Page 1: Table Of Contents
CONTENTS SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications Group 3 Periodic Replacement 1-13 SECTION 2 REMOVAL AND INSTALL OF UNIT Group 1 Major Components Group 2 Removal and Installation of Unit SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Operation Group 2 Troubleshooting 3-15 Group 3 Tests and Adjustments...
Page 2 SECTION 8 MAST Group 1 Structure Group 2 Operational Checks and Troubleshooting Group 3 Adjustment Group 4 Removal and Installation 8-10...
Page 3 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
Page 4 Revised edition mark(①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
Page 7 Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246...
Page 8 kgf・m to lbf・ft 1kgf・m = 7.233lbf・ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 11: Section 1 General
SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications Group 3 Periodic Replacement 1-13...
Page 12: Group 1 Safety Hints
GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. ・・ Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
Page 13 Be particularly careful when removing the radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using the machine, there is a danger that boiled oil may spurt out. ・ The procedure for releasing the hydraulic pressure is as follows : lower the fork to the ground, and stop the engine(Motor), move the control levers to each position two or three times.
Page 14 ・ Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. D35ASF09 ・ When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
Page 15 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 it.
Page 16: Group 2 Specifications
GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS D153OM01 Mast Fork 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 Operator's seat Carriage 12 Bonnet...
Page 17 2. SPECIFICATIONS C' C D153SP01 Model Unit HDF 15III HDF 18III Capacity 1500 1750 ← Load center Weight(Unloaded) 2800 2980 ← Lifting height 3300 ← Free lift ← Lifting speed(Unload/Load) mm/sec 520/480 Fork ← Lowering speed(Unload/Load) mm/sec 340/500 ← L×W×T L,W,T 920×100×35...
Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item Specification Unit Model ISUZU 4LE1PW-06 Type 4 cycle turbocharged diesel type Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, In-line Firing order 1-3-4-2 Combustion chamber type In-direct injection mm(in) Cylinder bore X stroke 85×96(3.35×3.78) Piston displacement cc(cu in)
Page 19 POWER TRAIN DEVICES Item Specification Model OKAMURA MD14 Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.8 : 1 Type Full-automatic power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick-down system 13.720 : 1 Overhaul ratio 14.090 : 1 Type Front-wheel drive type, fixed location...
Page 20 4. TIGHTENING TORQUE OF MAJOR COMPONENTS Items Size kgf・m lbf・ft Engine mounting bolt, nut M16×2.0 Engine Radiator mounting bolt, nut M 8×1.25 2.5±0.5 18.1±3.6 MCV mounting bolt, nut 7.45±1.5 54±10.8 M10×1.25 Hydraulic Steering unit mounting bolt M10×1.5 6.9±1.4 50±10 system Torque converter mounting bolt M 8×1.25 4.17...
Page 21 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT Coarse thread Bolt size kgf・m lbf・ft kgf・m lbf・ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7 M10×1.5...
Page 22 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 23 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature ° C (° F) Service Kind of Capacityℓ(U.S.gal) point fluid (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil Engine oil (2.1) SAE 10W-30...
Page 24: Group 3 Periodic Replacement
GROUP 3 PERIODIC REPLACEMENT For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degrees of wear at time of periodic maintenance;...
Page 25: Section 2 Removal And Install Of Unit
SECTION 2 REMOVAL AND INSTALL OF UNIT Group 1 Major Components Group 2 Removal and Install of Unit...
Page 26: Group 1 Major Components
SECTION 2 REMOVAL & INSTALL OF UNIT GROUP 1 MAJOR COMPONENTS D153RE01 Lift cylinder Torque converter 15 Counterweight Mast Engine 16 Air cleaner Fork assy 10 Rear wheel 17 Overhead guard Tilt cylinder Steering axle(rear axle) 18 Operator's seat Front wheel 12 Steering cylinder 19 Control valve Drive axle...
Page 27 GROUP 2 REMOVAL AND INSTALL OF UNIT Remove and install the following units as explained in the flow chart. 1. MAST REMOVAL Tilt cylinder Mast support Mast Support Tilt Cylinder Forks Forks Piping Piping Forks Fork D153RE02 Piping Raise the fork carriage to make it easy to remove the piping.
Page 28 Tilt cylinder pin Mast support cap Attach a crane to the stay at the top of the outer mast, and raise. Remove the mounting bolts of the cap from the mast, then slowly raise the mast. Tilt cylinder pin ※ 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...
Page 29 INSTALLATION Mast support cap Check the mast support bushing for wear, then tighten the cap mounting bolts. ・Tighten torgue : 19.9 ~ 27.0 kgf・m (144 ~ 195 lbf・ft) Tilt cylinder pin Hold the mast with a crane, operate the tilt control lever and align the holes, then knock in the pin. 2.
Page 30 3. TORQUE CONVERTER + TRANSMISSION + FRONT AXLE(POWER TRAIN ASSEMBLY) Leave the engine inside the frame, move the power train assembly as a unit to the front and remove. REMOVAL D353RE24 Mast See section on mast.(Page 2-2) Torque shaft Pull out about 200mm(7.9in) to make the front wheel free.
Page 31 Brake piping Disconnect the brake piping from the wheel cylinder end. Drive axle D153RE28 Remove the bolts, clevis pin and self T/M control valve locking pin. Inching Control valve piping valve spool Remove the hose because it is in the way when pulling the power train assembly out to the front.
Page 32 Hydraulic piping Hydraulic pump Mounting bolt Remove the pipe for the hydraulic pump installed on the engine side PTO. If the hose hangs down, a large amount of hydraulic oil will come out, so install a blind plug. Pump drive shaft Remove 2 mounting bolts for pump drive shaft tightened to the transmission.
Page 33 INSTALLATION Installation is in the reverse order to removal, but be careful of the following points. Tightening torque of mounting bolt for drive axle plate. ・26.8~32.0kgf・m(194~231lbf・ft) D153RE09 Tightening torque of mounting bolt for Mounting bolt transmission and engine. ・4.17kgf・m(30.2lbf・ft) Engine Spacer D153RE26...
Page 34 4. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL D35ARE22 Overhead guard Remove the wiring for the rear combination lamp on the rear stay of the overhead guard and air cleaner hose, Air cleaner hose then raise together with the bonnet.
Page 35 Flexible plate, mounting bolts installed to flywheel housing. For details, see page 2-6. Engine accessory Remove all wiring harnesses, cables and hoses between the engine and the dashboard and frame. ① Wiring harness to alternator and starter. ② Wiring harness for oil pressure and engine water temperature gauges.
Page 36 INSTALLATION Installation is in the reverse order to Loctite #243 removal, but be careful of the following points. 3.5~4kgf m (25.3~28.8lbf ft) Tighten the engine mounting bolts and Mounting bolt nuts. 7.5kgf m(54.2lbf ft) Tighten the engine mounting bracket bolts. ※...
Page 37 5. WHEEL BRAKE REMOVAL Brake piping Front wheel Brake, drum Parking brake Mounting assembly wire bolt Torque shaft Lock nut 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.
Page 38 When replacing the oil seal inside the hub, be careful to install the seal facing in the correct direction(Lip on outside) and knock into place. D353RE18 Wipe the inside of the brake drum clean, coat the lip of the seal with grease, and assemble the brake and drum assembly.
Page 39 6. REAR AXLE REMOVAL Counter Rear wheel Mounting Hose weight (Left side) bolt Mounting bolt D153RE19 Counterweight Install a lifting tool in the hole in the counterweight, and raise with a crane. Remove the mounting bolts, raise slightly and move to the rear. ・...
Page 40 Mounting bolt Put a block under the rear axle, support Truck on a truck, and raise the frame with a crane. Remove the mounting bolts installing to the frame, and pull out to the rear. There are shims between the support and rear axle to prevent play.
Page 41 7. OUTER PANELS D153RE23 2-16...
Page 42: Section 3 Power Train System
SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Operation Group 2 Troubleshooting 3-15 Group 3 Test and Adjustments 3-19 Group 4 Disassembly and Assembly 3-23...
Page 43: Group 1 Structure And Operation
SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN DIAGRAM The TORQFLOW transmission uses one-speed forward and one-speed reverse transmission. The torque converter, differential, and final drives are strengthened to match them with increased engine output and machine traveling performance. D153PT26 Brake drum Transmission...
Page 44 2. INSTALLATION VIEW D153PT05 Control valve Oil filter Temperature sender Dipstick Air breather...
Page 45 3. TRANSMISSION TORQUE CONVERTER The torque converter is directly bolted to the engine flywheel housing. Engine output is delivered from the flywheel to the flexible plate. ① Structure Ball bearing Output pressure adjusting valve spring Gear pump assembly Inlet relief valve spring Converter Input guide D153PT27...
Page 46 Hydraulic circuit Torque converter assy Torque converter Outlet port Inlet port To control valve Inlet pressure Outlet pressure detector port detector port Main relief valve To cooler Gear pump Drain Drain Strainer L15C3TC11...
Page 47 TORQFLOW TRANSMISSION SECTION A - A Hydraulic clutch Gear 2.744 2.818 ratio Center line Gear forward of engine Hypoid pinion Clutch Hypoid pinion Gear forward Gear Center line of differential D153PT01 Torque converter Hydraulic clutch Hypoid gear set Pump Forward shaft 10 Differential Torque converter housing Forward gear...
Page 48 OPERATION The torque converter consists of three elements; an impeller wheel connected to the input side and a turbine wheel and stator wheel connected to the output side. The torque converter is filled with oil. The engine rotates the impeller wheel and the impeller blade will give the fluid energy. Oil flows out along the path by centrifugal force, and this energy will give the turbine wheel torque.
Page 49 TRANSMISSION OPERATING MODES Forward INPUT OUTPUT D153PT02 In forward the torque converter is turned by the engine. The torque converter turbine shaft turns the forward/reverse clutch pack shaft(1) and clutch packs at turbine speed. The piston in the forward clutch pack(2) is pressurized by transmission fluid from the control valve. The piston applies pressure to the discs in the clutch pack, causing the clutch to engage.
Page 50 Reverse INPUT OUTPUT D153PT04 In reverse the torque converter is turned by the engine. The torque converter turbine shaft turns the forward/reverse clutch pack shaft(1) and clutch packs. The piston in the reverse clutch pack(2) is pressurized by transmission fluid from the control valve. The piston applies pressure to the discs in the reverse clutch pack, causing the clutch to engage.
Page 51 4. CONTROL VALVE STRUCTURE (From COOLER) (To COOLER) SECTION A-A D153PT28 Body 14 Spring 27 Snap ring Plug 15 Plug 28 Valve Piston 16 Piston 29 Spring Valve 17 Stopper 30 Stopper Stopper 18 Spring 31 Nut Valve 19 Spring 32 Screw Plate 20 O-ring...
Page 52 HYDRAULIC CIRCUIT Reverse clutch Forward clutch Control valve Directional Valve Accumulator valve Pedal Inching valve Main relief Engine valve 13.2 cc/rev 10.8~14.9 kgf/cm To torque converter D153PT11 OPERATION The control valve mainly consists of the main relief valve, inching valve, accumulator valve and directional valve.
Page 53 5. HYDRAULIC CLUTCH STRUCTURE(Reverse and forward 1st) Center line of Hydraulic clutch Center line of engine Clutch Hypoid pinion D153PT12 T/Plug 12 Spacer 23 Spring Seal ring 13 Ring 24 Washer Snap ring 14 Disc 25 Snap ring Spacer 15 Plate 26 Gear Spring 16 Piston...
Page 54 CLUTCH PACKS The clutch packs have a driving side and a driven side for each gear selection, a total of two(1 forward, 1 reverse). One clutch pack assembly has two selections on the same shaft, forward and reverse, and the clutches are back to back with a spur gear in the middle. The forward reverse clutch pack is driven by the turbine shaft of the torque converter.
Page 55 OPERATION Forward Reverse Reverse (From control valve) From T/M cooler Seal ling Forward (From control valve) D153PT24 When a gear is selected by the operator, the following happens. The clutch pack shaft is being driven by the torque converter. The spur gear and clutch pack body is attached to shaft and rotates with it. The clutch piston is pressurized by transmission fluid from the control valve.
Page 56 6. DRIVE AXLE STRUCTURE D153PT25 Housing 10 O-ring 18 Taper roller bearing Plug Support drive (L) 19 Plate 12 Hub 20 Nut Gasket 13 Washer 21 Bolt Plug 14 Bolt 22 Oil seal Support drive (R) 15 Retainer 23 Drive shaft Axle tube 16 O-ring 24 Washer...
Page 57: Group 2 Troubleshooting
GROUP 2 TROUBLESHOOTING Problem Probable cause Remedy 1. Excessive oil ・Improper oil level. ・Check oil level. Add or drain oil as temperature rise 1) Torque converter necessary. ・Impeller interfering with surroundings. ・After draining oil from oil tank and transmission, check and replace interfering parts.
Page 58 Problem Probable cause Remedy 3. Low output power ・Insufficient hydraulic pressure : 1) Torque converter - Low oil level. - Check oil level and add oil - Air sucked in. - Check joints and pipes. If necessary, retighten joint or replace packing.
Page 59 Problem Probable cause Remedy 4. Unusual oil pressure ・Control valve malfunctioning. 1) Oil pressure is high (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair. ・Cold weather. (high oil viscosity) ・When atmospheric temp is below freezing point(when normal oil pressure is recovered if heated to...
Page 60 Problem Probable cause Remedy ・Low oil level. ・Check oil level and add oil. 5. Power is not transmitted ・Inching valve and link lever improper- ・Check measure and adjust. 2) Transmission ly positioned. ・Forward/reverse spool and link lever ・Check and adjust. improperly positioned.
Page 61: Group 3 Tests And Adjustments
GROUP 3 TESTS AND ADJUSTMENTS 1. INCHING PEDAL Depress inching pedal fully, and move gear shift lever to FORWARD or REVERSE. 132~142mm Check that machine does not move even when engine speed is increased slightly. Adjust stopper bolt so that pedal height is 132~142mm (5.2~5.6in).
Page 62 2. HYDRAULIC PRESSURE Block wheels of truck, and pull parking lever. Install oil pressure gauge at inlet of control valve. Move direction control lever to FORWARD or REVERSE, depress accelerator pedal and run engine at 1500rpm. Measure clutch pressure and torque converter pressure and check that they are within specified range.
Page 63 ADJUSTMENT OF THE SIDE BEARING PRELOAD Tighten adjust screw gear(1) uniformly at 20kgf・m(145lbf・ft) L15C3DF03 ADJUSTING TOOTH CONTACT Coat the tooth face of the bevel pinion lightly with red lead(minimum). Rotate the bevel gear forward and backward. Inspect the pattern left on the teeth. ・...
Page 64 INCORRECT TOOTH CONTACT Heel Increase the shim thickness at the pinion shaft to move the pinion in direction A. Then move the bevel gear away from the pinion gear in direction B. Adjust the backlash again. L15C3TH03 Reduce the shim thickness at the pinion shaft to move the pinion in direction A.
Page 65: Group 4 Disassembly And Assembly
GROUP 4 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY Disassemble torque converter assembly Drain the transmission fluid and disconn- ect the torque converter assembly from the engine and the transmission. Disassemble input side of torque converter Remove the input plate bolts and the input plate, input guide, and O-rings.
Page 66 ② Ease the torque converter out of the housing so as not to damage the pump oil seal. L15C3TC04 Extract pump Remove the inner turbine shaft snap ring and all bolts holding the pump. Tool(s) required : 12mm socket wrench L15C3TC05 Extract turbine shaft ①...
Page 67 Extract valves ① Remove the two plugs. Tool(s) required : 24mm wrench. L15C3TC08 ② Remove the springs and pistons. Level the two sets-the springs especially- so that they do not get confused. Tool(s) required : 24mm wrench. L15C3TC09 Disassemble oil pump Remove the O-ring and philips screws and disassemble the pump.
Page 68 ASSEMBLY The assembly procedure is the reverse of the disassembly procedure above, but requires additional care as noted below. Assembly oil pump Return the gears and stator support to their positions before disassembly. Check the gear action. If the gears do not rotate smoothly, disassemble the pump and start over.
Page 69 TORQUE CONVERTER ASSEMBLY DRAWING L15C3TC12 L15C3TC13 3-27...
Page 70 CHECK AND INSPECTION Turbine Impeller Torque converter Stator Input plate Gear pump H, I Turbine shaft Housing Engine side Transmission side L15C3TC14 L15C3TC15 3-28...
Page 71 Unit : mm(in), kg(lb) Criteria Check item Remedy Standard size Repair limit Clearance between piston 0.015-0.025 0.065 Replace and housing hole (0.0006-0.001) (0.0025) piston Free 89.9 87.3 length (3.54) (3.43) Torque converter Installed inlet relief valve Torque length (2.48) (2.48) spring converter Installed...
Page 72 MAINTENANCE STANDARDS Hydraulic pressure Location Pressure (kgf/cm Cracking pressure (kgf/cm Torque converter input 3 ~ 7 Torque converter output 2 ~ 5.5 ※ Cracking pressure means the pressure at which the valve begins to open. Tightening torques Tightening torque in kgf・m(lbf・ft) Location Thread specifications...
Page 73 2. TRANSMISSION ※ Keep all parts in order as disassembly progresses. Take care to properly identify each part and its order of removal. If necessary, keep notes and put markings on parts using a non-destructive marker such as a felt-tipped pen. DISASSEMBLY Differential, torque converter, control valve ①...
Page 74 Pinion shaft ① Remove pinion shaft bolt(1). ② Fit a dolly block(copper rod) and tap the pinion shaft with a hammer to remove. L15C3TM03 Seal ring cap ① Remove bolt(2) and fit the bolt to the tapped hole. Remove the seal ring cap. ※...
Page 75 Disassembly of components of clutch pack assembly ※ The number shows the sequence of disassembly. L15C3CL01 Sealing 13 Spring 25 Snap ring Spring 14 Piston 26 Disc Spacer 15 Sealing 27 Plate Washer 16 Sealing 28 Ring Gear 17 Needle bearing 29 Ball Spacer 18 Shaft assembly...
Page 76 ASSEMBLY ※ Cleanliness is of extreme importance in the repair and overhaul of this assembly. Perform all disassembly work in a clean area. Overhaul the transaxle only in a clean, dust-free location, using clean tools and equipment. Dirt or grit will damage the highly-machined sufaces and result in premature failure of components.
Page 77 Idler shaft assembly ① Prefit gear(1) in the case. ② Fit bearing(2) on the idler shaft and install in the case. ③ Fix bearing(3) fix it with plate(4) and bolt (5). ・Tightening torque : 2.8 ~ 3.5kgf・m (20 ~25lbf・ft) L15C3TM09 Clutch pack assembly ①...
Page 78 TORQUEFLOW TRANSMISSION ASSEMBLY DRAWING Loctite #271 (screw hole side) Loctite #271(screw hole side) G2-L1(Lip portion) (Loctite #271 : Screw hole side) Match the stamps on the 18 ~ 20 kgf m (130 ~ 144lbf ft) inner and outer rings L15C3TM13 3-36...
Page 79 CHECK AND INSPECTION E2, H2 E1, H1 L15C3TM14 3-37...
Page 80 Unit : mm(in) Criteria Check item Remedy Standard size Repair limit 3.13-3.27 Thickness of drive plate (0.123-0.129) (0.114) Plate Replace 2.6(0.102) 2.90-3.05 Thickness of driven plate (Oil groove depth (0.114-0.120) Min0.2)(0.008) Clearance of abutment when 0.36-0.56 piston is inserted (0.014-0.002) Replace 0.15-0.35 Sealing...
Page 81 3. DIFFERENTIAL STRUCTURE TRANSMISSION Loctite #271 18~20 kgf m (130~144 lbf ft) 5~7.5 kgf m (36~54 lbf ft) Loctite #271(Hole side) (Run out : Max, 0.1 with dial guage reading) Adjust with item 12 9~16 kgf m (65~116 lbf ft) Loctite #271(Hole side) Starting torque : 35~43.5 kgf m (253~325 lbf ft)
Page 82 DIFFERENTIAL ASSEMBLY DRAWING Backlash : 0.18-0.23 mm (0.007-0.009 in) Runout is Max 0.1 5-7.5 kgf m (36-54.4 lbf ft) Loctite#271(screw portion) Starting torque 3.1-5.7 kgf m (22-41 lbf ft) Loctite#271(screw portion) 9-16 kgf m (65.3-116.0 lbf ft) Loctite#271(screw hole side) Loctite#271(screw hole side) 0.8-1.2 kgf m 15-17 kgf m...
Page 83 CHECK AND INSPECTION L15C3DF07 Unit : mm(in) Criteria Check item Remedy Standard size Repair limit Differential pinion gear and Scratches on the Replace (Replace bevel side gear teeth gear and pinion) 19.959-19.980 19.75 O.D of spider (0.785-0.787) (0.777) 20.0-20.021 20.1 I.D of differential pinion gear (0.787-0.788) (0.791)
Page 84 4. DRIVE AXLE DISASSEMBLY AND ASSEMBLY 15~21 kgf m (108~152 lbf ft) 6~8kgf m (43~58 lbf ft) Loctite #1215 All face of 0.6~1.5 kgf m (4.3~10.8 lbf ft) 6~8 kgf m (43~58 lbf ft) L15C3DA01 Housing 10 O-ring 19 Plate Plug Support drive(LH) 20 Nut...
Page 85 ASSEMBLY OF DRIVE AXLE 6.0-8.0 kgf m (43-58 lbf ft) Three Bond #1215 Loctite #271 (All face of flange) Starting torque 0.6-1.5 kgf m (4.3-10.8 lbf ft) 6.0-8.5 kgf m (43.2-61.2 lbf ft) Loctite #271 G2, L1 11.0-13.0 kgf m (79.2-93.6 lbf ft) G2,L1 Grease by 1/2-2/3 of space...
Page 86 INSTALLATION Perform installation in the reverse order to removal, paying attention to the following. Tightening torque converter case mounting bolt. ・Tightening torque : 6.0-7.5kgf・m (43-54lbf・ft) L15C3TIN01 Tightening flexible plate mounting bolt. ・Tightening torque : 2.8-3.5kgf・m (20-25lbf・ft) L15C3TIN02 Pedal assembly brake piping. ①...
Page 87: Section 4 Brake System
SECTION 4 BRAKE SYSTEM Group 1 Structure and Function Group 2 Operational Checks and Troubleshooting Group 3 Test and Adjustment...
Page 88: Group 1 Structure And Function
SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE There are two brake systems, the foot brake system and the hand brake system. In the foot brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
Page 89 3. BRAKE PEDAL AND PIPING The brake system provides two systems, a foot brake and a parking brake. In the foot brake system, the oil pressure which is generated in the master cylinder when the brake pedal is depressed is transmitted to the wheel cylinders. The piston of the wheel cylinder presses the brake shoes and then moves outward causing contact with the drums and braking force is obtained.
Page 90 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 are applied.
Page 91 5. WHEEL BRAKE STRUCTURE The wheel brake assembly mounts to the flange on the drive axle housing casting and is basically contained within the hub assembly. The inside of the hub is machined and acts as the brake drum. D153BS10 Back plate-LH/RH Shoe head pin 15 Shoe return spring...
Page 92 DISASSEMBLY AND ASSEMBLY DETAIL A Starting torque : 1.8 ~ 2.7 kgf m 13 ~ 19.5 lbf ft L15C3WB02 Check and inspection Unit : mm(in) Criteria Check item Remedy Standard size Repair limit Thickness of lining (0.17) (0.08) Free length 124 Deterioration of return spring (4.9) (5.36)
Page 93 6. BRAKE MASTER CYLINDER STRUCTURE D153BS09 Body Snap ring 13 Washer Piston Boot 14 Rod Secondary cup Spacer 15 Head Primary cup 10 Spring seat 16 Head pin Spring Union 17 Nut Plate 12 Union bolt 18 Cap DISASSEMBLY Remove the master cylinder boot(8) and remove the rod(14). Remove the snap ring(7) and take out the plate(6), the piston(2), the piston primary cup(4), and piston spring(5).
Page 94: Group 2 Operational Checks And Troubleshooting
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS BRAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. WHEEL BRAKE Compact wheel base chassis Measure lining at point with most wear, and check that lining thickness is at least 2.0mm(0.08in).
Page 95 2. TROUBLESHOOTING Problem cause Remedy ・Hydraulic system leaks oil. ・Repair and add oil. Insufficient braking force ・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. contact with drum.
Page 96 Problem cause Remedy ・Lining surface roughened. ・Repair by polishing or replace. Brake squeaks ・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 97: Group 3 Tests And Adjustments
GROUP 3 TESTS AND ADJUSTMENTS 1. ADJUSTMENT OF WHEEL BRAKE Adjust with engine stopped. Adjustment wheel Lever Jack up truck. Extend adjustment screw by clicking adjustment wheel teeth with a screwdriver until wheel(mounted on brake drum being adjusted) offers a light resistance when turned by hand.
Page 98 3. ADJUSTMENT OF PEDAL BRAKE PEDAL Pedal height from floor plate 132~142mm Adjust with stopper bolt. ・Pedal height : 132~142mm(5.2~5.6in) Play Adjust with rod of master cylinder ・Play : 10mm(0.4in) Micro switch for parking brake (if equipped) D153BS05 ① After assembling parking brake and parking cable, put the parking brake lever released.
Page 99 4. ADJUSTMENT OF WHEEL BRAKE Jack up truck, extend adjustment acrew by clicking adjustment wheel teeth with a screwdriver until wheel(mounted on brake drum being adjusted) offers a light resistance when turned by hand. Back Screw driver adjustment wheel by 25~30 teeth to shorten length of adjustment screw.
Page 100: Section 5 Steering System
SECTION 5 STEERING SYSTEM Group 1 Structure and Function Group 2 Operational Checks and Troubleshooting 5-10 Group 3 Disassembly and Assembly 5-12...
Page 101: Group 1 Structure And Function
SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Steering unit Steering cylinder Trail axle Hyd tank D153SE00 The steering system for this machine is composed of steering wheel assembly(1), steering unit(2), steering cylinder(3), trail axle(4) and pipings. The steering force given to the steering wheel enters the steering unit through the steering column.
Page 102 2. HYDRAULIC CIRCUIT MCV spool 8.5MPa 8MPa 15MPa D153SE01 Hydraulic gear pump Steering cylinder MCV (Priority valve) Suction filter Steering unit Hydraulic tank...
Page 103 NEUTRAL MCV spool 8.5MPa 8MPa 15MPa D153SE02 The steering wheel is not being operated so control spool(G) does not move. The oil from hydraulic gear pump(1) enters port P of MCV(Priority valve) and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(11).
Page 104 LEFT TURN MCV spool 8.5MPa 8MPa 15MPa D153SE03 When the steering wheel is turned to the left, the spool(G) within the steering unit(3) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit through the spool(D) of priority valve and flows to the gerotor(H).
Page 105 RIGHT TURN MCV spool 8.5MPa 8MPa 15MPa D153SE04 When the steering wheel is turned to the right, the spool(G) within the steering unit(3) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit through the spool(D) of priority valve and flows to the gerotor(H).
Page 106 3. STEERING UNIT STRUCTURE D153SE05 Dust seal Spacer 21 Relief valve assembly Housing assembly 12 O-ring 22 Spring Ball 13 Distributor plate 23 Shock valve, Complete Thread bushing 14 Gear wheel set 24 Ball O-ring 15 O-ring 25 Suction valve pin Bearing assembly 16 End cover 26 Screw...
Page 107 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 108 4. TRAIL AXLE STRUCTURE D153SE22 Steering axle 15 Needle bearing 29 Grease nipple Bolt 16 Oil seal 30 Grease nipple 17 Thrust cap bearing 32 Steering cylinder Knuckle-LH 18 Hub wheel 33 Lock plate Knuckle-RH 19 Hub bolt 34 Bolt Taper roller bearing 20 Hub nut 35 Trunnion block...
Page 109 TIGHTENING TORQUE AND SPECIFICATION Stroke 80 Apply loctite #277 29~32 kgf m (210~231 Greasing Fill 1/2 to 2/3 of the space in the hub with lithium grease Bearing end should be leveled with boss end Fix with split pin 6~9 kgf m (43~65 lbf SECTION A-A Center pin support...
Page 110: Group 2 Operational Checks And Troubleshooting
・ If minimum turning radius is not within±100mm (±4in)of specified value, adjust turning angle stopper bolt. Min turning radius(Outside) HDF 15III 1765mm HDF 18III 1765mm Hydraulic pressure of power Remove plug from outlet port of flow divider and install oil pressure gauge.
Page 111 Problem Cause Remedy ・Lockout loosening. ・Retighten. Steering wheel turns unstea- ・Metal spring deteriorated. ・Replace. dily. ・Gear backlash out of adjustment. ・Adjust. Steering system makes abn- ・Lockout loosening. ・Retighten. ormal sound or vibration. ・Air in oil circuit. ・Bleed air. Abnormal sound heard when Valve ・Faulty.
Page 112: Group 3 Disassembly And Assembly
GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE D153SE05 Dust seal Spacer 21 Relief valve assembly Housing assembly 12 O-ring 22 Spring Ball 13 Distributor plate 23 Shock valve, Complete Thread bushing 14 Gear wheel set 24 Ball O-ring 15 O-ring 25 Suction valve pin Bearing assembly...
Page 113 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) 5-13...
Page 114 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1kgf・m (0~54.4lbf・ft) 13mm socket spanner 6, 8mm and 12mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 5-70(2) TIGHTENING TORQUE L : Left port R : Right port T : Tank P : Pump...
Page 115 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 116 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 5-16...
Page 117 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 118 (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 119 (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 5-19...
Page 120 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 121 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 122 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) ※ ※ Assembly pattern for standard bearings 1 Outer bearing race 2 Thrust bearing 3 Inner bearing race 4 Spool 5 Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
Page 123 (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 124 (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 125 (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 126 (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 127 (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 128 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ・Tightening torque : 4.0 ±...
Page 129 (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) 5-29...
Page 130 2. STEERING CYLINDER STRUCTURE ※ Specifications ・Cylinder bore : 60mm ・Outer diameter : 72mm ・Stroke : 180mm ・Rod diameter : 40mm D503SE21 Tube assembly U-packing Slipper seal Rod assembly O-ring 10 O-ring Rod cover Du-bushing Ring Dust wiper Piston 12 Retaining ring 5-30...
Page 131 DISASSEMBLY ※ Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in a vice. Remove the gland by hooking a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube.
Page 132 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Fix the cylinder with a special tool and then install gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland assembly, and tighten it with torque 40±4kgf・m (289±29lbf・ft).
Page 133 3. TRAIL AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. D153SE22 Steering axle 15 Needle bearing 29 Grease nipple Bolt 16 Oil seal 30 Grease nipple 17 Thrust cap bearing 32 Steering cylinder Knuckle-LH 18 Hub wheel 33 Lock plate Knuckle-RH 19 Hub bolt...
Page 134 CHECK AND INSPECTION D153SE35 mm(in) Criteria Check item Remedy Standard size Repair limit Diameter of king pin 30(1.18) 29.8(1.17) Replace Vertical play of knuckle 0.2(0.008) Adjust with shims Diameter of center pin 50(1.96) 49.5(1.94) Replace Damage, wear Rear axle, hub, knuckle, bearing Replace Seizure, abnormal noise, defective rotation 5-34...
Page 135 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 136 Loosen special bolt(11) and spring washer(41). Pry out the retaining ring(13) and remove oil seal(16). Push out the king pin(12) without damaging the (10) knuckle(5). (11) Pull out the needle bearing(15). If defect is observed in needle bearing(15), pull it out by using extractor.
Page 137: Section 6 Hydraulic System
SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and Function Group 2 Operational Checks and Troubleshooting 6-19 Group 3 Disassembly and Assembly 6-23...
Page 138: Group 1 Structure And Function
SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 13MPa 8.5MPa 8MPa 15MPa D153HS01 Hydraulic gear pump Suction filter Main control valve Return filter Steering unit Down control valve Steering cylinder 10 Down safety valve Lift cylinder Hydraulic tank Tilt cylinder...
Page 139 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 13MPa Load check valve 8MPa 15MPa Steering system Return line D153HS02 When the lift control lever is pulled back, the spool on the first block moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of lift cylinder(5) by pushing the load check valve of the spool.
Page 140 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 13MPa Load check valve 8MPa 15MPa Steering system Return line D153HS03 When the lift control lever is pushed forward, the spool on the first block moves to lower position. The work port(1B) and the small chamber and the large chamber are connected to the return passage, so the lift will be lowered due to its own weight.
Page 141 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 13MPa Load check valve 8MPa 15MPa Steering system Return line D153HS05 When the tilt control lever is pushed forward, the spool on the second block moves to tilt forward position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of tilt cylinder(6) by pushing the load check valve of the spool.
Page 142 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 13MPa Load check valve 8MPa 15MPa Steering system Return line D353HS04 When the tilt control lever is pulled back, the spool on the second block moves to tilt backward position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the small chamber of tilt cylinder(6) by pushing the load check valve of the spool.
Page 143 2. HYDRAULIC GEAR PUMP STRUCTURE D153HS06 Gear plate Cover Oil seal Drive gear Pressure plate 10 Snap ring Driven gear Plate seal Flange head screw Mounting flange Back up ring OPERATION This pump comprised of an end cover, a body, bushings and a mounting flange bolted together with through bolts.
Page 144 3. MAIN CONTROL VALVE STRUCTURE (3 Spool) 11,13 15 7 23,29 25,28 21,30 Lift Tilt 3 Work ports SECTION A - A SECTION B - B D153HS07 Port name Size Inlet port 1-5/16-12UN Outlet port 1-5/16-12UN Gauge port PF1/4 Work port 1-1/16-12UN Special nut 15 Wiper...
Page 145 LIFT SECTION OPERATION Structure and description TO PS D153HS071 Connector assembly Oil passage Main relief valve Pilot passage PF port relief valve Damper EF passage(Main) Tank passage Orifice for control stand-by flow Chamber Orifice Damper orifice for 20 position Damper orifice for 2(spool)
Page 146 Operation ① Incase of not running the PF side circuit Part N Part M D153HS072 Position of spool and piston when PF port does not be operated when pump displacement is over the stand-by flow volume Q Oil flows from P(pump) port to PF side through passage H and orifice E. The pressure measured before orifice E is running through the passage I and acting on the head of spool 2, and the one measured after orifice E is running through the orifice G and acting on the tail of spool 2.
Page 147 ② When running PF side circuit D153HS073 Position of spool and piston when PF port operates when pump displacement is over the controlled flow Q For the pressure difference running type, K room flows to tank(T side). By the same reason, the piston 20 moves toward the direction of opened orifice E when the pressure of PF side reasoned to switching pressured P .
Page 148 LIFT SECTION OPERATION Lift position Load check valve(1) SECTION A-A D153HS08 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).
Page 149 Lower position D153HS09 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 150 TILT SECTION OPERATION Tilt forward position Load check valve(1) SECTION A-A Tilt lock spool Low pressure passage D153HS10 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).
Page 151 Tilt backward position Load check valve(1) SECTION A-A Low pressure passage 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 152 MAIN RELIEF VALVE Pressure setting A good pressure gage 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. Procedure ①...
Page 153 The loss of oil behind poppet C, effected by the opening of pilot poppet E. This shuts off the oil flow to the area behind relief valve poppet D, and causes a low pressure area internally. D153HS20 The imbalance of pressure on the inside as compared to that of the high pressure port HP, forces the relief valve poppet D to open and relieve the oil directly to the...
Page 154 4. LIFT CYLINDER D153HS12 Tube assy Wear ring O-ring Retaining ring 12 Stopper Piston Rod cover 13 Du bushing U-packing Dust wiper 14 Spacer Back up ring 10 U-packing 15 O-ring 5. TILT CYLINDER 18 17 20,21,22 16 12,13 14,15 D153HS13 Tube assy Rod cover...
Page 155 6. FREE LIFT CYLINDER 7,6 11,12,13 9,10 D153HS23 Tube assembly U-packing Steel ball Rod assembly Back up ring 12 Bleeder screw Ring Slyd ring 13 Set screw Gland nut O-ring Dust wiper 10 Back up ring 6-18...
Page 156: 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 2 minutes and measure hydraulic drift(amount forks move down and amount mast tilts forward).
Page 157 2. TROUBLESHOOTING SYSTEM Problem Cause Remedy ・Seal inside control valve defective. ・Replace spool or valve body. Large fork lowering speed. ・Oil leaks from joint or hose. ・Replace. ・Seal inside cylinder defective. ・Replace packing. ・Tilting backward : Check valve defec- ・Clean or replace. Large spontaneous tilt of mast.
Page 158 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 159 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 160: Group 3 Disassembly And Assembly
GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP ※ ※ Tools required ・Metric socket set ・Internal snap ring pliers ・Shaft seal sleeve ・Torque wrench : 13.8 kgf・m (100lbf・ft) It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
Page 161 Lift and remove end cover. PUMP 03 Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts. PUMP 04 (10) Remove rear bearing block from drive and idler shafts. PUMP 05 (11) Remove idler shaft from bearing block.
Page 162 (12) Remove drive shaft from mounting flange. There is no need to protect the shaft seal as it will be replaced as a new item. PUMP 07 (13) Remove the front bearing block. PUMP 08 (14) Turn mounting flange over, with shaft seal up, and remove the retaining ring with proper snap ring pliers.
Page 163 (17) Remove seals from both bearing blocks and discard. PUMP 11 INSPECT PARTS FOR WEAR Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be replaced as new items. Check drive shaft spline for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway.
Page 164 Inspect bearing blocks for excessive wear or scoring on the surfaces which are in contact with the gears. Also inspect the bearings for excessive wear or scoring. Inspect the area inside the gear housing. It is normal for the surface inside the gear housing to show a clean "wipe"...
Page 165 ASSEMBLY ※ New seals should be installed upon reassembly of pump. Install new shaft seal in mounting flange with part number side facing outboard. Press the seal into the seal bore until the seal reaches the bottom of the bore. Uniform pressure must be used to prevent misalignment or damage to the seal.
Page 166 Insert the drive end of the drive shaft through the bearing block with the seal side down, and the open side of the E- seal pointing to the intake side of the pump. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal.
Page 167 (13) Gently slide the gear housing over the rear bearing block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place with hands, do not force or use any tool. Check to make sure the intake port in the housing in on the same side as the open end of the E-seal and that the marked lines on the mounting flange and gear...
Page 168 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. ・Tighten torque : 11.1~11.8kgf・m (80~85lbf・ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
Page 169 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 puppet 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 170 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±lbf・ft Final torque one 3/4 nut to 74±8lbf・ft.
Page 171 3. LIFT CYLINDER STRUCTURE Down control valve Down safety valve ・ I.D×O.D×Stroke : 50×58×1185mm (2.0×2.3×46.6 in) ・ Rod O.D : 40mm (1.6 in) D153HS14 Tube assy Wear ring O-ring Rod assy Retaining ring 12 Stopper Piston Rod cover 13 Du bushing U-packing Dust wiper 14 Spacer...
Page 172 DISASSEMBLY Hold the cylinder tube in a vice, loosen the Guide Stopper 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.
Page 173 4. TILT CYLINDER STRUCTURE ・ I.D×O.D×Stroke : 70×82×114mm (2.7×3.2×4.5 in) ・ Rod O.D : 30mm (1.2 in) D153HS15 Tube assy Rod cover 16 O-ring Du bushing 10 Dust wiper 17 Eye Rod assy Du bushing 18 Bushing Piston 12 U-packing 19 Grease nipple O-ring 13 Back up ring...
Page 174 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 175: Section 7 Electrical System
SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location Group 2 Electrical Circuit Group 3 Component Specification 7-11...
Page 176: Group 1 Component Location
SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 14 15 16 17 18 19 20 D153EL00 Flasher lamp Master switch 15 Flasher relay Head lamp Battery 16 Operating panel Back horn 10 Start relay 17 Starter switch Combination switch Glow relay 18 Horn assembly Rear work lamp 12 Glow timer...
Page 177: Group 2 Electrical Circuit
SECTION 7 ELECTRICAL SYSTEM GROUP 2 ELECTRICAL CIRCUIT 2Wx2 FRONT FRONT OPERATING PANEL HEAD HEAD COMBI LH COMBI RH LAMP LAMP REVERSE SOL. FOWARD SOL. CD-18 10 11 12 E/OIL PS CL-16 CD-10 AIR CLEARNER SW CN-65 R/COMBI RH CL-15 BACK BZ CL-23 1800...
Page 178 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-60A] Alternator[CN-74(B+)] I/conn[CN-3(2)] Start switch OFF Fuse box[CN-36(10)]...
Page 179 POWER CIRCUIT CL-16 10 11 12 R/COMBI RH CN-1 CL-15 R/COMBI LH CN-3 2W 110 CN-74 CN60B CN60A ALTERNATOR FUSIBLE LINK CN-45 START MOTOR OPTION BATTERY CR-24 BRAKE SW GLOW RY MASTER SW B BR R1 R2 START KEY COMBI SWITCH GEAR SELECTOR HORN D153EL02...
Page 180 2. STARTING CIRCUIT OPERATING FLOW Battery(+) Start motor[CN-45(B+)] Fusible link[CN-60A] Altermator[CN-74(B+)] I/conn[CN-3(2)] Start switch[CS-2(B)] Fuse box[CN-36(10)] Horn[CN-25] Combi switch[CS-12(3)] ※ ※ The engine can be started only when the gearshift is in neutral position. When start key switch is in ON position Start switch ON [CS-2(Acc)] Fuse box[CN-36(7)] I/conn[CN-1(8)]...
Page 181 STARTING CIRCUIT 2Wx2 10 11 12 CN-1 ELE. FUEL PUMP CN-87 CN-3 2W 110 CN-74 CN60B CN60A FUSIBLE ALTERNATOR LINK CN-45 START MOTOR OPTION BATTERY CR-24 CR-23 GLOW RY START RY CN-40 MASTER SW B BR R1 R2 HORN START KEY GEAR SELECTOR COMBI SWITCH D153EL03...
Page 182 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 183 CHARGING CIRCUIT OPERATING PANEL 10 11 12 CN-2 W 505 CN-3 CN-74 CN60A ALTERNATOR CN-45 START MOTOR OPTION B BR R1 R2 CR-5 START KEY BATTERY MASTER SW D153EL04...
Page 184 4. PREHEATING CIRCUIT Combustion chamber glow plugs are used in order to give satisfactory starting of low ambient temperatures. OPERATING FLOW Battery(+) Start motor[CN-45(B+)] Fusible link[CN-60A] Alternator[CN-74(B+)] [CN-3(2)] Start switch[CS-2(B)] Fuse box[CN-36(10)] Fusible link[CN-60B] 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 185 PREHEATING CIRCUIT OPERATING PANEL 10 11 12 CN-1 CN-80 GLOW PLUG CN-3 CN-74 CN60B CN60A ALTERNATOR FUSIBLE LINK CN-45 START MOTOR OPTION BATTERY CR-24 GLOW RY (12V) CN-40 MASTER SW B BR R1 R2 START KEY D153EL05 7-10...
Page 186: Group 3 Component Specification
GROUP 3 COMPONENT SPECIFICATION Specification Remark Part name Battery 12V×75AH Reserve capacity : 130min -18° C Cold cranking ampere : 630A Charge acceptance : 10A Life cycle : 5200Cycle 5HR Capacity : 58AH Working lamp 12V, 55W License lamp 12V, 3.4W×12 Combination lamp 12V, 21W(T/S) 12V, 10W(Back)
Page 187 Connector part No. Connector No. of Type Destination number Female Male CN-1 MG610346 I/conn(Dashboard harness-frame harness) MG640348 CN-2 MG610339 I/conn(Dashboard harness-frame harness) MG640341 CN-3 DAEDONG I/conn(Dashboard harness-frame harness) 312-2P-F 312-2P-M CN-4 Support harness S810-004201 CN-5 Support harness S810-004201 CN-17 MG610043 Option CN-19 MG610043...
Page 188 Connector part No. Connector No. of Type Destination number Female Male Sensor and pressure switch CD-2 Fuel level sensor 263020003 CD-4 Stop lamp switch ST730018-3 CD-8 Water temp sender ST730018-3 CD-10 Air cleaner sensor ST730057-2 CD-18 Engine oil pressure switch GP140080 CD-29 T/M Oil temp switch...
Page 189 SECTION 8 MAST Group 1 Structure Group 2 Operational Checks and Troubleshooting Group 3 Adjustment Group 4 Removal and Installation 8-10...
Page 190 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) LIFT CYLINDER D153MS01 Outer mast Bushing Roller Shim(0.5, 1.0t) Inner mast 12 Shim(0.5, 1.0t) Roller Lift chain 13 Shim(0.5, 1.0t) Tilt cylinder pin Anchor bolt 14 Back up liner 10 Chain sheave...
Page 191 2. 3 STAGE MAST(TF MAST) Free lift cylinder Lift cylinder D153MS02 Outer mast Chain Middle mast Bushing 12 Cylinder head Inner mast Roller 13 Shim(0.5, 1.0t) Shim(0.5, 1.0t) Chain sheave 14 Back up liner Shim(0.5, 1.0t) 10 Anchor bolt...
Page 192 3. CARRIAGE, BACKREST AND FORK D153MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...
Page 193 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. ℓ=1070mm(42.1in) EX : mm(in) STD Fork assy Applicable model Standard Limit Thickness F5B129820 HDF15/18 III 40(1.6) 37(1.5) D153TA20...
Page 194 2. TROUBLESHOOTING MAST Problem Cause Remedy ・Deformed mast or carriage. ・Disassemble, repair or replace. Forks fail to lower. Fork fails to elevate ・Faulty hydraulic equipment. ・See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. ・Deformed mast assembly. ・Disassemble mast and replace damaged parts or replace complete mast assembly.
Page 195 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 196 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V MAST) INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the roller side face and mast at the closest position on the opposite side to the...
Page 197 2. MAST LOAD ROLLER(TF MAST) INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast and the middle mast, and adjust the clearance between the roller side face and mast at the closest position on the D353MS06...
Page 198 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 199 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are Anchor pin approximately 25mm(1inch) from the floor. Release fork anchor pins and slide forks, one by one, toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
Page 200 SIDE ROLLER Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Side roller Reverse the above procedure to assembly. ※...
Page 201 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) ① Remove the carriage assembly and Chain move them to one side. Hexagon ② Loosen and remove hexagon bolts and bolt washers securing lift cylinders to inner mast. ③ Loosen and remove hexagon bolts and Backup nuts securing lift cylinders to inner mast.
Page 202 3 stage mast(TF mast) ① Remove the carriage assembly and move it to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. ③ Loosen and remove band and special Mast washers securing lift cylinders to middle load roller mast.
Page 203 ELEVATING MAST Inner mast (V mast) ① After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. ② Lift inner mast upright straight up and out of outer mast section. ③...
Page 204 CHAIN Chain Chain sheave(V mast) Outer mast Chain ① Place a sling around carriage and attach sheave to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
Page 205 Chain sheave support(TF mast) ① Remove the carriage assembly and move to one side. ② After removing bolt to securing chain sheave support assembly to free lift cylinder. After a sling to the chain sheave support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
Page 206 ② ② Rust and corrosion Chains used on lift trucks are highly stressed precision components. It is very important that the “as-manufactured” ultimate strength and fatigue strength be maintained throughout the chain service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or roller chain because corrosion causes side plate cracking.
Page 207 ⑧ ⑧ Chain wear scale The chain can be checked for wear or stretching with the use of a chain wear scale. Stretching of a chain is due to the elongation of the pitch holes and wearing of the pin O.D. The greatest amount of stretching occurs at the areas of the chain that flex over the sheaves most frequently.
Page 208 ③ ③ Adjustment Chain adjustments are important for the following reasons : ・Equal loading of chain. ・Proper sequencing of mast. ・Prevent over-stretching of chains. ・Prevent chains from jumping off sheaves if they are too loose. ④ ④ Adjustment procedure ・With mast in its fully collapsed and vertical position, lower the fork to the floor. ・Adjust the chain length by loosening or tightening nut on the chain anchor.

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Hyundai HDF 15III Operation Manual

Section 1 General

Section 2 Removal and Install of Unit

Section 3 Power Train System

Section 4 Brake System

Section 5 Steering System

Section 6 Hydraulic System

Section 7 Electrical System

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