Hyundai HDF 50-7S Service Manual
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Hyundai HDF 50-7S Service Manual

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Table of Contents

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The following contains the Service Manual for the current Hyundai Construction
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Summary of Contents for Hyundai HDF 50-7S

  • Page 1 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 2 https://www.forkliftpdfmanuals.com/...
  • Page 3 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information. https://www.forkliftpdfmanuals.com/...
  • Page 4 Revised edition mark( Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 7 Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
  • Page 8 kgf m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9...
  • Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 11: Table Of Contents

    CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13 SECTION 2 REMOVAL AND INSTALLATION OF UNIT...
  • Page 12 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...
  • Page 13 CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13 SECTION 2 REMOVAL AND INSTALLATION OF UNIT...
  • Page 14 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...

  • Page 15: Section 1 General

    SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13 https://www.forkliftpdfmanuals.com/...

  • Page 16: 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 17 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 18 · 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 19 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 https://www.forkliftpdfmanuals.com/...

  • Page 20: Group 2 Specifications

    GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENTS D507OM54 Mast Forks 13 Counterweight Lift chain Overhead guard 14 Rear wheel Lift cylinder Turn signal lamp 15 Front wheel Backrest 10 Head lamp 16 Rear combination lamp Tilt cylinder 11 Operator's seat Carrige 12 Bonnet https://www.forkliftpdfmanuals.com/...
  • Page 21 2. SPECIFICATIONS D507SP01 Model Unit HDF 50-7S HDF 70-7S Capacity 5000 7000 Load center Weight(Unloaded) 8347 9680 Lifting height 3000 Free lift Lifting speed(Unload/Load) 500/470 500/450 Fork mm/sec Lowering speed(Unload/Load) 450/500 mm/sec L W T L,W,T 1200 150 60 1200 180 60...
  • Page 22 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE ITEM SPECIFICATION UNIT Model MITSUBISHI S6S-DT Type 4-cycle, in-line, Vertical OHV Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, in line Firing order 1-5-3-6-2-4 Combustion chamber type In direct injection Cylinder bore X stroke mm(in) 94 120(3.7 4.7) Piston displacement...
  • Page 23 POWER TRAIN DEVICES Item Specification Model F&S 300*16/4/-1(ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.5 : 1 Type Full auto, Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type 1 : 4.578 2 : 2.396 3 : 0.994 Overhaul ratio 1 : 4.593...
  • Page 24 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS ITEMS SIZE kgf m lbf ft Engine mounting bolt, nut M16 2.0 Engine Radiator mounting bolt, nut 6.9 1.4 50 10 M10 1.5 Torque converter mounting bolt 6.9 1.4 50 10 M10 1.5 Hydraulic MCV mounting bolt, nut 12.8 3.0 93 22...
  • Page 25 5. TORQUE CHART Use following table for unspecified torque. BOLT 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 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7...
  • Page 26 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat kgf m lbf ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 130.2 1" 151.9 1-1/4" 253.2 IPE AND HOSE(ORFS TYPE) Thread size(UNF) Width across flat mm kgf m lbf ft 9/16-18 28.9 11/16-16 36.2...
  • Page 27 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. 。 C (。 F) Capacityℓ(U.S.gal) Ambient temperature Service Kind of point fluid 5.0 ~ 7.0 ton (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W 17.5 Engine oil...

  • Page 28: 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 29: Section 2 Removal And Installation Of Unit

    SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2 https://www.forkliftpdfmanuals.com/...

  • Page 30: Group 1 Structure

    GROUP 1 STRUCTURE 8 9 10 11 12 13 14 15 16 17 D507OM21 Mast 10 Priority valve 19 Muffler Lift cylinder 11 Transmission 20 Silencer Tilt cylinder 12 Torque converter 21 Air cleaner Control valve 13 Engine 22 Overhead guard Fork 14 Exhaust pipe 23 Seat...

  • Page 31: 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 SHAFT TYPE FORKS Fork retainer Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Hanger bar Release fork retainer and remove cover.
  • Page 32 CARRIAGE With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor. Make sure the carriage is level, this will prevent any binding when the mast is raised.
  • Page 33 Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage to work area and lower the mast. Make sure that carriage remains on floor and does not bind while mast is being raised. Inspect all parts for wear or damage. Replace all worn or damaged parts.
  • Page 34 LIFT CYLINDER Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast. Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no slack or binding. Make sure the lift cylinder be tightened firmly for safety.
  • Page 35 TILT CYLINDER PIN MAST SUPPORT PIN Attach a crane to the stay at the top of the outer mast, and raise it. Remove the mounting bolts and pins from drive axle, then slowly raise outer mast. This operation is carried out under the machine, so use a pit, or if there is no pit, jack up the machine and loosen with an impact wrench.
  • Page 36 INSTALLATION After assembling mast components tatally without piping connections, install mast assembly to the equipment. Installation procedure for each of mast component is the reverse of the removal procedure. MAST SUPPORT PIN Check the mast support pins for wear, then install pins into the mast support bracket and drive axle.
  • Page 37 2. POWER TRAIN ASSEMBLY REMOVAL D503RE04 Mast Refer to section on mast(Page 2-3) https://www.forkliftpdfmanuals.com/...
  • Page 38 Brake piping Brake pipe Disconnect the brake piping from the wheel cylinder end. Brake valve Wheel brake(RH) Drive axle Wheel brake(LH) D507RE05 Parking brake cable Parking brake Disconnect parking brake cable from the lever wheel brake assembly. Parking brake cable Wheel brake(RH) Wheel...
  • Page 39 Remove drive axle mount bolts from the frame and then slowly pull out the truck with drive axle to the front. D503RE08 Remove propeller shaft from the transmi- ssion by loosening the mounting bolts. D503RE81 Inching linkage Remove the nut, clevis pins and self locking pin.
  • Page 40 Transmission cooling piping Disconnect cooling hose and connector from the transmission. Make sure that the coolant be drained from the hose. D507RE10 Torque converter Remove the cover on top face of the torque converter housing then remove the 4 mounting bolts installed on the engine flywheel.
  • Page 41 Using a moving truck slowly pull out transmission assembly to the front. D503RE13 INSTALLATION Installation is the reverse order to removal, but be careful of the following points. Tightening torque of mounting bolt for torque converter housing. 4.2~5.0kgf m(30~36lbf ft) D503RE16 Tightening torque of mounting bolt for drive axle.
  • Page 42 Tightening torque of mounting bolt for transmission and propeller shaft. 7.2~9.5kgf m(52~69lbf ft) D503RE15 2-13 https://www.forkliftpdfmanuals.com/...
  • Page 43 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 44 Torque converter housing cover, mounting bolts installed to flywheel housing. For details, see page 2-12. 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 45 Tightening torque of mounting bolt installing to torque converter housing. 6.0~8.9kgf m(43~64lbf ft) Radiator hoses Distance to insert hose : 42mm(1.65in) Air cleaner hose Insert the air cleaner hose securely and fit a clamp. Distance to insert hose Air cleaner hose : 89mm(3.5in) ENGINE (9010-9280) Engine end(MHI) : 60mm(2.36in)
  • Page 46 5. WHEEL BRAKE REMOVAL D503RE34 Front wheel Put a block under the mast and tilt forward, or jack up the bottom of the frame to raise the front wheels off the ground, then remove the front wheels. D507RE22 Brake, drum assembly. D503RE23 INSTALLATION Installation is in the reverse order to removal,...
  • Page 47 6. REAR AXLE REMOVAL D503RE35 D507RE30 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) HDF50-7S : 1,900kg(4,189lb) HDF70-7S : 3,150kg(6,945lb) 2-18 https://www.forkliftpdfmanuals.com/...
  • Page 48 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. D503RE31 Hose D503RE32 Mounting bolt Put a block under the steering axle, support on a truck, an raise the frame with a crane.

  • Page 49: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN COMPONENT OVERVIEW D507PT01 The power train consists of the following components : Torque converter Transmission Propeller shaft Drive axle Engine power is transmitted to the transmission through the torque converter. The transmission is a hydraulically engaged three speed forward, three speed reverse power shift type transmission.
  • Page 50 Hydraulic circuit Pressure Temp reducing sensor valve 9 bar Main pressure valve 16+2.5bar Valve block control circuit Converter Filter Back pressure Con. valve 4.3+3 bar safety valve By pass valve 11+2 bar 5.5 bar Pump 16+2 bar Main oil circuit Oil sump Lubrication D507PT31...
  • Page 51 2. TORQUE CONVERTER D503TM01 Turbine Pump Input shaft Stator Transmission pump The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the characteristics, and with it the favorable efficiency of a fluid clutch. The converter will be defined according to the engine power so that the most favorable operating conditions for each installation case are given.
  • Page 52 If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the turbine moment becomes equal to that of the pump moment. From this point on, the converter is working similar to a fluid clutch. A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the conversion range the moment upon the housing, and is released in the coupling range.
  • Page 53 3. TRANSMISSION LAYOUT D507TM03 Engine connection Input gear Clutch shaft(KR) Converter Clutch shaft 10 Clutch shaft(K1) Input shaft Power take-off 11 Output flange Transmission pump Clutch shaft(KV) 12 Clutch shaft(K3/output) https://www.forkliftpdfmanuals.com/...
  • Page 54 INSTALLATION VIEW 21 20 11 10 FRONT VIEW REAR VIEW D507PT26 Converter 13 Breather Converter bell 14 Electro - hydraulic control Lifting lugs 15 Temperature sensor behind the converter Inductive transmitter n central gear train 16 Connection to the oil cooler Inductive transmitter n turbine 17 Filter head Gearbox housing - Front section...
  • Page 55 OPERATION OF TRANSMISSION Gearbox diagram The multi-speed reversing transmission in countershaft design is power shiftable by hydraulically actuated multi-disk clutches. All gears are constantly meshing and carried on antifriction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 3-speed reversing transmission is equipped with 5 multi-disk clutches.
  • Page 56 Forward In forward, forward clutch and 1st, 2nd, 3rd clutch are engaged. Forward clutch and 1st, 2nd, 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston. 1st speed-forward Transmission diagram K3/AB Opinion direction of rotation Legend: AN = Input K3/AB KV = Clutch forward...
  • Page 57 Reverse In reserve, reserve clutch and 1st, 2nd, 3rd clutch are engaged. Reverse clutch and 1st, 2nd, 3rd are actuated by the hydraulic pressure applied to the clutch piston. 1st speed-reverse Transmission diagram K3/AB Opinion direction of rotation Legend: AN = Input K3/AB KV = Clutch forward KR = Clutch reverse...
  • Page 58 ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE SECTION A-A SECTION B-B D507PT03 Pressure reducing valve(9bar) Intermediate plate Main pressure valve (16 + 2bar) Duct plate Housing Vibration damper Plug(cable harness) 10 Follow - on slide Cover 11 Pressure regulator Valve block 3-10 https://www.forkliftpdfmanuals.com/...
  • Page 59 Transmission control, see schedule of measuring points, Oil circuit diagram and Electro-hydraulic control unit see page 3-2, 3-10. The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is sitting in the transmission on the engine-dependent input shaft. The feed rate of the pump is Q = 85 /min, at n = 2000 min...
  • Page 60 This is achieved by converter pressure back-up valve, rear-mounted to the converter, with an opening pressure of at least 4.3+3bar. The oil, escaping out of the converter, is directed to the oil cooler. From the oil cooler, the oil is directed to the transmission and there to the lubricating oil circuit, so that all lubricating points are supplied with cooled oil.
  • Page 61 GEAR SELECTOR(DW-3) The gear selector is designed for the mounting on the steering column left side. By a rotative motion, the positions(speeds) 1 to 3 are selected by tilting the lever, the driving direction(Forward (F) - Neutral(N) - Reverse(R)). For the protection from unintended start off, a neutral interlock is installed : Position "...
  • Page 62 Gear selector(DW-3) LEVER FOR MECHANICAL CODING GEAR SELECTOR NEUTRAL INTERLOCK OUTPUT FORWARD REVERSE NEUTRAL SPEED IN POSITION(NEUTRAL), F-R NOT SWITCHABLE CIRCUIT DIAGRAM SELECTOR TYPE PLATE GEAR POSITIONS AD3(B3) AD1(B1) ED1(+/VP) F = FORWARD AD6(N) N = NEUTRAL R = REVERSE AD4(FORWARD) D = MECANICAL NEUTRAL INTERLOCK 1 = 1st SPEED...
  • Page 63 TRANSMISSION ERROR DISPLAY Function The display can be used with the gear selector. It indicates speed and driving direction as well as the activated inching. When driving in the automatic mode, a bar indicator gives additionally also information about the selected driving range;...
  • Page 64 Display during operation Symbol Meaning Remarks Actual gear and direction F, N, R Central side shows actual gear 1, 2, 3 Right side shows actual direction Not neutral, waiting for neutral To engage a gear, first move shift selector to (Central and right side) after power up or a severse fault neutral position and again to F to R position...
  • Page 65 Definition of the error codes Introduction The error codes consists of two hexadecimal numbers. The first number shows the type of signal, the second number shows signal and the type of the error. Description of error codes First No. Meaning of number 1 hex Digital input signals 2 hex...
  • Page 66 Number Meaning of error code 3A hex Short circuit to battery voltage or open circuit at output speed input 3B hex Short circuit to ground or open circuit at output speed input 3C hex Logical error at output speed input 71 hex Short circuit to battery voltage at clutch K1 72 hex...
  • Page 67 Number Meaning of error code B1 hex Slippage at clutch K1 Slippage at clutch K2 B2 hex Slippage at clutch K3 B3 hex Slippage at clutch K4 B4 hex Slippage at clutch KV B5 hex B6 hex Slippage at clutch KR D1 hex Short circuit to battery voltage at power supply for sensors D2 hex...
  • Page 68 ELECTRONIC CONTROL FOR POWER TRANSMISSION Description of the basic functions The powershift transmission is equipped with TCU. The system is processing the desire of the driver according to the following criteria : Gear determination depending on gear selector position, driving speed and load condition. Protection from operating error as far as necessary, is possible via electronic protect- tion(programming).
  • Page 69 Legend 2 = Display 3 = Gear selector DW - 3 4 = Power supply connection 5 = Switch for enable inched(Option) 6 = Switch for driving program manual/Auto 1/Auto 2 9 = TCU(EST-37A) 11 = Wiring 14 = Cable to inductive transmitter speed central gear train 15 = Cable to inductive speed engine 16 = Cable to inductive transmitter speed turbine 17 = Cable to temperature measuring point behind the converter...
  • Page 70 Inching device This function is especially suitable for lift trucks. It allows to reduce the driving speed infinitely variable without modification of the engine speed in such a way that driving with a very low speed will be possible. In his way, the driver can move the vehicle very exactly to a determined position. At the same time and important part of the engine power for the output of the hydraulic system is at disposal by the high engine speed.
  • Page 71 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS The measurement have to be carried out with hot transmission(about 80~95 C) D50TM04 3-23 https://www.forkliftpdfmanuals.com/...
  • Page 72 OIL PRESSURE AND TEMPERATURE Port Description Size In front of converter - Opening pressure 11+2 bar M10x1 Behind converter - Opening pressure 4.3 + 3 bar M14x1.5 Clutch Forward 16 + 2 bar M10x1 Clutch reverse 16 + 2 bar M10x1 Clutch 16 + 2 bar...
  • Page 73 5. DRIVE AXLE A. DRIVE AXLE STRUCTURE D503DR02 Axle housing 14 Side gear 27 Taper roller bearing Air breather 15 thrust washer 28 Shin set(0.15, 0.20, 0.25t) plug 16 Pinion gear 29 Dowel pin Gasket 17 Spider 30 Gasket Plug 18 Ring gear 31 Carrier housing assembly Plug...
  • Page 74 WHEEL HUB D503DR03 O-ring 12 C-ring S 23 Thrust washer Brake tube 13 Carrier 24 Needle bearing Washer 14 Ring gear 25 Planetary gear Bolt 15 Nut 26 Bolt Bushing 16 Washer 27 Planetary housing Hub cover 17 bolt 28 O-ring Oil seal 18 Snap ring 29 O-ring...
  • Page 75 6. TIRE AND WHEEL B507AX68 Wheel rim Lock ring Valve assembly Tire Side ring Wheel nut The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with the ground to gain the power which drives the machine. Various types of tires are available to suit the purpose.

  • Page 76: Group 2 Operation And Maintenance

    GROUP 2 OPERATION AND MAINTENANCE 1. OPERATION DRIVING PREPARATION AND MAINTENANCE Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filters as well as the pipes must get filled with oil.
  • Page 77 - Upshifting in overrunning condition. In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if the speed of the vehicle on a downgrade should not be further increased. - Downshifting in overrunning condition. Downshifting in overrunning mode will be then carried out if the vehicle should be related. If the vehicle will be stopped and is standing with running engine and engaged transmission, the engine cannot be stalled.
  • Page 78 Now, the temperature must drop quickly(in about 2-3minutes) to normal values. If this is not the case, there is a trouble pending, which must be eliminated prior to continue working. The monitoring of the oil temperature(behind the converter) is additionally on the temperature gauge which is located on the dashboard.
  • Page 79 2. MAINTENANCE TRANSMISSION Oil level check At the oil level check, the vehicle has to be secured against rolling with blocks. The oil level check must be carried out as follows : - Oil level check(weekly) - At horizontally standing vehicle - Transmission in neutral position "...
  • Page 80 Oil change and filter replacement intervals First oil change after 100operating hours in service. Every further oil change after 1000operating hours in service, however at least once a year. At every oil change, the fine filter has to be replaced. Oil change and oil filling capacity The oil change has to be carried out as follows.
  • Page 81 D507PT19 Legend: 1 = Oil filter tube with oil dipstick 2 = Oil drain plug M38 1.5 3 = Attachment possibility oil level tube with oil dipstick(converter side) 4 = Filter head 5 = Fine filter Oil dipstick MEASURED AT LOW COLD IDLING-NEUTRAL D507PT20...
  • Page 82 0.57 kilograms(20 ounces) of low carbon steel. The drain plug must be checked for metal particles at every oil change interval. Hyundai recommends replacing the magnetic drain plug each time the oil is changed. Use the correct part. Pipe plugs will leak if used as a drain plug.
  • Page 83 If oil flows from the hole when you loosen the plug : The oil level is high. Let the oil drain to the correct level. Do not fill only through the axle housing bowl. If the oil level is below the bottom of the hole of the fill/level plug : Fill the axle at each wheel end and the axle housing bowl to the bottom of the fill plug hole with the specified oil.
  • Page 84 3. TROUBLESHOOTING BRAKE LEAKS ACTUATION FLUID Condition Possible cause Correction Internal leak : Fluid 1. Worn or damaged piston seal. 1. Replace piston seals. bypasses seals into axle 2. Melted or extruded piston seals. 2. Correct cause of overheating and replace and fills axle with fluid seals.
  • Page 85 BRAKE OVERHEATS Condition Possible cause Correction Overheating due to Inadequate coolant flow or heat 1. Install brake cooling system if not already excessive duty cycle. exchange. installed on vehicle. 2. Re-analyze and re-size brake cooling system if necessary. Inadequate coolant flow Low pump output, blocked filter or Check pump output at different operating coolant lines.
  • Page 86 BRAKE DOES NOT RELEASE Condition Possible cause Correction Vehicle does not move Damaged hydraulic system. Repair hydraulic system. Brakes dragging 1. More than 1.4bar(20psi) pressure 1. Repair hydraulic system so pressure is less applied when brakes released. than 1.4bar(20psi) when brakes released and while machine is operating in any mode.
  • Page 87 TABLE OF TRANSMISSION OF FAULT CODES Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Logical error at gear range signal TCU shifts transmission to Failure cannot be detected in Check the cables from TCU to TCU detected a wrong signal combination...
  • Page 88 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check the cable from TCU to S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch control the sensor speed input Check the connectors...
  • Page 89 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check the cable from TCU to the S.C. to ground at turbine speed input OP mode : Substitute clutch control This fault is reset after power sensor TCU measures a voltage less than 0.45V at...
  • Page 90 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check the cable from TCU to Logical error at internal speed input OP mode : Substitute clutch control This fault is reset after power the sensor TCU measures a internal speed over a...
  • Page 91 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Turbine speed zero doesn't fit to other Not used speed signals Check the sensor signal of Output speed zero doesn't fit to other Special mode for gear selection This fault is reset after power...
  • Page 92 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check the cable from TCU to S.C. to battery voltage at clutch K2 TCU shifts to neutral the gearbox The measured resistance value of the valve OP mode : Limp home...
  • Page 93 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check the cable from TCU to S.C. to ground at clutch K3 TCU shifts to neutral the gearbox The measured resistance value of the valve is OP mode : Limp home...
  • Page 94 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check the cable from TCU to S.C. to battery voltage at clutch KR TCU shifts to neutral the gearbox The measured resistance value of the valve OP mode : Limp home...
  • Page 95 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check the cable from TCU to S.C. to battery voltage at relay reverse No reaction the backup alarm device warning alarm OP mode : Normal...
  • Page 96 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check the cable from TCU to O.C. at relay starter interlock No reaction the starter interlock relay TCU detected a wrong voltage at the output OP mode : Normal Check the connectors from...
  • Page 97 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check pressure at clutch K1 Slippage at clutch K1 TCU shifts to neutral Check main pressure in the TCU calculates a differential speed at closed OP mode : Limp home system...
  • Page 98 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check pressure at clutch KV Slippage at clutch KV TCU shifts to neutral Check main pressure in the TCU calculates a differential speed at closed OP mode : Limp home system...
  • Page 99 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check cables and connectors S.C. to battery voltage at power supply for See fault codes No.21 to 2C to sensors, which are supplied sensors from AU1...
  • Page 100 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check fuse Error at valve power supply VPS2 Shift to neutral Check cables from gearbox to TCU switched on VPS2 and measured OP mode : TCU shutdown VPS2 is off or TCU switched off VPS2 and...
  • Page 101 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Check the cable from TCU to S.C. to battery voltage at display output No reaction the display TCU sends data to the display and OP mode : Normal...
  • Page 102 Fault code Int. code Meaning of the fault code Reaction of the TCU Possible steps to repair Remarks (Hex) (Dec) possible reason for fault detection Replace TCU General EEPROM fault No reaction Often shown together with TCU can't read non volatile memory OP mode : Normal fault code F2 TCU is defective...

  • Page 103: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY Electro-hydraulic control and filter (exchange filter) Mount the transmission to the assembly truck. (S)Assembly truck 5870 350 000 (S)Holding fixture 5870 350 124 Prior to start the disassembly, drain the oil D507TM11 Removal of the filter By means of the strap wrench separate the filter(1) from the filter head.
  • Page 104 Removal of the electric shift system Remove the shift system(1). Loosen the Torx screws(2) and separate the gearshift housing from the intermedi- ate sheet. (S)Socket spanner TX-27 5873 042 002 (S)Adjusting screw M6 5870 204 063 D507TM14 Remove the complete shift system(1) and the intermrdiate shaft(2).
  • Page 105 Separate the duct plate(3), and inter- mediate sheet(2) from the valve block(1). D507TM18 Remove the retaining clamp(1). D507TM19 Loosen the cap screws(1) and remove the cover. Remove the opposite cover. (S)Socket spanner TX-27 5873 042 002 D507TM20 Remove the wiring harness(1). Loosen the cap screws(3), remove the fixing plates and the pressure regul- ators(2).
  • Page 106 Loosen the cap screws, remove the fixing plates and the pressure regulators(1). (S)Socket spanner TX-27 5873 042 002 D507TM22 Loosen two cap screws(1) and fasten the adjusting screws(S) preliminarily (housing is spring-loaded). Following to this loosen the remaining cap screws. (S)Adjusting screws 5870 204 036 (S)Socket spanner...
  • Page 107 Remove the single parts on the opposite side analogously: 1 = Main pressure valve 2 = Vibration damper 3 = Follow-on slide D507TM26 Inductive transmitters, valves, oil filter and oil drain plug, screw plugs Mount the transmission to the assembly truck.
  • Page 108 Remove the positioned parts. 1 = Inductive transmitter n - Internal speed input 2 = Inductive transmitter n - Turbine 3 = Speed transmitter n - Output 4 = Cover(mounting possibility for oil filler tube) D507TM30 Engine connection, pressure oil pump and removal of the clutches Mount the transmission to the assembly truck.
  • Page 109 By means of the lifting equipment the converter bell(1) with pressure oil pump(5) are commonly to be separated from the transmission housing rear section(4). Remove the intermediate sheet(3) and the stator hollow shaft(2). (S)Eyebolts assortment 5870 204 002 (S)Lifting chain 5870 281 047 D507TM33 Separate the pressure oil pump(1) from...
  • Page 110 Remove the tab washer(2) and loosen the hexagon screws(1). D507TM37 Pull off the input shaft(1). Remove the shaft seal. (S)Two-armed puller 5870 970 003 D507TM38 Unsnap the retaining ring(1) from the power take-off and remove the O-ring(2). (S)Set of internal pliers 5870 900 013 D507TM39 Pull the pump shaft (1) out of the housing...
  • Page 111 By means of the lifting equipment separate the transmission housing rear section(1) from the transmission housing front section(2). (S)Eyebolts 2x(M20) 0636 804 003 (S)Ring nut(M12) 0664 462 774 (S)Lifting chain 5870 281 047 D507TM41 Loosen the cap screws(2) and remove the suction tube(1).
  • Page 112 Remove the pipes(system pressure from the electro-hydraulic control to the respective clutch). Remove the holding segment(6). The pipes are to disassembled in the following sequence: 1 = Pipe 2 = Pipe 3 = Pipe 4 = Pipe D507TM45 5= Pipe Remove all bearing outer rings(see arrows).
  • Page 113 Clutches KV/KR/K1/K2/K3 and Input See figure on the right. D507TM51 Clutch KV Remove the stud(1) and unsnap the piston ring(2). D507TM52 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 001 011 D507TM53...
  • Page 114 Unsnap the retaining ring(1). (S)Set of external pliers 5870 900 015 D507TM55 Press the clutch shaft(1) out of the idler(2). (S)Parting tool 5870 300 028 D507TM56 Unsnap the retaining ring(2) from the idler(1) and remove the ball bearing(3). (S)Set of internal pliers 5870 900 013 D507TM57 Remove the needle cage(1) from the...
  • Page 115 Rotate the shaft(2) by 180 and unsnap the piston ring(1). D507TM59 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 011 011 D507TM60 Clutch KR Remove the stud(1) and unsnap the piston ring(2).
  • Page 116 Pull the clutch(1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM63 Unsnap the retaining ring(1). (S)Set of external pliers 5870 900 015 D507TM64 Press the clutch shaft(1) out of the idler(2). (S)Parting tool 5870 300 028 D507TM65 Disassemble the idler(1). D507TM66 3-68 https://www.forkliftpdfmanuals.com/...
  • Page 117 Unsnap the retaining ring(2) from the idler(1) and remove the ball bearing. (S)Set of internal pliers 5870 900 013 D507TM67 Remove the needle cage(1) from the shaft(2). D507TM68 Shaft(2) and gear(1) cannot be separa- ted(shrink fit). D507TM69 Rotated the shaft(2) by 180 and unsnap the piston ring(1).
  • Page 118 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 011 011 D507TM71 Clutch K1 Remove the stud(1) and unsnap the piston ring(2). D507TM72 Pull the taper roller bearing(inner ring) from the shaft.
  • Page 119 Remove the complete axial bearing(1). D507TM75 Take off idler(1), remove the needle cage(2) and the complete axial bea- ring(3). D507TM76 Pull the clutch(1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM77 Rotated the shaft(2) by 180 and unsnap the piston ring(1). D507TM78 3-71 https://www.forkliftpdfmanuals.com/...
  • Page 120 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 011 011 D507TM79 Clutch K1 Remove the stud(1) and unsnap the piston ring(2). D507TM80 Pull the taper roller bearing(inner ring) ¤Ł...
  • Page 121 Remove the complete axial bearing(1). D507TM83 Take off idler(1), remove the needle cage(2) and the complete axial bea- ring(3). D507TM84 Pull the clutch(1), front the shaft. (S)Two-armed puller 5870 970 003 D507TM85 Rotated the shaft(2) by 180 and unsnap the piston ring(1). D507TM86 3-73 https://www.forkliftpdfmanuals.com/...
  • Page 122 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 011 011 D507TM87 Clutch K3 Unsnap the piston ring(1). D507TM88 Pull the taper roller bearing(inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert...
  • Page 123 Take off idler(1), remove the needle cage(2) and the complete axial bea- ring(3). D507TM91 Pull the clutch(1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM92 Rotated the shaft(2) by 180 and unsnap the piston ring(1). D507TM93 Pull the taper roller bearing(inner ring) from the shaft.
  • Page 124 Input Unsnap the piston ring(1). The turbine wheel shaft(2) and the input gear(3) are attached with a snap ring. The components are destroyed at separ- ation D507TM95 Pull the taper roller bearing(inner ring) from the input gear. (S)Gripping insert 5873 001 058 (S)Back-off insert 5870 026 100 (S)Rapid grip...
  • Page 125 2. TRANSMISSION ASSEMBLY Clutches KV/KR/K1/K2/K3 and input In the EST-37A(electronic transmission control)the gear change(filling times and pressure level) are controlled via the drive program of the transmission electronics. Additionally, the EST-37A monitors the disc clearance(clearance) of the clutches and if exceeded, a fault message is given in the transmission error display.
  • Page 126 Put the ball bearing(2) into the idler(1) until contact is obtained and fasten it by means of retaining ring(3). (S)Set of internal pliers D507TM104 Press in preassembled idler(1) until contact. D507TM105 Fasten the idler(1) by means of retaining ring(2). (S)Set of external pliers 5870 900 015 D507TM106 Heat up the inner diameter of the...
  • Page 127 Mount the clutch(1) until contact is obtained. Wear safty gloves. D507TM108 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM109 Install the piston ring(1). D507TM110 Install the stud(1). Tightening torque - - - - - - - - - - - - - - M =1.7kg m Check closing resp.
  • Page 128 Clutch KR Press the taper roller bearing(inner ring)(1) onto the shaft(2) until contact is obtained. D507TM112 Install the piston ring(1). D507TM113 Heat up the inner diameter of the gear(1)(approx. 120 C). (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 Wear safety gloves.
  • Page 129 Fasten the gear(1) by means of retaining ring(2). (S)Set of internal pliers 5870 900 015 D507TM116 Mount the needle bearing(1) onto the shaft(2). D507TM117 Put the ball bearing(2) into the idler(1) until contact is obtained and fasten it by means of retaining ring(3). (S)Set of internal pliers 5870 900 013 D507TM118...
  • Page 130 Fasten the idler(1) by means of retaining ring(2). (S)Set of internal pliers 5870 900 015 D507TM120 Heat up the inner diameter of the clutch(1)(approx. 120 C). (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 D507TM121 Mount the clutch(1) and press it until contact is obtained.
  • Page 131 Install the piston ring(1). D507TM124 Install the stud(1). Tightening torque - - - - - - - - - - - - - - M =1.7kg m Check closing resp. opening of the clutch by means of compressed air at the bore(2).
  • Page 132 Install the sealing cap(1). Wet the contact surface with(Loctite Type No. 262). D507TM128 Heat up the inner diameter of the clutch(1)(approx. 120 C). (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 D507TM129 Mount the clutch(1) and press it until contact is obtained.
  • Page 133 Mount the needle cage(1). D507TM132 Install the idler(1). D507TM133 Mount the axial washer(1), axial cage(2) Chamfer and running disc(3). Install chamfer(see arrow) of the running disc(3) showing towards the axial cage D507TM134 Fasten the idler(1) and the single parts by means of the retaining ring(2).
  • Page 134 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM136 Install the piston ring(1). D507TM137 Install the stud(1). Tightening torque - - - - - - - - - - - - - - M =1.7kg m Check closing resp. opening of the clutch by means of compressed air at the bore(2).
  • Page 135 Install the piston ring(1). D507TM140 Heat up the inner diameter of the clutch(1)(approx. 120 C). (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 D507TM141 Mount the clutch(1) until contact is obtained. Wear safety gloves. D507TM142 Mount the running disc(1), axial cage(2) and axial washer(3).
  • Page 136 Mount the needle cage(1). D507TM144 Install the idler(1). D507TM145 Mount the axial washer(1), axial cage(2) Chamfer and running disc(3). Install chamfer(see arrow) of the running disc(3) showing towards the axial cage. D507TM146 Fasten the idler(1) and the single parts by means of the retaining ring(2).
  • Page 137 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM148 Install the piston ring(1). D507TM149 Install the stud(1). Tightening torque - - - - - - - - - - - - - - M =1.7kg m Check closing resp. opening of the clutch by means of compressed air the bore(2).
  • Page 138 Install the piston ring(1). D507TM152 Install the sealing cap(1). Wet the contact surface with loctite type No.262. D507TM153 Heat up the inner diameter of the clutch(1)(approx. 120 C). (S)Hot- air blower 220V 5870 221 500 (S)Hot- air blower 110V 5870 221 501 D507TM154 Mount the clutch(1) until contact is obtained.
  • Page 139 Mount the running disc(1), axial cage(2) and axial washer(3). Chamfer Install chamfer(see arrow) of the running disc(3) showing toward the axial cage. D507TM156 Mount the needle cage(1). D507TM157 Install the idler(1). D507TM158 Mount the axial washer(1), axial cage(2) Chamfer and running disc(3). Install chamfer(see arrow) of the running disc(3) showing towards the axial cage.
  • Page 140 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM160 Install the piston ring(1). D507TM161 Install the screw plug(1). (S)Lever riveting tongs 5870 320 016 D507TM162 Check cosing resp. opening of the clutch by means of compressed air at the bore(1).
  • Page 141 Input Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM164 Press the taper roller bearing(inner ring)(1) until contact is obtained. D507TM165 Have the snap ring(1) engaged into the annular groove of the turbine wheel shaft(2). D507TM166 Mount the turbine wheel shaft until the snap ring engages into the recess of the input gear-turbine wheel shaft is axially fixed.
  • Page 142 ENGINE CONNECTION, PRESSURE OIL PUMP AND INSTALLATION OF THE CLUTCHES Install all bearing outer rings into the bearing bores of both transmission housing sections. Should contrary to the recommendations the taper roller bearing of the clutches as well as of the input not be replaced, the assignment(bearing inner and outer rings) has to be kept at least .
  • Page 143 Fasten the screen sheet(1) by means of cap screws(2). Tightening torque(M8/8.8) - - - M =2.3kg m D507TM174 The clutch is to be put into the transmiss- ion housing front section as described in the legend. 1 = Input shaft 2 = Clutch KV 3 = Clutch KR 4 = Clutch K2...
  • Page 144 Install the O-rings(3) and fasten the suction pipe(1) by means of cap scre- ws(2). Tightening torque(M8/8.8) - - - M =2.3kg m D507TM178 Grease the rectangular rings(see arrows) and align them, centrically. Wet the mounting face with sealing com- pound loctite(Type No.574) D507TM179 Cautiously place the transmission housing rear section(1) by means of the...
  • Page 145 Install the shaft seal(1) with the sealing lip showing to the oil sump. The exact installation position is obtained by using the specified mounting tool(S). Fill the shaft seal between dust lip and sealing lip with grease. Wet the outer diameter with spirit. (S)Mounting tool 5870 048 057 D507TM182...
  • Page 146 Install the retaining ring(1) and the O- ring(2). Grease the O-ring D507TM186 Install two adjusting screws and mount the stator hollw shaft(1). Observe the radial installation position. (S)Adjusting screws 5870 204 007 D507TM187 Install the converter safety valve(1) until contact. (S)Drive mandrel 5870 705 012 D507TM188...
  • Page 147 Cautiously place the converter bell(1) by means of the lifting equipment to the tran- smission until contact is obtained. (S)Eyebolts assortment 5870 204 002 (S)Lifting chain 5870 281 047 D507TM190 Pressure oil pump If running-in marks should be found in the pump housing or on the cam disc, the complete pump has to be replaced.
  • Page 148 Installation of the external and internal rotor Install the external rotor. Chamfer shows to the pump base (cannot be seen in the picture). Install the internal rotor. Gearing(arrow) shows downwards. D507TM194 Put on the cam disc and by means of two cap screws(1) fasten it radially.
  • Page 149 Fasten the converter bell, pressure oil pump and stator hollow shaft together by means of cap screws. Different bolted connections. 1 = Bolted connection converter bell/tran- smission housing rear section. Tightening torque(M10/8.8) - - M =4.7kg m 2 = Bolted connect. pressure oil pump/ stator hollow shaft transmission hous- D507TM197 ing rear section.
  • Page 150 Inductive transmitters, valves, oil filters and oil drain plug, screw plugs Install the converter pressure back-up valve. 1 = Piston 2 = Compression spring 3 = O-ring(27x2) 4 = Screw plug(30x1.5) Tightening torque - - - - - - - - - - - - - - - M =10.2kg m D507TM201 Install the differential pressure switch for...
  • Page 151 Installation of: 1 = Inductive transmiter - n Internal speed input 2 = Inductive transmitter - n Turbine 3 = Breather Tightening torque(1 and 2) - - M =3.1kg m Tightening torque(3) - - - - - - - - - - - - M =1.2kg m Fasten the coverplate(4) by means of hexagon screws(5).
  • Page 152 ELECTRO-HYDRAULIC CONTROL UNIT WITH PROPORTIONAL VALVES Different versions as to the positions of the wiring harness are possible. The following sketches shows the sections of the electro-hydraulic control unit. Pressure reducing valve (9 bar) Main pressure valve Housing (16+2 bar) Wiring harness Cover Cover...
  • Page 153 Mounting of the electric control unit All single parts are to be checked for damaged and replaced, if required. Prior to installation check the mobile parts in the housing for functionality. Piston can be replaced individually. Oil the single parts prior to installation acc. to the list of lubricants. Place the orifices(1) with the concave side showing upwards, until contact.
  • Page 154 Install two adjusting screws. Assembly flat gasket(1) and housing cover. Then place the housing cover by means of adjusting screws equally until contact. (S)Adjusting screws 5870 204 036 D507TM217 Preload the pistons with cap screws and remove the cyl. pins(assembly aid)again. D507TM218 Fasten the housing cover by means of cap screws(1).
  • Page 155 Preassemble the oppsite side The figure on the right shows the followi- ng single parts: 1 = Main pressure valve (1x, piston a. compr. spring) 2 = Vibration damper (3x, piston a. compr. spring) 3 = Follow-on slide (3x, piston a. compr. spring) D507TM221 Install the single parts acc to right figure.
  • Page 156 Mount the pressure regulators(1) and fasten them by means of fixing plates and cap screws. Install the fixing plate with the neck showing downwards Observe radial installation position of the pressure regulators. Tightening torque - - - - - - - - - - - - - M =0.56kg m D507TM224 Assemble the wiring harness(1) and...
  • Page 157 Install two adjusting screws. (S)Adjusting screws 5870 204 063 D507TM228 Screens(1) are to be flush mounted into the bores of the intermediate sheet, see arrows. Observe the installation position-the screens are showing upwards(to the duct plate). D507TM229 Put on the intermediate sheet(1) Screens(2) must show upwards.
  • Page 158 Provide the screw plugs(1) with new O- rings and install them. Tightening torque - - - - - - - - - - - - - M =0.61kg m D507TM232 Insert the pressure relief valve(1) and lock it with the indented ring(2). (S)Drive mandrel 5870 705 012 D507TM233...
  • Page 159 Mounting of the filter(pressure filter) Fasten the filter head(1) with new O-rings by means of cap screws(2) to the trans- mission housing. Tightening torque(M8) - - - - - - - - M =2.4kg m (S)Torque spanner 5870 203 034 (S)Socket spanner TX-40 5870 042 004 D507TM236 The filter is to be installed as follows:...
  • Page 160 3. DISASSEMBLY OF DRIVE AXLE 1) REMOVAL AND DISASSEMBLY OF WHEEL HUB Loosen drain plug with a torque wrench(1) and drain oil. D357DA01 Loosen 4 socket head bolts(2) and a plug(3) from the housing of planetary. D357DA02 Fit socket head bolt(2) into the 2 tap holes(4) and remove housing of planetary.
  • Page 161 Remove snap ring(5) from the housing of planetary. D357DA04 Remove 3 pins(6) with a plastic hammer. D357DA05 Remove needle bearing(8), planet gear(7) and thrust washer(9). D357DA06 Remove sun gear(10) and drive shaft(11). D357DA07 3-113 https://www.forkliftpdfmanuals.com/...
  • Page 162 Remove snap ring(12) and then remove sun gear(10) from the shaft(11). D357DA08 After removing bolt(13), remove ring gear(14) and torque plate assembly from the axle tube. D357DA09 (10) Remove snap ring from the ring gear(14) and disassemble internal gear carrier. D357DA10 (11) Remove bearing cup from the wheel hub...
  • Page 163 REMOVAL AND DISASSEMBLY OF AXLE HOUSING Loosen 12 bolts(1) and then remove carrier from the housing by using a lifting machine. D357DA12 For the reassembly, check rolling resistance and record it. Remove backing plate(2). D357DA13 Before removing differential assembly from carrier(3), check the location of cap(4) and mark it for reassembly.
  • Page 164 Disassemble bearing(6) from the differential housing and remove 12 bolts (7). D357DA15 Remove differential assembly from the carrier. After removing 12 mounting bolts(8) from the housing and then disassemble ring gear. D357DA16 Check the mark on the housing and separate the housing from the differential. If there is no mark, be sure to mark on the housing.
  • Page 165 (10) After loosening lock nut(9), remove yoke(11). (11) Remove drive bevel pinion shaft (10) by using a plastic hammer. Be careful not to damage bevel pinion shaft. 80D7AX08 (12) Remove shim(12) and spacer(13) from pinion shaft. Using a bearing puller, disassemble inner race of taper roller bearing from the pinion shaft.
  • Page 166 . REASSEMBLY OF DRIVE AXLE Clean all of the parts with cleaner and then remove remained loctite. Be careful not to spill cleaner on your body. Avoid drinking cleaner or breathing its fumes. Wear protective clothing, glasses and gloves. If spilled on the skin, flush your skin with water immediately. If swallowed, get medical attention immediately.
  • Page 167 Using different kinds of shims, adjust shim thickness as measured by previous equation. Place shims at the bearing place. Using a jig, assemble drive bearing so that the outer race contact with the bearing place. 80D7AX10 Heat inner race of bearing to max 100 and then assemble it to the pinion shaft.
  • Page 168 ADJUSTMENT OF PINION SHAFT Assemble bearing cup. Assemble spacer to the pinion shaft and then install measured shims onto the spacer. 80D7AX11 80D7AX091 Insert pinion shaft into the carrier. Assemble bearing cone, yoke and lock nut. Apply loctite #271 or #277 on the thread of pinion and then tighten lock nut.
  • Page 169 ASSEMBLY OF DIFFERENTIAL ASSEMBLY Assemble thrust washer, side gear and spider with gear and then install them to the differential housing. Apply grease on the bevel gear and thrust washer. D357DA31 Assemble differential housing. heck marks on the housing. Match two marks at the same position. D357DA32 Tighten 12 bolts(7) to the differential housing.
  • Page 170 Install differential assembly onto the carrier. Place the bearing cup and screw into the housing. At this moment, using a screw adjust rotation backlash. Install the dial gauge on the gear tooth and measure the backlash while rotating bevel gear. Rotation backlash : 0.18~0.23 (0.007~0.009 D357DA35...
  • Page 171 ASSEMBLY OF CARRIER Assemble carrier assembly into the axle housing. Apply loctite #271 or #277 to thread of bolt and then assemble at the tightening torque of 11~13 (79.6~94.0 kgf m lbf ft 80D7AX17 ASSEMBLY OF WHEEL HUB Insert bearing into wheel hub. Confirm that the bearing and wheel hub contact completely.
  • Page 172 Assemble square ring(4, 5) with oil(MOBIL 1 2 3 #424) to the brake housing. Assemble piston(3) after applying oil sufficiently and apply loctite #271 to spring(6) and 4 bolts(4). Tightening torque : 1.4~1.6 kgf m (10.1~11.6l bf ft heck the status of square ring and replace if damaged.
  • Page 173 Assemble sun gear to axle shaft and fix it with snap ring. Assemble axle shaft to the axle assembly. Apply grease on the shaft where bushing contacts. Apply grease to teeth parts of planetary gear. D357DA43 Assemble internal components of planetary carrier in the reverse order to disassembly.
  • Page 174 Assemble wheel hub and tighten plug(1). Tightening torque : 3.5~6.0 kgf m (25.3~43.4 lbf ft D357DA47 3-126 https://www.forkliftpdfmanuals.com/...

  • Page 175: Group 4 Adjustment

    GROUP 4 ADJUSTMENT Checking the ring gear backface runout Runout specification : 0.20mm(0.008-inch) maximum Attach a dial indicator on the mounting INDICATOR flange of the carrier. Rotate ring gear . Adjust the dial indicator so that the plunger or pointer is against the back surface of the ring gear.
  • Page 176 Adjusting the gearset backlash Backlash specification : 0.13~0.18mm (0.005-0.007inch) If the old gearset is installed, adjust the backlash to the setting that was measured before the carrier was disassembled. If a new gearset is installed, adjust the backlash to the correct specification for new gearsets.
  • Page 177 ADJUSTING TOOTH CONTACT PATTERN OF THE GEARSET Always check tooth contact pattern on the drive side of the gear teeth. Apply marking compound to approximately 12 teeth of the ring gear. HEEL BOTTOM DRIVE SIDE (CONVEX) D507AX57 D507AX58 Rotate ring gear forward and backward so that the 12 marked teeth go past the drive pinion six times to get a good contact pattern.
  • Page 178 LOW PATTERN D507AX61 GOOD PATTERN IN OPERATION (USED GEARS) D507AX62 High pattern : A high contact pattern Move pattern toward indicates that the pinion was installed too bottom shallow into the carrier. To correct, move the pinion toward the ring gear by decreasing the shim pack between pinion spigot and inner bearing cone.
  • Page 179 Heel pattern : Decrease the gearset Move pattern toward toe Move pattern toward toe backlash(within specified range) to move contact pattern toward toe and away from heel. Loosen adjusting ring this side Decrease backlash Tighten adjusting ring this side D507AX65 Toe pattern : Increase the gearset back- Move pattern toward heel lash(within specified range) to move contact...

  • Page 180: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17 Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-20 https://www.forkliftpdfmanuals.com/...

  • Page 181: Group 1 Structure And Function

    SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE There are two brake systems, the foot brake system and the hand brake system. In the foot (wheel) brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
  • Page 182 3. BRAKE PEDAL AND PIPING STRUCTURE(DRY TYPE) D507BS03 Brake pedal & bracket assembly Reservoir tank assembly Parking lever assembly Brake master cylinder https://www.forkliftpdfmanuals.com/...
  • Page 183 STRUCTURE(WET TYPE) D507BS40 Brake pedal & bracket assembly Reservoir tank assembly Parking lever assembly Brake master cylinder https://www.forkliftpdfmanuals.com/...
  • Page 184 DO AEB WORK Start engine after parking the machine on flat floor and blocking wheels. Release parking brake. With stepping on the service brake, operate T/M STALL(3 stage). (To avoid defect of clutch pack, repeat 10 sec of operation and 10 sec of placing neutral) When the T/M oil temperature reaches 75~80 C, lock the parking brake and then shift gear to neutral position to keep the machine at LOW RPM.
  • Page 185 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the front axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force. By treading the pedal further, the brake is applied. 122 - 128mm Pedal height Link assy...
  • Page 186 5. WHEEL BRAKE STRUCTURE(DRY TYPE) D507BS02 Back plate(LH, RH) Air breather 15 Lock washer Adapter Spring washer 16 Return spring Washer 10 Cylinder bolt 17 Return spring Holder 11 Lever shoe assembly 18 Pressure spring Spring washer 12 Brake shoe assembly 19 Plug Holder bolt 13 Adjuster assembly...
  • Page 187 6. WET DISK BRAKE STRUCTURE D507TM238 Spindle Service piston Parking lever Steel plate Parking piston fixing bolt 10 Parking lever shaft Disk plate Spline collar 11 Brake housing Parking piston Drive shaft OPERATION Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 188 7. BRAKE VALVE A. BRAKE VALVE(DRY TYPE) STRUCTURE 39 40 D507BS07 Stop ring 16 Stop ring 31 Push rod Seal 17 Seal 32 Connector Booster housing 18 Seal 33 Dust cover Seal 19 Seal 34 Plug Cylindrical thorn 20 Guide plug 35 Spring Flow valve 21 Seal...
  • Page 189 DISASSEMBLY All operations must be carried out with the greatest care, following the instructions carefully. The disassembly instructions are being provided in chronological. Unscrew the 4 screws(43), in order to be able to separate the front housing(3) from the rear housing(30).
  • Page 190 By means of retaining ring pinces remove retaining ring(16), accurnulator fitting(32) and then the second retaining ring(16). Remove rubber cap(33). Unscrew guide cap(20) and then extract rod(31) and spring(8). After the extraction of the rod(31) remove pin(5) and disassemble parts(1, 2, 6, 7, 22~25). Remove piston(27), extracting it from the side opposite to the threaded hole.
  • Page 191 D507BS10 Unscrew rear cap completely(15) by making sure that it’s not being disconnected abruptly; remove then O-ring, spring(10) and the joints(9). In order to remove the piston(9), knock the cylinder body on a piece of wood. Only at last unscrew valve(13). Remove the O-ring and the lip seal still inside the pump body with the aid of an “L”...
  • Page 192 ASSEMBLY The assembly must be carried out by following the so far described sequence but in reverse order, taking great care not to assemble the new gaskets back to front or upside down. Take the utmost care in assembling the components shown at stage 4, by assembling first of all valve(13), then piston(9), spring(10) and only afterwards the other components.
  • Page 193 B. BRAKE VALVE(WET TYPE) STRUCTURE 25 26 D507BS42 Plug 11 Seal 21 Seal 31 Spring Seal 12 Ring 22 Seal 32 Seal Spring 13 Seal 23 Booster housing 33 Plug Screw 14 Ball 24 Relief valve body 34 Seal Seal 15 Spring 25 Spring 35 Push rod...
  • Page 194 DISASSEMBLY All operations must be carried out with the greatest care, following the instructions carefully. The disassembly instructions are being provided in chronological. Unscrew the 4 screws(23), in order to separate the booster from the brake cylinder housing. Separate the two parts and remove the components that are inside from(25) to(36), in order to remove spring(26) and ball(27), you should remove seal(28) from piston containing the seal(25).
  • Page 195 Unscrew guide cap(37) and then remove O-ring(38), rod(39), spring(40) and the piston(50). Once rod(39) has been removed, take out pin(41) and all the components that are inside the rod from(42) to(49). Remove the lip seal inside the brake cylinder housing by means of on L-Iron. Remove all other seals from the disassembled components, namely drive(39), piston(50), O-ring housing(29) and valve(34).
  • Page 196 ASSEMBLY The assembly procedure must be carried out by following the sequence described before in reverse order, taking great care not to fit the new seals back to front or upside down. In order to fit the valve inside the piston containing the seal(25) following these instructions. Fit the seal into the appropriate tool and press ball and spring into the seat;...

  • Page 197: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS A. DRY TYPE 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.
  • Page 198 B. WET TYPE 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 (253 - 290...
  • Page 199 . TROUBLESHOOTING . DRY TYPE Problem ause Remedy Insufficient braking force Hydraulic system leaks oil. Repair and add oil. Hydraulic system leaks air. Bleed air. Lining surface soiled with water or oil. Clean or replace. Lining surface roughened or in poor Repair by polishing or replace.
  • Page 200 Problem ause Remedy Brake squeaks Lining surface roughened. Repair by polishing or replace. Lining worn. Replace. Poor shoe to lining contact. Replace. Excessively large friction between Clean and apply brake grease. shoe and back plate. Foreign matter on drum sliding surfa- Clean Drum sliding surface damaged or di- Replace.
  • Page 201 . WET TYPE Problem 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. Adjust tire pressure.

  • Page 202: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS 1. ADJUSTMENT OF WHEEL BRAKE (DRY TYPE) Adjust with engine stopped. Adjustment wheel Jack up truck. Extend adjustment screw by Lever clicking adjustment wheel teeth with a screwdriver until wheel(mounted on brake drum being adjusted) offers a light resistance when turned by hand.
  • Page 203 B. WET TYPE Air bleeding should be performed by two Vinyl tube persons : Air vent plug One rides on truck for depressing and releasing brake pedal : the other person is on the ground and removes cap from air vent plug on wheel cylinder.
  • Page 204 3. ADJUSTMENT OF PEDAL BRAKE PEDAL Pedal height from floor plate Adjust with stopper bolt. 122 - 128mm Pedal height Pedal height : 122~128mm(4.8~5.0in) dle stroke Adjust with rod of master cylinder Play : 4~6.5mm(0.16 ~ 0.25in) Micro switch for parking brake (if equipped) Stopper bolt D507BS04 After assembling parking brake and...

  • Page 205: Section 5 Steering System

    SECTION 5 STEERING SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13 https://www.forkliftpdfmanuals.com/...

  • Page 206: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1 Hydraulic gear pump 2 Priority valve Hyd tank 3 Steering unit 4 Steering cylinder 5 Steering wheel D507SE00 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, trail axle and piping.
  • Page 207 2. HYDRAULIC CIRCUIT 13.5MPa LS CF Brake valve D507SE01 Hydraulic gear pump Steering cylinder Priority valve 10 Suction filter Steering unit 14 Hydraulic tank https://www.forkliftpdfmanuals.com/...
  • Page 208 NEUTRAL 13.5MPa Brake valve D507SE02 The steering wheel is not being operated, so control spool(G) does not move. The oil from hydraulic gear pump(1) enters the port P of priority valve(3) and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(14), so the pump flow is routed to the main control valve through the EF port.
  • Page 209 LEFT TURN 13.5MPa LS CF Brake valve D507SE03 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) the steering unit through the spool(D) of priority valve and flows the gerotor(H).
  • Page 210 RIGHT TURN 13.5MPa LS CF Brake valve D507SE04 When the steering wheel is turned to the right, the spool(G) within the steering unit(4) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool(G) the steering unit through the spool(D) of priority valve and flows the gerotor(H).
  • Page 211 3. STEERING UNIT STRUCTURE Hydraulic circuit 26-4 26-3 26-1 26-2 SECTION B-B 25-6 25-5 25-4 25-3 25-2 25-1 SECTION A - A D507SE32 Dust seal 10 O-ring 19 Plate 25-3 Spring seat Retaining ring 11 O-ring 20 Cap screw 25-4 Spring Cap seal 12 Rolled screw 21 Housing...
  • Page 212 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 213 4. PRIORITY VALVE STRUCTURE 1-1/16-12UNF HYDRAULIC CIRCUIT 7/16-20UNF 3/4-16UNF 1-1/16-12UNF D353SE06 Body 5 Spring End plug Spool 6 O-ring 10 O-ring Spring pulg 7 Orifice End plug 8 Orifice OPERATION The oil from the hydraulic gear pump flows to the priority valve. The priority valve supplies a flow of oil to the steering system and lift, tilt system.
  • Page 214 5. TRAIL AXLE STRUCTURE Do not remove the stopper bolt unless necessary. D507SE24 Steer axle wa 12 Gasket 23 Grease nipple 34 Adaptor Knuckle 13 Cover 24 Hub 35 Cover Thrust bearing 14 With washer bolt 25 Hub bolt 36 Hexagon bolt Needle bearing 15 Grease nipple 26 Taper roller bearing...
  • Page 215 TIGHTENING TORQUE AND SPECIFICATION Split pin (Bend correctly) SECTION B-B Stroke 150mm Hub nut 61.2 kgf.m(443 lbf.ft) Fill 1/2 to 2/3 of the space in the hub with lithium 67.5 ~ 84.5 kgf.m grease (488 ~ 611 lbf.ft) SECTION A-A Gap:Under 0.1mm(0.004 in) D507SE07 Center pin support...

  • Page 216: 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) HDF 50-7S 3290mm(130in) HDF 70-7S 3370mm(133in) Hydraulic pressure of power Remove plug from outlet port of flow divider and install oil pressure gauge.
  • Page 217 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 steering wheel is turned fully Faulty.

  • Page 218: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE D507SE05 Dust seal 10 O-ring 19 Plate Retaining ring 11 O-ring 20 Cap screw Cap seal 12 Rolled screw 21 Housing Thrust bearing 13 Gerotor set 22 Spool Ball 14 Bearing race 23 Sleeve 15 Bore screw 24 Plate spring...
  • Page 219 TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-14 https://www.forkliftpdfmanuals.com/...
  • Page 220 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...
  • Page 221 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 222 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball and suction valve pins and balls. D353SE09 5-17 https://www.forkliftpdfmanuals.com/...
  • Page 223 Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and thrust bearing will be pushed out of the housing together.
  • Page 224 (12) Carefully press the spool out of the sleeve. 5-74(4) (13) Press the neutral position springs out of their slots in the spool. 5-75(1) (14) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (15) Screw out the plug using an 8mm hexagon socket spanner.
  • Page 225 (16) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (17) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (18) The pressure relief valve is now disassem- bled. D353SE13 5-20 https://www.forkliftpdfmanuals.com/...
  • Page 226 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 227 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 228 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) Assembly pattern for standard bearings Outer bearing race Thrust bearing Inner bearing race Spool Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 229 (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 230 (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 231 (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 232 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20 C. 5-82(2) (23) Place the distributor plate so that the...
  • Page 233 (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 234 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. Tightening torque : 4.0 0.5kgf m (28.9...
  • Page 235 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. Do not use a hammer! 5-85(2) 5-30 https://www.forkliftpdfmanuals.com/...
  • Page 236 2. PRIORITY VALVE STRUCTURE D353SE07 Body Spring End plug Spool O-ring 10 O-ring Spring plug Orifice End plug Orifice 5-31 https://www.forkliftpdfmanuals.com/...
  • Page 237 DISASSEMBLY Cleanliness is the primary means of assuring satisfactory the priority valve life. Select clean place. Before removing the piping, clean the surrounding area of valve ports. Fix the body(1) in a vise with copper or lead sheets. Do not over tighten jaws. Loosen plug(3) for LS port.
  • Page 238 Remove plug(4) and separate O-ring(6) and plug(3, 4) individually. D353SE17 ASSEMBLY Clean all metal parts in clean solvent and blow dry with air and correct any damage, burrs and rust. Do not wipe dry with cloth or paper towel. Replace seals such as O-ring with new ones as a rule and coat with grease.
  • Page 239 Install the O-ring(6) onto plug(3, 4) and install the plug(3, 4) into the body(1). Tighten torque : 4.5kgf m(32.5lbf ft) D353SE20 5-34 https://www.forkliftpdfmanuals.com/...
  • Page 240 3. STEERING CYLINDER STRUCTURE Specifications Cylinder bore : 80mm Outer diameter : 94mm Stroke(half) : 150mm Rod diameter : 55mm D507SE21 1 Tube assy Rod seal 11 Back up ring 2 Rod Back up ring 12 O-ring 3 Piston seal Dust wiper 13 Lock washer 4 Gland...
  • Page 241 DISASSEMBLY Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in & vice. Remove the cover by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube. Check wear condition of the sealing parts(O-ring, oil seal, dust seal, U-packing, bush).
  • Page 242 Install the dust wiper(8) to the gland(4) using a special installing tool. Coat the dust wiper with grease slightly before installing. Using a special tool, install gland assembly into the cylinder tube(1). Special tool D507SE29 Using a hook spanner, install the gland(4) ass- Hook spanner embly, and tighten it with torque 60 6kgf m (434 43lbf ft).
  • Page 243 4. TRAIL AXLE STRUCTURE Do not remove the stopper bolt unless necessary. D507SE24 Steer axle wa 12 Gasket 23 Grease nipple 34 Adaptor Knuckle 13 Cover 24 Hub 35 Cover Thrust bearing 14 With washer bolt 25 Hub bolt 36 Hexagon bolt Needle bearing 15 Grease nipple 26 Taper roller bearing...
  • Page 244 CHECK AND INSPECTION A1, A2 D507SE25 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 60(2.4) 59.5(2.3) Shaft ID of bushing 60(2.4) 59.5(2.3) 50(2.0) 49.8(2.0) OD of king pin Replace 22(0.9) 21.9(0.9) OD of steering cylinder pin 22(0.9) 21.9(0.9) OD of pin...
  • Page 245 DISASSEMBLY Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the balance weight part of the truck. Hub nut Loosen the hub nut and take off the steering wheel tire.
  • Page 246 ASSEMBLY In reassembling, have all parts washed, grease applied to lubricating parts, and all expendable items such as oil seal and spring washers replaced by new ones. Perform the disassembly in reverse order. Notch Tighten the set screw(10) of king pin(6). There is a notch in the middle of the king pin(6), make sure that this notch is on the set screw side.

  • Page 247: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19 https://www.forkliftpdfmanuals.com/...

  • Page 248: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT A2 B2 A3 B3 18.5MPa 13.5MPa 15.0MPa D507HS01 Hydraulic gear pump Lift cylinder Priority valve Suction filter Main control valve 10 Return filter Steering unit 11 Down control valve Brake valve 12 Down safety valve Steering cylinder...
  • Page 249 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 18.5MPa Lift Load check valve 15.0MPa Steering system Steering return line Brake system Brake return line D507HS02 When the lift control lever is pulled back, the spool on the first block is moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large chamber of lift cylinder(8) by pushing the load check valve of the spool.
  • Page 250 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 18.5MPa Lower 15.0MPa Steering system Steering return line Brake system Brake return line D507HS03 When the lift control is pushed forward, the spool on the first block is moved to lower position. The work port(B1) and the small chamber and the large chamber are connected to the return passage, so the lift will be lowered due to its own weight.
  • Page 251 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 18.5MPa Tilt forward 15.0MPa Load check valve Steering system Steering return line Brake system Brake return line D507HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
  • Page 252 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 18.5MPa Tilt backward 15.0MPa Load check valve Steering system Steering return line Brake system Brake return line D507HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
  • Page 253 2. HYDRAULIC GEAR PUMP STRUCTURE D507HS06 Body 11 Screw 21 Ring Body 12 Screw 22 Back up ring Rear cover 13 Grub screw 23 Back up ring Cover 14 Washer 24 Sleeve bearing Thrust plate 15 Washer 25 Flange Thrust plate 16 Seal 26 Hub Drive gear...
  • Page 254 3. MAIN CONTROL VALVE STRUCTURE (3 Spool) Port name Size Inlet port 1-5/16-12UNF Outlet port 1-5/16-12UNF Gauge port PF1/4 Work port 1-1/16-12UNF D353HS07 Special nut 15 Screw 29 Spool housing O-ring 16 Wiper 30 Spool housing Plug 17 O-ring 31 Spool housing O-ring 18 Spring seat 32 Outlet housing...
  • Page 255 LIFT SECTION OPERATION Lift position D353HS08 When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flow into lift cylinder port(B1). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 256 Lower position D353HS09 When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (B1) T. In lift lower position the fork drops due to its own weight.
  • Page 257 TILT SECTION OPERATION Tilt forward position D353HS10 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flow into tilt cylinder port(A2). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage.
  • Page 258 Tilt backward position D353HS11 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flows into tilt cylinder port(B2).
  • Page 259 MAIN RELIEF VALVE Pressure setting A good pressure gauge must be installed in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit.
  • Page 260 The loss of oil behind poppet C, effected by the opening of pilot poppet E, causes poppet C to move back and seat against pilot puppet E. This shuts off the oil flow to the area behind relief valve poppet D, and causes a low pressure area internally.
  • Page 261 4. LIFT CYLINDER 13 15 10 11 14 4,5 7,8 D507HS12 Tube assy Cushion seal 13 Dust wiper Retaining ring 14 O-ring Piston Retaining ring 15 O-ring Piston seal 10 Gland 16 Spacer Back up ring 11 Du bushing 17 O-ring Wear ring 12 Rod seal 5.

  • Page 262: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Load maximum load, set mast vertical and raise 1m from ground. Wait for 10 minutes measure hydraulic drift(amount forks move down and amount mast tilts forward).
  • Page 263 2. TROUBLESHOOTING SYSTEM Problem cause Remedy Large fork lowering speed. Seal inside control valve defective. Replace spool or valve body. Oil leaks from joint or hose. Replace. Seal inside cylinder defective. Replace packing. Large spontaneous tilt of Tilting backward : Check valve defec- Clean or replace.
  • Page 264 HYDRAULIC GEAR PUMP Problem Cause Remedy Pump does not develop full System relief valve set too low or Check system relief valve for proper pressure. leaking. setting. Oil viscosity too low. Change to proper viscosity oil. Pump is worn out. Repair or replace pump.
  • Page 265 LIFT CYLINDER Problem Cause Remedy Oil leaks out from gland Foreign matters on packing. Replace packing. through rod. Unallowable score on rod. Smooth rod surface with an oil stone. Unusual distortion of dust seal. Replace dust seal. Chrome plating is striped. Replace rod.

  • Page 266: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP STRUCTURE D507HS06 Body 11 Screw 21 Ring Body 12 Screw 22 Back up ring Rear cover 13 Grub screw 23 Back up ring Cover 14 Washer 24 Sleeve bearing Thrust plate 15 Washer 25 Flange Thrust plate 16 Seal...
  • Page 267 GENERAL INSTRUCTION Cleanliness Cleanliness is the primary means of assuring satisfactory hydraulic pump life. Components such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears should be washed in solvent, air dried, and oiled immediately. Certain cleaning solvents are flammable.
  • Page 268 And remove drive gear(7), driven gear(8), thrust plate(5), keeping gears as straight as possible, and body(1) also. D507PMP03 Front section Loosen and remove the clamp bolts(11) from the body(2). Coat the sharp edges of the drive shaft (9) with adhesive tape and smear a clean grease on the shaft end extension to avoid any damaging lip of the shaft seal(20) when removing the cover(4).
  • Page 269 Cover assembly Cover Remove snap ring(21) with proper tool(Only when it is needed to replace shaft seal). Remove the shaft seal(20) taking care not to give any damage on the surface of shaft hole(Only when it is needed to replace shaft seal). D507PMP07 REASSEMBLY Cover...
  • Page 270 Insert the steel bushing(28) into body(2) and assemble middle section and flange(25). D507PMP10 Insert the complete pressure plate (6+17+23) into body(2) while keeping the plate straight. Seal side should face to the flange(25), opposite side of gears. Pay attention to the direction of seal. (opened side should face suction side always) D507PMP11...
  • Page 271 Tighten the bolts(11) with washer(15) in a crisscross pattern to torque value of 28.6kgf.m(207lbf.ft). D507PMP14 Rear section Smear clean grease on the seal(19) to avoid drifting away of seal from the body(1) and assemble middle section and rear cover(3). D507PMP15 Locate the seals(16) on the groove pre- arranged on the thrust plates(5).
  • Page 272 Locate driving gear(7) and driven gear(8) while keeping the gears straight. Locate pressure plate(5+22+16) with care for the direction. D507PMP18 Locate hub(26) into rear section. Rear section D507PMP19 Tighten the bolts(12) with washer(14) in a crisscross pattern to torque value of 4.6kgf.m(33.3lbf.ft).
  • Page 273 2. MAIN CONTROL VALVE Lay out valve components on a clean, flat working surface. The inlet assembly will include an O-ring, and the spool section(s) include an O-ring, a load check poppet and a load check spring. Tools required for basic valve assembly include 3/4 and 11/16 open or box end wrenches and a torque wrench with thin wall sockets.
  • Page 274 Position valve assembly with the mounting pads of the end sections on a flat surface. To obtain proper alignment of end sections relative to the spool sections apply downward pressure to the end sections ; Snug tie rod nuts to about 10lbf ft. Final torque the two 11/16 nuts to 48 5lbf ft ;...
  • Page 275 3. LIFT CYLINDER STRUCTURE I.D O.D stroke(standard) 85 98 1335mm (3.3 3.9 52.6in) Rod O.D : 60mm(2.4in) D507HS19 Tube assy 10 Gland 11 Du bushing Piston 12 Rod seal Piston seal 13 Dust wiper Back up ring 14 O-ring Wear ring 15 O-ring Cushion seal 16 Spacer...
  • Page 276 DISASSEMBLY Hold the cylinder tube in a vice, loosen the cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn. Lever up the edge of the guide, then turn the guide in again and the guide can be removed.
  • Page 277 4. TILT CYLINDER STRUCTURE I.D O.D stroke : 110 124 338mm (4.3 4.9 13.3in) Rod O.D : 50mm(2.0in) D507HS22 Tube assy O-ring 17 Nylon nut 10 Back up ring 18 Rod eye Gland 11 Lock washer 19 Hexagon bolt DU bushing 12 O-ring 20 Hexagon nut Rod seal...
  • Page 278 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 279: 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 280: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION Dash board side D507EL06 Convert 11 Hazard switch 21 Start switch Operating panel 12 Transmission temp gauge 22 High horn Glow timer 13 Relay 4P 23 Brake switch Detector 14 Beacon lamp 24 Glow relay Flasher unit 15 Battery...

  • Page 281: Group 2 Electrical Circuit

    SECTION 7 ELECTRICAL SYSTEM GROUP 2 ELECTRICAL CIRCUIT 1. HDF50/70-7S D507SEL011 https://www.forkliftpdfmanuals.com/...
  • Page 282 2. HDF50/70-7 https://www.forkliftpdfmanuals.com/...
  • Page 283 MEMORANDUM https://www.forkliftpdfmanuals.com/...
  • Page 284 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+)] Fusible link[CN-60] Glow relay[CR-24(3)] Start relay[CR-23] Fusible link[CN-95] Alternator[CN-74(B+)]...
  • Page 285 POWER CIRCUIT START KEY SW B BR R1 R2 CR-24 1.25BR 1.25B GLOW RY CN-74 CN-3 COMBI SW ALTERNATOR CS-11 CN-60 FUSIBLE LINK CS-12 CN-95 CR-23 START RY CN-25 CN-45 HORN START MOTOR BATTERY MASTER SW 12V X 2 D507EL02 https://www.forkliftpdfmanuals.com/...
  • Page 286 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-95] Start switch[CS-2(3)] Start relay[CR-23] The engine can be started only when the gearshift is in neutral position. When start key switch is in ON position Start switch ON [CS-2(4)] Fuse box[No.5 Gear selector switch[CS-15(3)] When start key switch is START position...
  • Page 287 STARTING CIRCUIT START KEY SW ANTI-RESTART RELAY B BR R1 R2 CN-3 CN-74 GEAR SELECTOR S/W ALTERNATOR CN-95 CS-14 FUSIBLE LINK CR-23 CS-15 START RY CN-45 START MOTOR BATTERY MASTER SW 12V X 2 D507EL03 https://www.forkliftpdfmanuals.com/...
  • Page 288 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator release the start switch to the ON position. Charging current generated by operating alternator flows into the battery. The current also flows from alternator to each electrical component through the fusible link(CN-60) and the fuse box.
  • Page 289 CHARGING CIRCUIT START KEY SW ANTI-RESTART RELAY B BR R1 R2 CN-2 CN-74 ALTERNATOR CN-3 CN-95 OPERATING PANEL FUSIBLE LINK CR-23 START RY CN-45 START MOTOR BATTERY MASTER SW 12V X 2 D507EL04 https://www.forkliftpdfmanuals.com/...
  • Page 290 4. PREHEATING CIRCUIT Combustion chamber glow plugs are used in order to give satisfactory starting of low ambient temperatures. OPERATING FLOW Battery(+) terminal Fusible link[CN-95] I/conn[CS-2(3)] Start switch(B) Glow relay[CR-24] When you turn the start switch to the ON position, the glow relay makes the glow plugs operated and the glow lamp of the cluster turned ON.
  • Page 291 PREHEATING CIRCUIT START KEY SW FUSE BOX B BR R1 R2 GLOW TIMER CN-1 CN-80 CN-2 GLOW PLUG CR-24 1.25BR 1.25B GLOW RY CN-74 CN-3 ALTERNATOR CN-60 FUSIBLE LINK OPERATING PANEL CN-95 CR-23 START RY CN-45 START MOTOR BATTERY MASTER SW 12V X 2 D507EL05 7-11...

  • Page 292: Group 3 Component Specification

    GROUP 3 COMPONENT SPECIFICATION Specification Part name 90AH RC : 130min Battery CCA : 630A Working lamp 24V, 70W License lamp 24V, 3W x 2 24V, 25/10W (Stop/Tail) 24V, 25W (Turn) Rear Combination lamp 24V, 10W (Back Up) Head lamp 24V, 70W Flasher lamp 24V, 25/10W...

  • Page 293: Group 4 Connector Destination

    GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 S814-012100 I/conn(Dashboard harness-frame harness) S814-012001 CN-2 S814-008100 I/conn(Dashboard harness-frame harness) S814-008001 CN-3 I/conn(Dashboard harness-frame harness) MG640944-5 MG650943-5 CN-4 LH support harness S810-004201 CN-5 Support harness S810-004201 CN-8 Transmission display...
  • Page 294 Connector part No. Connector No. of Type Destination number Female Male CS-23 Beacon lamp switch 593757 CS-41 Hazard switch 593757 CS-42 Inching switch 593757 CS-59 Auto manual switch 593757 CS-69 Rear work switch 593757 Lamp CL-15 Combination lamp-LH S814-006100 CL-16 Combination lamp-RH S814-006100 CL-21...

  • Page 295: Group 5 Troubleshooting

    GROUP 5 TROUBLESHOOTING Trouble symptom Probable cause Remedy Lamps dimming even at maxi- Faulty wiring. Check for loose terminal and discon- mum engine speed. nected wire. Lamps flicker during engine Improper belt tension. Adjust belt tension. operation. Charge lamp does not light d- Charge lamp defective.
  • Page 296 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...
  • Page 297 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) Outer master Inner master Lift cylinder Lift cylinder Drive Axle D507MS01 Outer mast Lift chain Chain sheave bearing Roller bearing Anchor bolt 10 Anchor bolt Tilt cylinder pin Side roller bearing 11 Roller bearing Mast mounting pin Inner mast...
  • Page 298 2. 3 STAGE MAST(TF MAST) Middle master Outer master Inner master Tilt cylinder Lift cylinder Lift cylinder Free Lift cylinder D507MS011 Outer mast Mast mounting pin 11 Chain Shim Wear plug 12 Sheave bracket Roller bearing Middle mast 13 Inner mast Side roller bearing Sheave Tilt cylinder pin...
  • Page 299 3. CARRIAGE, BACKREST AND FORK HOOK ON TYPE(STD) Hook on type fork Extension fork D507MS03 Backrest Side roller Carriage Fork Roller Extension fork https://www.forkliftpdfmanuals.com/...
  • Page 300 SHAFT TYPE(OPTION) Shaft type fork Extension fork D507MS02 Carriage & backrest Side roller Hanger bar Fork Fork retaining Extension fork Roller https://www.forkliftpdfmanuals.com/...
  • Page 301 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. EX : =1200mm(47in) mm(in) STD Fork assy Applicable model Standard Limit Thickness F14710011 HDF50-7S 60(2.4) 48(1.9) F14710111 HDF70-7S...
  • Page 302 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 damag-ed parts or replace complete mast assembly.
  • Page 303 FORKS Problem cause Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear wear and reduces the thickness of the limit, replace fork. fork. Inspection for thickness is needed. Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...
  • Page 304 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm(19in). Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the roller side face and mast at the closest position on the opposite side to the following value by adjust bolt.
  • Page 305 CARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, middle and lower rollers after loosen the adjust screws from the side rollers. Shift the carriage to one side to bring the roller into contact with the inner mast, and measure the clearance between the roller side face...
  • Page 306 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS HOOK ON TYPE Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Backrest Release fork anchor pins and slide one fork at a time toward the center of the carriage Anchor pin where a notch has been cut in the bottom Carriage...
  • Page 307 3. CARRIAGE ASSEMBLY CARRIAGE With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor.
  • Page 308 CARRIAGE LOAD ROLLER BEARING Carriage load Remove carriage as outlined in the roller bearing carriage removal paragraph. Using the plier, remove retaining rings Retaining ring from load roller bearing bracket. Using a plier, remove load roller bearings from load roller bearing bracket. Reverse the above procedure to assem- ble.
  • Page 309 3 STAGE MAST(TF MAST) Remove the carriage assembly and move it to one side. Loosen and remove hexagon bolt secur- Mast load roller ing bottom cylinder from outer mast. Loosen and remove set screws and nuts securing lift cylinders to middle mast. Attach chains or sling to the inner and Chain middle mast section at top crossmember.
  • Page 310 5. CHAIN CHAIN SHEAVE Place a sling around carriage and attach Outer mast Chain to an overhead hoist. Lift carriage high Sheave enough so that the tension on the chain Inner mast over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 311 Sheave support(TF mast) Remove the carriage assembly and move to one side. After removing bolt to securing sheave support assembly to free lift cylinder. Attach a sling to the sheave support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder. Move assembly to work area. Remove retaining ring securing sheave to sheave support.
  • Page 312 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 313 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 314 Adjustment Chain adjustments are important for the following reasons : Equal loading of chain. Proper sequencing of mast. Prevent over-stretching of chains. Prevent chains from jumping off sheaves if they are too loose. Adjustment procedure With mast in its fully collapsed and vertical position, lower the fork to the floor. Adjust the chain length by loosening or tightening nut on the chain anchor.
  • Page 315 SERVICE MANUAL for HYUNDAI HEAVY INDUSTRIES CO.,LTD. August 2008 99616-25000 Pub. No. 99616-25000 Printed in Japan Pub. No. https://www.forkliftpdfmanuals.com/...
  • Page 316     https://www.forkliftpdfmanuals.com/  ...
  • Page 317 INTRODUCTION This service manual describes the specifications, maintenance and service procedures for Mitsubishi diesel engines. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts.
  • Page 318 https://www.forkliftpdfmanuals.com/...
  • Page 319 INTRODUCTION How to use this manual This service manual consists of several Groups, which are arranged so as to allow you to make reference quickly to specifications, maintenance standards, adjustment procedures and service procedures including methods for disassembly, inspection, repair and reassembly of the Mitsubishi Diesel Engine (standard model for land use). A short summary describing the content of each Group is given in the General Contents page, and there is also a detailed table of contents at the beginning of each Group.
  • Page 320 INTRODUCTION Terms used in this manual Nominal means the rated (design) size or magnitude of a part to be measured. Standard means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of tolerance.
  • Page 321 INTRODUCTION Safety Cautions WARNING Fire and explosion Keep flames away Care about fuel, oil and exhaust gas leakage Store fuel and engine oil in a well If any fuel, oil or exhaust gas leakage is found, immedi- ventilated designated area. ately take corrective measures to stop it.
  • Page 322 INTRODUCTION WARNING Stay clear of all rotating and moving parts Install protective covers on rotating parts Lockout and tagout Make sure the protective covers for Be sure to lockout and tagout before starting inspection engine rotating parts are properly and maintenance. installed as intended.
  • Page 323 INTRODUCTION WARNING WARNING Be careful of burns Be careful of exhaust fume poi- soning Do not touch the engine during or immedi- ately after operation Operate engine in well-ventilated area Do not touch the engine during or If the engine is installed in an en- immediately after operation...
  • Page 324 INTRODUCTION CAUTION WARNING Be careful of falling down Be careful of handling fuel, engine oil and LLC Lift engine correctly To lift the engine, always use a cor- Use only specified fuel, engine oil and long- rect wire rope capable of withstand- life coolant (LLC) ing the engine weight.
  • Page 325 INTRODUCTION CAUTION CAUTION Service battery When abnormality occurs Handle the battery correctly Stop overheated engine after cooling run • Never use flames or allow sparks Even if the engine comes to overheat, do not stop the to generate near the battery. The engine immediately.
  • Page 326 INTRODUCTION CAUTION Other cautions Modification of engine prohibited Warming-up operation Unauthorized modification of the engine will void the After starting the engine, run the engine at low idling manufacturer’s warranty. speeds for 5 to 10 minutes for warming-up. Start the Modification of the engine may not only cause engine work after this operation is completed.
  • Page 327 INTRODUCTION Maintenance of air cleaner or pre-cleaner Avoidance of prolonged time of starter oper- The major cause of abnormal wear on engine parts is ation dust entering with intake air. Worn parts produce many Do not operate the starter for more than 10 seconds at problems such as an increase of oil consumption, de- a time even if the engine does not start.
  • Page 328 INTRODUCTION CAUTION About warning labels Maintenance of warning labels Make sure all warning/caution labels are legible. Clean or replace the warning/caution labels when the description and/or illustration are not clear to read. For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened.
  • Page 329 GENERAL CONTENTS Group Name Contents Group No. External view System flow diagrams General Engine serial number location Main specifications Tips on disassembling and reassembling Maintenance service data Service data Tightening torque table Regarding submission of parts for EPA exhaust gas regulation Service tools Special tool Determining overhaul timing...
  • Page 330 https://www.forkliftpdfmanuals.com/...
  • Page 331 GENERAL 1. External view........1-2 2. System flow diagrams .....1-4 2.1 Fuel system - flow diagram ...... 1-4 2.2 Lubrication system - flow diagram ... 1-4 2.3 Cooling system - flow diagram....1-5 2.4 Inlet and exhaust system - flow diagram.. 1-5 3.

  • Page 332: External View

    GENERAL 1. External view S6S-Y3T61HF Fuel filter Oil cooler Water pump (Coolant inlet) Coolant drain plug Flywheel Front Rear Magnet valve (Stop solenoid) Oil filter Fuei injection pump Relief valve Oil drain plug Engine left view S6S-Y3T61HF Oil level gauge Air inlet Turbocharger (Exhaust outlet)
  • Page 333 GENERAL S6S-Y3T62HF Oil cooler Magnet valve (Stop solenoid) Oil level gauge Fuel filter Water pump Coolant drain plug (Coolant inlet) Flywheel Front Rear Fuei injection pump Oil filter Relief valve Oil drain plug Engine left view S6S-Y3T62HF Turbocharger Air inlet Oil filler (Exhaust outlet) Oil filler...

  • Page 334: System Flow Diagrams

    GENERAL 2. System flow diagrams 2.1 Fuel system - flow diagram Fuel filter Fuel inlet Fuel leak-off pipe Fuel injection nozzle Fuel return pipe Fuel outlet Fuel injection pump Fuel system - flow diagram 2.2 Lubrication system - flow diagram Piston Oil jet Turbocharger...

  • Page 335: Cooling System - Flow Diagram

    GENERAL 2.3 Cooling system - flow diagram Thermostat Cooling outlet Oil cooler Cylinder head Bypass hose Water jacket Water pump Cooling inlet Cooling system - flow diagram 2.4 Inlet and exhaust system - flow diagram Inlet Turbocharger Exhaust Inlet Exhaust Blow-by gas Discharge Exhaust manifold...

  • Page 336: Engine Serial Number Location

    GENERAL 3. Engine serial number location The engine serial number is stamped on the right side of cylinder block. Engine serial number Engine serial number location https://www.forkliftpdfmanuals.com/...

  • Page 337: Main Specifications

    GENERAL 4. Main specifications Table 1-1 Main specifications (1 / 3) Engine model S6S-Y3T61HF S6S-Y3T62HF Type Water cooled, 4 cycle diesel engine, turbocharged No. of cylinders - arrangement 6 cylinder in-line Combustion system Swirl chamber type Valve mechanism Overhead Cylinder bore × stroke 94 ×...
  • Page 338 GENERAL Table 1-1 Main specifications (2 / 3) Engine model S6S-Y3T61HF S6S-Y3T62HF Forced circulation type Lubricating method (pressure feed by oil pump) Standard Class CF-4 oil SAE No.30 (API service classification) Engine oil Engine total: approx. 16.5 L [4.36 U.S. gal.] Engine oil capacity (approx.
  • Page 339 GENERAL Table 1-1 Main specifications (3 / 3) Engine model S6S-Y3T61HF S6S-Y3T62HF Voltage - polarity 24V - negative (-) ground Model number M008T60373 Pinion meshing type Pinion shift Starter Output 24 V - 5 kW Ring gear and pinion ratio 10/122 Type 3-phase alternating current, with rectifier...

  • Page 340: Tips On Disassembling And Reassembling

    GENERAL 5. Tips on disassembling and reassem- bling This service manual specifies the recommended procedures to be followed when servicing Mitsubishi engines. The manual also specifies the special tools that are required for the work, and the basic safety precautions to follow when working.
  • Page 341 SERVICE DATA 1. Maintenance service data ....2-2 1.1 General ............ 2-2 1.2 Basic engine ..........2-3 1.3 Fuel system..........2-6 1.4 Lubrication system ........2-6 1.5 Cooling system ........2-7 1.6 Inlet and exhaust system ......2-7 1.7 Electrical system ........2-8 2.

  • Page 342: Maintenance Service Data

    SERVICE DATA 1. Maintenance service data 1.1 General Table 2-1 Maintenance service data table - General Unit: mm [in.] Inspection point Nominal Standard Limit Remark Maximum rotation speed (No-load) 2570 ± 50 min Minimum rotation speed (No-load) 820 ± 25 min When oil and water 3.2 MPa 2.8 MPa...

  • Page 343: Basic Engine

    SERVICE DATA 1.2 Basic engine Table 2-2 Maintenance service data table - Basic engine (1 / 4) Unit: mm [in.] Inspection point Nominal Standard Limit Remark ø 19 19.010 to 19.030 Rocker bushing inside diameter [0.75] [0.7484 to 0.7492] ø 19 18.980 to 19.000 Rocker Rocker shaft outside diameter...
  • Page 344 SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (2 / 4) Unit: mm [in.] Inspection point Nominal Standard Limit Remark 93.955 to 93.985 93.770 [3.6990 to 3.7002] [3.6917] Outside diameter ø 94 94.205 to 94.235 94.020 0.25 [0.0098]/OS (at piston skirt) [3.70] [3.7089 to 3.7100]...
  • Page 345 SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (3 / 4) Unit: mm [in.] Inspection point Nominal Standard Limit Remark 0.04 0.10 Runout [0.0016] or less [0.0039] 6.682 6.382 to 6.782 6.182 Inlet [0.2631] [0.2513 to 0.2670] [0.2434] Cam lift 6.722...

  • Page 346: Fuel System

    SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (4 / 4) Unit: mm [in.] Inspection point Nominal Standard Limit Remark Replace bearings before 0.200 limit is reached. Regrind [0.0079] crank journal and use next Clearance between main bearing and crank- 0.050 to 0.110 crank journal Main bearing...

  • Page 347: Cooling System

    SERVICE DATA 1.5 Cooling system Table 2-5 Maintenance service data table - Cooling system Unit: mm [in.] Inspection point Nominal Standard Limit Remark Temperature at which valve starts 76.5 ± 1.5°C opening [170 ± 3.5°F] Thermostat Temperature at which valve lift is 90 ±...

  • Page 348: Electrical System

    SERVICE DATA 1.7 Electrical system Table 2-7 Maintenance service data table - Electrical system Unit: mm [in.] Inspection point Nominal Standard Limit Remark ø 32 31.4 Outside diameter [1.26] [1.236] 0.05 0.10 Commutator Runout [0.0020] or less [0.0039] 0.4 to 0.6 Undercut depth [0.016 to 0.024] [0.008]...

  • Page 349: Tightening Torque Table

    SERVICE DATA 2. Tightening torque table 2.1 Major bolt tightening torque 2.1.1 Basic engine Table 2-8 Tightening torque table - Basic engine Threads Torque Description Dia × Pitch Remark N·m kgf·m lbf·ft (mm) Cylinder head 12 × 1.75 118 ± 5 12 ±...

  • Page 350: Lubrication System

    SERVICE DATA 2.1.3 Lubrication system Table 2-10 Tightening torque table - Lubrication system Threads Torque Description Dia × Pitch Remark N·m kgf·m lbf·ft (mm) Oil pan 8 × 1.25 11.3 ± 1.5 1.15 ± 0.15 8.3 ± 1.1 Oil pan drain plug 20 ×...

  • Page 351: Standard Bolt And Nut Tightening Torque

    SERVICE DATA 2.2 Standard bolt and nut tightening torque 2.2.1 Metric automobile screw thread Table 2-14 Metric automobile screw thread Threads Width Strength classification Dia × Pitch across flats 10.9 (mm) (mm) [in.] N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft M6 ×...

  • Page 352: Regarding Submission Of Parts For Epa Exhaust Gas Regulation

    SERVICE DATA 3. Regarding submission of parts for EPA exhaust gas regulation CAUTION When replacing parts, be sure to use OEM designated parts. If OEM parts are not used, the exhaust emission's war- ranty be voided. New parts may be updated due to improvement. Fuel and exhaust system repairs should only be con- ducted by an authorized Mitsubishi forklift truck dealer.
  • Page 353 SERVICE TOOLS 1. Special tool........3-2 https://www.forkliftpdfmanuals.com/...
  • Page 354 SERVICE TOOLS 1. Special tool Table 3-1 Special tool list (1 / 3) Tool name Part No. Shape Engine compression pressure measuring Compression gauge 33391-02100 0 to 7 MPa {0 to 71.4 kgf/cm²} [0 to 1015.54 psi] Engine compression pressure Gauge adapter 30691-21100 measuring...
  • Page 355 SERVICE TOOLS Table 3-1 Special tool list (2 / 3) Tool name Part No. Shape Camshaft, thrust plate and Socket 34491-00300 rocker bracket installation Valve guide installer 32A91-00100 Valve guide installation Camshaft bushing Camshaft bushing installer set 30691-00010 removal/installation Idler bushing Idler bushing installer 30091-07300 removal/installation...
  • Page 356 SERVICE TOOLS Table 3-1 Special tool list (3 / 3) Tool name Part No. Shape Oil seal sleeve installer Oil seal sleeve installation of 30691-13010 guide set crankshaft rear side Piston installer 34491-00200 Piston installation Oil pump bushing installer 32A91-00400 Oil pump bushing installation Ring pliers 49160-90101...
  • Page 357 DETERMINATION OF OVERHAUL 1. Determining overhaul timing ...4-2 2. Testing compression pressure ..4-3 https://www.forkliftpdfmanuals.com/...
  • Page 358 DETERMINATION OF OVERHAUL 1. Determining overhaul timing In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in engine oil consumption and blow-by gas are also considered to evaluate the engine condition. Besides, such symptoms as a decrease in output, increase in fuel consumption, decrease in oil pressure, difficulty of engine starting and increase in noise are also considered for judging the overhaul timing, although those symptoms are often affected by other causes, and are not always effective to judge the overhaul timing.
  • Page 359 DETERMINATION OF OVERHAUL 2. Testing compression pressure CAUTION (a) Be sure to measure the compression pressure for all the cylinders. It is not a good practice to mea- sure the compression pressure for only one cylin- Compression Gauge adapter der, and presume the compression for the gauge P/N:30691-21100 P/N:33391-02100...
  • Page 360 https://www.forkliftpdfmanuals.com/...
  • Page 361 DISASSEMBLY OF BASIC ENGINE 1. Disassembling and inspecting cylinder head and valve mechanism ....5-2 1.1 Removing rocker shaft assembly..... 5-3 1.2 Disassembling rocker shaft assembly..5-3 1.3 Removing cylinder head bolt....5-3 1.4 Removing cylinder head assembly ..5-4 1.5 Removing valve and valve spring .... 5-4 1.6 Removing valve stem seal .......

  • Page 362: Disassembling And Inspecting Cylinder Head And Valve Mechanism

    DISASSEMBLY OF BASIC ENGINE 1. Disassembling and inspecting cylinder head and valve mechanism Replace Wear Damaged threads, Worn valve cap contact worn rod contact surface surface, clogged oil holes Wear, clogged oil holes Wear at both ends, deflection Crack, damage, carbon deposits, Fatigue, damage water scale adhesion Replace...

  • Page 363: Removing Rocker Shaft Assembly

    DISASSEMBLY OF BASIC ENGINE 1.1 Removing rocker shaft assembly CAUTION Adjusting screw Always loosen shorter bolts first. Failing to do so may Rocker bracket bolt cause the damage to the rocker shaft bracket. (1) Loosen the rocker arm adjusting screws by rotating about one turn.

  • Page 364: Removing Cylinder Head Assembly

    DISASSEMBLY OF BASIC ENGINE 1.4 Removing cylinder head assembly CAUTION Cylinder head When removing the cylinder head gasket, be careful not to damage the cylinder head or crankcase surface with tools such as a screwdriver. (1) Remove the cylinder head bolt. (2) Remove the cylinder head assembly by lifting it up.

  • Page 365: Disassembling And Inspecting Flywheel

    DISASSEMBLY OF BASIC ENGINE 2. Disassembling and inspecting flywheel Replace Crack, abnormality of knock hole Lip wear, damage or aging Crack, knock hole defect, gear damage Damaged threads Disassembling and inspecting flywheel Disassembling sequence 1 Flywheel 2 Rear plate 3 Oil seal 4 Gasket https://www.forkliftpdfmanuals.com/...

  • Page 366: Removing Flywheel

    DISASSEMBLY OF BASIC ENGINE 2.1 Removing flywheel CAUTION (a) Be careful not to cut yourself with the ring gear when pulling out the flywheel. Be careful not to drop or hit the flywheel when removing. (b) The person who holds the pulley must be very careful to assure safety by communicating with the person who is removing the flywheel.

  • Page 367: Disassembling And Inspecting Damper, Gear Case, Timing Gear And Camshaft

    DISASSEMBLY OF BASIC ENGINE 3. Disassembling and inspecting damper, gear case, timing gear and camshaft S6S-Y3T61HF Wear, damage Flaking, Replace Clogging of oil uneven contact, hole, wear damage, key groove Wear, damage defect, abnormal wear bushings Clogged oil hole Wear Replace Replace Flaking,...
  • Page 368 DISASSEMBLY OF BASIC ENGINE S6S-Y3T62HF Wear, damage Flaking, uneven contact, Replace Clogging of oil damage, hole, wear key groove defect, abnormal wear Wear, damage bushings Clogged oil hole Wear Replace Replace Flaking, uneven contact, damage, key groove defect, Replace abnormal wear Lip wear, bushings damage or aging...

  • Page 369: Removing Crankshaft Pulley And Damper

    DISASSEMBLY OF BASIC ENGINE 3.1 Removing crankshaft pulley and damper CAUTION The bar that stops the crankshaft from turning may come off. Pay special attention to safety. (1) Screw two guide bolts into the threaded holes at the rear end of the crankshaft. Stick a bar across the guide bolts to prevent the crankshaft from turning.

  • Page 370: Removing Timing Gear Case

    DISASSEMBLY OF BASIC ENGINE 3.3 Removing timing gear case S6S-Y3T62HF CAUTION The front plate is bolted to the crankcase from inside the gear case. Do not attempt to remove the front plate together with the gear case by tapping. (1) Remove bolts from the timing gear case. (2) Remove the timing gear case.

  • Page 371: Measuring Idler Gear And Camshaft Gear End Play

    DISASSEMBLY OF BASIC ENGINE 3.5 Measuring idler gear and camshaft gear end play Using a feeler gauge or dial gauge, measure the end play of idler gear and camshaft gear. If the measured value exceeds the limit, replace the thrust plate with a new one.

  • Page 372: Removing Oil Pump Gear

    DISASSEMBLY OF BASIC ENGINE 3.9 Removing oil pump gear (1) Remove the oil pump gear tightening nut. (2) Remove the oil pump gear. Oil pump gear Removing oil pump gear 3.10 Removing idler gear (1) Remove the thrust plate bolt. (2) Remove the idler gear while turning the gear.

  • Page 373: Separating Camshaft Gear

    DISASSEMBLY OF BASIC ENGINE 3.13 Separating camshaft gear Using hydraulic press, remove the camshaft gear and thrust Punch out with hydraulic press plate from the camshaft. Note: Do not remove the camshaft gear from the camshaft Camshaft gear unless the camshaft gear or the thrust plate is defective.

  • Page 374: Disassembling And Inspecting Piston, Connecting Rod, Crankshaft And Crankcase

    DISASSEMBLY OF BASIC ENGINE 4. Disassembling and inspecting piston, connecting rod, crankshaft and crankcase Wear, damage Surface scratches, cracks, Fatigue damage, wear, carbon deposits Wear Cracks, Wear clogged oil holes Wear, clogged oil holes Damaged threads Serration for cracks, wear Scratches on inside and outside surfaces, seizing, flaking, wear...

  • Page 375: Removing Connecting Rod Cap

    DISASSEMBLY OF BASIC ENGINE 4.1 Removing connecting rod cap (1) Lay the engine on its side. (2) Mark the cylinder number on the connecting rod and connecting rod cap so that their combination is not changed when reassembling. (3) Remove the connecting rod caps. Note: Mark the cylinder No.

  • Page 376: Removing Piston Ring

    DISASSEMBLY OF BASIC ENGINE 4.4 Removing piston ring Remove the piston rings using piston ring pliers. Piston ring pliers P/N:31391-12900 Removing piston ring 4.5 Removing piston pin and piston (1) Using ring pliers, remove the snap ring. (2) Using a wooden block and mallet, remove the piston pin, and separate the piston from the connecting rod.

  • Page 377: Removing Crankshaft

    DISASSEMBLY OF BASIC ENGINE 4.7 Removing crankshaft CAUTION Be careful not to damage bearings when removing the crankshaft. (1) Slowly lift the crankshaft straight up. (2) Arrange the bearings in the order of disassembly so that their original positions are restored when reassembling. Note: (a) When raising the crankshaft, do not allow wire or chain to come into contact with the crankshaft.
  • Page 378 https://www.forkliftpdfmanuals.com/...
  • Page 379 INSPECTION AND REPAIR OF BASIC ENGINE 1. Inspecting and repairing cylinder head 3.11 Inspecting tappet........6-14 and valve mechanism .....6-2 3.11.1 Contact surface of camshaft....6-14 1.1 Measuring clearance between rocker 3.11.2 Contact surface of push rod ....6-14 bushing and rocker shaft......6-2 3.12 Inspecting V-belt groove wear....

  • Page 380: Inspecting And Repairing Cylinder Head And Valve Mechanism

    INSPECTION AND REPAIR OF BASIC ENGINE 1. Inspecting and repairing cylinder head and valve mechanism 1.1 Measuring clearance between rocker bushing and rocker shaft Measuring direction Measure the rocker assembly inside diameter and the rocker Measuring shaft diameter. If the clearance exceeds the limit, replace direction either rocker assembly or rocker shaft with a new one.

  • Page 381: Replacing Valve Guide

    INSPECTION AND REPAIR OF BASIC ENGINE 1.3 Replacing valve guide Valve guide remover CAUTION P/N:32A91-00300 Because valve guides must be inserted to the speci- fied amount, be sure to use a valve guide installer. (1) To remove valve guides, use a valve guide remover. Pulling out valve guide (2) To press-fit valve guides, use a valve guide installer.

  • Page 382: Inspecting Valve Face

    INSPECTION AND REPAIR OF BASIC ENGINE 1.4 Inspecting valve face Apply a thin coat of lead-free coloring paste on the valve face, and strike the valve face against the valve seat using a valve lapper to check for contact condition. If the contact is not even, or any defects are found, or if the Valve lapper limit is exceeded, reface or replace the valve.

  • Page 383: Refacing Valve Seat

    INSPECTION AND REPAIR OF BASIC ENGINE 1.6 Refacing valve seat (1) Use the valve seat cutter or valve seat grinder to reface the valve seat. After refacing, sand the valve seat lightly using 400 grit sandpaper, inserting it between the cutter and valve seat.

  • Page 384: Replacing Valve Seat

    INSPECTION AND REPAIR OF BASIC ENGINE 1.7 Replacing valve seat (1) To remove the valve seat, weld a stud to the valve seat as illustrated. Then, insert a rod into the valve guide Weld Shaft hole from the top of the cylinder head, and press out the valve seat with the rod.

  • Page 385: Lapping Valve And Valve Seat

    INSPECTION AND REPAIR OF BASIC ENGINE 1.8 Lapping valve and valve seat Always lap the valve against the valve seat after refacing the valve seat or after replacing the valve. (1) Apply a thin coat of lapping compound evenly to the valve face.

  • Page 386: Measuring Distortion Of The Bottom Surface Of The Cylinder Head

    INSPECTION AND REPAIR OF BASIC ENGINE 1.10 Measuring distortion of the bottom surface of the cylinder head CAUTION Refacing of cylinder head should be kept to an abso- lute minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping (contact between piston and valve).

  • Page 387: Removing Combustion Jet

    INSPECTION AND REPAIR OF BASIC ENGINE 1.12 Removing combustion jet Replace the combustion jet only when it has a defect or Round rod crack. (1) Insert a round bar (approx; ø6 mm [0.24 in.]) into glow plug hole, and tap the combustion jet inner face perimeter lightly to pull out the combustion jet.

  • Page 388: Inspecting And Repairing Flywheel

    INSPECTION AND REPAIR OF BASIC ENGINE 2. Inspecting and repairing flywheel 2.1 Measuring flatness of flywheel Place the flywheel on a surface plate and move a dial gauge on the friction surface of the flywheel to measure the flatness. Grind the friction surface of the flywheel if the limit is exceeded.

  • Page 389: Inspecting And Repairing Timing Gear And Camshaft

    INSPECTION AND REPAIR OF BASIC ENGINE 3. Inspecting and repairing timing gear and camshaft 3.1 Measuring timing gear backlash Measure the backlash of the timing gears by using one of the following two methods; measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by inserting a feeler gauge between...

  • Page 390: Measuring Camshaft Runout

    INSPECTION AND REPAIR OF BASIC ENGINE 3.4 Measuring camshaft runout Measure the camshaft runout using a dial gauge. If the limit is exceeded, correct the camshaft using a press, or replace the camshaft with a new one. Note: With a dial gauge set on the camshaft, rotate the camshaft one turn and read the gauge indication.

  • Page 391: Replacing Camshaft Bushing

    INSPECTION AND REPAIR OF BASIC ENGINE 3.7 Replacing camshaft bushing 3.7.1 Removing camshaft bushing Adapter (1) Install a camshaft bushing installer set to the camshaft Bushing bushing. (2) Remove the camshaft bushing by tapping the end of the rod of camshaft bushing installer set. Camshaft bushing installer set P/N:30691-00010...

  • Page 392: Replacing Idler Shaft

    INSPECTION AND REPAIR OF BASIC ENGINE 3.9 Replacing idler shaft To remove the idler shaft, use the idler shaft puller. Idler shaft puller P/N:MH061077 Note: When installing the idler shaft into the crankcase, orient the idler shaft so that its oil hole faces the upper crankcase.

  • Page 393: Inspecting V-Belt Groove Wear

    INSPECTION AND REPAIR OF BASIC ENGINE 3.12 Inspecting V-belt groove wear Check the V-belt groove of the pulley for wear. Attach a new V-belt around the pulley, apply high tension and measure the sinkage of V-belt. If the wear appears excessively, and the belt top surface 1.6 mm [0.06 in.] sinks 1.6 mm [0.06 in.] or more down from the top edge of or less...

  • Page 394: Inspecting And Repairing Piston, Connecting Rod, Crankshaft And Crankcase

    INSPECTION AND REPAIR OF BASIC ENGINE 4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase 4.1 Measuring crankcase top surface distor- tion CAUTION Refacing of cylinder head should be kept to an abso- lute minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping (contact between piston and valve).

  • Page 395: Measuring Cylinder Inside Diameter

    INSPECTION AND REPAIR OF BASIC ENGINE 4.2 Measuring cylinder inside diameter (1) Measure the inside diameter of the cylinder at three Measuring levels, i.e., upper (with much stepped wear), middle, directions and lower levels, in both directions parallel to and perpendicular to the crankshaft direction.

  • Page 396: Measuring Piston Outside Diameter

    INSPECTION AND REPAIR OF BASIC ENGINE 4.3 Measuring piston outside diameter (1) Measure the piston outside diameter of the piston skirt Direction at right angles to piston pin at right angles to the piston pin. If it exceeds the limit, replace the piston with a new piston.

  • Page 397: Measuring Clearance Between Piston Ring Groove And Piston Ring

    INSPECTION AND REPAIR OF BASIC ENGINE 4.5 Measuring clearance between piston ring groove and piston ring CAUTION Remove carbon deposits from pistons and check the entire circumference of the piston. (1) Remove deposits such as carbon from each ring groove. (2) Check each ring groove for wear or damage.

  • Page 398: Measuring Piston Protrusion

    INSPECTION AND REPAIR OF BASIC ENGINE 4.7 Measuring piston protrusion CAUTION Piston protrusion must always meet the standard, as the amount of protrusion not only influences on the engine performance, but also it is important to prevent valve interference. Measure the protrusion of each piston following the instructions below.

  • Page 399: Measuring Clearance Between Connecting Rod Bearing And Crankpin

    INSPECTION AND REPAIR OF BASIC ENGINE 4.8 Measuring clearance between connecting 54 ± 5 N·m rod bearing and crankpin Measuring Measuring {5.5 ± 0.5 kgf·m} directions points [40 ± 3.6 lbf·ft] CAUTION When grinding crankpins, be sure to grind all the pins to the same size.

  • Page 400: Replacing Connecting Rod Bushing

    INSPECTION AND REPAIR OF BASIC ENGINE 4.10 Replacing connecting rod bushing Use a connecting rod bushing installer to replace the Connecting rod bushing installer P/N:32A91-00500 connecting rod bushing. Match marks side (1) With the bushing joints oriented as shown in the illustration, align the oil hole of bushing with the oil hole of connecting rod, and press-fit the connecting rod bushing into the connecting rod.

  • Page 401: Inspecting Connecting Rod Bearing

    INSPECTION AND REPAIR OF BASIC ENGINE 4.12 Inspecting connecting rod bearing Inspect the connecting rod bearings. If any defect is found, replace it with a new one. Scratches Flaking Fusion Inspecting connecting rod bearing 4.13 Measuring connecting rod end play (1) Install the connecting rods onto the respective crankpins and tighten the connecting rod cap bolts to the specified torque.

  • Page 402: Measuring Crankshaft Journal Outside Diameter

    INSPECTION AND REPAIR OF BASIC ENGINE 4.15 Measuring crankshaft journal outside diam- eter Measure the crankshaft journal diameter using micrometer. Check the crankshaft journal for circularity, cylindricity and clearance between the bearing and journal. If the measurement value is below the repair limit, grind the Measuring Measuring direction...

  • Page 403: Grinding Crankshaft

    INSPECTION AND REPAIR OF BASIC ENGINE 4.17 Grinding crankshaft R3 mm R3 mm CAUTION [0.12 in.] [0.12 in.] (a) When grinding crank journals, be sure to grind all the journals to the same size. (b) Finish the fillet radius to the specified dimension. Grind the crankshaft journal (or pin) to the diameter that fits R3 mm the inside diameter of the next undersize main (or...

  • Page 404: Measuring Crankshaft End Play

    INSPECTION AND REPAIR OF BASIC ENGINE 4.18 Measuring crankshaft end play (1) Measure the crankshaft end play (clearance between the +0.039 +0.015 [1.22 in.] crank arm at the thrust force receiving journal and the 0.00 bearing cap with thrust plate attached). If the limit is exceeded, replace the thrust plate with a new one.

  • Page 405: Replacing Crankshaft Gear

    INSPECTION AND REPAIR OF BASIC ENGINE 4.20 Replacing crankshaft gear 4.20.1 Removing crankshaft gear Using a gear puller, remove the gear from the crankshaft. Crankshaft gear Note: Do not strike the gear with a hammer. Puller P/N:MH061326 Removing crankshaft gear 4.20.2 Installing crankshaft gear (1) Install the key on the crankshaft.

  • Page 406: Installing Oil Seal Sleeve

    INSPECTION AND REPAIR OF BASIC ENGINE 4.22 Installing oil seal sleeve Oil seal sleeve CAUTION installer set Be careful not to dent or damage the oil seal sleeve P/N:30691-13010 circumference. Guide When installing the oil seal sleeve, apply the oil to the P/N:30691-13100 inside of the oil seal sleeve, and drive it into the crankshaft by using oil seal sleeve installer set.

  • Page 407: Inspecting Main Bearing Surface

    INSPECTION AND REPAIR OF BASIC ENGINE 4.24 Inspecting main bearing surface Check the inside surface of each main bearing shell for abnormal contact, scratches, corrosion and peeling from Scratch on the inner and outer circumference, foreign material. Also check the outside surface of each corrosion, and detachment bearing shell which comes into contact with the crankcase or main bearing cap for abnormal seating.
  • Page 408 https://www.forkliftpdfmanuals.com/...
  • Page 409 REASSEMBLY OF BASIC ENGINE 1. Reassembling piston, connecting rod, 4. Reassembling cylinder head and valve crankshaft and crankcase ....7-2 mechanism ........7-16 1.1 Installing main bearing ......7-2 4.1 Cleaning cylinder head bottom surface.. 7-16 1.2 Installing thrust plate ........ 7-2 4.2 Installing valve stem seal .......

  • Page 410: Reassembling Piston, Connecting Rod, Crankshaft And Crankcase

    REASSEMBLY OF BASIC ENGINE 1. Reassembling piston, connecting rod, crankshaft and crankcase 1.1 Installing main bearing Main bearing CAUTION upper Do not apply oil to the bearing outer surface, as the oil may cause bearing seizure. (1) Press the upper main bearing into position by aligning Oil groove its lug to the lug groove on the crankcase.

  • Page 411: Installing Main Bearing Caps

    REASSEMBLY OF BASIC ENGINE 1.5 Installing main bearing caps Apply ThreeBond 1212 to corner of cap CAUTION The foremost and rearmost caps should be installed so that they are flush with the crankcase surface. Install the main bearing caps from the front side in the order of the numbers marked on them.

  • Page 412: Measuring Crankshaft End Play

    REASSEMBLY OF BASIC ENGINE 1.8 Measuring crankshaft end play Attach a dial gauge to the end of the crankshaft to measure the end play. If the end play deviates from the standard value, loosen the main bearing cap bolts and retighten. Make sure that the crankshaft turns freely.

  • Page 413: Installing Piston Ring

    REASSEMBLY OF BASIC ENGINE 1.10 Installing piston ring CAUTION Piston ring plier Top mark No.1 P/N:31391-12900 A marking is stamped near the end gap to indicate the compression ring top face of piston ring. Install all piston rings with this mark facing upward.

  • Page 414: Installing Connecting Rod Bolt And Connecting Rod Bearing

    REASSEMBLY OF BASIC ENGINE 1.12 Installing connecting rod bolt and connect- ing rod bearing Lug groove (1) Press fit the connecting rod bolts into the connecting rod. Note: When press fitting the bolt, make sure that the bolt fully contacts its seating position without any interference with the shoulder of mounting surface.

  • Page 415: Installing Connecting Rod Cap

    REASSEMBLY OF BASIC ENGINE 1.14 Installing connecting rod cap (1) Install the connecting rod cap with its match mark facing on the same side as the match mark on the connecting rod. (2) Tighten the connecting rod cap nuts evenly and progressively to the specified torque.

  • Page 416: Reassembling Timing Gear And Camshaft

    REASSEMBLY OF BASIC ENGINE 2. Reassembling timing gear and camshaft 2.1 Installing oil pump Install a new O-ring to the oil pump case, and install the oil pump to the crankcase. Oil pump O-ring Installing oil pump 2.2 Installing front plate (1) Clean the gasket mounting surface.

  • Page 417: Installing Camshaft Gear And Thrust Plate

    REASSEMBLY OF BASIC ENGINE 2.3 Installing camshaft gear and thrust plate Press fit with CAUTION hydraulic press Be careful not to damage the cam of the camshaft or bushing. Camshaft gear Warm the camshaft gear and insert the thrust plate without fail when installing the gear.

  • Page 418: Installing Idler Gear

    REASSEMBLY OF BASIC ENGINE 2.6 Installing idler gear (1) Apply engine oil to the idler gear shaft. (2) Install the idler gear with its match marks aligned with Idler gear the marks on the crankshaft gear and camshaft gear. (3) Attach the thrust plate to the idler gear and tighten the 34 ±...

  • Page 419: Installing Oil Pump Gear

    REASSEMBLY OF BASIC ENGINE 2.7 Installing oil pump gear (1) Install the oil pump gear to the oil pump shaft. (2) Tighten the jam nut to the specified torque. Oil pump gear 33 ± 5 N·m {3.4 ± 0.5 kgf·m} [24.6 ±...

  • Page 420: Installing Front Oil Seal

    REASSEMBLY OF BASIC ENGINE 2.10 Installing front oil seal Using an installer, install new oil seal in the timing gear case. Make sure the oil seal is flush with the gear case. Installer Installing front oil seal 2.11 Installing timing gear case S6S-Y3T62HF (1) Aligning with the dowel pins, install the gasket to the Gasket...

  • Page 421: Installing Oil Pan

    REASSEMBLY OF BASIC ENGINE 2.13 Installing oil pan (1) Clean the mount surfaces of the crankcase, timing gear case, and oil pan. (2) Squeeze ThreeBond 1207C (32A91-05100: liquid gasket) in a 4 mm [0.16 in.] diameter bead all around the oil pan flange periphery, and spread it. (3) Install the oil pan to the crankcase within five minutes of applying the liquid gasket.

  • Page 422: Installing Cover

    REASSEMBLY OF BASIC ENGINE 2.14 Installing cover S6S-Y3T62HF Tighten the cover mounting bolts evenly. Cover Installing cover S6S-Y3T61HF Bearing case Cover Installing cover 2.15 Installing crankshaft pulley and damper Prevent crankshaft CAUTION from rotating The bar could come off. Be very careful. (1) Screw two guide bolts into the threaded holes at the rear end of the crankshaft.

  • Page 423: Reassembling Flywheel

    REASSEMBLY OF BASIC ENGINE 3. Reassembling flywheel 3.1 Installing oil seal Apply a small quantity of grease to the new oil seal, and install the oil seal to the rear plate. Rear plate Apply grease Be careful of the oil seal installation direction. Note: Use an oil seal with a sleeve if the oil seal contacting surface of the crankshaft is worn.

  • Page 424: Reassembling Cylinder Head And Valve Mechanism

    REASSEMBLY OF BASIC ENGINE 4. Reassembling cylinder head and valve mechanism 4.1 Cleaning cylinder head bottom surface CAUTION Do not use liquid gasket on the cylinder head. Taking care not to damage the cylinder head bottom surface, remove residue of old gasket. Note: First, roughly scrape off residue of old gasket using a scraper.

  • Page 425: Installing Cylinder Head Gasket

    REASSEMBLY OF BASIC ENGINE 4.4 Installing cylinder head gasket CAUTION Do not use liquid gasket on the cylinder head. (1) Make sure that there is no dirt or dents on the top surfaces of the crankcase and pistons. (2) Place new gasket on the crankcase by aligning it with dowel pins on the crankcase.

  • Page 426: Inserting Push Rod

    REASSEMBLY OF BASIC ENGINE 4.7 Inserting push rod (1) Insert each push rod into its hole in the cylinder head. (2) Make sure that the ball end of each push rod is placed Push rod correctly on the tappet cup. Tappet Inserting push rod 4.8 Reassembling rocker shaft assembly...

  • Page 427: Determining Top Dead Center Of No. 1 Cylinder Compression Stroke

    REASSEMBLY OF BASIC ENGINE 4.10 Determining top dead center of No. 1 cylin- der compression stroke 4.10.1 When reusing the damper (1) Attach a socket and ratchet handle to the nut of crankshaft pulley, and rotate the crankshaft in the normal direction (clockwise when viewed from the front of the engine.) (2) Stop turning the crankshaft when the notch mark...
  • Page 428 https://www.forkliftpdfmanuals.com/...
  • Page 429 FUEL SYSTEM 1. Removing fuel system.....8-2 1.1 Removing fuel filter ........8-2 1.2 Removing fuel injection pipe ....8-3 1.3 Removing fuel injection pump....8-4 2. Disassembling, inspecting and reassembling fuel system....8-5 2.1 Disassembling and inspecting fuel filter... 8-5 2.2 Changing fuel filter ........8-6 2.3 Disassembling and inspecting fuel injection nozzle............

  • Page 430: Removing Fuel System

    FUEL SYSTEM 1. Removing fuel system CAUTION Cover the openings on the injection pump, nozzle inlet connector and injection pipe to prevent dust from entering the fuel system. 1.1 Removing fuel filter Removing fuel filter Removing sequence 1 Fuel hose 2 Fuel filter 3 Fuel filter bracket https://www.forkliftpdfmanuals.com/...

  • Page 431: Removing Fuel Injection Pipe

    FUEL SYSTEM 1.2 Removing fuel injection pipe Replace Removing fuel injection pipe Removing sequence 1 Fuel return pipe 6 No. 5 fuel injection pipe 2 No. 1 fuel injection pipe 7 No. 6 fuel injection pipe 3 No. 2 fuel injection pipe 8 Fuel leak-off pipe 4 No.

  • Page 432: Removing Fuel Injection Pump

    FUEL SYSTEM 1.3 Removing fuel injection pump Replace Removing fuel injection pump Removing sequence 1 Bracket 2 Fuel injection pump 3 Bracket https://www.forkliftpdfmanuals.com/...

  • Page 433: Disassembling, Inspecting And Reassembling Fuel System

    FUEL SYSTEM 2. Disassembling, inspecting and reassembling fuel system 2.1 Disassembling and inspecting fuel filter Crack and damaged threads Replace Clogged, cracks. Replace: Every 500 hrs. Replace Disassembling and inspecting fuel filter Disassembling sequence 1 Level sensor 2 Filter element 3 Body https://www.forkliftpdfmanuals.com/...

  • Page 434: Changing Fuel Filter

    FUEL SYSTEM 2.2 Changing fuel filter WARNING (a) When handling fuel, make sure no open flames 15 ± 3 N·m are nearby. {1.5 ± 0.3 kgf·m} (b) Wipe off any spilled fuel. Spilled fuel becomes a [11.1 ± 2.2 lbf·ft] fire hazard.

  • Page 435: Disassembling And Inspecting Fuel Injection Nozzle

    FUEL SYSTEM 2.3 Disassembling and inspecting fuel injection nozzle Replace Wear Settling, breakage Wear, damage Carbon deposit, nozzle hole clogging Disassembling and inspecting fuel injection nozzle Disassembling sequence 1 Nozzle retaining nut 4 Pressure pin 7 Nozzle holder 2 Nozzle tip assembly 5 Pressure spring 8 Gasket 3 Distance piece...

  • Page 436: Inspecting And Adjusting Fuel Injection Valve Opening Pressure

    FUEL SYSTEM 2.4 Inspecting and adjusting fuel injection valve opening pressure Nozzle tester CAUTION Never touch the spray hole during injection (1) Mount the nozzle on the nozzle tester. (2) Pump the tester handle at a rate of approximately one cycle per second while observing the pressure at which injection starts.

  • Page 437: Cleaning And Inspecting Nozzle Tip

    FUEL SYSTEM 2.6 Cleaning and inspecting nozzle tip (1) Clean the needle valve and body of the nozzle tip in a clean wash oil. (2) After cleaning, assemble the needle valve and the body Nozzle tip end in a clean diesel oil. Note: The needle valve and body are precision parts.

  • Page 438: Reassembling Fuel Injection Nozzle

    FUEL SYSTEM 2.7 Reassembling fuel injection nozzle 36.8 ± 2.5 N·m {3.75 ± 0.25 kgf·m} [27.1 ± 1.8 lbf·ft] 58.8 ± 5.9 N·m {6 ± 0.6 kgf·m} [43.4 ± 4.3 lbf·ft] Reassembling fuel injection nozzle 8-10 https://www.forkliftpdfmanuals.com/...

  • Page 439: Inspecting And Cleaning Gauze Filter Of Distribute Type Fuel Injection Pump

    FUEL SYSTEM 2.8 Inspecting and cleaning gauze filter of distribute type fuel injection pump WARNING Keep flames away when handling a diesel fuel. Wipe off any spilled fuel thoroughly. Spilled fuel could cause a fire. CAUTION Cover the openings on the fuel injection pump to prevent dust from entering the fuel system. When output shortage and/or hunting of the engine occurred, the gauze filter may be dirty.

  • Page 440: Installing Fuel System

    FUEL SYSTEM 3. Installing fuel system 3.1 Installing fuel injection pump Replace Installing fuel injection pump 8-12 https://www.forkliftpdfmanuals.com/...

  • Page 441: Installing Fuel Injection Pipe

    FUEL SYSTEM 3.2 Installing fuel injection pipe 19.6 ± 1.9 N·m 29.4 ± 2.9 N·m {2 ± 0.2 kgf·m} {3 ± 0.3 kgf·m} 22.6 ± 1.9 N·m [14.5 ± 1.4 lbf·ft] [21.7 ± 2.2 lbf·ft] {2.3 ± 0.2 kgf·m} [16.6 ± 1.4 lbf·ft] 58.8 ±...

  • Page 442: Installing Fuel Filter

    FUEL SYSTEM 3.3 Installing fuel filter Installing fuel filter 8-14 https://www.forkliftpdfmanuals.com/...
  • Page 443 LUBRICATION SYSTEM 1. Removing lubrication system ..9-2 1.1 Removing oil filter and relief valve ... 9-2 1.2 Removing oil cooler ......... 9-3 1.3 Removing oil pump, oil pan and oil strainer ..........9-4 2. Disassembling, inspecting and reassembling lubrication system ..9-5 2.1 Disassembling and inspecting oil pump...

  • Page 444: Removing Lubrication System

    LUBRICATION SYSTEM 1. Removing lubrication system 1.1 Removing oil filter and relief valve Replace Replace Removing oil filter and relief valve Removing sequence 1 Oil filter 2 Relief valve https://www.forkliftpdfmanuals.com/...

  • Page 445: Removing Oil Cooler

    LUBRICATION SYSTEM 1.2 Removing oil cooler Replace Replace Replace Removing oil cooler Removing sequence 1 Oil cooler assembly 2 Oil cooler gasket https://www.forkliftpdfmanuals.com/...

  • Page 446: Removing Oil Pump, Oil Pan And Oil Strainer

    LUBRICATION SYSTEM 1.3 Removing oil pump, oil pan and oil strainer Replace Replace Removing oil pump, oil pan and oil strainer Removing sequence 1 Oil pump 2 Oil pan 3 Oil strainer 4 Safety valve https://www.forkliftpdfmanuals.com/...

  • Page 447: Disassembling, Inspecting And Reassembling Lubrication System

    LUBRICATION SYSTEM 2. Disassembling, inspecting and reassembling lubrication system 2.1 Disassembling and inspecting oil pump Replace Disassembling oil pump Disassembling sequence 1 O-ring 2 Shaft assembly 3 Outer rotor 4 Pump case https://www.forkliftpdfmanuals.com/...

  • Page 448: Inspecting Oil Pump

    LUBRICATION SYSTEM 2.2 Inspecting oil pump 2.2.1 Measuring clearance between outer rotor and inner rotor Measure the clearance between the outer rotor and the inner rotor. If measured value exceeds the limit, replace the oil Feeler gauge pump with new one. Item Standard Limit...

  • Page 449: Measuring Clearance Between Main Shaft And Pump Case

    LUBRICATION SYSTEM 2.2.4 Measuring clearance between main shaft and pump case Measuring Measure the diameter of the shaft and the inside diameter of Measuring directions directions the bore in the case for the shaft to find the clearance between the two. If the clearance exceeds the limit, replace Measuring the oil pump assembly.

  • Page 450: Reassembling Oil Pump

    LUBRICATION SYSTEM 2.3 Reassembling oil pump Flush Flush Reassembling oil pump https://www.forkliftpdfmanuals.com/...

  • Page 451: Disassembling And Inspecting Oil Cooler

    LUBRICATION SYSTEM 2.4 Disassembling and inspecting oil cooler Clogging, crack Replace Crack, deformation Replace Disassembling and inspecting oil cooler Disassembling sequence 1 Oil cooler case 2 Oil cooler element https://www.forkliftpdfmanuals.com/...

  • Page 452: Inspecting Oil Filter

    LUBRICATION SYSTEM 2.5 Inspecting oil filter Apply engine oil to the gasket when installing Clogged, cracks. Replace: Every 500 hrs. Inspecting oil filter 9-10 https://www.forkliftpdfmanuals.com/...

  • Page 453: Inspecting Relief Valve

    LUBRICATION SYSTEM 2.6 Inspecting relief valve (1) Check the relief valve and its seat for contact. Check the spring for fatigue and damage. If faulty, replace the relief valve with a new one. (2) Measure the relief valve opening pressure. If the pressure does not fall within the standard range, replace the relief valve with a new one.

  • Page 454: Installing Lubrication System

    LUBRICATION SYSTEM 3. Installing lubrication system 3.1 Installing oil pump, oil pan and oil strainer 69 ± 5 N·m {7 ± 0.5 kgf·m} [50.6 ± 3.6 lbf·ft] 11.3 ± 1.5 N·m {1.15 ± 0.15 kgf·m} [8.3 ± 1.1 lbf·ft] 78 ± 5 N·m {8 ±...

  • Page 455: Installing Oil Cooler

    LUBRICATION SYSTEM 3.2 Installing oil cooler Replace Replace Replace Installing oil cooler 9-13 https://www.forkliftpdfmanuals.com/...

  • Page 456: Installing Oil Filter And Relief Valve

    LUBRICATION SYSTEM 3.3 Installing oil filter and relief valve Replace 49 ± 4.9 N·m Replace {5 ± 0.5 kgf·m} [36.2 ± 3.6 lbf·ft] Installing oil filter and relief valve 9-14 https://www.forkliftpdfmanuals.com/...
  • Page 457 COOLING SYSTEM 1. Removing cooling system .....10-2 1.1 Removing thermostat......10-2 1.2 Removing water pump, water pump pulley and V-belt............10-3 2. Disassembling, inspecting and reassembling cooling system ..10-4 2.1 Disassembling and inspecting thermostat ..........10-4 2.2 Inspecting thermostat......10-5 2.3 Disassembling water pump....

  • Page 458: Removing Cooling System

    COOLING SYSTEM 1. Removing cooling system 1.1 Removing thermostat Replace Crack, deterioration, damage Crack, water leakage, damage Removing thermostat Removing sequence 1 Hose 2 Thermostat assembly 3 Gasket 10-2 https://www.forkliftpdfmanuals.com/...

  • Page 459: Removing Water Pump, Water Pump Pulley And V-Belt

    COOLING SYSTEM 1.2 Removing water pump, water pump pulley and V-belt Crack, Replace deformation, damage Replace Crack, extension, wear, damage Removing water pump, water pump pulley and V-belt Removing sequence 1 V-belt 3 Water pump assembly 5 Water pump spacer 2 Water pump pulley 4 Gasket 6 Gasket...

  • Page 460: Disassembling, Inspecting And Reassembling Cooling System

    COOLING SYSTEM 2. Disassembling, inspecting and reassembling cooling system 2.1 Disassembling and inspecting thermostat Replace Disassembling thermostat Disassembling sequence 1 Cover assembly 3 Gasket 5 Thermostat case 2 Gasket 4 Thermostat 10-4 https://www.forkliftpdfmanuals.com/...

  • Page 461: Inspecting Thermostat

    COOLING SYSTEM 2.2 Inspecting thermostat CAUTION [0.35] Be careful of burns or a fire when measuring tempera- ture, as it involves a high-temperature and open flame. 76.5 °C 90°C [170°F] [194°F] To test the thermostat operation, immerse the thermostat in a Temperature container filled with water.

  • Page 462: Disassembling Water Pump

    COOLING SYSTEM 2.3 Disassembling water pump Crack, water leakage, deformation Replace Crack, water leakage, damage, impeller and shaft rotation Disassembling water pump Disassembling sequence 1 Water pump cover 2 Gasket 3 Water pump 2.4 Inspecting water pump Check to make sure that the impeller and shaft of water pump rotate smoothly without noise and irregularities.

  • Page 463: Installing Cooling System

    COOLING SYSTEM 3. Installing cooling system 3.1 Installing water pump, water pump pulley and V-belt Water pump and water pump cover fixing bolts (×3) Replace Crack, 9.8 ± 1 N·m deformation, {1 ± 0.1 kgf·m} damage [7.2 ± 0.7 lbf·ft] Replace 32.4 ±...

  • Page 464: Installing Thermostat

    COOLING SYSTEM 3.2 Installing thermostat 18.1 ± 1.5 N·m {1.85 ± 0.15 kgf·m} [13.4 ± 1.1 lbf·ft] Replace Crack, deterioration, damage Crack, water leakage, damage Installing thermostat 10-8 https://www.forkliftpdfmanuals.com/...
  • Page 465 INLET AND EXHAUST SYSTEMS 1. Removing turbocharger, inlet and exhaust systems ......11-2 1.1 Removing turbocharger ......11-2 1.2 Removing inlet manifold......11-3 1.3 Removing exhaust manifold....11-4 2. Disassembling, inspecting and reassembling inlet and exhaust systems ......11-5 2.1 Measuring exhaust manifold distortion .. 11-5 2.2 Disassembling and inspecting turbocharger...........

  • Page 466: Removing Turbocharger, Inlet And Exhaust Systems

    INLET AND EXHAUST SYSTEMS 1. Removing turbocharger, inlet and exhaust systems 1.1 Removing turbocharger Replace Replace Replace Removing turbocharger Removing sequence 1 Oil pipe 2 Oil pipe 3 Air hose 4 Turbocharger 11-2 https://www.forkliftpdfmanuals.com/...

  • Page 467: Removing Inlet Manifold

    INLET AND EXHAUST SYSTEMS 1.2 Removing inlet manifold Replace Replace Removing inlet manifold Removing sequence 1 Air inlet elbow 2 Inlet manifold 11-3 https://www.forkliftpdfmanuals.com/...

  • Page 468: Removing Exhaust Manifold

    INLET AND EXHAUST SYSTEMS 1.3 Removing exhaust manifold Replace Removing exhaust manifold Removing sequence 1 Exhaust manifold 11-4 https://www.forkliftpdfmanuals.com/...

  • Page 469: Disassembling, Inspecting And Reassembling Inlet And Exhaust Systems

    INLET AND EXHAUST SYSTEMS 2. Disassembling, inspecting and reassembling inlet and exhaust systems 2.1 Measuring exhaust manifold distortion (1) Check the flange for crack. (2) Check the flange surface for distortion. If the distortion Straight edge exceeds the standard, retouch the surface or replace it. Item Standard 0.2 mm...

  • Page 470: Disassembling And Inspecting Turbocharger

    INLET AND EXHAUST SYSTEMS 2.2 Disassembling and inspecting turbocharger Contact between turbine wheels and housing, cracks or distortion Vane distortion or damage Contact between compressor wheels and cover Distortion of flange on turbine side Replace Disassembling and inspecting turbocharger Disassembling sequence 1 Coupling assembly 4 Compressor cover 2 Turbine housing...

  • Page 471: Removing Turbine Housing

    INLET AND EXHAUST SYSTEMS 2.2.1 Removing turbine housing Loosen the coupling assembly as shown, and separate the Compressor cover turbine housing. Note: The positional relationship between the turbine Cartridge assembly housing and the cartridge assembly is very important. Therefore before disassembling, mark Coupling...

  • Page 472: Installing Compressor Cover

    INLET AND EXHAUST SYSTEMS 2.2.4 Installing compressor cover Install the compressor cover, paying attention to its orientation. Compressor cover Installing compressor cover 2.2.5 Installing snap ring CAUTION (a) Be sure to install the snap ring in the correct direc- tion. (b) Lightly drive both ends of the snap ring using a Ring pliers screwdriver and a hammer to insert the ring se-...

  • Page 473: Cleaning

    INLET AND EXHAUST SYSTEMS 2.3 Cleaning CAUTION Combined use with an ultrasonic cleaning unit can (a) When using a commercial neutral detergent, be help to remove contaminants easily. sure to use non-corrosive type. (b) Be careful not to damage components. When cleaning the compressor cover and the turbine housing, observe the followings: (1) Visually check the parts condition before cleaning to...

  • Page 474: Reassembling Turbocharger

    INLET AND EXHAUST SYSTEMS 2.3.2 Reassembling turbocharger 8.3 ± 0.5 N·m {0.85 ± 0.05 kgf·m} [6.1 ± 0.4 lbf·ft] Replace Reassembling turbocharger CAUTION (a) Change the following parts at reassembling · O-ring (b) Replace the compressor cartridge assembly if its vanes are distorted or cracked.
  • Page 475 INLET AND EXHAUST SYSTEMS 2.3.3 Installing turbine housing Install the turbine housing to the cartridge assembly by aligning the marks put during disassembly. Turbine housing Cartridge assembly Installing turbine housing 2.3.4 Installing coupling assembly Apply Molykote grease or equivalent to threads of the coupling assembly nut, and tighten the nut to the specified torque.

  • Page 476: Installing Turbocharger, Inlet And Exhaust Systems

    INLET AND EXHAUST SYSTEMS 3. Installing turbocharger, inlet and exhaust systems 3.1 Installing exhaust manifold Replace 18.1 ± 3.4 N·m {1.85 ± 0.35 kgf·ft} [13.4 ± 2.5 lbf·ft] Installing exhaust manifold 11-12 https://www.forkliftpdfmanuals.com/...

  • Page 477: Installing Inlet Manifold

    INLET AND EXHAUST SYSTEMS 3.2 Installing inlet manifold Replace Replace Installing inlet manifold 11-13 https://www.forkliftpdfmanuals.com/...

  • Page 478: Installing Turbocharger

    INLET AND EXHAUST SYSTEMS 3.3 Installing turbocharger 16.2 ± 2.5 N·m {1.65 ± 0.25 kgf·m} [11.9 ± 1.8 lbf·ft] Replace Replace 4 ± 0.5 N·m {0.41 ± 0.05 kgf·m} [3.0 ± 0.37 lbf·ft] Replace 4 ± 0.5 N·m {0.41 ± 0.05 kgf·m} [3.0 ±...
  • Page 479 ELECTRICAL SYSTEM 1. Removing electrical system ..12-2 2.6 Inspecting and repairing alternator..12-20 1.1 Removing starter........12-2 2.6.1 Inspecting stator ........12-20 1.2 Inspection before removing alternator ... 12-3 2.6.2 Inspecting rectifier ......... 12-20 1.2.1 Inspecting alternator operation....12-3 2.6.3 Measuring field coil........ 12-21 1.2.2 Handling precaution .........12-3 2.7 Reassembling alternator ......

  • Page 480: Removing Electrical System

    ELECTRICAL SYSTEM 1. Removing electrical system 1.1 Removing starter Removing starter Removing sequence 1 Starter 12-2 https://www.forkliftpdfmanuals.com/...

  • Page 481: Inspection Before Removing Alternator

    ELECTRICAL SYSTEM 1.2 Inspection before removing alternator 1.2.1 Inspecting alternator operation Locate the cause of faulty charging from malfunctions described below. Do not remove the alternator for inspection and repair unless inspection cannot be performed with the alternator installed on the engine. Adjusted value of voltage regulator is high.

  • Page 482: Removing Alternator

    ELECTRICAL SYSTEM 1.3 Removing alternator S6S-Y3T61HF Removing alternator Removing sequence 1 Alternator 2 Adjusting plate 3 Bracket 12-4 https://www.forkliftpdfmanuals.com/...
  • Page 483 ELECTRICAL SYSTEM S6S-Y3T62HF Removing alternator Removing sequence 1 Alternator 2 Adjusting plate 3 Bracket 12-5 https://www.forkliftpdfmanuals.com/...

  • Page 484: Removing Glow Plug

    ELECTRICAL SYSTEM 1.4 Removing glow plug Removing glow plug Removing sequence 1 Connection plate 2 Glow plug 12-6 https://www.forkliftpdfmanuals.com/...

  • Page 485: Disassembling, Inspecting And Reassembling Electrical System

    ELECTRICAL SYSTEM 2. Disassembling, inspecting and reassembling electrical system 2.1 Inspection before disassembling starter 2.1.1 Inspecting magnetic switch Perform the inspection as described below. If faulty, replace the magnetic switch with a new one. Switch CAUTION Do not apply current continuously for longer than 10 seconds.

  • Page 486: No Load Test

    ELECTRICAL SYSTEM 2.1.2 No load test Switch CAUTION Use as thick a wire as possible and firmly tighten each Ammeter terminal. When detecting the rotation at the tip of the pinion, be careful, as the pinion pops out during operation. Battery (1) Connect the starter to the circuit as shown in the Volt meter...

  • Page 487: Disassembling And Inspecting Starter

    ELECTRICAL SYSTEM 2.2 Disassembling and inspecting starter Open circuit, short Abnormal noise, rotation Abnormal noise, rotation Damage, wear, open circuit, short, ground Replace Wear, damage Wear, damage Wear, damage Wear, damage Replace Replace Overrunning Replace clutch function Open circuit, short Wear Brush dust accumulation, local wear, rust,...

  • Page 488: Removing Pinion Set

    ELECTRICAL SYSTEM 2.2.1 Removing pinion set CAUTION The starter generates heat when current is being applied. Remove the pinion within 10 seconds. (1) Connect the starter to the circuit as shown in the Battery illustration. (2) Turn the switches SW1 and SW2 ON to move the Disconnect lead wire with pinion out and then turn the SW2 OFF to stop the terminal, which connected...

  • Page 489: Removing Magnetic Switch

    ELECTRICAL SYSTEM 2.2.2 Removing magnetic switch Disconnect the leads, and remove the magnetic switch. Magnet switch 2.2.3 Removing rear bracket Remove the through bolts and screws of the brush holder, and then remove the rear bracket. 2.2.4 Removing brush holder and brush assem- Rear bracket Apply a socket (of the same diameter as the commutator) to Brush holder...

  • Page 490: Inspecting And Repairing Starter

    ELECTRICAL SYSTEM 2.3 Inspecting and repairing starter 2.3.1 Inspecting brushes for wear Measure the length of the brushes. If the measured value is less than the limit, replace both the brush holder assembly and the brush assembly with new ones. Measure the length of the Item...

  • Page 491: Measuring Commutator Outside Diameter12-13

    ELECTRICAL SYSTEM 2.3.5 Measuring commutator outside diameter Measure the commutator outside diameter. If the measured value is less than the limit, replace the armature with a new one. Item Nominal Limit ø32 mm 31.4 mm Commutator outside diameter [1.26 in.] [1.236 in.] Measuring commutator outside diameter 2.3.6...

  • Page 492: Inspecting Field Coil

    ELECTRICAL SYSTEM (3) Check continuity between segments in various combinations. If poor or no continuity is found, replace the armature with a new one. Inspecting continuity between segment 2.3.8 Inspecting field coil (1) Check for no continuity between the end of the coil (brush) and the yoke.

  • Page 493: Inspecting Magnetic Switch

    ELECTRICAL SYSTEM 2.3.13 Inspecting magnetic switch Inspect the magnetic switch for following items. Replace Terminal B Terminal S the magnetic switch if it is defective. (1) Open circuit of coil Check continuity between terminal S and terminal M, also check continuity between terminal S and ground. if continuity does not exist, the coil has an open circuit.

  • Page 494: Reassembling Starter

    ELECTRICAL SYSTEM 2.4 Reassembling starter 10.8 ± 1 N·m {1.1 ± 0.1 kgf·m} [8 ± 0.7 lbf·ft] Apply grease Apply grease Apply grease Reassembling starter 2.4.1 Installing gear shaft (1) Install the lever to the overrunning clutch. Planetary gear (2) Fit the internal gear into the gear shaft. (3) Put the gear shaft into the overrunning clutch.

  • Page 495: Disassembling And Inspecting Alternator12-17

    ELECTRICAL SYSTEM 2.5 Disassembling and inspecting alternator Rotation Rotation Crack, damage Crack, damage Short or open circuit Coil open circuit, ground Disassembling and inspecting alternator Disassembling sequence 1 Pulley (with fan) 4 Coil 7 Regulator assembly 2 Front bracket assembly 5 Stator coil 8 Rectifier assembly 3 Rotor assembly...

  • Page 496: Removing Field Coil

    ELECTRICAL SYSTEM 2.5.2 Removing field coil CAUTION When removing the field coil, be sure to observe the removal order of screws. Screw Otherwise, the outlet lines of the field coil will be dam- aged. If all the screws are removed, the coil will fall with its own weight.

  • Page 497: Removing Front Bearing

    ELECTRICAL SYSTEM 2.5.5 Removing front bearing Remove the screw, and then remove the bearing retainer and Front bracket front bearing from the front bracket. Front bearing Removing front bearing 2.5.6 Removing stator CAUTION Stator Lead wire Unsoldering must be finished as quickly as possible. Rectifier Extended heating will damage the diodes.

  • Page 498: Inspecting And Repairing Alternator

    ELECTRICAL SYSTEM 2.6 Inspecting and repairing alternator 2.6.1 Inspecting stator (1) Checking continuity between lead wires. Check continuity between a pair of lead wires. Also check for no continuity between a pair of lead wires and other pairs of lead wires. If defective, replace the stator.

  • Page 499: Measuring Field Coil

    ELECTRICAL SYSTEM 2.6.3 Measuring field coil Measure resistance between the terminals of the field coil. Field coil If the measured value deviates from the standard value, replace the field coil with a new one. Measuring field coil 12-21 https://www.forkliftpdfmanuals.com/...

  • Page 500: Reassembling Alternator

    ELECTRICAL SYSTEM 2.7 Reassembling alternator 147 ± 15 N·m {15 ± 1.5 kgf·m} [108.4 ± 11.1 lbf·ft] Reassembling alternator 2.7.1 Installing rectifier assembly and regulator assembly Rear bracket Install the rectifier assembly and regulator assembly on the rear bracket. Rectifier Regulator assembly Installing rectifier assembly and regulator assembly 12-22...

  • Page 501: Installing Stator

    ELECTRICAL SYSTEM 2.7.2 Installing stator CAUTION Stator Lead wire Soldering must be finished as quickly as possible. Rectifier Extended heating will damage the diodes. Install the stator and solder the leads of the stator to the rectifier. Installing stator 2.7.3 Installing front bearing Drive the front bearing into the front bracket and secure the Front bracket...

  • Page 502: Assembling Stator And Front Bracket

    ELECTRICAL SYSTEM 2.7.6 Assembling stator and front bracket Assemble the front bracket, stator and rear bracket, and Stator Front bracket secure them with through bolts. Rear bracket Installing stator and front bracket 2.8 Inspecting glow plug 2.8.1 Continuity test of glow plug As shown in the illustration, check the continuity between the terminal and body.

  • Page 503: Inspecting Magnetic Valve (Stop Solenoid)

    ELECTRICAL SYSTEM 2.9 Inspecting magnetic valve (stop solenoid) 2.9.1 Continuity test of magnetic valve (stop solenoid) Inspect the continuity between the terminal and body as shown in the illustration. If there is no continuity or if the resistance is lower than the standard value, replace the magnetic valve assembly with new one.

  • Page 504: Installing Electrical System

    ELECTRICAL SYSTEM 3. Installing electrical system 3.1 Installing glow plug 1.25 ± 0.25 N·m {0.13 ± 0.03 kgf·m} [0.94 ± 0.2 lbf·ft] 17.5 ± 2.5 N·m {1.75 ± 0.25 kgf·m} [12.7 ± 1.81 lbf·ft] Installing glow plug 12-26 https://www.forkliftpdfmanuals.com/...

  • Page 505: Installing Alternator

    ELECTRICAL SYSTEM 3.2 Installing alternator S6S-Y3T61HF Installing alternator 12-27 https://www.forkliftpdfmanuals.com/...
  • Page 506 ELECTRICAL SYSTEM S6S-Y3T62HF Installing alternator 12-28 https://www.forkliftpdfmanuals.com/...

  • Page 507: Installing Starter

    ELECTRICAL SYSTEM 3.3 Installing starter Installing starter 12-29 https://www.forkliftpdfmanuals.com/...
  • Page 508 https://www.forkliftpdfmanuals.com/...
  • Page 509 ADJUSTMENT AND OPERATION 1. Adjusting engine......13-2 1.1 Inspecting and adjusting valve clearance13-2 1.1.1 Inspecting valve clearance .......13-2 1.1.2 Adjusting valve clearance ......13-2 1.2 Draining fuel system ......13-3 1.2.1 Draining fuel filter ........13-3 1.3 Bleeding fuel system......13-3 1.3.1 Bleeding fuel filter........13-3 1.4 Inspecting and adjusting fuel injection timing .............

  • Page 510: Adjusting Engine

    ADJUSTMENT AND OPERATION 1. Adjusting engine 1.1 Inspecting and adjusting valve clearance Inspect and adjust the valve clearance when the engine is cold. Item Standard Inlet Valve clearance 0.25 mm [0.0098 in.] (when engine is cold) Exhaust 1.1.1 Inspecting valve clearance (1) Inspect the valve clearance for all cylinders in the firing order by turning the crankshaft to the specified degrees in the normal direction (clockwise when viewed from...

  • Page 511: Draining Fuel System

    ADJUSTMENT AND OPERATION 1.2 Draining fuel system WARNING (a) When draining the fuel filter, fuel flows out with the water. Wipe up any spilled fuel thoroughly. Spilled fuel could cause a fire. (b) Tighten the drain plug securely after draining water otherwise fuel may leak out, and it could lead to a fire.

  • Page 512: Inspecting And Adjusting Fuel Injection Timing

    ADJUSTMENT AND OPERATION 1.4 Inspecting and adjusting fuel injection timing 1.4.1 Adjusting fuel injection timing When the fuel injection pump is replaced, adjust the fuel injection timing after the replacement. To adjust it, bring No. 1 cylinder piston to top dead center on compression stroke.
  • Page 513 ADJUSTMENT AND OPERATION (4) Put a mark B on the flange plate where aligned with the mark A of the fuel injection pump. Alignment mark of fuel injection pump CAUTION Flange plate When removing the flange plate from the fuel injection Fuel injection Front pump...
  • Page 514 ADJUSTMENT AND OPERATION (8) Install the flange plate and the fuel injection pump gear to the fuel injection pump. (9) Align the mark A of the fuel injection pump with the mark B which was marked above procedure (4) and tighten the nut.

  • Page 515: Inspecting V-Belt And Adjusting V-Belt Tension

    ADJUSTMENT AND OPERATION 1.5 Inspecting V-belt and adjusting V-belt tension CAUTION (a) If defects such as cuts or surface separations are found during inspection, replace the V-belt. (b) Keep oil and grease away from the V-belt, since they may cause the V-belt to slip and shorten the service life. (c) Excessive V-belt tension can cause rapid wear of the alternator bearing and shorten the service life of the V- belt.

  • Page 516: Break-In Operation

    ADJUSTMENT AND OPERATION 2. Break-in operation 2.3 Break-in operation time After the engine is overhauled, install the engine to the dynamometer, and run the engine for break-in operation and The relationship between the load in break-in operation and inspection. the operation time is as shown below. 2.1 Starting up Break-in operation time (1) Before starting the engine, check the levels of coolant,...

  • Page 517: Performance Test (Jis Standard)

    ADJUSTMENT AND OPERATION 3. Performance test (JIS standard) The following describes the procedures specified in "Earth moving machinery - Engines - Part 1: Test code of net power (JIS D0006-1)" and "Earth moving machinery - Engines - Part 2: Standard format of specifications and testing methods of diesel engines (JIS D0006-2)."...

  • Page 518: Calculation Of Corrected Power

    ADJUSTMENT AND OPERATION 3.4.2 Calculation of corrected power Multiply the measured brake power or torque by the calculated diesel engine correction factor to obtain a corrected value. If the applicable range of the correction formula is exceeded, indicate the corrected values and record the test conditions on the test record.

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