Hyundai HDF 35III Operation Manual
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Hyundai HDF 35III Operation Manual

Hyundai HDF 35III Operation Manual

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CONTENTS
1-1
1-5
1-13
2-1
2-2
3-1
3-16
3-20
3-22
4-1
4-9
4-12
5-1
5-11
5-13
6-1
6-16
6-20
7-1
7-2
7-11
7-12
7-14

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Summary of Contents for Hyundai HDF 35III

  • 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 INSTALLATION 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 3-16 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.
  • 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 D35AOM54 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 Operator's seat Lift bracket 12 Bonnet...
  • Page 17 2. SPECIFICATIONS D35ASP01 Model Unit HDF 35III HDF 45III Capacity 3500 4500 ← Load center Weight(Unloaded) 5746 6631 ← Lifting height 3000 ← Free lift Lifting speed(Unload/Load) mm/sec 575/520 495/440 Fork Lowering speed(Unload/Load) mm/sec 400/500 305/380 L×W×T L,W,T 1070×127×50 1220×150×50 ←...
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE ITEM SPECIFICATION UNIT Model HYUNDAI D4DA-C1 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 Direct injection mm(in) Cylinder bore X stroke 104×115(4.1×4.5)
  • Page 19 POWER TRAIN DEVICES Item Specification Model ZF W280 Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.39 : 1 Type Full-automatic power shift Gear shift(FR/RR) 1/1, 2/1 Adjustment Electrical single lever type, kick-down system 18.571 : 1 Transmission 18.994 : 1 Overhaul...
  • 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 6.9±1.4 50±10 M10×1.5 MCV mounting bolt, nut 12.8±3.0 93±22 M12×1.75 Hydraulic Steering unit mounting bolt 5.0±1.0 36±7.2 M10×1.5 system Priority valve mounting bolt 2.5±0.5 18.1±3.6 M 8×1.25...
  • 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 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 0.85 ~ 1.25 M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7...
  • 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 (2.2) 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 Installation Of Unit

    SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Major components Group 2 Removal and installation of unit...
  • Page 26 SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 MAJOR COMPONENTS D353RE01 Lift cylinder Steering cylinder Mast Muffler Fork assy Radiator Tilt cylinder Counterweight Front wheel Air cleaner Drive axle Overhead guard Transmission Operator's seat Torque converter Control valve Engine Steering wheel Rear wheel Hydraulic pump...
  • Page 27 GROUP 2 REMOVAL AND INSTALLATION 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 D353RE02 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 under the machine, then slowly raise. ※ This operation is carried out from under the machine, so use a pit, or if there is no pit, jack up the machine and loosen with an impact wrench.
  • 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) Tift 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. D353RE28 Remove the bolts, clevis pin and self Inching cable locking pin. T/M control valve Bolt D353RE05 Control valve piping Remove the hose because it is in the way when pulling the power train assembly out to the front.
  • Page 32 Hydraulic piping Remove the pipe for the hydraulic pump installed on the transmission 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 cap. ・26.8~32.0kgf・m(194~231lbf・ft) Drive axle cap D353RE09 Tightening torque of mounting bolt for transmission and drive axle. ・7.29kgf・m(52.7lbf・ft) D353RE25 Tightening torque of mounting bolt for...
  • 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, 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 removal, but be careful of the following points. Tighten the engine mounting bolts and nuts. Tighten the engine mounting bracket bolts. ※ Do not remove the bolts unless necessary. Loctite is coated on the thread of bolt. So if the bolts must be removed, coat the loctite(#243) when installing.
  • 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 Spring balance assemble the brake and drum assembly.
  • Page 39 6. REAR AXLE REMOVAL Counter Rear wheel Mounting Hose weight (Left side) bolt D353RE19 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 D353RE23 2-16...

  • Page 42: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation Group 2 Troubleshooting 3-16 Group 3 Test and adjustments 3-20 Group 4 Disassembly and assembly 3-22...

  • 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 two-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. D353PT26 Brake drum Hydraulic gear pump...
  • Page 44 2. INSTALLATION VIEW Forward 1st Reverse 1st Forward 2nd D353PT05 Control valve Thermostat switch Suction filter Air breather Dipstick...
  • 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. D353PT27 ・3-element, 1-stage, 2-phase Turbine shaft ・Size : 279.4mm(11in) Stator ・Stall speed : 2075rpm Impeller ・Maximum input pressure : 7kgf/cm Housing...
  • Page 46 TORQFLOW TRANSMISSION D353PT01 Torque converter Transmission case Differential Gear pump Hydraulic clutch(1st) Hydraulic clutch(2nd) Torque converter gear Forward shaft Drive gear Idler gear Forward gear Stator hub Gear pump drive Forward gear Torque converter housing Hypoid gear set...
  • Page 47 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 48 TRANSMISSION OPERATING MODES Forward 1st D353PT02 In forward 1st the torque converter is turned by the engine. The torque converter turbine shaft turns the 1st forward/reverse clutch pack shaft(1) and clutch packs at turbine speed. The piston in the forward 1st 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 49 Forward 2nd D353PT03 In forward 2nd the torque converter is turned by the engine. The torque converter turbine shaft turns the 1st forward/reverse clutch pack shaft(1) and clutch packs. The gear(2) welded between the clutch packs turns with the shaft. This gear engages the gear(3) welded to the 2nd forward clutch pack(4), turning the clutch pack.
  • Page 50 Reverse D353PT04 In reverse the torque converter is turned by the engine. The torque converter turbine shaft turns the 1st 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 Body Cap plug Spring Piston Piston Dust seal O-ring O-ring Inching spool Piston Spring Washer Snap ring Spring Spool Spring Gasket Spring Piston Cover Spring Orifice Hexagon bolt Stopper Steel ball Spring washer Spring Piston Spring...
  • Page 52 HYDRAULIC CIRCUIT (2-SPEED) D353PT11 OPERATION The control valve mainly consists of the regulator valve, cold relief valve, pressure detecting valve, inching valve and electro valve. The discharged oil from the gear pump enters regulator valve of the control valve and its pressure is adjusted 12~15kg/cm (171~213psi).
  • Page 53 5. HYDRAULIC CLUTCH STRUCTURE Reverse and forward 1st D353PT12 Piston ring Thrust washer Bushing Piston ring Gear Shaft Drive plate Taper roller bearing Washer Friction plate Seal ring Washer Back plate Piston Washer Washer Gear Drum Spring Seal ring Snap ring Snap ring Ball plug 3-11...
  • Page 54 Forward 2nd D353PT13 Piston ring Spring Seal ring Piston ring Snap ring Piston Drive plate Spring Input shaft Friction plate Gear Ball plug Back plate Washer Piston ring Snap ring Washer Bushing Washer Taper roller bearing Drum 3-12...
  • Page 55 CLUTCH PACKS The clutch packs have a driving side and a driven side for each gear selection, a total of three(2 forward, 1 reverse). One clutch pack assembly has two selections on the same shaft, forward 1st and reverse, and the clutches are back to back with a spur gear in the middle. The other has only one selection on the shaft, forward 2nd, with a spur gear welded to it.
  • Page 56 OPERATION D353PT24 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. The pressurized piston compresses the drive plates and the friction plates, causing them to rotate together.
  • Page 57 6. DRIVE AXLE STRUCTURE D353PT25 Housing assy Washer Drive axle shaft-RH Housing Hub assy Drive axle shaft-LH Sleeve Lock nut Spacer Oil seal Washer Air breather Taper roller bearing Bolt Plug Taper roller bearing Spring washer Plug Bolt Washer Wheel brake assy-RH Hexagen nut Oil seal Wheel brake assy-LH...

  • Page 58: 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 tra- nsmission, check and replace interfe- ring parts.
  • Page 59 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 repla- ce packing.
  • Page 60 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 fr- eezing point (when normal oil pressure is recover-...
  • Page 61 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 62: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS 1. INCHING PEDAL Stopper bolt Depress inching pedal fully, and move gear shift lever to FORWARD or REVERSE. Check that machine does not move even when engine speed is increased slightly. Adjust stopper bolt so that pedal height is 143~153mm (5.6~6.0in).
  • Page 63 Move direction control lever to FORWARD or REVERSES, and run engine at maximum speed. Check that maximum engine speed is within specified range. ※ ※ This check raises the temperature of the oil in the torque converter, so do not run this test for a long period. Stall speed HYUNDAI D4DA-C1 1980 3-21...

  • Page 64: Group 4 Disassembly And Assembly

    GROUP 4 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY Torque converter ① Remove the torque converter assembly from the torque converter housing. ② Loosen the bolts to repair flexible plate. D353PT29 Differential and caps ① Remove the locking cotter pins. ② Remove the differential cap bolts and caps.
  • Page 65 Pump drive D353PT32 ① Remove the transmission pump from the torque converter housing. ② Remove the bolts holding the pump drive gears in the bulkhead plate. ③ Remove the pump drive gear and bearings by tapping them out from the torque converter side. ④...
  • Page 66 Bulk head D353PT33 ① Remove the pinion shaft cap and gasket from the bulkhead plate. ② Using a hammer and punch, bend back the locking tabs on the washer located between the two bearing nut on the pinion shaft. ③ Remove the bearing nut, washer, and the retaining bearing nut from the pinion shaft.
  • Page 67 Shaft assembly D353PT34 ① The pinion shaft and output gear are now supported by the pinion holding tool on the pinion gear. ② Bend back the locking tabs on the washer and remove the nut, washer, and the output gear. ※...
  • Page 68 ASSEMBLY ※ ※ Before beginning assembly of the transmission, be sure all parts are clean. Replace all O-ring, oil rings, and seals when putting transmission back together. Hypoid pinion assembly ① Install pinion shaft seal, shims, bearing, and the pinion shaft and gear. ※...
  • Page 69 Bulk head D353PT38 ① Slide the spacer back onto the pinion shaft. ② Slide the output gear back onto the pinion shaft. It may be necessary to lift the clutch packs and forward shaft slightly to slide output gear into position. ③...
  • Page 70 Pump drive D353PT39 Seal caps ① Install seal ring caps on transmission case. ② Measure clearance between caps and case without shims with thickness gauge. ③ Select shim thickness over 0.2~0.4mm from the above measurement. ④ Insert shims and confirm that the shaft could be turned by hand without locking.
  • Page 71 Differential and hypoid gear ① Using a sling and hoist, install the differential assembly, including bearings, in the carrier. ② Set gear backlash between 0.2~0.3mm. ③ Tighten screw nut of bearing as 2.7~3.4kgf・m. ④ Tighten cap bolt as 35~40kgf・m. ⑤ Recheck backlash of 0.2~0.3mm.
  • Page 72 2. CONTROL VALVE STRUCTURE D353PT09 Body Washer Stopper Plug Snap ring Spring Spring Spring Spring Piston Spool Piston Spring Orifice Piston Gasket Ball Dust seal Cover O-ring Hexagon bolt Block O-ring Spring washer O-ring Piston Solenoid valve Inching spool Spring Hexagon bolt Piston Spring...
  • Page 73 TOOLS ・ Socket : 13 & 38mm ・ Torque wrench ・ Hexagon wrench : 4 & 5mm ・ Loctite(242) ・ Hammer ・ Snap-ring plyer CLEANING AND PREPARING COMPONENT Cleaning Wash body with high pressure washer(3 step) and then clean it with TCE(Tri Chioro Ethylene). Blow body with pressurized air.
  • Page 74 DISASSEMBLY D353PT41 A. Body ① ① Inching spool part ・ Pull out piston(6) and release cap(5) with 38mm socket. ・ Tilt the body(1) and slide inching spool(11) down by itself. ・ Confirm spring output. ② ② Cover ・ Release 4 bolts(20, M8) with 13mm socket. ③...
  • Page 75 ASSEMBLY D353PT41 A. Body ① Install PT 1/8 plug(2) with 5mm wrench after injecting loctite 242 on the plug. ② Put the pins(10, 32) into the pin hole and then adjust location. ③ Press the ball(31) into the orifice side hole, and hammer it so that the ball can be inserted over 2/3 of hole depth.
  • Page 76 D353PT41 D. Total installstion Spool ① Insert piston(23), 2 springs(24, 25) and stopper(26) orderly into the biggest hole(Ø33). ② Insert piston and 2 springs(27, 28) orderly into the second biggest hole(Ø18). ③ Insert spool(17), and spring(18) into Ø15 hole. ④ Lastly insert piston(4) and spring(3) into Ø14 hole.
  • Page 77 3. CLUTCH PACK STRUCTURE D353PT21 Piston ring Thrust washer Bushing Piston ring Gear Input shaft Drive plate Taper roller bearing Washer Friction plate Seal ring Washer Back plate Piston Washer Washer Gear Drum Spring Seal ring Snap ring Snap ring Ball plug Taper roller bearing DISASSEMBLY...
  • Page 78 D353PT21 Remove the snap ring(8) on the clutch pack shaft and lift out the piston return spring(7) and two washers(20, 21). Slide the clutch piston(13) up out of the drum(22). Inspect all parts for wear or distortion. Replace the large piston ring(2) on the clutch piston. (10) Replace the small piston ring(1) on the clutch pack shaft where the piston rides.
  • Page 79 4. DRIVE AXLE STRUCTURE D353PT10 Housing & sleeve Socket bolt Lock washer Air breather Hardened washer Bolt Square plug Hub assembly Spring washer Plug Drive axle shaft-RH Cone washer Wheel brake assembly-RH Drive axle shaft-LH Oil seal Wheel brake assembly-LH Lock nut Socket plug DRIVE AXLE SHAFT...
  • Page 80 WHEEL HUB ASSEMBLY Disassembly ① Bend taps back on lock washer securing lock nut on end of axle housing tube. ② Remove lock nut(12) and lock washer(13). ③ Lock hub assembly(9) slightly to unseat outer bearing. Support weight of hub and slide bearing off of axle housing tube.

  • Page 81: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM Group 1 Structure and function Group 2 Operational checks and troubleshooting Group 3 Test and adjustment 4-12...

  • Page 82: 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 83 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 84 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 85 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. D353BS10 Back plate-LH/RH Spring washer Return spring...
  • Page 86 6. HYDRO MASTER BRAKES NOT APPLIED (STATIC MODE) D353BS08 ① Brake fluid from master cylinder is not under pressure since pedal is not applied. This fluid is supplied to the hydraulic cylinder, then to the relay valve. ② Vacuum is applied to the vacuum side of the relay valve. ③...
  • Page 87 BRAKE APPLIED (DYNAMIC MODE) D353BS11 ⑨ When the brakes are applied, foot pressure from the brake pedal is transformed to hydraulic pressure by the master cylinder (not shown). This hydraulic pressure is applied, at the Hydro master, to the hydraulic cylinder and to the relay valve. ⑩...
  • Page 88 RETURN TO STATIC When the pedal is released, the relay valve closes off ambient side (atmospheric pressure) and re opens vacuum side. This applies vacuum to chamber A and the return spring moves the piston back (to the left) as the pressures on both sides of the piston equalize. At the same time the master cylinder pressure against the hydraulic cylinder piston is relieved, and the brakes are released.
  • Page 89 INSPECTION Clean and check these components. ※ Use isopropyl alcohol or brake fluid for washing the components. Do not use gasoline, kerosene or any other mineral oils. When using alcohol, do not leave rubber parts in the liquid for more than 30 seconds.

  • Page 90: 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 91 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 92 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 93: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS 1. ADJUSTMENT OF WHEEL BRAKE Adjust with engine stopped. Jack up truck. Extend adjustment screw by Adjustment wheel 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 94 3. ADJUSTMENT OF PEDAL Stopper bolt BRAKE PEDAL Pedal height from floor plate Adjust with stopper bolt. ・Pedal height : 143~153mm(5.7~6.0in) Play Adjust with rod of master cylinder 143~153mm ・Play : 10mm(0.4in) Micro switch for parking brake (if equipped) D353BS05 ①...

  • Page 95: Section 5 Steering System

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

  • Page 96: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Hydraulic gear pump Priority valve Steering unit Steering cylinder Steering wheel Trail axle D353SE00 The steering system for this machine is composed of steering wheel assembly(5), steering unit(3), steering cylinder(4), trail axle(6) and pipings. The steering force given to the steering wheel enters the steering unit through the steering column.
  • Page 97 2. HYDRAULIC CIRCUIT D353SE01 Hydraulic gear pump Steering cylinder Priority valve Suction filter Steering unit Hydraulic tank...
  • Page 98 NEUTRAL D353SE02 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 priority valve(2) and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(12). So, the pump flow is routed to the main control valve through the EF port.
  • Page 99 LEFT TURN D353SE03 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 100 RIGHT TURN D353SE04 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 101 3. STEERING UNIT STRUCTURE D353SE32 Dust seal O-ring seal Housing Check valve Retaining ring Rolled screw Spool 25-1 Guide Cap seal Gerotor set Sleeve 25-2 Shim Thrust bearing Bearing race Relief valve 25-3 Spring Ball Bore screw 24-1 Plug 25-4 Washer Drive shaft 24-2 O-ring Suction valve...
  • Page 102 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 103 4. PRIORITY VALVE STRUCTURE D353SE06 Body Spring End plug Spool O-ring O-ring Spring pulg Orifice End plug 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. The steering flow is controlled by the steering unit to operate the steering cylinder.
  • Page 104 5. TRAIL AXLE STRUCTURE D353SE22 Trail axle Taper roller bearing Split pin Knuckle-RH Slot nut Steering cylinder assy Knuckle-LH Serration bolt Lock plate Needle bearing Hub nut Hexagon bolt Shim(0.2t) Full thread bolt Bushing Special bolt Hexagon nut Support Spring washer Link-RH Shim(1.0t) Plug...
  • Page 105 TIGHTENING TORQUE AND SPECIFICATION Center pin support Type Unit single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of degree 79.2 / 57.4 wheels(Inside/Outside) Tread mm(in) 1,120(44) D353SE08 5-10...

  • Page 106: 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 35III 2500mm HDF 45III 2535mm Hydraulic pressure of power Remove plug from outlet port of flow divider and install oil pressure gauge.
  • Page 107 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 108: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE D353SE05 Dust seal O-ring Plate Retaining ring O-ring seal Cap screw Cap seal Rolled screw Housing Thrust bearing Gerotor set Spool Ball Bearing race Sleeve Bore screw Relief valve Spacer Drive shaft Check valve Center spring End cap...
  • Page 109 TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-14...
  • Page 110 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 111 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 112 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball and suction valve pins and balls. D353SE09 5-17...
  • Page 113 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 114 (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 (14) Screw out the plug using an 8mm hexagon socket spanner.
  • Page 115 (15) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (16) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (17) The pressure relief valve is now disassem- bled. D353SE13 5-20...
  • Page 116 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 117 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 118 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 119 (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 120 (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 121 (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 122 (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 123 (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 124 (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 125 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. ※ Do not use a hammer! 5-85(2) 5-30...
  • Page 126 2. PRIORITY VALVE STRUCTURE D353SE07 Body Spring End plug Spool O-ring O-ring Spring plug Orifice End plug Orifice 5-31...
  • Page 127 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 128 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. ※...
  • Page 129 Install the O-ring(6) onto plug(3, 4) and install the plug(3, 4) into the body(1). ・Tighten torque : 4.5kfg・m(32.5lbf・ft) D353SE20 5-34...
  • Page 130 3. STEERING CYLINDER STRUCTURE 14 12 10 11 D353SE21 Tube assy Back up ring Piston seal Bushing Wear ring Gland O-ring Ring Dust wiper Piston Retaining ring Rod seal O-ring ※ Specifications ・Inner diameter : 75mm ・Outer diameter : 86mm ・Stroke : 115mm ・Rod outer diameter : 50mm...
  • 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 hook 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. Set a special tool the cylinder, gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland assembly, and tighten it with torque 40±4kgf・m (289±29lbf・ft).
  • Page 133 4. TRAIL AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. D353SE22 Trail axle Taper roller bearing Split pin Knuckle-RH Slot nut Steering cylinder assy Knuckle-LH King pin Serration bolt Lock plate Needle bearing Hub nut Hexagon bolt Shim(0.2t) Full thread bolt Bushing...
  • Page 134 CHECK AND INSPECTION D353SE35 mm(in) Criteria Remedy Check item Standard size Repair limit Diameter of king pin 35(1.38) 34.8(1.370) Replace Vertical play of knuckle 0.2(0.008) Adjust with shims Diameter of center pin 55(2.12) 54.5(2.1) Replace Damage, wear Rear axle, hub, knuckle, bearing Replace Seizure, abnormal noise, defective rotation 5-39...
  • 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 (7) and washer (8). Remove plug (9). (10) Push out the king pin (4) without damaging the knuckle arm (3). (11) Pull out the thrust bearing (11). If defect is observed in needle bearing (5), 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 6-16 Group 3 Disassembly and assembly 6-20...

  • Page 138: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT D353HS01 Hydraulic gear pump Tilt cylinder Priority valve Suction filter Main control valve Return filter Steering unit Down control valve Steering cylinder Down safety valve Lift cylinder Hydraulic tank...
  • Page 139 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION D353HS02 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(6) by pushing the load check valve of the spool.
  • Page 140 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION D353HS03 When the lift control lever 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 141 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION D353HS05 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large chamber of tilt cylinder(7) by pushing the load check valve of the spool.
  • Page 142 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION D353HS04 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the small chamber of tilt cylinder(7) by pushing the load check valve of the spool.
  • Page 143 2. HYDRAULIC GEAR PUMP STRUCTURE D353HS06 Bolt Seal Drive gear Spring washer Bushing Flange End cover Bushing Shaft seal O-ring Body Circlip Back up seal Driven gear 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) 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 D353HS07 Special nut Screw Spool housing O-ring Wiper Spool housing Plug O-ring Spool housing O-ring Spring seat Outlet housing O-ring Spring Puppet...
  • Page 145 LIFT SECTION OPERATION Lift position Load check valve(1) SECTION A-A 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).
  • Page 146 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 147 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).
  • Page 148 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 149 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.
  • Page 150 The loss of oil behind puppet C, effected by the opening of pilot puppet E, causes puppet C to move back and seat against pilot puppet E. This shuts off the oil flow to the area behind relief valve puppet D, and causes a low pressure area internally.
  • Page 151 4. LIFT CYLINDER 8 14 13 D353HS12 Tube assy Retaining ring Guide Gland Bushing Piston Dust wiper O-ring Piston seal Rod seal Spacer Back up ring O-ring O-ring Wear ring 5. TILT CYLINDER D353HS13 Tube assy Gland Rod eye Bushing Dust wiper Spherical bearing Bushing...
  • Page 152 6. FREE LIFT CYLINDER D353HS23 Tube assembly Wear ring Retaining ring Rod assembly Set screw O-ring Piston Gland Back up ring Check valve U-Packing Steel ball Retaining ring Back up ring Set screw Piston seal Dust wiper 6-15...

  • Page 153: 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 154 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 155 HYDRAULIC GEAR PUMP Problem Cause Remedy ・System relief valve set too low or ・Check system relief valve for proper Pump does not develop full pressure. leaking. setting. ・Oil viscosity too low. ・Change to proper viscosity oil. ・Pump is worn out. ・Repair or replace pump.
  • Page 156 LIFT CYLINDER Problem Cause Remedy ・Foreign matters on packing. ・Replace packing. Oil leaks out from gland ・Unallowable score on rod. ・Smooth rod surface with an oil stone. through rod. ・Unusual distortion of dust seal. ・Replace dust seal. ・Chrome plating is striped. ・Replace rod.

  • Page 157: 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 158 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 159 (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 160 (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 161 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 162 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 163 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 164 (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 housing...
  • Page 165 (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 166 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 167 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 168 3. LIFT CYLINDER STRUCTURE ・ I.D ×O.D×Stroke (standard) 3.5 ton : 65×73×1335 mm (2.6×2.9×52.6 in) 4.5 ton : 70×82×1335 mm (2.8×3.2×52.6 in) ・ Rod O.D : 50mm (2 in) D353HS14 Tube assy Retaining ring Guide Gland Bushing Piston Dust wiper O-ring Piston seal Rod seal...
  • Page 169 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 170 4. TILT CYLINDER STRUCTURE ・ I.D ×O.D×Stroke : 90×102×188 mm (3.5×4.0×7.4 in) ・ Rod O.D : 45mm (1.8 in) D353HS15 Tube assy 10 Gland 18 Eye Bushing Dust wiper 19 Spherical bearing 12 Bushing 20 Retaining ring Piston 13 Rod seal 21 Hexagon bolt O-ring 14 Back up ring...
  • Page 171 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 172: Section 7 Electrical System

    SECTION 7 ELECTRICAL SYSTEM Group 1 Component location Group 2 Electrical circuit Group 3 Component specification 7-11 Group 4 Connector destination 7-12 Group 5 Troubleshooting 7-14...

  • Page 173: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION D353EL00 Flasher lamp Start switch Head lamp Regulator Fuse box Master switch Gear selector Back horn Combination switch Start relay Horn button Fuel level sender Battery Rear work lamp Work light, Hazard switch License lamp Operating panel Combination lamp...

  • Page 174: Group 2 Electrical Circuit

    SECTION 7 ELECTRICAL SYSTEM GROUP 2 ELECTRICAL CIRCUIT FRONT HEAD OPERATING PANEL HEAD FRONT LAMP COMBI RH LAMP COMBI LH 9 10 11 12 CD-29 DETECTOR PARKING T/M OIL TEMP REGULATOR SWITCH (NC) CD-10 AIR CLEARNER SW CD-8 R/COMBI RH WATER TMEP SENSOR CL-15 (OPTION)
  • Page 175 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+)] Glow relay[CR-24] Start relay[CR-23(3)] Alternator[CN-74(B+)] Fusible link[CN-60] [CN-3]...
  • Page 176 POWER CIRCUIT D353EL02...
  • Page 177 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-60] Start switch[CS-2(3)] Start relay[CR-23(3)] ※ ※ The engine can be started only when the gearshift is in neutral position. When start key switch is in ON position Fuse box[No.5 →11] Start switch ON [CS-2(4)] Engine stop relay[CR-47(2)] Engine stop relay[CR-47(4) →...
  • Page 178 STARTING CIRCUIT D353EL03...
  • Page 179 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 180 CHARGING CIRCUIT D353EL04...
  • Page 181 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-60] I/conn[CS-2(3)] Start switch(B) Start relay[CR-24] ※ When you turn the start switch to the HEAT position, the glow relay makes the glow plugs operated and the glow lamp of the cluster turned ON.
  • Page 182 PREHEATING CIRCUIT D353EL05 7-10...

  • Page 183: Group 3 Component Specification

    GROUP 3 COMPONENT SPECIFICATION Specification Remark Part name Battery 12V×68AH Reserve capacity : 110min -18° C Cold cranking ampere : 600A Charge acceptance : 21A Life cycle : 4400Cycle 5HR Capacity : 54AH Working lamp 24V, 45W 24V, 3W×2 License lamp Combination lamp 24V, 25/10W (Stop/Tail) 24V, 21W...

  • Page 184: Group 4 Connector Destination

    GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 S814-114001 I/conn(Dashboard harness-frame harness) S814-014001 CN-2 S814-112001 I/conn(Dashboard harness-frame harness) S814-012001 CN-3 MG650943-5 I/conn(Dashboard harness-frame harness) MG640944-5 CN-4 S814-104001 Support harness CN-5 S814-104001 Support harness CN-25 MOLEX Horn...
  • Page 185 Connector part No. Connector No. of Type Destination number Female Male CD-8 Water temperature sensor S819-040222 CD-10 Air cleaner switch 730057-2 CD-18 Engine oil pressure switch S819-010122 CD-29 T/M temperature switch S819-010122 7-13...

  • Page 186: Group 5 Troubleshooting

    GROUP 5 TROUBLESHOOTING Trouble symptom Probable cause Remedy ・Faulty wiring. ・Check for loose terminal and discon- Lamps dimming even at maxi- mum engine speed. nected wire. ・Improper belt tension. ・Adjust belt tension. Lamps flicker during engine operation. ・Charge lamp defective. ・Replace.
  • Page 187 SECTION 8 MAST Group 1 Structure Group 2 Operational checks and troubleshooting Group 3 Adjustment Group 4 Removal and installation 8-10...
  • Page 188 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) D353MS01 Outer mast Bushing Chain sheave Shim(0.5, 1.0t) Inner mast Roller Roller Lift chain Back up liner Tilt cylinder pin Anchor bolt Shim(0.5, 1.0t)
  • Page 189 2. 3 STAGE MAST(TF MAST) D353MS02 Outer mast Chain Shim(0.5, 1.0t) Bushing Sheave bracket Roller Middle mast Inner mast Back up liner Sheave Shim(0.5, 1.0t) Tilt cylinder pin Anchor bolt...
  • Page 190 3. CARRIAGE, BACKREST AND FORK HDF35-3 D353MS03 Carriage Side roller Backrest Fork assy Load roller Extension fork...
  • Page 191 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 S173896-02 HDF35III 50(2.0) 48(1.9) F173936-01 HDF45III...
  • Page 192 2. TROUBLESHOOTING MAST Problem cause Remedy ・Deformed mast or carriage. ・Disassemble, repair or replace. Forks fail to lower. ・Faulty hydraulic equipment. ・See troubleshooting hydraulic pump Fork fails to elevate and cylinders in section 6, hydraulic system. ・Deformed mast assembly. ・Disassemble mast and replace damag-ed parts or replace complete mast assembly.
  • Page 193 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 194 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 195 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 196 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 197 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 at time toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 198 SIDE ROLLER Remove carriage as outlined in the carriage assembly removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. ※...
  • Page 199 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) ① Remove the carriage assembly and move them to one side. ② Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast. ③ Loosen and remove hexagon bolts and nuts securing lift cylinders to inner mast.
  • Page 200 3 stage mast(TF mast) ① Remove the carriage assembly and move to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. ③ Loosen and remove bolts and special washers securing lift cylinders to middle mast. ④...
  • Page 201 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 202 CHAIN Chain sheave(V mast) ① Place a sling around carriage and attach 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 203 Sheave support(TF mast) ① Remove the carriage assembly and move to one side. ② 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.
  • Page 204 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 205 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 206 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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Hdf 45iii

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