Hyundai HDF 20-5 Operation Manual
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Hyundai HDF 20-5 Operation Manual

Hyundai HDF 20-5 Operation Manual

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CONTENTS
1-1
1-5
1-13
2-1
2-2
3-1
3-15
3-19
3-23
4-1
4-6
4-9
5-1
5-10
5-12
6-1
6-17
6-21
7-1
7-2
7-9
7-12

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Summary of Contents for Hyundai HDF 20-5

  • 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 Structure 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 8-11...
  • 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13...

  • Page 12: Group 1 Safety Hints

    GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. · Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
  • Page 13 Be particularly careful when removing the radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using the machine, there is a danger that boiled oil may spurt out. · The procedure for releasing the hydraulic pressure is as follows : lower the fork to the ground, and stop the engine(Motor), move the control levers to each position two or three times.
  • Page 14 · Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. 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 D255GE01 Mast Forks 12 Bonnet Lift chain Overhead guard 13 Counterweight Lift cylinder Turn signal lamp 14 Rear wheel Backrest 10 Head lamp 15 Front wheel Tilt cylinder 11 Operator's seat 16 Rear combination lamp Carriage...
  • Page 17 2. SPECIFICATIONS C' C D255SP01 Model Unit HDF 20-5 HDF 25-5 HDF 30-5 Capacity 2000 2500 3000 ← ← Load center Weight(Unloaded) 3440 3800 4300 Lifting height ← ← 3300 Free lift ← ← Lifting speed(Unload/Load) Fork 700/680 700/670 580/530...
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE ITEM SPECIFICATION UNIT Model YANMAR 4TNE98-HYF(IDI) Type 4-cycle, in-line overhead valve 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 98×110 Piston displacement cc(cu in)
  • Page 19 POWER TRAIN DEVICES Item Specification Type 3 Element, 1 stage, 2 phase Torque converter Stall ratio Type Power shift Gear shift(FR/RR) Adjustment Electrical single lever type, kick-down system Transmission 16.028 : 1 Overhaul ratio 18.317 : 1 Type Front-wheel drive type, fixed location Axle Gear Hypoid gear type...
  • 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 Torque converter mounting bolt 6.9±1.4 50±10 M10×1.5 Hydraulic MCV mounting bolt, nut 6.9±1.4 50±10 M10×1.5 system Steering unit mounting bolt 6.9±1.4 50±10 M10×1.5...
  • 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 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 4.0 ~ 6.0...
  • 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. 。 C (。 F) Capacityℓ(U.S.gal) Ambient temperature Service Kind of point fluid HDF20/25/30-5 (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil Engine oil (2.1)

  • 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 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...

  • Page 26: Group 1 Structure

    SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE D255RE01 Mast Transmission 17 Muffler Lift cylinder 10 Torque converter 18 Counterweight Carriage & backrest 11 Engine 19 Radiator Tilt cylinder 12 Air cleaner 20 Seat Main control valve 13 Steering cylinder 21 Overhead guard Fork 14 Hydraulic pump...

  • Page 27: Group 2 Removal And Installation Of Unit

    GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Forks Anchor pin ① Lower the fork carriage until the forks are Carriage approximately 25mm(1in) from the floor. ② Release fork anchor pins and slide one Backrest fork at a time toward the center of the...
  • Page 28 ② While supporting lift chains, remove the split pins and slide out chain anchor pins Outer mast from the chain anchors of stationary upright. Split Lift chain Chain anchor D255RE05 ③ Pull the chains out of the sheaves and Mast drape them over the front of the carriage.
  • Page 29 PIPING ① Remove the return hoses and clamps attached to the cylinder. ② Remove the return hoses from the Band connector. clamp Hose ③ clamp Remove hose assembly, connector, Return down safety valve from the lift cylinder. hose ④ Disconnect hose assembly from the flow regulator.
  • Page 30 INNER MAST ① Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. Inner mast Outer mast D255RE10 TILT CYLINDER PIN MAST SUPPORT CAP ①...
  • Page 31 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. ※ Installation procedure for each of mast component is the reverse of the removal procedure. MAST SUPPORT CAP ① Check the mast support cap and spring pin for wear. ②...
  • Page 32 2. POWER TRAIN ASSEMBLY REMOVAL B153RE00 Mast Refer to section on mast. Brake piping and T/M cooling piping Disconnect the brake pipes and T/M Brake master cooling pipes from powerline assembly. Brake cylinder pipe T/M cooling Powerline pipe assembly D255RE13 Parking brake cable Disconnect parking brake cable from the wheel brake assembly.
  • Page 33 Powerline assembly Crane ① Attach a crane to the filt cylinder notches Dashboard on the dashboard and raise the machine Powerline Mounting bolt assembly enough for truck to slide under powerline assembly. Frame ② Put the block between the truck and powerline assembly.
  • Page 34 3. ENGINE Lever the torque converter, transmission and drive axle inside the frame, the remove the engine assembly. REMOVAL Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and Crane flasher lamp on the stay of the overhead guard and then raise it together with the bonnet.
  • Page 35 Engine accessory Radiator Remove all wiring harnesses, cables and hoses between the engine and the dashboard and frame. Hose ① Wiring harness to alternator and starter. Engine ② Wiring harness for oil pressure and assembly engine water. Overflow hose Reservoir tank D255RE20 Radiator hose...
  • Page 36 INSTALLATION Installation is in the reverse order to Loctite #243 removal, but be careful of the following 5.5-8.3kgf m (40~60 lbf ft) points. Mounting bolt Tighten the engine mounting bolts and 7.5kgf m(54.2lbf ft) nuts. Tighten the engine mounting bracket bolts. Do not remove the bolts unless necessary.
  • Page 37 4. WHEEL BRAKE REMOVAL 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 loosen the hub nuts to remove wheels. Hub nut D255RE24 Brake, drum assembly The oil seal inside the hub acts as a seal...
  • Page 38 Wipe the inside of the brake drum clean, coat the lip of the seal with grease, and assemble the brake and drum assembly. Adjust a spring balance to the hub bolt Spring balance and adjust the nut to give a starting force of 12 to 20kgf(27~44lbf).
  • Page 39 5. REAR AXLE REMOVAL Mounting bolt Counterweight D255RE29 Counterweight Install a lifting tool in the hole in the counterweight, and raise it with a crane. Remove the mounting bolts and raise the counterweight slightly and move it to the rear side. ·...
  • Page 40 Rear wheels ※ Before removing rear wheels lift up the rear side with a crane or jack up. Rear wheel Remove cap, split pin and then loosen castle nut. Take out rear wheel assembly with Wheel hub Castle Taper taper roller bearing and oil seal. roller bearing D255RE30...

  • Page 41: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-15 Group 3 Test and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19 Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23...

  • Page 42: 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. D255PT26 Brake drum Transmission...
  • Page 43 2. INSTALLATION VIEW D255PT05 Control valve Oil filter Temperature sender Dipstick Air breather...
  • Page 44 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. Structure Ball bearing Output pressure adjusting valve spring Gear pump assembly Inlet relief valve spring Converter Input guide D153PT27...
  • Page 45 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 46 TORQFLOW TRANSMISSION SECTION A - A Hydraulic clutch GEAR Center line 16.028 18.317 RATIO Gear forward of engine Hypoid pinion Clutch Hypoid pinion Gear forward Gear Center line of differential D255PT01 Torque converter Hydraulic clutch Hypoid gear set Pump Forward shaft 10 Differential Torque converter housing Forward gear...
  • 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 INPUT OUTPUT D255PT02 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 49 Reverse INPUT OUTPUT D255PT04 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 50 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 51 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 control valve D153PT11 OPERATION The control valve mainly consists of the main relief valve, inching valve, accumulator valve and directional valve.
  • Page 52 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 53 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 54 OPERATION Forward Reverse Reverse (From control valve) From T/M cooler Seal ling Forward (From control valve) D255PT24 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 55 6. DRIVE AXLE STRUCTURE D255PT25 Housing 14 Nut 22 Oil seal 15 Nut 23 Bolt Plug 16 Bearing 24 Spring washer Plug 17 Oil seal 25 Brake assy(LH) Gasket 18 Bearing 26 Brake assy(RH) 10 Shaft 19 Plate 27 Reamer bolt 11 Hub 20 Nut 28 Bolt...

  • Page 56: Group 2 Troubleshooting

    GROUP 2 TROUBLESHOOTING rouble symptom robable cause Remedy 1. Excessive oil temperature rise ·Improper oil level. ·Check oil level. Add or drain oil as 1) Torque converter necessary. ·Impeller interfering with surroundings. ·After draining oil from oil tank and tra- nsmission, check and replace interfe- ring parts.
  • Page 57 Trouble symptom robable cause Remedy 3.Low output power 1) Torque converter ·Insufficient hydraulic pressure : - Low oil level. - Check oil level and add oil. - Air sucked in. - Check joints and pipes. If necessary, retighten joint or repla- ce packing.
  • Page 58 Trouble symptom robable cause Remedy 4.Unusual oil pressure 1) Oil pressure is high ·Control valve malfunctioning. (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair. ·Cold weather. (high oil viscosity) ·When atmospheric temp is below fr- eezing point (when normal oil pressure is recover-...
  • Page 59 Trouble symptom robable cause Remedy 5. Power is not transmitted ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. 6. Oil leakage ·Oil leaks from oil seal. ·Disassemble and check for wear of (Transmission and torque seal lips and mating sliding surfaces...

  • Page 60: 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. Check that machine does not move even when engine speed is increased slightly. Adjust stopper bolt so that pedal height is 140~150mm (5.5~5.9in).
  • Page 61 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 62 ADJUSTMENT OF THE SIDE BEARING PRELOAD Tighten adjust screw gear(1) uniformly at 20kgf·m(145lbf·ft) L15C3DF03 ADJUSTING TOOTH CONTACT Forward side Coat the tooth face of the bevel pinion lightly with red lead(minimum). Heel Rotate the bevel gear forward and backward. Inspect the pattern left on the teeth. ·...
  • Page 63 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 64: 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 65 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 66 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 67 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 68 TORQUE CONVERTER ASSEMBLY DRAWING D255TC12 L15C3TC13 3-27...
  • Page 69 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 70 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 71 AINTENANCE STANDARDS Hydraulic pressure Location Pressure (kgf/cm Cracking pressure (kgf/cm Torque converter input 5 ~ 7 Torque converter output 2.2 ~ 4 ※ 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 72 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.
  • Page 73 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. D255TM03 Seal ring cap ① Remove bolt(2) and fit the bolt to the tapped hole. Remove the seal ring cap. ※...
  • Page 74 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 75 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 76 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) D255TM09 Clutch pack assembly ①...
  • Page 77 TORQUEFLOW TRANSMISSION ASSEMBLY DRAWING Loctite #271(Screw hold side) Loctite #271(Screw hold side) G2-L1(Lip portion) (Loctite #271 : Screw hole side) Match the stamps on the 35 ~ 43.5 kgf m(253 ~ 315 lbf ft) inner and outer rings D255TM13 3-36...
  • Page 78 CHECK AND INSPECTION E2, H2 E1, H1 D255TM14 3-37...
  • Page 79 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 80 3. DIFFERENTIAL STRUCTURE TRANSMISSION Loctite #271 35~43.5 kgf m (253~315 lbf ft) 5~7.5 kgf m (36~54 lbf ft) Loctite #271(Hole side) (Run out : Max, 0.1 with dial guage reading) 16~20 kgf m (116~145 lbf ft) Loctite #271(Hole side) Starting torque : 3.1~5.7 kgf m (22~41 lbf ft) Adjust with screw gear(12) D255DF04...
  • Page 81 DIFFERENTIAL ASSEMBLY DRAWING Backlash : 0.10-0.18 mm (0.004-0.007 in) Runout is Max 0.1 Starting torque (1) 3.1-5.7 kgf m (22-41 lbf ft) Loctite#271(screw portion) Loctite#271(screw portion) 5-7.5 kgf m 16-20 kgf m (36-54.4 lbf ft) (116-145 lbf ft) Loctite#271(screw hole side) 35-43.5 kgf m (253-315 lbf ft) D255DF05...
  • Page 82 CHECK AND INSPECTION D255DF07 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) 24.959-24.980 24.75 O.D of spider (0.983-0.984) (0.974) 25.0-25.1 25.2 I.D of differential pinion gear (0.984-0.988) (0.992)
  • Page 83 4. DRIVE AXLE(DRY RYPE) DISASSEMBLY AND ASSEMBLY Loctite #1215 6~8 kgf m All face of flange (43~58 lbf ft) Loctite #271 32.5~43.5 kgf m (235~315 lbf ft) Starting torque 0.6~1.5 kgf m (4.3~10.8 lbf ft) 30~50 kgf m (217~362 lbf ft) 10~13 kgf m (72~94 lbf ft) D255DA01...
  • Page 84 ASSEMBLY OF DRIVE AXLE 6-8 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) 10~13 kgf m (72-94 lbf ft) Loctite #271 30-50 kgf m G2,L1 (217-362 lbf ft) Loctite #271 32.5-43.5 kgf m...
  • Page 85 INSTALLATION Perform installation in the reverse order to removal, paying attention to the following. Tightening torque converter case mounting bolt. Mounting bolt ·Tightening torque : 6.0-7.5kgf·m (43-54lbf·ft) D255TIN01 Tightening flexible plate mounting bolt. Flexible plate ·Tightening torque : 2.8-3.5kgf·m mounting bolt (20-25lbf·ft) D255TIN02 Pedal assembly brake piping.

  • Page 86: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6 Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9...

  • Page 87: 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 88 3. BRAKE PEDAL AND PIPING(DRY TYPE) 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 89 4. INCHING PEDAL AND LINKAGE(DRY TYPE) 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 90 5. WHEEL BRAKE(DRY ONLY) 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. 10 3 31 161713 28,29 Section A-A...
  • Page 91 6. BRAKE MASTER CYLINDER(DRY TYPE) STRUCTURE D255BS04 Body Spacer 13 Rod 18 Band bolt Piston Plate 14 Yoke 19 Band plate Primary cup Key wire 15 Nut 20 Band washer Secondary cup 10 Boot 16 Nipple 21 Cap Spring 11 Check valve 17 Band 22 Cap Spring seat...

  • Page 92: 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 is 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 93 . TROUBLESHOOTING Problem cause Remedy Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil. ·Hydraulic system leaks air. ·Bleed air. ·Lining surface soiled with water or oil. ·Clean or replace. ·Lining surface roughened or in poor ·Repair by polishing or replace. contact with drum.
  • Page 94 Problem cause Remedy Brake squeaks ·Lining surface roughened. ·Repair by polishing or replace. ·Lining worn. ·Replace. ·Poor shoe to lining contact. ·Replace. ·Excessively large friction between ·Clean and apply brake grease. shoe and back plate. ·Foreign matter on drum sliding surfa- ·Clean ·Drum sliding surface damaged or di- ·Replace.

  • Page 95: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS 1. ADJUSTMENT OF WHEEL BRAKE(DRY ONLY) Adjust with engine stopped. Jack up truck. Extend adjustment screw by clicking adjustment wheel teeth with a Adjustment wheel Lever screwdriver until wheel(mounted on brake drum being adjusted) offers a light resistance when turned by hand.
  • Page 96 3. ADJUSTMENT OF PEDAL(DRY TYPE) 1 1 ) BRAKE PEDAL Pedal height from floor plate Adjust with stopper bolt. ·Pedal height : 140~150mm(5.5~5.9in) Adjust with rod of master cylinder ·Play : 10~15mm(0.4~0.6in) Micro switch for parking brake (if D255BS08 equipped) ①...

  • Page 97: Section 5 Steering System

    SECTION 5 STEERING SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12...

  • Page 98: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1 Steering unit 2 Steering cylinder 3 Steering wheel 4 Trail axle To Hydraulic tank D255SS01 The steering system for this machine is composed of steering wheel assembly(3), steering unit(1), steering cylinder(2), trail axle(4) and pipings.
  • Page 99 2. HYDRAULIC CIRCUIT D255SS02 Hydraulic gear pump Steering cylinder Priority valve Suction filter Steering unit 12 Hydraulic tank...
  • Page 100 NEUTRAL D255SS03 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.
  • Page 101 LEFT TURN D255SS04 When the steering wheel is turned to the left, the spool(G) within the steering unit(4) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(4) through the spool(D) of priority valve(2) and flows to the gerotor(H).
  • Page 102 RIGHT TURN D255SS05 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) where it is directed out of the right work port(R).
  • Page 103 3. STEERING UNIT STRUCTURE D255SS06 Dust seal 14 Bearing race 24-3 Spring seat Retaining ring 15 Bore screw 24-4 Spring Cap seal 16 Drive 24-5 Spool Thrust bearing 17 End cap 24-6 Bushing Ball 18 Gland bushing 25 Check valve 19 Plate 25-1 Guide Spacer...
  • Page 104 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 105 4. TRAIL AXLE STRUCTURE D22SS07 Steering axle 15 Needle bearing 28 Shim Knuckle 16 Plate plug 29 Shim Intermediate link 17 Retaining ring 30 Special washer Grease nipple 18 King pin 31 Split pin Set screw 19 Hub bolt 32 Steer cylinder 20 Hub 33 Shim Bolt...
  • Page 106 TIGHTENING TORQUE AND SPECIFICATION Stroke 95 Apply loctite #277 49.5~66.5 kgf m(358~481 lbf ft) 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 SECTION A-A D255SS09 Center pin support...

  • Page 107: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS Check item Checking procedure Steering wheel · Set rear wheels facing straight forward, then turn steering wheel to left and right. 30-60mm Measure range of steering wheel movement before rear wheel starts to move. (1.2-2.4 in) Range should be 30~60mm at rim of steering wheel.
  • Page 108 Problem Cause Remedy Steering wheel turns unstea- ·Lockout loosening. ·Retighten. dily. ·Metal spring deteriorated. ·Replace. Steering system makes abn- ·Gear backlash out of adjustment. ·Adjust. ormal sound or vibration. ·Lockout loosening. ·Retighten. ·Air in oil circuit. ·Bleed air. Abnormal sound heard when Valve ·Faulty.

  • Page 109: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE D255SS06 Dust seal 14 Bearing race 24-3 Spring seat Retaining ring 15 Bore screw 24-4 Spring Cap seal 16 Drive 24-5 Spool Thrust bearing 17 End cap 24-6 Bushing Ball 18 Gland bushing 25 Check valve 19 Plate 25-1 Guide...
  • Page 110 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 111 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 112 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 113 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. ※ On some pins in which there are two springs. D353SE09 5-16...
  • Page 114 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 115 (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 116 (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 117 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 118 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 119 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 120 (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 121 (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 122 (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 123 (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 124 (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 125 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ·Tightening torque : 3.0 ±...
  • Page 126 (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 127 2. STEERING CYLINDER STRUCTURE D255SS11 Tube assembly Rod seal O-ring Back up ring 10 O-ring Gland Dust wiper 11 Piston seal DU bushing Snap ring 12 Pin bush 5-30...
  • Page 128 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 129 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 60±6kgf·m (434±43lbf·ft).
  • Page 130 3. TRAIL AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. D22SS07 Steering axle 15 Needle bearing 28 Shim Knuckle 16 Plate plug 29 Shim Intermediate link 17 Retaining ring 30 Special washer Grease nipple 18 King pin 31 Split pin Set screw 19 Hub bolt...
  • Page 131 CHECK AND INSPECTION D255SS12 mm(in) Criteria Check item Remedy Standard size Repair limit Diameter of king pin 45(1.77) 44.8(1.76) 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 132 DISASSEMBLY ※ Servicing work on the knuckle part can be Tire carried out without removing the axle assy from chassis. Taper roller bearing The work can be done by jacking up the Washer balance weight part of the truck. Split pin Loosen the castle nut and take off the steering Slotted nut wheel tire.
  • Page 133 Loosen set screw(5) and nut(6). Pry out the retaining ring(17) and needle bearing(15). Push out the king pin(18) without damaging the (10) knuckle(2). (11) Remove the split pin(31) and the link pin(12). Then, remove the knuckle(2). ※ Repeat the same procedure for the other side.

  • Page 134: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-17 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-21...

  • Page 135: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT D255HS01 Hydraulic gear pump Tilt cylinder Priority valve Suction filter Main control valve Return filter Steering unit 10 Down control valve Steering cylinder 11 Down safety valve Lift cylinder 12 Hydraulic tank...
  • Page 136 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 4B 4A 15.0MPa LIFT TILT AUX1 AUX2 20.0MPa Steering system Return line D255HS02 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(3) and then goes to the large chamber of lift cylinder(6) by pushing the load check valve of the spool.
  • Page 137 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 4B 4A 15.0MPa LIFT TILT AUX1 AUX2 20.0MPa Steering system Return line L15C3HS03 When the lift control lever is pushed forward, the spool on the first block moves to lower position. The work port(1A) and the small and the large chamber of lift cylinder are connected to the return passage, so the fork will be lowered due to its own weight.
  • Page 138 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 4B 4A 15.0MPa LIFT TILT AUX1 AUX2 20.0MPa Steering system Return line D255HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
  • Page 139 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 4B 4A 15.0MPa LIFT TILT AUX1 AUX2 20.0MPa Steering system Return line D255HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
  • Page 140 2. HYDRAULIC GEAR PUMP STRUCTURE D255HS06 Housing Oil seal 11 Side plate 2 Body Idle gear 12 Bushing Rear cover 13 Bolt Snap ring O-ring 14 Copper washer Drive gear 10 Side plate 1 OPERATION This pump comprises of a rear cover, a body, a housing, bushings and a mounting flange bolted together.
  • Page 141 3. MAIN CONTROL VALVE STRUCTURE (4- Spool) ANTI-STALL ORIFICE 1.2(TILT BLOCK ONLY) AUX2 AUX1 TILT LIFT SECTION J-J VIEW F-F SECTION H-H VIEW G-G 8 9 10 Port name Size Inlet port 1-1/16-12UNF-2B Outlet port 1-1/16-12UNF-2B SECTION T-T SECTION E-E D255HS07 Lift block assy 13 Relief piston...
  • Page 142 INLET SECTION OPERATION Structure and description Relief valve piston Relief valve piston D255HS071 Hydrostat plug 15 Relief plug O-ring 17 Relief spring 10 Hydrostat spring 18 Pilot poppet 11 Hydrostat sleeve 29 O-ring 13 Relief piston 32 Seat 14 Nut 33 Seat...
  • Page 143 Operation Secondary relief valve To neutral passage To aux block 15.0MPa System relief valve 20.0MPa To neutral passage To load check valve D255HS072 Oil flows from P(pump) port to reservoir(T) by pushing hydrostat spool(1). Before the center bypass line closed, hydrostat spool is keep opening, so pump port(P) and tank port(T) are always connected in operation to minimize heat generation.
  • Page 144 LIFT SECTION OPERATION Lift position Load check valve D255HS08 When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flow into lift cylinder port(1A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 145 Lower position Load check valve D255HS09 When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (1A)→T.
  • Page 146 TILT SECTION OPERATION Tilt forward position Tilt lock spool Load check valve D255HS10 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flow into tilt cylinder port(2B). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage.
  • Page 147 Tilt backward position Tilt lock spool Load check valve D255HS11 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flows into tilt cylinder port(2A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 148 MAIN RELIEF VALVE Pressure setting A good pressure gauge must be installed Seat Relief plug in the line which is in communication with Lock nut the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit.
  • Page 149 4. LIFT CYLINDER D255HS18 Tube assembly Wear ring 11 O-ring Retaining ring 12 Guide Piston Gland 13 DU bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 5. TILT CYLINDER 18 17 16 19,20,21 11,12 13,14 3 4 6 5 D255HS19...
  • Page 150 6. FREE LIFT CYLINDER D255HS20 Tube assembly Check valve 11 Dust wiper Back up ring 12 Snap ring Piston Set screw 13 O-ring Piston seal Gland 14 Back up ring Wear ring 10 Rod seal 6-16...

  • Page 151: 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 152 . TROUBLESHOOTING SYSTEM Problem Cause Remedy Large fork lowering speed. ·Seal inside control valve defective. ·Replace spool or valve body. ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. Large spontaneous tilt of ·Tilting backward : Check valve defec- ·Clean or replace.
  • Page 153 YDRAULIC 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 154 IFT 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 155: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP ※ Tools required ·Metric socket set ·Internal snap ring pliers ·Shaft seal sleeve ·Torque wrench It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
  • Page 156 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 157 (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 158 (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 159 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 160 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 161 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 162 (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 163 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. ·Tighten torque : 3.0~4.0kgf·m (22~29lbf·ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
  • Page 164 2. MAIN CONTROL VALVE DISASSEMBLY ※ hydraulic components manufactured to a high precision. Consequently before disassembling or assembling, it is essential to select an especially clean place. In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.
  • Page 165 Pull out spool assembly from the block. D255CV20 Using a jig, vise the spool assembly. Remove spring seat, spring, seal, plate, dust wiper and O-ring from the spool assembly. D255CV19 Loosen blind plugs. D255CV18 Loosen blind plugs. D255CV17 6-31...
  • Page 166 Loosen plugs. D255CV16 Loosen hydrostat plug, spring and sleeve from the inlet block. ※ When disassembling sleeve, use a forceful magnet. D255CV15 (10) Remove secondary relief valve. D255CV14 (11) Remove spring and relief assembly. D255CV13 6-32...
  • Page 167 (12) Remove pilot poppet. D255CV12 (13) Remove relief valve assembly and then disassemble relief assembly, relief spring, pilot poppet in order from the relief valve assembly. D255CV11 (14) When removing C-ring, as the picture, using a thin and soft tool, push up the C- ring out of block.
  • Page 168 (16) Remove adjust plug from the block. D255CV08 (17) C-ring and adjuster assembly and disassembly tool. D255CV06 (18) For easy reassembly, check out the direction of adjuster. D255CV07 (19) For easy reassembly, check out the direction of adjuster. D255CV05 6-34...
  • Page 169 (20) Remove spring. D255CV04 (21) Remove poppet. D255CV03 (22) Procedure from (14) to (21) is load check valve disassembly. Remove O-ring and back up ring from adjust plug. D255CV02 (23) Separate inlet block, mid block and outlet block each other by loosening the long socket bolts from the block assembly.
  • Page 170 ASSEMBLY With socket bolts fasten inlet block, mid block and outlet block into one block. ·Tightening torque : 5.0kgf·m(36.2lbf·ft) D255CV01 Assemble load check valve in the order of poppet, spring, adjuster, adjust plug and C-ring. D255CV02 Install poppet into load check valve hole. D255CV03 Install spring into load check valve hole.
  • Page 171 Install adjuster into load check valve hole. D255CV05 A tool for disassembly and assembly of C- ring or adjuster. When assembling adjuster, push one of two adjuster wings into the groove of block and then the other in a same method. D255CV06 Assemble adjuster with attention of the direction of wings.
  • Page 172 Install C-ring into load check valve hole so that cut side can face the center line of the block. D255CV09 (10) Assemble relief valve assembly. D255CV11 (11) Install pilot poppet into relief valve hole. D255CV12 (12) Install spring and relief assembly into relief valve hole.
  • Page 173 (13) Install secondary relief valve. ·Tightening torque : 2.5kgf·m(18.1lbf·ft) D255CV14 (14) Assemble hydrostat assembly in the order of hydrostat sleeve, spring and plug. ※ Check the direction of sleeve. ※ Use a forceful magnet to pull out the sleeve. D255CV15 (15) Install plug.
  • Page 174 (17) Using a jig, vise a spool assembly. Assemble in the order of O-ring, dust wiper, seal plate, spring seat, and plug of each spool. ·Tightening torque : 2.0kgf·m(14.5lbf·ft) D255CV19 (18) Install spool assembly into the block assembly. D255CV20 (19) Cover the return cap onto the return spring side of spool assembly and then tighten the socket bolt as following torque.
  • Page 175 (21) After assembling seal plate tighten socket bolt as following torque. ·Tightening torque : 1.2kgf·m(8.7lbf·ft) ·Install dust wiper so as lip side to face outside. D255CV23 (22) This is complete assembly procedure. D255CV24 6-41...
  • Page 176 3. LIFT CYLINDER STRUCTURE Down control valve Down safety valve · I.D×O.D×Stroke : 50×58×1630mm (2.0×2.3×64.2 in) · Rod O.D : 40mm (1.6 in) D255HS24 Tube assy Wear ring 11 O-ring Rod assy Retaining ring 12 Guide Piston Gland 13 Du bushing Piston seal Dust wiper 14 Spacer...
  • Page 177 DISASSEMBLY Hold the cylinder tube in a vice, loosen the Guide cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn. Lever up the edge of the guide, then turn the guide in again and the guide can be removed.
  • Page 178 4. TILT CYLINDER STRUCTURE · I.D×O.D×Stroke : 75×86×138mm (3.0×3.4×5.4 in) · Rod O.D : 35mm (1.4 in) D255HS27 Tube assy Rod cover 15 O-ring Dust wiper 16 Eye Piston 10 DU bushing 17 Bushing Piston seal 11 Rod seal 18 Grease nipple Wear ring 12 Back up ring 19 Hexagon bolt...
  • Page 179 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 180: Section 7 Electrical System

    SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2 Group 3 Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 Group 4 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12...

  • Page 181: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION D255EL01 Flasher lamp Back buzzer 11 Relay Work lamp Operating panel 12 Fuse box Combination switch Flasher relay 13 Switch assembly Horn assembly Detector 14 Warning buzzer Combination lamp 10 Start switch 15 Battery...

  • Page 182: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT D255EL02...
  • Page 183 OPSS (Operator Presence Sensing System) OPTION REAR WORK FUEL BACK FUEL WATER BEACON OPERATING PANEL SENDOR BUZZER CLEARNER SEPARATOR FRONT HEAD FRONT HEAD LAMP COMBI LH LAMP COMBI RH LAMP START KEY S/W WARNING RELAY BUZZER POWER CL-16 HEATER CN-19 R/COMBI RH 0.7? CL-15...
  • Page 184 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-95B(1→2)] QGS controller[CR-24(2)] Fusible link[CN-95A(1→2)] Safety relay[CR-23(1)] Alternator[CN-74(B+)]...
  • Page 185 POWER CIRCUIT D255EL03...
  • Page 186 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-95A] Start switch[CS-2(3)] Safety relay[CR-23, 2P(1)] Fusible link[CN-95B] QGS controller[CR-24, 2P(2)] ※T he engine can be started only when the gearshift is in neutral position. When start key switch is in ON position Start switch ON [CS-2(4)] Fuse box[No.
  • Page 187 STARTING CIRCUIT D255EL04...
  • Page 188 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-95A) and the fuse box.
  • Page 189 CHARGING CIRCUIT D255EL05...

  • Page 190: Group 3 Component Specification

    GROUP 3 COMPONENT SPECIFICATION Specification Remark Part name Battery CCA : 720A 20HR : 90AH CMF 90(322×172×213) Working lamp 12V, 55W 12V, 3.4W×12 License lamp Combination lamp 12V, 21W(T/S) 12V, 10W(Back) 12V, 5W (Tail) 12V, 21W(Stop) Head lamp 12V, 55W Flasher lamp 12V, 23/8W 12V, 20A...
  • Page 191 Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Dashboard harness-frame harness) S814*008001 S814-108001 CN-2 I/conn(Dashboard harness-frame harness) S814-014100 S814-114100 CN-3 I/conn(Dashboard harness-frame harness) MG640944-5 MG650943-5 CN-4 Support harness-LH S810-004202 CN-5 MOLEX Support harness-RH 110-4P-F CN-17 Power output S814-004100 CN-18 Power...
  • Page 192 Connector part No. Connector No. of Type Destination number Female Male Sensor and pressure switch CD-2 Fuel level sensor S810-003201 CD-4 Brake switch S822-014000 CD-8 Water temp sender S819-010122 CD-9 Water temp switch S819-010122 CD-10 DAEDONG Air cleaner switch 110-6PR CD-18 Engine oil pressure sender S822-014000...

  • Page 193: Group 4 Troubleshooting

    GROUP 4 TROUBLESHOOTING Trouble symptom Probable cause Remedy Lamps dimming even at maxi- ·Faulty wiring. ·Check for loose terminal and discon- mum engine speed. nected wire. Lamps flicker during engine ·Improper belt tension. ·Adjust belt tension. operation. Charge lamp does not light d- ·Charge lamp defective.
  • Page 194 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11...

  • Page 195: Group 1 Structure

    SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) TILT CYLINDER LIFT CYLINDER CARRIAGE D255MS01 Outer mast Anchor bolt 10 Trunnion cap Inner mast Chain wheel bearing 11 Bushing Roller Retaining ring 12 Roller Shim(0.5, 1.0t) Tilt cylinder pin 13 Shim(0.5, 1.0t) Chain...
  • Page 196 2. 2 STAGE MAST(VG MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE D255MS02 Outer mast Shim(0.5, 1.0t) 11 Bushing Inner mast Roller 12 Sheave Chain Shim(0.5, 1.0t) 13 Sheave bracket Anchor bolt Tilt cylinder pin 14 U-bolt Back up liner 10 Support cap...
  • Page 197 3. 3 STAGE MAST(TF MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE D255MS021 Outer mast Roller 11 Sheave Middle mast Shim(0.5, 1.0t) 12 Tilt cylinder pin Inner mast Back up liner 13 Support cap Chain Shim(0.5, 1.0t) 14 Bushing Anchor bolt 10 Sheave bracket 15 U-bolt...
  • Page 198 4. CARRIAGE, BACKREST AND FORK D255MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...

  • Page 199: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. ℓ=1050mm(41.3in) EX : mm(in) STD Fork assy Applicable model Standard Limit Thickness F173796-02 HDF20/25-5 45(1.8) 40(1.6) Limit : within 10% of original HDF30-5...
  • Page 200 . TROUBLESHOOTING MAST Problem Cause Remedy Forks fail to lower. ·Deformed mast or carriage. ·Disassemble, repair or replace. Fork fails to elevate ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. ·Deformed mast assembly. ·Disassemble mast and replace damaged parts or replace complete mast assembly.
  • Page 201 ORKS Problem Cause Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear wear and reduces the thickness of the limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...

  • Page 202: Group 3 Adjustment

    GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V, VF 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 203 2 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...
  • Page 204 ARRIAGE LOAD ROLLER Outer mast Adjust Bring into Measure the clearance when the center of screw contact the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, middle Side and lower rollers after loosen the adjust roller Carriage screws from the side rollers.

  • Page 205: Group 4 Removal And Installation

    GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1inch) from the floor. 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 206 SIDE ROLLER Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. ※...
  • Page 207 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) ① Remove the carriage assembly and Chain move them to one side. Stud ② Loosen and remove hexagon bolts and bolt washers securing lift cylinders to inner Inner mast mast.
  • Page 208 2 stage mast(TF mast) ① Remove free lift chain connected between carriage and free lift cylinder. Chain ② Remove the carriage assembly and move them to one side. Stud ③ Loosen and remove hexagon bolts and bolt Inner washers securing lift cylinders to inner mast mast.
  • Page 209 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 210 ELEVATING MAST Inner mast (V, VF 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 211 CHAIN Chain Chain sheave(V, VF mast) Outer mast 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 212 Chain wheel bearing support(TF mast) ① Remove the carriage assembly and move to one side. ② After removing bolt to securing chain wheel bearing support assembly to free lift cylinder. After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 213 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 214 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 215 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 djustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor. ·Adjust the chain length by loosening or tightening nut on the chain anchor.

This manual is also suitable for:

Hdf 25-5Hdf 30-5Hdf 15-5Hdf 18-5

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