20D7TM009 3-26...
  • Page 79 Remove snap ring. 20D7TM010 Remove bolt. 20D7TM011 Remove out wheel bolt. 20D7TM012 Remove bolt on the back side of filter. 20D7TM013 Remove bolt. 20D7TM014 3-27...
  • Page 80 Connect disassembly bolt. 20D7TM015 Disassemble torque converter housing. 20D7TM016 Disassemble spacer. 20D7TM017 After disassemble. 20D7TM018 Disassemble output gear assembly set. 20D7TM019 3-28...
  • Page 81 Disassemble connection. 20D7TM020 Extract band brake. 20D7TM021 Disassemble forward clutch gear. 20D7TM022 Disassemble reverse clutch gear. 20D7TM023 After disassemble. 20D7TM024 3-29...
  • Page 82 ASSEMBLY Assembly of transmission case outside part ( ( 1) Plug assembly Before assemble taper plug, spread loctite #577. Assemble the upper part taper plug of hydraulic pipe. 20D7TM025 Assemble installation part taper plug of control valve. 20D7TM026 Assemble space installation part. 20D7TM027 Assemble the left taper plug.
  • Page 83 Confirm torque. ·Tightening torque : 3.5~4.5 kgf·m (25~33 lbf·ft) 20D7TM029 O O il seal pressurizer of cam shaft Spread sealant on oil seal. Spread loctite #592 on the out wheel of oil seal. Spread grease on inside wheel of oil seal. 20D7TM030 Pressurize oil seal.
  • Page 84 Assembly of transmission case inside ( ( 2) Assembly of bearing and parking control shaft Pressurize R part of bearing out wheel. R part : Installation part of reverse clutch gear. 20D7TM034 Pressurize O part of bearing out wheel. O part : Installation part of output gear assembly. 20D7TM035 Pressurize F part of bearing out wheel.
  • Page 85 Assemble nut. 20D7TM038 Spread grease on bearing out wheel. When installing taper roller bearing, make sure whether or not it is close. Spread grease in taper roller bearing. 20D7TM039 A A ssembly of forward / reverse clutch pack Confirm seal ring of reverse clutch. Spread grease on seal ring of clutch pack.
  • Page 86 Confirm seal ring of forward clutch. 20D7TM043 Spread oil on seal ring of forward clutch. 20D7TM044 Assemble forward clutch at transmission. After finishing assembly, make sure whether or not revolution of forward/reverse clutch pack is good. 20D7TM045 A A ssembly of parking brake system Fix small connection in PBB.
  • Page 87 Spread grease on cam shaft. 20D7TM048 Fix large connection in cam shaft. 20D7TM049 Fit large connection in PBB. 20D7TM050 Assemble an eccentric shaft in PBB. 20D7TM051 A A ssembly of output gear assembly Assembly output gear. 20D7TM052 3-35...
  • Page 88 Confirm gear revolution condition. 20D7TM053 ( ( 3) Assembly of spacer sub assembly Assembly of oil pump Assemble O-ring of charging pump. Spread grease at O-ring surface. 20D7TM054 Spread sealant on charging pump. Spread loctite #5127 at stator shaft lower in oil pump. 20D7TM055 Spread sealant on the whole surface.
  • Page 89 Spread sealant on hexagon bolt. Spread loctite #242 at bolt. 20D7TM058 Confirm assembly and torque. ·Tightening torque : 3.5~4.0 kgf·m (25~29 lbf·ft) 20D7TM059 A A ssembly of inlet and outlet of pressure adjustment valve in torque converter and pressure checking port Fix steel ball in spacer.
  • Page 90 Confirm torque. ·Tightening torque : 3.5~4.5 kgf·m (25~33 lbf·ft) 20D7TM063 Spread sealant on hex bolt. 20D7TM064 Confirm torque. ·Tightening torque : 3.5~4.5 kgf·m (25~33 lbf·ft) 20D7TM065 A A ssembly of bearing cup After measuring the transmission case, spacer and each clutch pack and estimating a proper amount of shim.
  • Page 91 Pressurize O part of bearing out wheel. 20D7TM068 Assembly of torque converter housing sub assembly ( ( 4) Assembly of temperature sensor and O-ring Spread loctite #577 on temperature sensor. 20D7TM069 Confirm assembly and torque. ·Tightening torque : 3.0~4.0 kgf·m (22~29 lbf·ft) 20D7TM070 Assemble O-ring and spread grease.
  • Page 92 Fix strainer in torque converter housing. 20D7TM073 Temporarily assemble plug. 20D7TM074 Confirm torque. ·Tightening torque : 8~10 kgf·m (58~72 lbf·ft) 20D7TM075 A A ssembly of sub assembly ( ( 5) Assembly of transmission case and spacer sub assembly Spread oil. 20D7TM076 Fix O-ring.
  • Page 93 Spread loctite #5127 on transmission case. 20D7TM078 Pressurize lock pin. 20D7TM079 Assemble space. 20D7TM080 Confirm gear revolution condition. 20D7TM081 T T orque converter assembly Spread loctite #5127 on space. 20D7TM082 3-41...
  • Page 94 Work roller. Pay attention to tear O-ring of torque converter and oil pump. 20D7TM083 Fit torque converter housing in space. 20D7TM084 Spread loctite #277 on bolt. 20D7TM085 Temporarily assemble bolt. 20D7TM086 Confirm torque. ·Tightening torque : 5.5~6.5 kgf·m (40~47 lbf·ft) 20D7TM087 3-42...
  • Page 95 Transmission outside assembly Fastening of transmission case bolt Revolve 90¡£ . 20D7TM088 Spread sealant on socket bolt. 20D7TM089 Temporarily assemble at transmission case. 20D7TM090 Confirm torque. 20D7TM091 Spread sealant on hexagon bolt. Spread loctite #277 on bolt. 20D7TM092 3-43...
  • Page 96 Confirm torque. ·Tightening torque : 5.5~6.5 kgf·m (40~47 lbf·ft) 20D7TM093 O O il filter assembly Temporarily assemble filter. 20D7TM094 Confirm fastening. ·Tightening torque : 0.8~1.2 kgf·m (5.8~8.7 lbf·ft) 20D7TM095 P P arking brake part assembly Assemble snap ring. 20D7TM096 Spread loctite #277 on support pin. 20D7TM097 3-44...
  • Page 97 Temporarily assemble support pin. 20D7TM098 Confirm torque. ·Tightening torque : 2.0~3.0 kgf·m (14~22 lbf·ft) 20D7TM099 Fix parking lever. 20D7TM100 Assemble snap ring. 20D7TM101 Fix spring and spread loctite #277 on bolt. 20D7TM102 3-45...
  • Page 98 Temporarily assemble parking bracket. 20D7TM103 Confirm torque. ·Tightening torque : 0.6~0.8 kgf·m (4.3~5.8 lbf·ft) 20D7TM104 T T he way to adjusting parking brake Tighten the adjustment shaft and loosen the shaft a 3/4 revolution. ·Tightening torque : 0.65kgf·m (4.7lbf·ft) Tighten the nut. ·Tightening torque : 3kgf·m (221lbf·ft) Spread loctite #592 Position eccentric shaft...
  • Page 99 Spread loctite #577 on nipple plug. 20D7TM106 Temporarily assemble oil pressure pipe and seal washer at the same time. 20D7TM107 Spread sealant on nipple plug. 20D7TM108 Temporarily assemble oil pressure pipe and seal washer at the same time. 20D7TM109 Confirm torque. ·Tightening torque : 3.5~4.0 kgf·m (25~29 lbf·ft) 20D7TM110...
  • Page 100 Oil seal output gear assembly Spread loctite #592 on the out wheel of oil seal. 20D7TM111 Pressurize oil seal. 20D7TM112 Spread grease on inside wheel of oil seal. 20D7TM113 Control valve assembly As assembling, use guide pin at two spot. Fix guide pin.
  • Page 101 Assemble hex bolt and confirm torque. ·Tightening torque : 3~4 kgf·m (22~29 lbf·ft) 20D7TM116 A A ir breather and oil level gauge guide pipe assembly Assemble air breather. Air breather Spread loctite #577 on air breather. 20D7TM117 Spread sealant on oil level gauge guide. Spread loctite #608 on pipe.
  • Page 102 2. DRIVE AXLE DISASSEMBLY Drive axle. 20D7AXLE001 Remove the bolt of axle shaft. 20D7AXLE002 Extract the left axle shaft. 20D7AXLE003 Extract the right axle shaft. 20D7AXLE004 3-50...
  • Page 103 Remove the bolt of plate / nut. 20D7AXLE005 Extract the nut. 20D7AXLE006 Extract the plate. 20D7AXLE007 Extract the hub bearing. 20D7AXLE008 Extract the hub. 20D7AXLE009 3-51...
  • Page 104 Remove the bolt of flange shaft. 20D7AXLE010 Extract the flange shaft. 20D7AXLE011 Disassemble the piston brake. 20D7AXLE012 Disassemble the carrier assembly. 20D7AXLE013 Fix the carrier assembly. 20D7AXLE014 3-52...
  • Page 105 Remove the bolt of carrier cap. 20D7AXLE015 Extract the carrier cap. 20D7AXLE016 Remove the left adjusting cap of bearing cup. 20D7AXLE017 Remove the right adjusting cap of bearing cup. 20D7AXLE018 Disassemble the differential assembly. 20D7AXLE019 3-53...
  • Page 106 After disassemble the carrier. 20D7AXLE020 ASSEMBLY Assembly of carrier assembly Differential device assembly Assemble spider and the differential pinion. 20D7AXLE021 Assemble the washer and the differential gear. 20D7AXLE022 Assemble the spider and the differential. 20D7AXLE023 3-54...
  • Page 107 Assemble the washer and the differential gear. 20D7AXLE024 Assemble the differential case. 20D7AXLE025 Fix the bolt. 20D7AXLE026 Confirm the differential gear backlash. Adjust backlash of differential gear within 0.015mm. 20D7AXLE027 Assemble the ring gear. 20D7AXLE028 3-55...
  • Page 108 Assemble the bearing of differential. 20D7AXLE029 Assembly of carrier sub assembly Adjusting shim and pinion shaft assembly Fix the carrier case. 20D7AXLE030 Measure a gap(A) for deciding an amount of shim with feeler gauge. Determine shim X. ¡⁄ X = A¡ Mounting distance (MD) of pinion gear Ex 1) A = 0.5, MD value = - 0.2 X = 0.5 + 0.2 = 0.7mm Ex 2) A = 0.5, MD value = + 0.2...
  • Page 109 Pressurize the bearing cone into the pinion shaft. 20D7AXLE034 Fix the pinion shaft. 20D7AXLE035 Set the ball. 20D7AXLE036 Fix the fixing jig. 20D7AXLE037 Fix the ball. 20D7AXLE038 3-57...
  • Page 110 Revolve the carrier case in 180¡£ . 20D7AXLE039 Fix the spacer. 20D7AXLE040 Shim measuring gauge 1 insert. 20D7AXLE041 Shim measuring gauge 2 insert. 20D7AXLE042 Put the shim measuring block. 20D7AXLE043 3-58...
  • Page 111 Measure a gap (B). Determine shim X. X = B - End play (0.03~0.06) Ex 1) B = 0.5, X = 0.5 - (0.03~0.06) = 0.47~0.44mm 20D7AXLE044 Remove the pinion shaft. 20D7AXLE045 Assemble the bearing cup. 20D7AXLE046 Assemble and fit the pinion. 20D7AXLE047 Assemble the shim.
  • Page 112 Fix the bearing cone. 20D7AXLE049 Assembly of carrier sub assembly Pressurize the oil seal. 20D7AXLE050 Fix the U-joint flange. Assemble U-joint flange in preload 0.01~0.19 kgf 20D7AXLE051 Fix the O-ring. 20D7AXLE052 Temporarily assemble the nut. Spread loctite #242 on nut. 20D7AXLE053 3-60...
  • Page 113 Fasten the torque. ·Tightening torque : 16.2~19.1 kgf·m (117~138 lbf·ft) 20D7AXLE054 Confirm the preload. 20D7AXLE055 Perform the calking. Calking 20D7PT34 Assemble the differential sub in case. 20D7AXLE057 Fix the steel ball. Paint marking(Both sides) 20D7PT35 3-61...
  • Page 114 Temporarily assemble the carrier cap. 20D7AXLE059 Fasten the torque. Spread loctite #277 on bolt. ·Tightening torque : 26.8~32 kgf·m (194~231 lbf·ft) 20D7AXLE060 A A djust backlash Assemble the RING BRG ADJUST. 20D7AXLE062 Adjust the RING BRG ADJUST. 20D7AXLE063 Measure backlash. 20D7AXLE064 3-62...
  • Page 115 Fasten RING BRG ADJUST. 20D7AXLE065 Measure backlash again. Bachlash of pinion shaft and ring gear is 0.15~0.2mm (0.006~0.008 in) If backlash is wrong, carry out adjusting work. Adjust the left / right of RING BRG ADJUST by one and one clip. 20D7AXLE066 Fit position.
  • Page 116 A A ssembly of carrier assembly Pressurize lock pin into drive axle. 20D7AXLE069 Spread sealant on the installation surface of carrier. 20D7AXLE070 Fix assembly guide bar. 20D7AXLE071 Fit carrier at drive axle housing. Spread loctite #5127 on drive axle housing. 20D7AXLE072 Spread loctite #277 on the spring washer bolt.
  • Page 117 Temporarily assemble bolt and confirm torque. ·Tightening torque : 6~7 kgf·m (43~51 lbf·ft) 20D7AXLE074 T T RAVELING BRAKE SYSTEM ASSEMBLY Piston assembly Fix large quad ring into brake. 20D7AXLE075 Fix small quad ring into brake. When assembling quad ring, pay attent to chopping. 20D7AXLE076 Spread oil on the piston.
  • Page 118 Set assembly jig. 20D7AXLE079 Assemble close to drive axle housing. 20D7AXLE080 Pressurize lock pin. 20D7AXLE081 Measure projection degree of piston. Manage projection degree of piston in 0.6~0.9mm. 20D7AXLE082 F F riction plate and plate assembly Pressurize oil seal into flange. 20D7AXLE083 3-66...
  • Page 119 Assemble snap ring at socket. 20D7AXLE084 Fix socket gear into flange shaft. 20D7AXLE085 Fix plate into socket gear. 20D7AXLE086 Fix friction plate into socket gear. 20D7AXLE087 Fix friction plate and confirm the direction. 20D7AXLE088 3-67...
  • Page 120 Assemble snap ring at socket. 20D7AXLE089 Measure stepped pulley between flange and plate and record. Manage stepped pulley of flange 0.6~0.9mm. 20D7AXLE090 F F lange shaft assembly Select flange shaft. 20D7AXLE091 Spread loctite # 5127. 20D7AXLE092 Spread on the whole surface of flange shaft. 20D7AXLE093 3-68...
  • Page 121 Fit flange into drive axle housing. 20D7AXLE094 Spread loctite #242 on bolt. 20D7AXLE095 Fasten bolt. ·Tightening torque : 9~11.5 kgf·m (65~83 lbf·ft) 20D7AXLE096 H H ub assembly Hub sub assembly Pressurize bolt. 20D7AXLE097 Put a bearing cup on the upper and lower of hub. 20D7AXLE098 3-69...
  • Page 122 Pressurize bearing cup. 20D7AXLE099 Spread grease on the bearing of flange. 20D7AXLE100 Fix bearing into hub. 20D7AXLE101 Spread grease in the oil seal. 20D7AXLE102 Spread sealant on the outside of oil. 20D7AXLE103 3-70...
  • Page 123 Pressurize oil seal. 20D7AXLE104 Spread grease on the bearing of axle. 20D7AXLE105 Fix bearing into hub. 20D7AXLE106 Spread grease on hub. 20D7AXLE107 Hub assembly Spread grease on the flange shaft. 20D7AXLE108 3-71...
  • Page 124 Fix hub. 20D7AXLE109 Fix plate. 20D7AXLE110 Fix nut. 20D7AXLE111 Fasten torque and loosen. ·Tightening torque : 21~25 kgf·m (152~181 lbf·ft) 20D7AXLE112 Adjust preload. ·0.6~0.8 kgf·m 20D7AXLE113 3-72...
  • Page 125 Fit the position of plate, nut and hole. 20D7AXLE114 Spread loctite #277. 20D7AXLE115 Confirm torque. ·Tightening torque : 0.8~1.2 kgf·m (5.8~11 lbf·ft) 20D7AXLE116 A A xle shaft assembly Spread loctite #5127 on axle shaft. 20D7AXLE117 Fix into hub. 20D7AXLE118 3-73...
  • Page 126 Close to hub. 20D7AXLE119 Spread loctite #277 on bolt. ·Tightening torque : 6~7 kgf·m (43~51 lbf·ft) 20D7AXLE120 Fasten torque. 20D7AXLE121 T T he rest part assembly Assemble the air breather into LH. 20D7AXLE122 Assemble the air breather into RH. Spread loctite #577 on the air breather. ·Tightening torque (LH, RH) : 1.5~2 kgf·m (11~14 lbf·ft) 20D7AXLE123...
  • Page 127 Assemble hanger bolt. 20D7AXLE124 Fix dipstick. 20D7AXLE125 Assemble the magnetic plug. Spread loctite #577 on plug. Loctite #577 20D7PT36 3-75...

  • Page 128: 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 129: 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. The foot brake adopts the brake system of oil type at drive axle. Oil pressure is generated in maximum 140 through brake oil input path of the left and right kgf/cm drive axle housing, this pressure allows the piston brake to advance and compresses a friction plate...
  • Page 130 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. The foot brake adopts the brake system of oil type at drive axle. Oil pressure is generated in maximum 140 through brake oil input path of the left and right kgf/cm drive axle housing, this pressure allows the piston brake to advance and compresses a friction plate...
  • Page 131 3. BRAKE PEDAL AND PIPING STRUCTURE T/M control valve Transmission Drive axle 20D7BS01 Brake pedal Reservoir tank assembly Parking lever assembly Brake master cylinder...
  • Page 132 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the drive 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. Idle stroke: 1~3mm Floor plate Control valve...
  • Page 133 5. WET DISK BRAKE STRUCTURE 2 3 4 20D7PT20 Drive axle housing Piston brake Socket gear Square ring Plate Snap ring Square ring Friction plate Flange shaft OPERATION Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 134 6. BRAKE VALVE STRUCTURE 20 19 18 17 20D7BS03 Front housing 11 Seal 20 O-ring Rear housing 12 Seal 21 Check ball Push rod 13 Seal 22 O-ring Bellows 14 Seal 23 Check spring Master piston 15 Relief piston 24 Cage Lock washer 16 Shim 25 Air bent...
  • Page 135 DISASSEMBLY Remove push rod (3), bellows (4), air vent (25) and bolt (28). 20D7BS04 Remove front housing (1), rear housing (2), servo spring (10), servo piston (9) and master piston (5). 20D7BS05 Remove relief plug (18) with O-ring (19), relief spring (17), shim (16) and relief piston (15).
  • Page 136 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 137: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS B B RAKE 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 138 2 2 . TROUBLESHOOTING Problem c c ause Remedy Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil. ·Hydraulic system leaks air. ·Bleed air. ·Disk worn. ·Replace. ·Brake valve malfunctioning. ·Repair or replace. ·Hydraulic system clogged. ·Clean. Brake acting unevenly. ·Tires unequally inflated.

  • Page 139: 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 on the ground and removes cap from air Air vent plug vent plug on wheel cylinder.
  • Page 140 ( ( 3) Micro switch for parking brake (if equipped) Lever stroke 12.1 After assembling parking brake and parking cable, put the parking brake lever released. Loosen the nut for parking brake plate to play up and down. Micro switch Move up the plate so that the stopper can be contacted with the pin and then Rachet...

  • Page 141: Section 5 Steering System

    SECTION 5 STEERING SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14...

  • Page 142: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 20L7SS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and pipings. The steering force given to the steering wheel enters the steering unit through the steering column.
  • Page 143 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering cylinder Steering wheel Steering unit Hydraulic tank Gear pump 20L7SS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and pipings. The steering force given to the steering wheel enters the steering unit through the steering column.
  • Page 144 2. HYDRAULIC CIRCUIT 9.0MPa 20L7SS02 Gear pump with priority valve Suction strainer Steering unit Return filter Steering cylinder 10 Hydraulic tank...
  • Page 145 NEUTRAL 9.0MPa 20L7SS03 The steering wheel is not being operated so control spool(G) does not move. The oil from hydraulic gear pump(1) moves the priority valve spool(D) to the left. Oil flow into LS port to the hydraulic tank(10). So, the pump flow is routed to the main control valve.
  • Page 146 LEFT TURN 9.0MPa 20L7SS04 When the steering wheel is turned to the left, the spool(G) within the steering unit(4) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through the spool(D) of priority valve in gear pump(1) and flows to the gerotor(H).
  • Page 147 RIGHT TURN 9.0MPa 20L7SS05 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 in gear pump (1) and flows to the gerotor(H).
  • Page 148 3. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing 14 Bearing race 24 Plate spring Ball 15 Bore screw 25 P-port check valve.
  • Page 149 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 150 4. STEERING AXLE STRUCTURE 20L/25L/30L-7, 20G/25G/30G-7 20D7SS07 Steering axle 17 Hub 33 Thrust washer Knuckle-RH 18 Hub bolt 34 Pin Knuckle-LH 19 Hub nut 35 Spring washer Special bolt 20 Hub cap 36 Hardened washer King pin 21 Steering link 37 Upper cover Taper roller bearing 22 Steering cylinder...
  • Page 151 20LC/25LC/30LC-7, 20GC/25GC/30GC-7 20L7SS06 Steering axle 14 King pin washer 27 Hex bolt Knuckle-RH 15 Needle bearing 28 Hex nut Knuckle-LH 16 Thrust bearing 29 Lock plate Oil seal 17 Shim (0.13t) 30 Hex bolt Taper roller bearing 18 Shim (0.25t) 31 Steering cylinder Taper roller bearing 19 Clevis pin...
  • Page 152 TIGHTENING TORQUE AND SPECIFICATION 20L/25L/30L-7, 20G/25G/30G-7 Stroke 86mm Stroke 86mm Apply loctite #277 49.5~66.5 kgf m(358~481 lbf ft) 20D7SS08 Type Unit Center pin support single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of wheels(Inside/Outside) degree...
  • Page 153 20LC/25LC/30LC-7, 20GC/25GC/30GC-7 Stroke Stroke 78 0.5mm 78 0.5mm Apply loctite #277 49.5~66.5 kgf m(358~481 lbf ft) 20L7SS08 Type Unit Center pin support single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of wheels(Inside/Outside) degree 72.7 / 50.1 Tread...

  • Page 154: Group 2 Operational Checks And Troubleshooting

    Fit bar and a piece of chalk at outside edge of counterweight to mark line of · turning radius. · If minimum turning radius is not within 100mm ( 4in)of specified value, adjust turning angle stopper bolt. Min turning radius(Outside) 20L-7, 20G-7 2252mm(89in) 20LC-7, 20GC-7 2038mm(80in) 25L-7, 25G-7 2300mm(91in) 25LC-7, 25GC-7...
  • Page 155 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 156: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing 14 Bearing race 24 Plate spring Ball 15 Bore screw 25 P-port check valve.
  • Page 157 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) 5-15...
  • Page 158 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 159 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 160 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) 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.
  • Page 161 Take ring, bearing races and thrust bearing from sleeve and spool. The outer (Thin) bearing race can sometimes "stick" in the housing, therefore check that it has come out. 5-74(1) (10) Press out the cross pin. Use the special screw from the end cover. 5-74(2) A small mark has been made with a pumice stone on both spool and sleeve...
  • Page 162 (12) Press the neutral position springs out of their slots in the spool. 5-75(1) (13) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (14) Screw out the plug using an 8mm hexagon socket spanner. Remove seal washers. D353SE10 (15) Unscrew the setting screw using an 8mm...
  • Page 163 (16) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (17) The pressure relief valve is now disassem- bled. D353SE13 5-21...
  • Page 164 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 165 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 166 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) Assembly pattern for standard bearings 1 Outer bearing race 2 Thrust bearing 3 Inner bearing race 4 Spool 5 Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 167 (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 168 (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 169 (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 170 (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 5-82(2) (23) Place the distributor plate so that the channel holes match the holes in the...
  • Page 171 (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 172 (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 : 3.0 0.6kgf·m (21.7...
  • Page 173 (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) 5-31...
  • Page 174 2. STEERING CYLINDER STRUCTURE 20L/25L/30L-7 D255SS11 Tube assembly Rod seal O-ring Back up ring 10 O-ring Gland Dust wiper 11 Piston seal DU bushing Snap ring 12 Pin bush 5-32...
  • Page 175 20LC/25LC/30LC-7 L255SS11 Tube assembly Bushing Rod assembly U-packing Piston seal Dust wiper Wear ring O-ring Gland 5-33...
  • Page 176 DISASSEMBLY Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in a vice. Remove the gland by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube. Check wear condition of the sealing parts.
  • Page 177 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Set a special tool the cylinder, gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland assembly and tighten it with torque 45 4.5kgf·m (325 32.5lbf·ft).
  • Page 178 3. STEERING AXLE STRUCTURE 20L/25L/30L-7, 20G/25G/30G-7 Do not remove the stopper bolt unless necessary. 20D7SS07 Steering axle 17 Hub 33 Thrust washer Knuckle-RH 18 Hub bolt 34 Pin Knuckle-LH 19 Hub nut 35 Spring washer Special bolt 20 Hub cap 36 Hardened washer King pin 21 Steering link...
  • Page 179 20LC/25LC/30LC-7, 20GC/25GC/30GC-7 20L7SS06 Steering axle 14 King pin washer 27 Hex bolt Knuckle-RH 15 Needle bearing 28 Hex nut Knuckle-LH 16 Thrust bearing 29 Lock plate Oil seal 17 Shim (0.13t) 30 Hex bolt Taper roller bearing 18 Shim (0.25t) 31 Steering cylinder Taper roller bearing 19 Clevis pin...
  • Page 180 CHECK AND INSPECTION 2 2 0L/25L/30L-7, 20G/25G/30G-7 A1,A2 20D7SS10 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 55(2.2) 54.5(2.1) Shaft ID of bushing 55(2.2) 55.5(2.2) 35(1.4) 34.5(1.4) Replace OD of king pin 20(0.8) 19.5(0.8) OD of steering cylinder pin OD of pin 20(0.8)
  • Page 181 2 2 0LC/25LC/30LC-7, 20GC/25GC/30GC-7 A1,A2 20L7SS10 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 50(2.0) 49.5(1.9) Shaft ID of bushing 50(2.0) 50.5(2.0) Replace OD of king pin 35(1.4) 34.5(1.4) 17(0.7) 16.5(0.6) OD of steering cylinder pin OD of pin 17(0.7) 16.5(0.6)
  • Page 182 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 counter weight part of the truck. 20L/25L/30L-7, 20G/25G/30G-7 Loosen the hub nut and take off the steering wheel tire.
  • Page 183 Loosen special bolt (4) and spring washer (35). Remove hexagon bolt (39) and upper cover (37). Push out the king pin (5) without damaging the knuckle arm (3). If defect is observed in bearing (6), pull it out by using extractor. Remove spilt pin (13), plain washer(25) and link pin(24).
  • Page 184 Loosen special bolt(27) and spring washer(28). Pry out the retaining ring(15) and remove oil seal(13). Push out the king pin(36) without damaging the knuckle(2). Pull out the needle bearing(17). If defect is observed in needle bearing(17), pull it out by using extractor. Remove the split pin(25) and the clevis pin(26).
  • Page 185 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. 20L/25L/30L-7, 20G/25G/30G-7 Tighten the special bolt (4) and washer (35) of king pin (5).
  • Page 186 20LC/25LC/30LC-7, 20GC/25GC/30GC-7 Tighten the special bolt(27) of king pin. There is a notch in the middle of the king pin(36), make sure that this notch is on the special bolt side. Do not hammer to drive in needle bearing(17) because it will break. Notch Always use drive-in tool.

  • Page 187: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-23...

  • Page 188: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT (Non OPSS and non boosted brake) 20L7HS01 Gear pump with priority valve Tilt cylinder Main control valve Suction strainer Steering unit Return filter Steering cylinder Down safety valve Lift cylinder 10 Hydraulic tank...
  • Page 189 SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT (Non OPSS and non boosted brake) 4B 4A 3B 3A 16.5MPa LIFT TILT AUX1 AUX2 22.0MPa 9.0MPa 20L7HS01 Gear pump with priority valve Tilt cylinder Main control valve Suction strainer Steering unit Return filter...
  • Page 190 HYDRAULIC CIRCUIT (OPSS and boosted brake) 3B 3A 4B 4A LIFT 16.5MPa AUX2 TILT AUX1 22.0MPa TO BRAKE 20L7HS02 Hydraulic gear pump Lift cylinder Dual flow divider Tilt cylinder Main control valve Suction strainer Brake valve 10 Return filter Steering unit 11 Down safety valve Steering cylinder 12 Hydraulic tank...
  • Page 191 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 4B 4A 3B 3A 16.5MPa LIFT TILT AUX1 AUX2 22.0MPa Steering system 9.0MPa Return line 20L7HS03 When the lift control lever is pulled back, the spool on the first block moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of lift cylinder(5) by pushing the load check valve of the spool.
  • Page 192 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 3B 3A 4B 4A LIFT 16.5MPa TILT AUX1 AUX2 22.0MPa Steering system 9.0MPa Return line 20L7HS04 When the lift control lever is pushed forward, the spool on the first block moves to lower position. The work port(1A) and the small and the large chamber of lift cylinder are connected to the return passage, so the fork will be lowered due to its own weight.
  • Page 193 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 4B 4A 3B 3A 16.5MPa TILT LIFT AUX1 AUX2 22.0MPa Steering system 9.0MPa Return line 20L7HS05 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
  • Page 194 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 4B 4A 3B 3A 16.5MPa LIFT TILT AUX1 AUX2 22.0MPa Steering system 9.0MPa Return line 20L7HS06 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
  • Page 195 2. HYDRAULIC GEAR PUMP STRUCTURE (Booster brake) 5 12 9 10 11 13 14 20D7HS14 Housing Drive gear 12 Side plate Body Idle gear 13 Oil seal Rear cover Side plate 14 Snap ring Bushing 10 O-ring 15 Bolt O-ring 11 Back up ring 16 Washer...
  • Page 196 STRUCTURE (Non booster brake) 29,30 2 7 9 10 11 1 13 14 SECTION B - B" 20L7HS07 Housing 11 Back up ring 21 Spring Body 12 Side plate 22 Plug Priority valve body 13 Oil seal 23 O-ring Bushing 14 Snap ring 24 Adjust screw O-ring...
  • Page 197 3. MAIN CONTROL VALVE STRUCTURE (4- Spool) 16 15 SECTION H - H SECTION T - T SECTION E - E VIEW G - G VIEW F - F VIEW I - I Port name Size Inlet port 1-1/16-12UNF-2B Outlet port 1-1/16-12UNF-2B 20D7HS07 Lift block assy...
  • Page 198 INLET SECTION OPERATION Structure and description (Relief valve piston) Relief valve piston 20D7HS08 Hydrostat plug 14 Relief plug O-ring 16 Relief spring 10 Hydrostat spring 17 Pilot poppet 11 Hydrostat sleeve 28 O-ring 12 Relief piston 29 System relief seat 13 Nut 30 Secondary relief seat 6-10...
  • Page 199 Operation Secondary relief valve To neutral passage To aux block 16.5MPa To neutral passage System relief valve 22.0MPa To load check valve 20L7HS15 Oil flows from P(pump) port to reservoir(T) by pushing hydrostat spool(1). Before the center bypass line closed, hydrostat spool is keep opening, so pump port(P) and tank port(T) are always connected in operation to minimize heat generation.
  • Page 200 LIFT SECTION OPERATION Lift position Load check valve 20D7HS09 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 and flow into lift cylinder port(1A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 201 Lower position Load check valve 20D7HS10 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 (1A) In lift lower position the fork drops due to its own weight.
  • Page 202 TILT SECTION OPERATION Tilt forward position Tilt lock spool Load check valve 20D7HS11 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 and flow into tilt cylinder port(2B). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage.
  • Page 203 Tilt backward position Tilt lock spool Load check valve 20D7HS12 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 and flows into tilt cylinder port(2A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 204 MAIN RELIEF VALVE Pressure setting Relief plug Seat A good pressure gauge must be installed Lock nut O-ring 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 205 4. LIFT CYLINDER D255HS18 Tube assembly Wear ring 11 O-ring Retaining ring 12 Guide Piston Gland 13 DU bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 5. TILT CYLINDER 20,21,22 11,10 15,14 23 18 19 13,12 20L7HS19 Tube assembly...
  • Page 206 6. FREE LIFT CYLINDER 11,12 13,14 20L7HS20 Tube assembly Check valve 11 Dust wiper Retaining ring 12 Retaining ring Piston Set screw 13 O-ring Piston seal Gland 14 Back up ring Wear ring 10 U-packing 6-18...

  • Page 207: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM 1 1 ) 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).
  • Page 208 2 2 . TROUBLESHOOTING SYSTEM Problem C C 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 209 HYDRAULIC GEAR PUMP Problem C C 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 210 LIFT CYLINDER Problem C C 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 211: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP Tools required ·Metric socket set ·Internal snap ring pliers ·Shaft seal sleeve ·Torque wrench It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
  • Page 212 Lift and remove end cover. PUMP 03 Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts. PUMP 04 (10) Remove rear bearing block from drive and idler shafts. PUMP 05 (11) Remove idler shaft from bearing block.
  • Page 213 (12) Remove drive shaft from mounting flange. There is no need to protect the shaft seal as it will be replaced as a new item. PUMP 07 (13) Remove the front bearing block. PUMP 08 (14) Turn mounting flange over, with shaft seal up, and remove the retaining ring with proper snap ring pliers.
  • Page 214 (17) Remove seals from both bearing blocks and discard. PUMP 11 INSPECT PARTS FOR WEAR Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be replaced as new items. Check drive shaft spline for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway.
  • Page 215 Inspect bearing blocks for excessive wear or scoring on the surfaces which are in contact with the gears. Also inspect the bearings for excessive wear or scoring. Inspect the area inside the gear housing. It is normal for the surface inside the gear housing to show a clean "wipe"...
  • Page 216 3 3 ) ASSEMBLY New seals should be installed upon reassembly of pump. Install new shaft seal in mounting flange with part number side facing outboard. Press the seal into the seal bore until the seal reaches the bottom of the bore. Uniform pressure must be used to prevent misalignment or damage to the seal.
  • Page 217 Insert the drive end of the drive shaft through the bearing block with the seal side down, and the open side of the E- seal pointing to the intake side of the pump. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal.
  • Page 218 (13) Gently slide the gear housing over the rear bearing block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place with hands, do not force or use any tool. Check to make sure the intake port in the housing in on the same side as the open end of the E-seal and that the marked lines on the mounting flange and gear...
  • Page 219 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. ·Tighten torque : 3.0~4.0kgf·m (22~29lbf·ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
  • Page 220 2. MAIN CONTROL VALVE Remove bolt (1) to separate the valve section. 20D7MCV01 Divide the valve body. Aux2 Aux1 Tilt Lift T-cover 20D7MCV02 Remove dust cap (3) and bolt (2) from the valve body. 20D7MCV03 Remove attachment spool (4) from the valve body.
  • Page 221 Remove O-ring seals (5) from the valve body. 20D7MCV05 Remove tilt spool (6) from the valve body. 20D7MCV06 Remove lift spool (7) from the valve body. Remove lock poppet (8) from the valve body. Remove normal close solenoid valve (9, Opt) from the valve body.
  • Page 222 Remove relief plugs (15), springs (14) and poppets (13). 20D7MCV09 Remove normal open solenoid valve (16, Opt) from the valve body. 20D7MCV10 6-34...
  • Page 223 3. LIFT CYLINDER STRUCTURE Down safety valve D255HS24 Tube assy Wear ring 11 O-ring Rod assy Retaining ring 12 Guide Piston Gland 13 Du bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 6-35...
  • Page 224 DISASSEMBLY Hold the cylinder tube in a vice, loosen the Guide 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 225 4. TILT CYLINDER STRUCTURE 20L7HS27 Tube assembly Bushing 17 Washer 10 U-packing 18 Eye Piston 11 Back up ring 19 Bushing Glyd ring 12 Dust wiper 20 Hexagon bolt Wear ring 13 Stop ring 21 Spring washer O-ring 14 O-ring 22 Lock nut Nylon nut 15 Back up ring...
  • Page 226 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 227: Section 7 Electrical System

    SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2 Group 3 Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12 Group 4 Connector Destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13...

  • Page 228: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 20L7EL02 Flasher lamp Back buzzer 11 Switch assembly Work lamp Forward-reverse lever 12 Fuse box Combination switch Operating panel 13 OPSS unit Horn assembly Start switch 14 Flasher unit Combination lamp 10 Horn button 15 Battery...
  • Page 229 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 9 10 11 12 HYUNDAI 20L7EL02 Flasher lamp Back buzzer 11 Switch assembly Work lamp Forward-reverse lever 12 Fuse box Combination switch Operating panel 13 OPSS unit Horn assembly Start switch 14 Flasher unit...

  • Page 230: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT DASHBOARD PART FRAME / ENGINE PART F/COMBI H/LAMP CN-17 CLUSTER BI-FUEL TIER 3 CD-2 FOR CABIN CR-11 FUEL SENDER (GASOLINE) FLASHER UNIT BI-FUEL NON-CERT CR-5 CD-2 CN-7 CS-73 FUEL SENDER (GASOLINE) RELAY NEUTRAL CS-2 START KEY CN-61 CN-8 CR-13...
  • Page 231 FUEL SYSTEM CIRCUIT(TIER 3, LPG) 20L7EL07...
  • Page 232 FUEL SYSTEM CIRCUIT(TIER 3, BI-FUEL) 20L7EL06...
  • Page 233 FUEL SYSTEM CIRCUIT(NON-CERT, LPG) 20L7EL08...
  • Page 234 FUEL SYSTEM CIRCUIT(NON-CERT, BI-FUEL) 20L7EL09...
  • Page 235 MEMORANDUM...
  • Page 236 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(12,13,14)] Start switch[CS-2(3)] Fuse box[CN-36] (No.1) Cab[CN-7(1)]...
  • Page 237 POWER CIRCUIT CL-16 CS-2 CN-36 HORN/STOP LAMP TURN LAMP CLUSTER 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR TRAVEL - ACC 4 BR - ACC BI-FUEL SELECT 2 R2 R/COMBI RH - ST START KEY CLUSTER CN-17 CL-15 WORK/BEACON LAMP...
  • Page 238 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] I/conn[CN-1(12,13,14)] Start switch[CS-2(3)] T 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(4)] Fuse box[No. 5] I/conn[CN-1(19)] Fuel system interface[CN-6(1)] When start key switch is START position...
  • Page 239 STARTING CIRCUIT CS-2 CN-36 HORN/STOP LAMP TURN LAMP CLUSTER CR-5 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR TRAVEL - ACC 4 BR - ACC BI-FUEL SELECT 2 R2 - ST RELAY NEUTRAL START KEY CLUSTER WORK/BEACON LAMP FOR CABIN OPSS...

  • Page 240: Group 3 Component Specification

    GROUP 3 COMPONENT SPECIFICATION Part name Specification Remark CCA : 550 Battery 20HR : 60AH CMF 60(223 168 220) 12V, 55W Working lamp License lamp 12V, 3.4W 2 12V, 21W(T/S) 12V, 10W(Back) Combination lamp 12V, 5W (Tail) 12V, 21W(Stop) 12V, 55W Head lamp 85 10 C/M, (23W 23W) 2 3W 2 Flasher lamp...

  • Page 241: Group 4 Connector Destination

    GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Dashboard harness-frame harness) 1743059-2 1743062-2 CN-2 I/conn (Dashboard harness-travel ext harness) MG610331 MG640329 CN-4 I/conn (Dashboard harness-head guard harness) MG640348 MG610346 CN-5 Support harness-RH S810-004201 CN-6 Fuel system interface connection...
  • Page 242 Connector part No. Connector No. of Type Destination number Female Male Sensor and pressure switch CD-2 Fuel level sensor MG610043 CD-4 DEUTSCH Brake switch DT04-2P-E005 CD-10 Air cleaner switch ST730057-2 CD-29 T/M temp switch 172320-2 7-14...

  • Page 243: Group 5 Troubleshooting

    GROUP 5 TROUBLESHOOTING Trouble symptom P P 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 d- ·Charge lamp defective.
  • Page 244 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11...

  • Page 245: Group 1 Structure

    SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) 20D7MS01 Outer mast Anchor bolt 10 Trunnion cap Inner mast Chain wheel bearing 11 Bushing Roller Retaining ring 12 Roller Shim(0.5, 1.0t) Tilt cylinder pin 13 Shim(0.5, 1.0t) Chain...
  • Page 246 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) TILT CYLINDER LIFT CYLINDER CARRIAGE 20D7MS01 Outer mast Anchor bolt 10 Trunnion cap Inner mast Chain wheel bearing 11 Bushing Roller Retaining ring 12 Roller Shim(0.5, 1.0t) Tilt cylinder pin 13 Shim(0.5, 1.0t) Chain...
  • Page 247 2. 2 STAGE MAST(VF MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE 20D7MS02 Outer mast Shim(0.5, 1.0t) 11 Bushing Inner mast Roller 12 Sheave Chain Shim(0.5, 1.0t) 13 Sheave bracket Anchor bolt Tilt cylinder pin 14 U-bolt Back up liner 10 Support cap...
  • Page 248 3. 3 STAGE MAST(TF MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE 20D7MS21 Outer mast Roller 11 Sheave Middle mast Shim(0.5, 1.0t) 12 Tilt cylinder pin Inner mast Back up liner 13 Support cap Chain Shim(0.5, 1.0t) 14 Bushing Anchor bolt 10 Sheave bracket 15 Clamp...
  • Page 249 4. CARRIAGE, BACKREST AND FORK D255MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...

  • Page 250: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1 1 ) FORKS Measure thickness of root of forks and check that it is more than specified value. EX : =1050mm(41.3in) mm(in) STD Fork assy Applicable model Standard Limit Thickness 20L(C)/25L(C)-7 F173796-02 45(1.8)
  • Page 251 2 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 252 F F ORKS 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 253: Group 3 Adjustment

    GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V, VF MAST) INNER/OUTER MAST ROLLER CLEAR- 1 1 ) 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 254 2 2 . MAST LOAD ROLLER(TF MAST) 1 1 ) 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...
  • Page 255 C C ARRIAGE 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 256: Group 4 Removal And Installation

    GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1inch) from the floor. Knob Turn knob up and slide forks, one by one, Spring toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 257 SIDE ROLLER Remove carriage as outlined in the carriage 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. Adjustment ·...
  • Page 258 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Chain Remove the carriage assembly and Stud move them to one side. bolt Loosen and remove hexagon bolts and Inner mast washers securing lift cylinders to inner mast. Backup Loosen and remove hexagon bolts and liner nuts securing lift cylinders to inner mast.
  • Page 259 2 stage mast(VF mast) Remove free lift chain connected between carriage and free lift cylinder. Chain Remove the carriage assembly and move them to one side. Stud Loosen and remove hexagon bolts and bolt Inner washers securing lift cylinders to inner mast mast.
  • Page 260 3 stage mast(TF mast) Remove the carriage assembly and move to one side. Loosen and remove hexagon bolt securing bottom cylinder from outer mast. Loosen and remove bolts and special washers securing lift cylinders to middle mast. Attach chains or sling to the inner and middle mast section at top crossmember.
  • Page 261 ELEVATING MAST Inner mast (V, VF mast) 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. Lift inner mast upright straight up and out of outer mast section. Replace and reverse above procedure to install.
  • Page 262 CHAIN Chain Chain sheave(V, VF mast) Outer mast Place a sling around carriage and attach Sheave to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 263 Chain wheel bearing support(TF mast) Remove the carriage assembly and move to one side. 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 264 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 265 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 266 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. A A 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.
  • Page 267 L4GC MODEL SHOP MANUAL (FOR INDUSTRIAL USE)
  • Page 268 Hyundai Motor Co., Inc. makes efforts to enhance quality and build better parts and service data for you. We want to assist you in every way possible with this manual and your purchase of HYUNDAI engine is highly appreciated.
  • Page 269 IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all en- gines as well as the personal safety during work. This manual provides general directions for the efficient service methods and procedures. There are numerous variations in procedure, techniques, tools and parts for servicing engines, as well as in the skill of the individual technician.
  • Page 270 CONTENTS GENERAL ENGINE MECHANICAL SYSTEM ENGINE ELECTRICAL SYSTEM FUEL SYSTEM...
  • Page 271 CHAPTER 1. GENERAL 1. GENERAL ................1- 1 2. RECOMMENDED LUBRICANTS AND CAPACITIES ... 1- 5 3. SCHEDULED MAINTENANCE ..........1- 6...
  • Page 272 GENERAL ENGINE IDENTIFICATION NUMBER LO- CATION The engine identification number is stamped on the left side of the top edge of the exhaust manifold cylinder block. L4GC200A ENGINE IDENTIFICATION NUMBER The engine identification number consists of 11 digits. 1. Engine fuel L : LPG 2.
  • Page 273 GENERAL SAFETY NOTICE 1. REMOVING AND DISASSEMBLING After finding the malfunctioning reason and determining the removal and disassembly if necessary, simultaneously with checking the defect parts, start the job as the instruction of the shop manual. To prevent mal-assembly and to ease job, put punch marks or identification marks on the places where not affect nor- mal function and exterior.
  • Page 274 GENERAL 4. PARTS 1) When replacing parts, necessarily use the Hyundai genu- Genuine parts ine parts. 2) It is recommended to use spare parts prepared in the set or kit. 3) Spare parts can be different from actual assembled parts...
  • Page 275 GENERAL TIGHTENING TORQUE TABLE OF STANDARD PARTS Torque (kg·m) Bolt nominal diameter Pitch (mm) (mm) Head mark 4 Head mark 7 L4GC205A L4GC206A L4GC207A L4GC208A 0.3 ~ 0.4 0.5 ~ 0.6 0.5 ~ 0.6 0.9 ~ 1.1 1.25 1.2 ~ 1.5 2.0 ~ 2.5 1.25 2.5 ~ 3.0...
  • Page 276 RECOMMENDED LUBRICANTS AND CAPACITIES RECOMMENDED LUBRICANTS AND CAPACITIES LUBRICANTS CAPACITIES Description Capacities Specified oil Oil pan Above API SG Oil filter Engine oil (10W/30 or 15W/40) Total Coolant (for engine) It varies according to the radiator capacity...
  • Page 277 SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE ENGINE OIL CLASSIFICATION Recommended API classification: Above SG Recommended SAE viscosity classification Applied temperature Recommended SAE viscosity number range until replacement ˚C *1 : 5W-20 engine oil is recommended for everywhere If 5W-20 is not applicable, proper engine oil will be possible according to temperature ranges. L4GC209A The following lubricants should be selected for all engines to enhance excellent performance and maximum effect.
  • Page 278 SCHEDULED MAINTENANCE CHECKING ENGINE OIL LEVEL 1. Check that the oil level is between MIN and marks on the engine oil level gauge. 2. If the oil level is below MIN mark, add oil until the level is within the specified ranges. 3.
  • Page 279 SCHEDULED MAINTENANCE REPLACING ENGINE OIL FILTER 1. Remove the oil filter using a filter wrench. 2. When installing new parts, after applying engine oil to the O-ring, tighten the oil filter securely by hand. 3. Tighten the oil filter to the specified torque. Oil filter 1.2 ~ 1.6 kg·m 4.
  • Page 280 SCHEDULED MAINTENANCE 3. Check the plug clearance using a plug clearance gauge and if the value is not within the specified values, adjust it by bending the ground clearance. When installing a new spark plug, install it after checking the uniform plug clearance. Spark plug clearance 0.7 ~ 0.8mm Clearance...
  • Page 281 SCHEDULED MAINTENANCE 1-10 REPLACING OXYGEN SENSOR Oxygen sensor is as a fuel mixture control unit, if it is damaged, exhaust gas will be bad as well as engine performance. So, if the oxygen sensor is defected, necessarily replace it. L4GC215A COOLING SYSTEM Check the cooling system hoses for damage and looseness or inspect the joints for coolant leaks.
  • Page 282 SCHEDULED MAINTENANCE 1-11 COOLANT VISCOSITY MEASUREMENT Run the engine until the coolant is mixed completely, drain a little of coolant to determine the coolant viscosity at a safe operating temperature, measure the coolant viscosity and ad- just it to the specified value. REPLACING COOLANT CAUTION If the coolant is hot, injury can happen, so when the...
  • Page 283 CHAPTER 2. ENGINE MECHANICAL SYSTEM 1. GENERAL ................ 2- 1 2. CYLINDER BLOCK ............2-20 3. MAIN MOVING SYSTEM ........... 2-29 4. COOLING SYSTEM ............2-56 5. LUBRICATION SYSTEM ........... 2-62 6. INTAKE AND EXHAUST SYSTEM ........2-64 7. CYLINDER HEAD ASSEMBLY .......... 2-69 8.

  • Page 284: General

    GENERAL GENERAL OUTLINE L4GC001A...
  • Page 285 GENERAL L4GC002A...
  • Page 286 GENERAL GENERAL SPECIFICATIONS Description Specification Limit GENERAL Type Series, DOHC Cylinder number Bore 82 mm Stroke 93.5 mm Displacement 1,975 cc Compression ratio Firing order 1 - 3 - 4 - 2 100 rpm Ignition timing BTDC 8° 5 ° Valve timing Intake Open...
  • Page 287 GENERAL Description Specification Limit VALVE Stem O.D Intake 5.965 ~ 5.980 mm Exhaust 5.950 ~ 5.965 mm Thickness of valve head (Margin) Intake 1.15 mm 0.8 mm Exhaust 1.35 mm 1.0 mm Valve stem to guide clearance Intake 0.02 ~ 0.05 mm 0.1 mm Exhaust 0.035 ~ 0.065 mm...
  • Page 288 GENERAL Description Specification Limit CONNECTING ROD BEARING 0.024 ~ 0.044 mm Oil clearance 0.25, 0.50, 0.75 Under size CRANKSHAFT 45 mm Pin O.D 57 mm Journal O.D Less than 0.03 mm Bend Less than 0.01 mm Out-of cylindricity of journal and pin 0.06 ~ 0.260 End play Under size of pin...
  • Page 289 GENERAL TORQUE SPECIFICATIONS Description Standard (Kg·m) Cylinder block Engine support bracket bolt and nut 3.5 ~ 5.0 Engine support bracket spare bolt 4.3 ~ 5.5 Oil pressure switch 1.3 ~ 1.5 Cylinder head Cylinder head bolt 2.5+(60° ~ 65° ) + (60° ~ 65° ) 3.0+(60°...
  • Page 290 GENERAL Description Standard (Kg·m) Thermostat inlet fitting nut 1.5 ~ 2.0 Thermostat housing mounting nut 1.5 ~ 2.0 Water pump mounting bolt 2.0 ~ 2.7 Alternator brace bolt 2.0 ~ 2.7 Water temperature sensor 2.0 ~ 4.0 Alternator support bolt and nut 2.0 ~ 2.5 Water pump pulley 0.8 ~ 1.0...
  • Page 291 GENERAL SPECIAL TOOLS Tool (number and name) Illustration Crankshaft front oil seal installer Installation of front oil seal (09214-32000) L4GC006A Crankshaft front oil seal guide Installation of front oil seal (09214-32100) L4GC007A Removal and installation of Removal and installation of engine mounting bushing mounting bushing (09216-22000)
  • Page 292 GENERAL Tool (number and name) Illustration Valve guide installer Removal and installation of valve guide (09221-22000(A/B)) L4GC011A Cylinder head bolt wrench Removal and tightening of cylinder head (09221-32001) bolt L4GC012A Valve stem oil seal installer Installation of valve stem oil seal (09222-22001) L4GC013A Valve spring compressor holder and...
  • Page 293 GENERAL 2-10 Tool (number and name) Illustration Crankshaft rear oil seal installer 1. Installation of engine rear oil seal 2. Installation of crankshaft rear oil seal (09231-21000) L4GC016A Removal and installation of intake and Piston pin removal and installation kit exhaust valve (09234-33001) (Use with 09222-29000)
  • Page 294 GENERAL 2-11 TROUBLESHOOTING Symptom Possible cause Remedy Low compression Replace gasket Cylinder head gasket damaged Replace ring Worn or damaged piston ring Repair or replace piston and cylinder block Worn piston or cylinder Worn or damaged valve seat Repair or replace valve and seat ring Low oil pressure Insufficient engine oil Check engine oil level...
  • Page 295 GENERAL 2-12 Symptom Possible cause Remedy Replace Thermostat defective Abnormally low cool- ant temperature Repair or replace Water wiring defective Retighten Loose connecting part Oil cooling system leak Replace Cracked or damaged hose, pipe, and oil cooler Exhaust gas leak Loose connecting part Retighten Pipe or muffler damaged...
  • Page 296 GENERAL 2-13 SERVICE AND ADJUSTING PROCE- DURE CHECKING ENGINE OIL Good 1. Be sure that the oil is between F and L marks of the dipstick. L4GC019A 2. If the oil level is below L mark, add about 1L of oil. 3.
  • Page 297 GENERAL 2-14 7. With the throttle valve opened, crank the engine to measure the compressed pressure. 15kg/cm Standard Standard(250~400rpm) Limit 14kg/cm 8. Follow the procedures (no.6-7) to each cylinder and check that compressed pressure values of all cylinders are within the limit.
  • Page 298 GENERAL 2-15 ADJUSTING TIMING BELT TENSION Adjust the tension as the following order. 1. Turn the steering wheel completely counterclockwise. 2. While the engine oil pan is supported with a wooden block, raise the vehicle using a jack. CAUTION At this time carefully raise the vehicle not to over- load parts.
  • Page 299 GENERAL 2-16 TROUBLESHOOTING 1. Checking coolant leaks 1) After the coolant temperature drops below 38°C loosen the radiator cap. 2) Check that the coolant level reaches filler neck. 3) Install the radiator cap tester to the radiator filler neck and apply a pressure of 1.4kg/cm While maintaining it for 2 minutes, check the radiator, hose, and connecting part for leak.
  • Page 300 GENERAL 2-17 CAUTION • If the coolant contains less than 30% of antifreeze, anticorrosion is decreased. • If the coolant contains more than 60% of antifreeze, the engine will be fatally affected, resulting from decreased anti-freezing and engine cooling. Use only the recommended antifreeze and do not mix with other production.
  • Page 301 GENERAL 2-18 2. Using a tension gauge BORROUGHS type 1) Type BORROUGHS BT - 33 - 73F Dial NIPPONDENSO BTG - 2 Spindle 2) How to use Insert the belt between the gauge hook and spindle Hook and press the tension gauge handle. V-ribbed belt Spindle Leave the handle and read the gauge.
  • Page 302 GENERAL 2-19 3. Tighten the bolt A and then tighten B to the specified torque. CAUTION • If the belt tension is too excessive, noise as well as early wear of belt occurs and the water pump bearing and alternator bearing are damaged. •...

  • Page 303: Cylinder Block

    CYLINDER BLOCK 2-20 CYLINDER BLOCK COMPONENTS Oil pressure switch T:1.3~1.5 Tightening torque: kg·m L4GC029A REMOVAL Adaptor 1. Remove the cylinder head, timing belt, front case, flywheel and piston. 2. Remove the oil pressure switch. L4GC030A...
  • Page 304 CYLINDER BLOCK 2-21 INSPECTION CYLINDER BLOCK 1. Inspect the cylinder block for scratch, fur and rust visually, check for invisible crack or other deformation using a proper tool and repair or replace if necessary. 2. Measure flatness of the cylinder block upper surface using a straight edge and a thickness gauge.
  • Page 305 CYLINDER BLOCK 2-22 INSTALLATION Install the following parts in order. 1. Crankshaft 2. Flywheel 3. Piston 4. Cylinder head...
  • Page 306 CYLINDER BLOCK 2-23 FRONT CASE, OIL PUMP COMPONENTS Cylinder block Front case gasket Oil pump cover Oil pump outer gear Oil pump inner gear Front case Front oil seal T : 2~2.7 Relief plunger T : 1.0~1.2 Relief spring Oil filter Oil screen gasket T : 4.0~5.0 Oil pan...
  • Page 307 CYLINDER BLOCK 2-24 REMOVAL Mounting mark 1. Remove the timing belt. 2. Remove all oil pan tightening bolts. 3. Separate the oil pan from the cylinder block by tapping on the oil pan with a rubber hammer and then remove the oil pan.
  • Page 308 CYLINDER BLOCK 2-25 OIL PUMP GEAR [Body clearance] 1. Check the gear tooth surface for wear and damage. 2. Measure clearance between the outer gear and front case. Item Standard Body clearance 0.12 ~ 0.185mm Tip clearance 0.025 ~ 0.069mm Outer gear 0.04 ~ 0.09mm Side clearance...
  • Page 309 CYLINDER BLOCK 2-26 RELIEF VALVE AND SPRING 1. Check the relief valve inserted in the front case for perturbation. 2. Check the relief spring for deformation or damage. 43.8mm Free height 3.7kg/40.1mm Load INSTALLATION Mounting mark OIL PUMP 1. Install the outer and inner gears to the front case. 2.
  • Page 310 CYLINDER BLOCK 2-27 FRONT CASE B 3 pieces 1. Install the gasket and front case assembly and tighten the C 1 pieces bolt to the specified torque. Items Values 25mm 20mm Bolt length 45mm A 1 pieces D 2 pieces 38mm L4GC039A 2.0 ~ 2.7kg·m...
  • Page 311 CYLINDER BLOCK 2-28 7. Install the oil pan and tighten the bolt to the specified torque. Oil pan bolt 1.0 ~ 1.2kg·m...

  • Page 312: Main Moving System

    MAIN MOVING SYSTEM 2-29 MAIN MOVING SYSTEM CAMSHAFT, HLA, TIMING CHAIN, CHAIN GUIDE COMPONENTS T : 0.25~0.35 Center cover T : 0.8~1.0 Cylinder head cover Gasket T : 0.8~1.0 Bearing cap(rear) Chain guide Intake camshaft Bearing cap(front) Camshaft oil seal Exhaust camshaft Camshaft sprocket T : 10~12...
  • Page 313 MAIN MOVING SYSTEM 2-30 REMOVAL 1. Remove the breeder hose and P.C.V hose. 2. Remove the center cover. 3. Remove the ignition coil and spark plug. 4. Remove the timing belt upper cover. 5. Remove the cylinder head cover. 6. Remove the tensioner. 7.
  • Page 314 MAIN MOVING SYSTEM 2-31 INSPECTION CAMSHAFT 1. Check the camshaft journal for wear and if the journal is seriously worn, replace the camshaft. 2. Check the cam lobe for damage and if the lobe is severely damaged or worn, replace the camshaft. Items Limit Standard...
  • Page 315 MAIN MOVING SYSTEM 2-32 5) If the valve noise is still heard after following the above step 4), replace the hydraulic lash adjuster(HLA) which makes noise. 6) If the valve noise is heard after replacing parts, neces sarily repeat the above step 4). 7) After air-bleeding the system and replacing parts to remove noise, if the valve noise is re-heard 2-3 days after, it might be affected from defective HLA, so re...
  • Page 316 MAIN MOVING SYSTEM 2-33 6. Remove the cylinder head cover. 1) Disconnect the spark plug cable. 2) Disconnect the PCV hose and intake hose. 3) Disconnect the accelerator cable. 4) Remove the cylinder head cover and gasket. 7. Place the cylinder no.1 to the dead point. 1) Rotate the crankshaft pulley so as to align it with T mark on the timing belt low cover.
  • Page 317 MAIN MOVING SYSTEM 2-34 6. Check the valve gap. 1) Measure the gap between the camshaft and valve lift using a gauge. Valve gap (Engine coolant temperature : 20°) Intake 0.12 ~ 0.28mm Exhaust 0.20 ~ 0.36mm Intake side IN. 2 IN.
  • Page 318 MAIN MOVING SYSTEM 2-35 2) Rotate the crankshaft pulley so as to align it with mark on the timing belt low cover. 3) Check the valve gap. Intake side IN. 2 IN. 1 Rear side EX. 1 EX. 3 Exhaust side Adjusting valve at no.1 compression dead point L4GC055A 7.
  • Page 319 MAIN MOVING SYSTEM 2-36 2) Using the special tool(09222-2D000), press the valve liter downward and install the stopper between the cam (09222 - 2D000) Pliers shaft and valve lifter. Stopper L4GC057A 3) Remove the adjusting shim using a small screwdriver and a magnet.
  • Page 320 MAIN MOVING SYSTEM 2-37 6) Install a new adjusting shim. 7) After measuring the valve gap, check that it is within the specified values. Valve gap (Engine coolant temperature: 20°) Intake 0.12 ~ 0.28mm Exhaust 0.20 ~ 0.36mm REASSEMBLY 1. After cleaning sealant remnants of the cylinder head and cylinder head cover, apply new sealant(LOCTITE NO.5999).
  • Page 321 Head cover Sealant Sealant Cylinder head 3 VIEW "D", "E", "F" VIEW "D", "E", "F" VIEW "G"...
  • Page 322 MAIN MOVING SYSTEM 2-39 2. Install the cylinder head cover. Cylinder head cover 0.8 ~ 1.0kg·m 3. Connect the accelerator cable. 4. Connect the PCV hose and intake hose to the head cover. 5. Connect the spark plug cable. 6. Install the timing belt upper cover. 7.
  • Page 323 MAIN MOVING SYSTEM 2-40 4. Timing chain 1) Check the timing chain bushing and plate portion for wear and if those are severely worn, replace those. Mounting mark L4GC061A INSTALLATION Timing mark Exhaust timing 1. Install HLA chain sprocket CAUTION Tappet and shim should be installed to the original position.
  • Page 324 MAIN MOVING SYSTEM 2-41 4. Check that the camshaft is smoothly turned by hand. After checking, remove the bearing cap and camshaft and install MLA. 5. Check that the dowel pin on the exhaust camshaft sprocket is installed upward. L4GC066A 6.
  • Page 325 MAIN MOVING SYSTEM 2-42 9. Install the cylinder head cover. Apply sealant as shown in the illustration. Cylinder head cover 0.8 ~ 1.0kg·m Apply engine oil to the oil seal lip to help install the cylinder head cover oil seal to the spark plug pipe smoothly. CAUTION •...
  • Page 326 MAIN MOVING SYSTEM 2-43 CRANKSHAFT COMPONENTS Crankshaft center bearing T : 1.1~1.2 Crankshaft upper bearing Thrust bearing Crankshaft position sensor wheel Crankshaft Crankshaft center bearing Crankshaft lower bearing Main bearing cap T : 2.7~3.3+(60 ~ 65 ) Tightening torque : kg·m L4GC072A...
  • Page 327 MAIN MOVING SYSTEM 2-44 DISASSEMBLY 1. Remove the timing belt train, front case, flywheel, cylinder head assembly, and oil pan. 2. Remove the rear plate and rear oil seal. 3. Disconnect the connecting rod cap. 4. Remove the main bearing cap. (Arrange it in order) 5.
  • Page 328 MAIN MOVING SYSTEM 2-45 3. Measuring oil clearance 1) Measure O.D of the crankshaft journal and pin. 2) Measure diameter of the crankshaft bore and connect- ing rod bore. 3) Measure the thickness of the crankshaft and connect- ing rod bearing. 4) Calculate clearance by subtracting O.D of the journal pin and thickness of the bearing from diameter of the bore.
  • Page 329 MAIN MOVING SYSTEM 2-46 5. Install the bearing cap and tighten the cap bolt to the speci- fied torque from the center in order. (Tighten the bearing cap bolts to the specified torque by tightening bolts step by step 2-3 times equally) Main bearing cap bolt 2.7 ~ 3.3kg·m+(60°...
  • Page 330 MAIN MOVING SYSTEM 2-47 FLYWHEEL & HOUSING COMPONENTS Flywheel T : 12~13 Ring gear T : 8~10 T : 4.3~5.5 T : 0.8~1.2 T : 4.3~5.5 T : 4.3~5.5 Tightening torque : kg·m L4GC077A REMOVAL 1. Remove the flywheel. 2. Remove the flywheel housing.
  • Page 331 MAIN MOVING SYSTEM 2-48 INSPECTION 1. Check the ring gear for damage and crack and replace it if necessary. ASSEMBLY 1. Install the flywheel housing and tighten the bolt to the speci- fied torque. 2. Install the flywheel assembly and tighten the bolt to the specified torque.
  • Page 332 MAIN MOVING SYSTEM 2-49 PISTON AND CONNECTING ROD COMPONENTS No.1 piston ring No.2 piston ring Piston Bolt Connecting rod Upper bearing Connecting rod bearing Lower bearing Connecting rod bearing cap T : 5.0 ~ 5.3 Tightening torque : kg·m L4GC078A...
  • Page 333 MAIN MOVING SYSTEM 2-50 DISASSEMBLY Press ram 1. Remove the cylinder head assembly. NOTE Put an identification mark on the connecting rod Installer and cap before disassembly to refer to the original position and direction. Support 09234-33001 2. Remove the oil pan and remove the oil screen. 3.
  • Page 334 MAIN MOVING SYSTEM 2-51 2. To measure the end gap of piston ring, insert the piston ring to the cylinder bore. At this time, smoothly insert the ring to the piston so as to place the ring and cylinder wall to No.1 right position.
  • Page 335 MAIN MOVING SYSTEM 2-52 3. Using a connecting rod aligner, measure bending and tor- sion of rod and if the measured value is around the limit, correct the rod with a press. But when the rod is severely bended or damaged, neces- sarily replace it.
  • Page 336 MAIN MOVING SYSTEM 2-53 4) Rotate the push rod to a half turn, remove the piston connecting rod assembly from the support. 5) After press fitting the piston pin, check that the con- necting rod for smooth slip and free movement. 2.
  • Page 337 MAIN MOVING SYSTEM 2-54 2) After installing no.2 piston ring, install no.1 piston ring. CAUTION No.1 • Face the size mark and manufacturer mark on the ring surface upward when installing the piston ring. • Take care not to change no.1 and no.2 pis- No.2 ton rings.
  • Page 338 MAIN MOVING SYSTEM 2-55 5. Inspect clearance of the connecting rod big end. Clearance of connecting rod big end 0.1 ~ 0.25mm L4GC090A 6. Install the oil screen. 7. Install the oil pan. 8. Install the cylinder head.

  • Page 339: Cooling System

    COOLING SYSTEM 2-56 COOLING SYSTEM COOLANT PIPE AND HOSE COMPONENTS T : 1.5~2.0 Water temperature sensor T : 1.5~2.0 T : 1.5~2.0 Tightening torque : kg·m L4GC091A...
  • Page 340 COOLING SYSTEM 2-57 INSPECTION Check the coolant pipe and hose for crack, damage, and clog- ging and replace it if necessary. INSTALLATION After getting water around O-ring, insert it the groove in the coolant intake pipe end and press-fit the pipe. CAUTION •...
  • Page 341 COOLING SYSTEM 2-58 WATER PUMP COMPONENTS Water pump Water pump pulley T : 0.8~1.0 Gasket T : 2.0~2.7 Belt Tightening torque : kg·m L4GC092A...
  • Page 342 COOLING SYSTEM 2-59 REMOVAL 1. Check each part for crack, damage, and wear and replace the water pump if necessary. 2. Check the bearing for damage, abnormal noise and bad rotation and replace the water pump if necessary. 3. Check the seal unit for leak and replace the water pump assembly if necessary.
  • Page 343 COOLING SYSTEM 2-60 THERMOSTAT COMPONENTS Gasket Thermostat Thermostat housing Gasket T : 1.5 ~ 2.0 Water inlet fitting Tightening torque : kg·m L4GC095A INSPECTION 1. Check the valve closed at room temperature. 2. Check for defect or damage. 3. Heat the thermostat as shown in the illustration and mea- sure the valve open temperature and full open temperature.
  • Page 344 COOLING SYSTEM 2-61 FAN DRIVE COMPONENTS T : 4.3~5.5 T : 2.0~2.5 T : 2.0~2.5 Tightening torque : kg·m L4GC097A REMOVAL 1. Remove the fan pulley. 2. Remove the fan bracket. INSTALLATION Installation is the reverse order of removal.

  • Page 345: Lubrication System

    LUBRICATION SYSTEM 2-62 LUBRICATION SYSTEM OIL PRESSURE SWITCH Oil pressure switch is located on the front right side of the en- gine and if oil pressure in the lubrication system drops less than 0.29kg/cm , the oil pressure warning lamp illuminates. Hexagonal width of this switch is 24mm.
  • Page 346 LUBRICATION SYSTEM 2-63 4. Front case (Oil pump) 5. Timing belt 6. Timing belt cover...

  • Page 347: Intake And Exhaust System

    INTAKE AND EXHAUST SYSTEM 2-64 INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD COMPONENTS Exhaust manifold gasket Exhaust manifold T : 1.5~2.0 Tightening torque : kg·m L4GC100A...
  • Page 348 INTAKE AND EXHAUST SYSTEM 2-65 REMOVAL 1. Remove the heat protector. 2. Detach the exhaust manifold from the cylinder head. L4GC101A INSPECTION 1. Check the exhaust manifold for damage and crack. 2. Check the welding part between the exhaust manifold and catalyst for crack and damage.
  • Page 349 INTAKE AND EXHAUST SYSTEM 2-66 INTAKE MANIFOLD COMPONENTS T : 5.0 ~ 6.0 T : 4.3 ~ 5.5 T : 1.5 ~ 2.0 Tightening torque : kg·m L4GC103A CAUTION Do not tighten parts excessively, observe the speci- fied torque.
  • Page 350 INTAKE AND EXHAUST SYSTEM 2-67 REMOVAL 1. Disconnect the map sensor and the connector. 2. Disconnect the air hose from the throttle body. 3. Remove the accelerator cable. 4. Remove the P.C.V valve hose. 5. Disconnect the vacuum hoses. 6. Disconnect the fuel injector connector and the wiring harness.
  • Page 351 INTAKE AND EXHAUST SYSTEM 2-68 INSTALLATION 1. After replacing the intake manifold gasket, install it to the cylinder head and then to the intake manifold. 2. Install the delivery pipe and injector assembly to the intake manifold. L4GC105A CAUTION Check that the injector is interfered with the injec- tor hole in the intake manifold.
  • Page 352 CYLINDER HEAD ASSEMBLY 2-69 CYLINDER HEAD ASSEMBLY CYLINDER HEAD ASSEMBLY COMPONENTS T : 0.8 ~ 1.0 M10 : 2.3~2.7 kg-m + 60˚~65˚ + 60˚~65˚ M12 : 2.8~3.2 kg-m + 60˚~65˚ + 60˚~65˚ Tightening torque : kg·m L4GC107A 1. Cylinder block 4.

  • Page 353: Cylinder Head Assembly

    CYLINDER HEAD ASSEMBLY 2-70 T : 0.8~1.0 T : 4.1~5.1 T : 1.4~1.5 T : 10.0~12.0 Tightening torque : kg·m L4GC108A 14. OCV(Oil control valve) filter 1. MLS(Mechanical valve clearance 7. Key 15. Camshaft bearing cap adjusting system 8. Chain sprocket 16.
  • Page 354 CYLINDER HEAD ASSEMBLY 2-71 DISASSEMBLY 1. Using the special tool cylinder head bolt wrench (09221- 32001) , tighten the cylinder head bolts in order by tighten- ing 2-3 times as shown in the illustration. • Take care not to come the cylinder head gasket debris into the cylinder.
  • Page 355 CYLINDER HEAD ASSEMBLY 2-72 INSPECTION CYLINDER HEAD 1. Check the cylinder head for crack, damage and leak. 2. Clean out fur, adhesive and accumulated carbon and after cleaning the oil passage, bleed the passage with com- pressed air to check it for clogging. 3.
  • Page 356 CYLINDER HEAD ASSEMBLY 2-73 VALVE SPRING 1. Measure free height of the valve spring and replace the spring if the measured value exceeds the limit. 2. Using a square, measure squareness of each spring and replace it if the measured value is out of squareness excessively.
  • Page 357 CYLINDER HEAD ASSEMBLY 2-74 VALVE SEAT RING REPLACEMENT 0.3mmR 1. If the valve seat insert is excessively worn, cut the insert 0.5~1.0mm ring wall as shown in the illustration A using a valve seat cutter at a normal temperature. New hole Removal Old hole 0.15~0.3mm...
  • Page 358 CYLINDER HEAD ASSEMBLY 2-75 VALVE GUIDE REPLACEMENT Because the valve guide is press-fitted, replace the valve guide as the following procedures using a valve guide installer or proper tool. 1. Remove the valve guide pressed toward cylinder block us- ing a push rod of valve guide installer. 2.
  • Page 359 CYLINDER HEAD ASSEMBLY 2-76 ASSEMBLY 09222-22001 CAUTION • Prior to assembly, clean each component. • Apply a new engine oil to the perturbation part and rotation part. L4GC120A 1. After installing the spring seat, insert the stem seal to the valve guide.
  • Page 360 CYLINDER HEAD ASSEMBLY 2-77 5. Clean out all gasket surfaces of the cylinder block and cyl- inder head. 6. Put new cylinder head gaskets on the cylinder block with the identification marks faced upward. Do not apply seal- ant to the gasket and do not reuse the used cylinder head gasket.
  • Page 361 TIMING BELT 2-78 TIMING BELT COMPONENTS T : 10.0 ~ 12.0 T : 2.3 ~ 2.9 T : 4.3 ~ 5.5 T : 16.0 ~ 17.0 Tightening torque : kg·m L4GC124A 1. Timing belt upper cover. 4. Cylinder head cover 7.
  • Page 362 TIMING BELT 2-79 REMOVAL 1. Loosen the water pump pulley belt. Water pump pulley 2. Loosen the alternator bolt. 3. Remove the water pump pulley and belt. drive belt L4GC125A 4. Crankshaft pulley. 5. Remove the timing belt cover. L4GC126A 6.
  • Page 363 TIMING BELT 2-80 10. Remove the idler. 11. Loosen the camshaft sprocket bolt and remove the cam- shaft sprocket. L4GC129A 12. Remove the crankshaft sprocket bolt and remove the crank- shaft sprocket and flange. 13. Remove the timing belt tensioner.
  • Page 364 TIMING BELT 2-81 INSPECTION SPROCKET, TENSIONER, IDLER 1. Check the camshaft sprocket, crankshaft sprocket, tensioner and idler for wear, crack and damage and re- place it if necessary. 2. Check the tensioner and idler pulley for smooth rotation, check for play and noise, and replace it if necessary. L4GC130A 3.
  • Page 365 TIMING BELT 2-82 Description Specification Glossy back side. Due to non-elasticity 1. Back side rubber is hardened and hardening, when pressing it with the tip of a finger, there is no sign of it. L4GC132A 2. Back side rubber is cracked L4GC133A 3.
  • Page 366 TIMING BELT 2-83 ASSEMBLY 1. Install the flange and crankshaft sprocket taking care of Special washer installation direction as shown in the illustration. Crankshaft Crankshaft sprocket bolt 17 ~ 18kg·m Crankshaft Flange sprocket L4GC143A 2. Install the camshaft sprocket and tighten the bolt to the specified torque.
  • Page 367 TIMING BELT 2-84 6) Install the timing belt not to loosen in the following order. Crankshaft sprocket(A) Idler pulley(B) Camshaft sprocket(C) Timing belt tensioner(D). (After installing timing belt, auto tensioner may be installed) L4GC144A 7) Be sure that timing mark on each sprocket is placed on the proper position.
  • Page 368 TIMING BELT 2-85 14) Install the crankshaft pulley(A) together with the flange, tighten the bolt(B). When installing, align the crankshaft key with the pul- ley groove. Crankshaft pulley bolt Tightening torque 16.0 ~ 17.0kgf·m L4GC146A 15) Install the timing belt upper cover. Tightening torque 0.8 ~ 1.0kgf·m 16) Install the water pump pulley.
  • Page 369 CHAPTER 3. ENGINE ELECTRICAL SYSTEM 1. GENERAL ................ 3- 1 2. IGNITION SYSTEM ............3- 3 3. CHARGING SYSTEM ............3- 9 4. STARTING SYSTEM ............3- 25...
  • Page 370 GENERAL GENERAL SPECIFICATIONS #1 TDC SENSOR Item Specification Type Non-contacting type Advance system Controlled by ECU Ignition order 1 3 4 2 CRANKSHAFT POSITION SENSOR Item Specification Type Non-contacting type Advance system Controlled by ECU Ignition order 1 3 4 2 IGNITION COIL Item Specification...
  • Page 371 GENERAL ALTERNATOR Item Specification Type Battery voltage sensing type Rated output 13.5V 90A 1,000 ~ 18,000rpm Regulator adjusting voltage 14.4 0.3V/20°C Temperature compensation 3mV/°C Voltage regulator type Electro-magnetic, Built-in type NOTE 1. Cold cranking ampere : It means that terminal voltage is maintained 7.2V or more at a certain temperature and battery current is supplied for 30 seconds.
  • Page 372 IGNITION SYSTEM IGNITION SYSTEM GENERAL 1. If the ignition switch is ON, the battery voltage is supplied to 1 coil of ignition coil. 2. By rotation of the crank position sensor wheel, ignition sig- nal in ECU is actuated the power transistor and repeat ground or shut off of 1 current of ignition coil.
  • Page 373 IGNITION SYSTEM INSPECTION OF IGNITION TIMING 1. Inspection condition Coolant temperature : 80-90°C(At normal temperature) Lamp, cooling fan and all accessories : OFF Transaxle : In neutral position (Auto : N) Parking brake : ON 2. Inspection 1) Connect the timing light. L4GC300A 2) After inserting the clip backward the connector, con- nect the tachometer with the special tool (09273-24000)
  • Page 374 IGNITION SYSTEM INSPECTION OF IGNITION COIL 1. 1 coil resistance measurement Measure resistance between no.1 and no.3 terminals of ig- nition coil. (For no.1 and no.4 cylinders) And measure resistance between no.3 and no.2 terminals of ignition coil. (For no.2 and no.3 cylinders) 1A.
  • Page 375 IGNITION SYSTEM INSPECTION OF SPARK PLUG Inspection and clean 1. Disconnect the spark plug cable from the spark plug. Remove the spark plug cable by pulling the cable cap with hand. 2. Remove all spark plugs from the cylinder head using a spark plug wrench.
  • Page 376 IGNITION SYSTEM SPARK PLUG ANALYSIS State Contact point is Contact point is black white Description •Density of the fuel • Density of the fuel mixture is thick mixture is thin •Lack of air intake •Ignition timing is fast •Spark plug is tight •Lack of torque L4GC300A SPARK PLUG TEST...
  • Page 377 IGNITION SYSTEM SPARK PLUG CABLE INSPECTION 1. Check the cap for outer crack. 2. Measure resistance. 3. Inspect resistance. Spark plug cable NO.1 11.2kΩ L4GC307A NO.2 9.5kΩ NO.3 6.9kΩ NO.4 5.5kΩ TEST 1. With the engine at idle, disconnect the spark plug cable one by one and inspect change of the engine performance each time.
  • Page 378 CHARGING SYSTEM CHARGING SYSTEM GENERAL Charging system consists of battery, alternator with a built-in regulator, charging warning lamp and wire. Because there are 6 diodes (3 (+) diodes, 3(-) diodes) built in alternator, AC current is rectified to DC current and DC current is detected in B terminal of alternator.
  • Page 379 CHARGING SYSTEM 3-10 TROUBLESHOOTING Charging system defect is almost caused by lack of pan belt tension and faulty function of wiring, connector, and voltage regulator. One of most important thing during troubleshooting of charging system is determining the reason between overcharging and lack of charging.
  • Page 380 CHARGING SYSTEM 3-11 TROUBLESHOOTING PROCEDURE INSPECTION BEFORE STARTING 1. Charging warning lamp inspection Does charging warning lamp illuminate with ignition switch in IG position? Not illuminated Illuminated Alternator female current supply circuit cut off, Alternator charging fault Replace alternator L4GC311A 2.
  • Page 381 CHARGING SYSTEM 3-12 3. Alternator and outer terminal connection inspection Is B terminal tightening nut securely tightened ? Normal Terminal is moving Faulty B terminal nut tightening causes overheat and charging fault by contact between terminal and B terminal Retighten and test L4GC313A Is there no missing of L-S connector? Normal...
  • Page 382 CHARGING SYSTEM 3-13 INSPECTION AFTER STARTING 1. Inspection of alternator charging warning lamp operation test Is charging warning lamp turned OFF? Illuminated Not illuminated Generator female circuit is normal but generator component is faulty (Check for power generation) Replace generator L4GC317A 2.
  • Page 383 CHARGING SYSTEM 3-14 DROP OF ELECTRIC PRESSURE TEST "B" terminal OF ALTERNATOR OUTPUT WIRE This test is to check that wiring is correctly connected between Alternator the alternator B terminal and battery (+) terminal. PREPARATION 1. Turn the ignition switch OFF. Ammeter 2.
  • Page 384 CHARGING SYSTEM 3-15 RESULT 1. If voltmeter reading is within the standard, it is normal. Test voltage Maximum 0.2V 2. If voltmeter reading is more than the standard, mostly wir- ing is faulty. In this case, inspect wirings between the alter- nator and the battery (+) terminal as well as between the alternator B terminal and the fusible link.
  • Page 385 CHARGING SYSTEM 3-16 5. Connect a DC ampere meter (0-100V) between B termi- nal and the disconnected output wire. Connect (+) lead wire to the terminal B and (-) lead wire to the disconnected output wire. Voltmeter Ammeter NOTE Do not use clips or equivalent owing to high current and Use bolts and nuts to tighten each connecting Charge part securely.
  • Page 386 CHARGING SYSTEM 3-17 RESULT 1. Ammeter reading should be higher than the limit. If the read- ing is low even though the alternator output wire is normal, remove the alternator from the vehicle and inspect it. Output current limit 70% of rated current NOTE •...
  • Page 387 CHARGING SYSTEM 3-18 DISASSEMBLY AND INSTALLATION L4GC322A 8. Rotor coil 15. Rectifier assembly 1. Nut 9. Rear bearing 16. Stud bolt 2. Pulley 10. Bearing cover 17. Brush holder assembly 3. Bushing 11. Stator coil 18. Brush holder bolt 4. Front cover assembly 12.
  • Page 388 CHARGING SYSTEM 3-19 REMOVAL AND INSTALLATION 1. Disconnect the battery (A) terminal. L4GC323A 2. Disconnect the alternator B terminal and then the con- nector (A). Loosen the clip (B). L4GC324A 3. Loosen the alternator tension adjusting bolt (A) and the al- ternator fixing bolt (B).
  • Page 389 CHARGING SYSTEM 3-20 DISASSEMBLY 1. After removing the mounting nuts (B), remove the genera- tor cover (A) using a screwdriver. L4GC326A 2. Loosen 3 mounting bolts (A) and disconnect the brush holder assembly (B). L4GC327A 3. Remove the slip ring guide (A). L4GC328A 4.
  • Page 390 CHARGING SYSTEM 3-21 5. Loosen 4 through bolts. L4GC330A 6. Separate the rotor and cover. L4GC048A...
  • Page 391 CHARGING SYSTEM 3-22 INSPECTION ROTOR 1. Inspect the rotor coil for continuity and check for continuity between slip rings. If resistance is too low, circuit is short and if the resistance is too high, circuit is opened. So replace the rotor assembly in both cases.
  • Page 392 CHARGING SYSTEM 3-23 RECTIFIER 1. (+) rectifier When inspecting continuity between (+) rectifier and stator coil lead connecting terminal using an ohmmeter, there must have only one direction continuity. If there is both direction continuity, replace the rectifier assembly owing to short cir- cuit of diode.
  • Page 393 CHARGING SYSTEM 3-24 INSTALLATION 1. After placing the alternator, insert the support bolt. (At this time do not insert the nut.) Alternator 2. After pressing forward the alternator, Contact the alternator front bracket with front case (A) as shown in the illustration. Support bolt 3.
  • Page 394 STARTING SYSTEM 3-25 STARTING SYSTEM GENERAL Starting system consists of battery, start motor, solenoid switch, ignition switch, inhibiter switch (Only for A/T), contact wire, and battery case. When the ignition key is turned to “ST” position, current is sending to start motor solenoid coil, the solenoid plunger and clutch shift lever is actuated, and the clutch pinion is engaged with the ring gear resulting in cranking.
  • Page 395 STARTING SYSTEM 3-26 TROUBLESHOOTING Starting system problem can be classified into Start motor is not operating , Start motor is operating but engine is not starting , and There is a lot of time taken to start engine . When the starting system has problems, before removing the start motor, find where the problem happens.
  • Page 396 STARTING SYSTEM 3-27 COMPONENTS L4GC343A 1. Screw 6. Lever 11. Magnetic switch 16. Yoke assembly 2. Front bracket 7. Plate 12. Planetary gear holder 17. Armature 3. Stop ring 8. Packing B 13. Planetary gear 18. Brush holder 4. Stopper 9.
  • Page 397 STARTING SYSTEM 3-28 INSPECTION (AFTER REMOVAL) Carbon pile rheostat INSECTION OF PINION CLEARANCE Ammeter 1. Disconnect the wire from M terminal. 2. Connect a 12V battery between S terminal and M Battery Start motor terminal. Voltmeter 3. If the switch is turned ON, the pinion is moving. CAUTION This test should be done as soon as possible not to L4GC344A...
  • Page 398 STARTING SYSTEM 3-29 RETURN TEST OF SOLENOID 1. Connect the connector from M terminal. 2. Connect a 12V battery between S terminal and M terminal. CAUTION This test should be done as soon as possible not to damage the coil (in 10 seconds). 3.
  • Page 399 STARTING SYSTEM 3-30 2. SHORT CIRCUIT TEST OF AMARTURE COIL Inspect the armature coil in the growler and if there is short circuit, replace the coil. During core rotation, if the blade attached in the core is vibrated, the armature is short. L4GC350A 3.
  • Page 400 STARTING SYSTEM 3-31 6. BRUSH If the brush is worn out to the limit, replace the brush. Wear limit L4GC354A 7. BRUSH HOLDER Check continuity between the (+) side brush holder and the base. If there is continuity, replace the brush holder assembly.
  • Page 401 STARTING SYSTEM 3-32 10. INSTALLATION OF REAR BRACKET 1) Before removing the bushing, measure the bushing press-fit depth. 2) Remove the bushing as shown in the illustration. 3) Press-fit a new bushing as the depth measured proce- dure 1). L4GC358A ASSEMBLY 1.
  • Page 402 CHAPTER 4. FULE SYSTEM AND OTHER 1. GENERAL ................ 4- 1 2. INJECTOR ............... 4- 14 4. PVC VALVE ..............4- 16...
  • Page 403 GENERAL GENERAL SPECIFICATIONS Item Specification Fuel filter Type High pressure type Fuel pump (Including fuel filter) Type Tank built-in electric type Driving Electric motor Input sensor Map sensor Type Piezo electric type 0.8-1.1V(at idle) Output voltage 4.5-5V(opened) Type Thermostat type Intake temperature sensor Resistance - 3.0 (at 20°C)
  • Page 404 GENERAL INSPECTION STANDARD Standard Item BTDC 2 ° 5 ° Ignition timing (2.0DOHC) RPM (2.0DOHC) 100rpm Neutral, N, P A/CON OFF TIGHTENING TORQUE Item Specified value (kg·m) Water temperature sensor 1.5 ~ 2.0 Oxygen sensor 5.0 ~ 6.0 Fuel supply pipe mounting bolt 1.0 ~ 1.3 Throttle body mounting bolt 1.5 ~ 2.0...
  • Page 405 GENERAL TROUBLESHOOTING When inspecting and repairing the engine, start from the basic unit. If symptoms happen such as (A) engine is not starting (B) irregular idling (C) insufficient acceleration, inspect the basic unit as below. 1. POWER 1) Battery 2) Fusible link 3) Fuse 4) Injector 2.
  • Page 406 GENERAL INSTRUCTION FOR MPI INSPECTION 1. When checking the alternator for charging, never remove battery (+) terminal. (If peak voltage of alternator is not absorbed by battery, it is possible to burn out ECU power terminal element.) 2. 1. When inspecting circuit, use a digital multi-meter or a LED of 1M or more.
  • Page 407 GENERAL MPI TROUBLESHOOTING PROCEDURE SYMPTOM • ENGINE IS NOT STARTING o Battery o Battery Power check Power check 1. Connection 1. Connection 2. Specific gravity 2. Specific gravity 3. Driving belt 3. Driving belt 4. Voltage 4. Voltage o Fusible link o Fusible link o Ignition switch o Ignition switch...
  • Page 408 GENERAL Fuel supply to injector check o Fuel line (Leak, Deformation) o Fuel in tank o Fuel pump o Fuel pressure o Fuel filter o Fuel pressure regulator o Regulator (-) pressure check Ignition plug inspection Standard: 1.0-1.1mm o Inspect compression if necessary o Wiring connection o ECU power 1.
  • Page 409 GENERAL RPM inspection ISA inspection Standard : 700 100rpm Spark plug inspection Compression inspection Not OK Standard: 0.7-0.8mm o Inspect compression if necessary o Compression Standard: 15.5-16.5 kg/cm (50 - 400 rpm) o Fuel pump Fuel pressure inspection o Fuel filter o Fuel pressure regulator o Regulator (-) pressure check Injector inspection...
  • Page 410 GENERAL Fault code Self-diagnosis inspection o Use Hi-scan Warning display number reading Spark plug inspection Fuel system inspection o Disconnect injector connector o With spark plug removed 8-10mm away from cylinder block, crank and inspect strong spark o Fuel pump Fuel pressure inspection o Fuel filter o Fuel pressure regulator...
  • Page 411 GENERAL TROUBLESHOOTING GUIDE • The following number represents inspection order. Item Sub symptom Not cranking Starter is rotating but not cranking Incomplete combustion Increasingly cranking Normally difficult to start Difficult to start when cold Difficult to start when hot Incorrect initial idling Low RPM Irregular idling Engine hesitation or deceleration...
  • Page 412 GENERAL 4-10 Item Sub symptom Not cranking Starter is rotating but not cranking Incomplete combustion Increasingly cranking Normally difficult to start Difficult to start when cold Difficult to start when hot Incorrect initial idling Low RPM Irregular idling Engine hesitation or deceleration After starting, engine stops soon After depressing acceleration pedal, engine stops After releasing acceleration pedal, engine stops...
  • Page 413 GENERAL 4-11 SENSOR CHARACTERISTICS • OXYGEN SENSOR Item Detail Criterion • When oxygen sensor voltage is 1.4V or more • With air fuel ratio in closed loop control When oxygen sensor voltage is 0.048 or less for 27 seconds Except idling (more than certain rpm and negative pressure), when cooling temperature is 15°C and in case of 0.348V <...
  • Page 414 GENERAL 4-12 • CRANKSHAFT POSITION SENSOR (CPS) Item Detail Criterion • During 4 camshaft signals, if there is no CKP pulse signal, determine it as fault and after this, increase counter per crankshaft signal. (Determine it together with camshaft position sensor every time) •...
  • Page 415 GENERAL 4-13 • CAMSHAFT POSITION SENSOR (NO.1 TDC SENSOR), VEHICLE SPEED SENSOR Item Detail Vehicle speed sensor • When 400rpm or more, (-) pressure of Criterion • During 4 camshaft signals, there is no 574mb or more, and negative pressure signal changed at camshaft position limit is less than 121mb, there is no sensor...
  • Page 416 INJECTOR 4-14 INJECTOR INSPECTION FUNCTION AND OPERATING PRINCIPLE Injector as a electronic controlled fuel injection unit, is solenoid valve which supplies exactly calculated fuel as a spray to en- gine to best combustion under the condition of various engine load and speed. For fuel consumption reduction, engine performance enhance- L4GC258A ment and emission reduction, ECM controls fuel injection to...
  • Page 417 INJECTOR 4-15 CIRCUIT DIAGRAM [CIRCUIT DIAGRAM] [CONNECTING INFORMATION] ECM (CBG-K) Injector #1 (CBG24-1) INJECTOR #1 (CBG24-1) Injector #1 control Terminal Connecting area Function Main relay Main relay Power (B+) Injector #2 (CBG24-2) ECM CBG-K (25) Injector #1 control Injector #2 control Main relay INJECTOR #2 (CBG24-2) Injector #3 (CBG24-3)
  • Page 418 PCV VALVE 4-16 PCV VALVE OUTLINE AND OPERATING PRINCIPLE Intake Manifold Side (No Vacuum) Intake Manifold Side (High Vacuum) Locker Cover Side Locker Cover Side L4GC260A L4GC261A Engine condition Engine condition No operating At idle or deceleration PCV valve PCV valve No operating Full operating Vacuum path...
  • Page 419 PCV VALVE 4-17 SERVIE PROCEDURE REMOVAL 1. After disconnecting the vacuum hose(A), remove the PCV valve(B). L4GC264A INSTALLATION Install the PCV valve and connect the vacuum hose. Tightening torque 0.8 ~ 1.2kgf·m INSPECTION 1. Remove the PCV valve. 2. Check the plunger for movement by inserting a thin stick (A) toward the valve (B) nut.

This manual is also suitable for:

25l-730l-720g-725g-730g-7

Table of Contents