Hyundai 20DT-7 Operation Manual
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Hyundai 20DT-7 Operation Manual

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Group 1 Safety hints -------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ---------------------------------------------------------------------------------------------------- 1-5
Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-13
Group 1 Major components -------------------------------------------------------------------------------------------- 2-1
Group 2 Removal and installation of unit ---------------------------------------------------------------------- 2-2
Group 1 Structure and operation ----------------------------------------------------------------------------------- 3-1
Group 2 Troubleshooting ------------------------------------------------------------------------------------------------ 3-19
Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 3-25
Group 1 Structure and function -------------------------------------------------------------------------------------- 4-1
Group 2 Operational checks and troubleshooting -------------------------------------------------------- 4-5
Group 3 Tests and adjustments ------------------------------------------------------------------------------------- 4-7
Group 1 Structure and function -------------------------------------------------------------------------------------- 5-1
Group 2 Operational checks and troubleshooting -------------------------------------------------------- 5-10
Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 5-12
Group 1 Structure and function -------------------------------------------------------------------------------------- 6-1
Group 2 Operational checks and troubleshooting -------------------------------------------------------- 6-17
Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 6-21
Group 1 Component location ----------------------------------------------------------------------------------------- 7-1
Group 2 Electrical circuit ------------------------------------------------------------------------------------------------- 7-2
Group 3 Component Specification --------------------------------------------------------------------------------- 7-10
Group 4 Connector Destination -------------------------------------------------------------------------------------- 7-11
Group 5 Troubleshooting ------------------------------------------------------------------------------------------------ 7-13
CONTENTS
CONTENTS

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Summary of Contents for Hyundai 20DT-7

  • Page 1: Table Of Contents

    CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ---------------------------------------------------------------------------------------------------- 1-5 Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-13 SECTION 2 REMOVAL & INSTALLATION SECTION 2 REMOVAL & INSTALLATION Group 1 Major components -------------------------------------------------------------------------------------------- 2-1 Group 2 Removal and installation of unit ---------------------------------------------------------------------- 2-2 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM...
  • Page 2 SECTION 8 MAST 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 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 will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 5 3. CONVERSION TABLE 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 Example Method of using the Conversion Table to convert from millimeters to inches...
  • Page 6 Millimeters to inches 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...
  • Page 7 Liter to U.S. Gallon 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...
  • Page 8 kgf·m to to lbf lbf·ft ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 9 kgf/cm kgf/cm to to lbf/in 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...
  • Page 10 TEMPERATURE 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 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 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 Way to use dipstick Push the dipstick fully into the guide, and then pull out. Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request the HYUNDAI Forklift distributor to carry out...

  • Page 16: Group 2 Specifications

    GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS 20DTOM01B Mast Forks 13 Counterweight Lift chain Overhead guard 14 Rear wheel Lift cylinder Turn signal lamp 15 Front wheel Backrest 10 Head lamp 16 Rear combination lamp Tilt cylinder 11 Operator's seat Lift bracket...
  • Page 17 2. SPECIFICATIONS C' C D255SP01 Model Unit 20DT-7 25DT-7 30DT-7 33DT-7 Capacity 2000 2500 3000 3300 Load center Weight (Unloaded) 3417 3731 4186 4492 Lifting height 3005 3205 Free lift Fork Lifting speed (Unload/Load) mm/sec 590/570 590/550 480/460 480/450 Lowering speed (Unload/Load)
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item Unit Specification Model WIA WC30D Type Vertical, water-cooled, 4-cycle diesel Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion type Swirl Cylinder bore X stroke mm (in) 98 98 (3.9 3.9 Piston displacement cc (cu in)
  • Page 19 POWER TRAIN DEVICES Item Specification Model KAPEC 280 DJ Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type Power shift Gear shift(FWD/REV) Transmission Control Electrical single lever type, kick-down system 1.143 : 1 Overhaul ratio 1.143 : 1 Type Front-wheel drive type, fixed location...
  • Page 20 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Items Size kgf·m lbf·ft Engine mounting nut (bracket-frame) M12×1.25 9.7±1.9 13.7±13.7 Engine mounting bolt (engine-bracket) M10×1.25 7.4±1.5 10.8±10.8 Engine Engine mounting nut (mount-frame) M12×1.75 12.8±3 92.6±21.7 Radiator mounting bolt, nut M 8×1.25 2.5±0.5 18±3.6...
  • Page 21 5. TORQUE CHART 5. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread Bolt size kg·m lb·ft kg·m lb·ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25...
  • Page 22 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size Width across flat (mm) kgf·m lbf·ft 9/16-18...
  • Page 23 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature C ( F) Service point Kind of fluid Capacity (U.S. gal) (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) SAE 5W-40 SAE 30 Engine oil Engine oil...

  • Page 24: Group 3 Periodic Replacement

    GROUP 3 PERIODIC REPLACEMENT GROUP 3 PERIODIC REPLACEMENT For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time of periodic maintenance;...

  • Page 25: Section 2 Removal & Installation

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

  • Page 26: Group 1 Major Components

    SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 MAJOR COMPONENTS GROUP 1 MAJOR COMPONENTS 9 10 20DTOM21 Mast Torque converter 17 Radiator Lift cylinder 10 Engine 18 Operator's seat Tilt cylinder 11 Steering cylinder 19 Overhead guard Control valve 12 Hydraulic pump...

  • Page 27: Group 2 Removal And Installation Of Unit

    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 1. MAST 1) 1) REMOVAL REMOVAL L15C3RE001 (1) (1) Forks Forks Backrest ① Lower the fork carriage until the forks are Knob approximately 25mm (1in) from the floor.
  • Page 28 ② While supporting lift chains, remove nuts and split pin from the anchor bolt. Lift chain Outer mast Split pin 20D7RE05 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain Block 20D7RE06...
  • Page 29 (4) (4) Piping Piping ① Remove the return hoses and clamps attached to the cylinder. ② Remove hose assembly, valve and tee from the lift cylinder. Band clamp ※ Hose Put blind plugs in the piping immediately clamp after removing hoses. Return hose This prevents the hydraulic oil from...
  • Page 30 (6) (6) Inner mast 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. Be careful the mast not to swing or fall. Inner mast Outer...
  • Page 31 2) 2) INSTALLATION 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. (1) (1) Mast support cap Mast support cap ①...
  • Page 32 2. POWER TRAIN ASSEMBLY 2. POWER TRAIN ASSEMBLY 1) 1) REMOVAL REMOVAL D503RE04 (1) (1) Mast Mast Refer to section on mast (Page 2-2)
  • Page 33 (2) (2) Brake piping Brake piping Brake valve Disconnect the brake piping from the Brake pipe brake housing of drive axle. When disconnecting the brake piping When disconnecting the brake piping and refilling the oil for the brake housing and refilling the oil for the brake housing of the drive axle take to extreme care of the drive axle take to extreme care not to spill it on the work site.
  • Page 34 (4) (4) Drive axle Drive axle ① Attach a crane to the tilt cylinder notches on the dashboard and raise the machine. ② Loosen hexagonal bolts (1) connection drive axle to the transmission. ③ Put the block under the drive axle and support under the drive axle with a truck.
  • Page 35 (7) (7) Torque converter Torque converter ① Remove the cover on top face of the Cover torque converter housing then remove the 8 mounting bolts installed on the engine flywheel. To rotate the flywheel, remove 1 mounting bolt, then insert a turning tool in the mounting hole.
  • Page 36 2) 2) INSTALLATION INSTALLATION Installation is the reverse order to removal, but be careful of the following points. Tightening torque ·Bolt (1):5.9~8.9 kgf·m (42.7~64.3 lbf·ft) Bolt (1) ·Bolt (2):2.7~4.1 kgf·m (19.5~29.7 lbf·ft) ·Bolt (3):5.9~8.9 kgf·m (42.7~64.3 lbf·ft) ·Bolt (4):62~68 kgf·m (448~491 lbf·ft) Bolt (5) ·Bolt (5):7.5 kgf·m (54.2 lbf·ft) Bolt (4)
  • Page 37 3. ENGINE 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL REMOVAL 1) 1) D503RE25 (1) (1) Overhead guard Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and flasher lamp on the stay of the overhead guard and then raise it together with the bonnet.
  • Page 38 (2) (2) Remove the torque converter housing cover, mounting bolts installed to flywheel housing. For details, see page 2-10. (3) (3) Engine accessory Engine accessory Engine Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. ① Wiring harness to alternator and starter.
  • Page 39 Tightening torque of mounting bolt installing to torque converter housing. ·5.9~8.9 kgf·m (42.7~64.3 lbf·ft) Counterweight (4) (4) Radiator hoses Radiator hoses ·Distance to insert hose : 40 mm (1.5 in) (5) (5) Air cleaner hose Air cleaner hose Engine ① Insert the air cleaner hose securely and fit a clamp.
  • Page 40 Hold the counterweight with hoist bars, and raise it with a crane. Remove the mounting bolts, raise slightly and move it slowly to rear side. ·Weight of counterweight (standard) 20DT-7 : 1,060 kg (2,240 lb) 25DT-7 : 1,370 kg (3,020 lb) 30DT-7 : 1,690 kg (3,730 lb)
  • Page 41 (2) (2) Rear wheel Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. 20D7RE28 (3) (3) Hose Hose Drain hydraulic oil in the hoses and cylinders before removing them. Remove the fitting and then disconnect the hoses.

  • Page 42: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation ------------------------------------------------------------------------------------ 3-1 Group 2 Troubleshooting ------------------------------------------------------------------------------------------------- 3-19 Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 3-25...

  • Page 43: Group 1 Structure And Operation

    SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN DIAGRAM 1. POWER TRAIN DIAGRAM 1) 1) STRUCTURE STRUCTURE 20DF7TPT26 Engine Drive shaft Brake Transmission Drive axle...
  • Page 44 2) 2) SPECIFICATION SPECIFICATION Item Specification Model KAPEC 280 DJ Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type Power shift Gear shift(FWD/REV) Transmission Control Electrical single lever type, kick-down system 1.143 : 1 Overhaul ratio 1.143 : 1 Type...
  • Page 45 2. TORQUE CONVERTER 2. TORQUE CONVERTER STRUCTURE STRUCTURE 1) 1) 11 21 15L7APT03 Hexagon bolt Plug Air breather Plain washer O-ring Magnetic plug Flexible plate Torque converter housing Temperature sensor Torque converter assembly Hexagon bolt Inner oil strainer Shaft Torque converter cover Oil strainer spring Snap ring O-ring...
  • Page 46 2) 2) OPERATION OPERATION The torque converter is connected with a flywheel by a flexible plate, engine output is delivered from the flywheel to the flexible plate. The exterior of the torque converter is protected by the torque converter housing. The torque converter housing forms the oil path for the oil pump, it includes the oil strainer filtering sucked oil through this oil path and the oil level gauge measuring oil level of the transmission inside.
  • Page 47 3. TRANSMISSION 3. TRANSMISSION STRUCTURE STRUCTURE 1) 1) 15L7APT28 Control valve Output gear Torque converter Temperature sensor Turbine wheel Oil strainer Impeller wheel Idle gear Stator wheel Forward clutch pack Forward clutch gear Input shaft Oil pump Reverse clutch pack Reverse clutch gear...
  • Page 48 2) 2) INSTALLATION VIEW INSTALLATION VIEW 15L7APT05 1 Torque converter 5 Air breather 2 Temperature sensor 6 Transmission oil filter 3 Control valve 7 Transmission output (Universal joint link part) 4 Oil level pipe and dipstick 3) 3) OPERATION OPERATION The torque converter is an automatic fluid drive.
  • Page 49 OPERATING MODES OPERATING MODES Forward Forward (1) (1) Input → Torque converter → Clutch shaft → Forward clutch gear → Output gear → Output 15L7APT29 (2) (2) Reverse Reverse Input → Torque converter → Clutch shaft → Reverse clutch gear → Output gear → Output 15L7APT30...
  • Page 50 5) 5) TRANSMISSION CASE AND CONTROL VALVE TRANSMISSION CASE AND CONTROL VALVE (1) (1) Structure Structure 20DF7TPT07 Transmission case 12 Socket bolt Cylinder gear Oil seal 13 Oil gauge Idle gear Ball 14 Clamp Output gear Spring 15 Socket bolt Socket bolt O-ring 16 Flange bolt...
  • Page 51 (2) (2) Operation Operation The transmission case includes the function of a control valve, an oil filter and a parking brake. The oil filter is charge of filtering sucked oil by an oil pump before transmitting sucked oil to a control valve and a torque converter.
  • Page 52 6) 6) CONTROL VALVE CONTROL VALVE (1) (1) Operation Operation 15L7APT08 Modulation Inching valve pressure check port Solenoid valve Forward clutch pressure check port Inching spool Reverse clutch pressure check port Main relief valve Main pressure check port The control valve consists of the main relief valve, solenoid valve, modulation valve and inching valve.
  • Page 53 (2) (2) Structure Structure Main relief valve Modulation Forward clutch pressure check port Inching valve pressure check port Main pressure check port Reverse clutch pressure check port Inching spool Solenoid valve 15L7APT22 1 Plug 11 Spring 21 Stopper 2 O-ring 12 Solenoid valve 22 Spring 3 Spring...
  • Page 54 7) 7) CLUTCH CLUTCH (1) (1) Operation Operation Reverse Forward 15L7APT31 Forward clutch plugging pressure delivery line ( Reverse clutch plugging pressure delivery line ( Clutch pack lubrication line ( When (forward/reverse) mode is selected through the solenoid valve of control valve, the flux flowed by the oil pump flows into forward (reverse) clutch pack in 9~14.2 kgf/cm (128~202 psi) of pressure through the oil path of transmission inside.
  • Page 55 (2) (2) Structure Structure 15L7APT11 1 Shaft 11 Seal ring 21 Wire ring 2 Seal ring 12 Piston 22 Plate 3 Needle bearing 13 Quad ring 23 Clutch drum 4 Ring 14 Quad ring 24 Spacer 5 Seal ring 15 Plate 25 Snap ring 6 Bushing 16 Friction plate...
  • Page 56 8) 8) OUTPUT GEAR OUTPUT GEAR (1) (1) Operation Operation The output gear is engaging the forward clutch gear and reverse clutch gear together. If a driver selects forward, the forward clutch gets plugging, the forward clutch gear revolves and the power of forward clutch gear is delivered to output gear.
  • Page 57 4. DRIVE AXLE 4. DRIVE AXLE INSTALLATION VIEW INSTALLATION VIEW 1) 1) 15L7APT15 Carrier assembly Traveling brake Oil level gage Drive axle housing 2) 2) STRUCTURE STRUCTURE 15L7APT16 Pinion shaft Axle shaft Ring gear Traveling brake Differential device Hub reduction The drive axle is connected with the transmission output gear and universal joint.
  • Page 58 3) 3) CARRIER ASSEMBLY CARRIER ASSEMBLY (1) (1) Operation Operation Carrier sub assy includes differential device and parking brake. The pinion shaft is supported by the taper roller bearing in the carrier case and the bolt at the end of pinion shaft and transfers the power which is delivered from the drive shaft assy to the ring gear assembled from bolts at a differential device.
  • Page 59 (2) (2) Structure Structure 15L7APT18 1 Parallel pin 5 Actuator 9 Eccentric shaft 2 Parking plate 6 Push pin 10 Lever 3 Friction plate-parking 7 Parking spline 4 Cone spring 8 Carrier case cover 3-17...
  • Page 60 4) 4) DIFFERENTIAL DEVICE DIFFERENTIAL DEVICE (1) (1) Operation Operation Since the ring gear is linked with the right of the differential case and the bolt, the power transferred to the ring gear makes the differential device revolve. And also, the left and right of the differential case are connected with the left and right of the axle shaft and the spline respectively, it delivers the power to the final drive.

  • Page 61: Group 2 Troubleshooting

    GROUP 2 TROUBLESHOOTING GROUP 2 TROUBLESHOOTING 1. TRANSMISSION 1. TRANSMISSION Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 1. Output does not go up 1. Output does not go up 1) Torque converter · · - Torque converter oil The oil is in short supply.
  • Page 62 Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 2. Power is not transmitted 2. Power is not transmitted · · 1) Torque converter The flexible plate is broken. Change the flexible plate. · · The oil is in short supply. Replenish oil.
  • Page 63 Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 4. Clutch or converter oil 4. Clutch or converter oil pressure is too high pressure is too high · · 1) Torque converter Viscosity of oil is too high (at cold time). Warm up the torque converter if the temperature of torque converter oil is below outside air temperature.
  • Page 64 2. DRIVE AXLE 2. DRIVE AXLE Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 1. Noise and vibration 1. Noise and vibration · · 1) Drive axle Lubricating oil shortage. Check oil level and refill lubricating oil. · ·...
  • Page 65 Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 2. Oil leakage 2. Oil leakage · · 1) External leakage Excess of oil. Check oil level. Set of oil amount. · · Using different oil. Change oil. · · Blocking air breather.
  • Page 66 Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 4. Brake does not apply 4. Brake does not apply · · 1) Service brake. Empty fluid reservoir. Fill reservoir to correct level with - Low or no pressure specified fluid. ·...

  • Page 67: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF TRANSMISSION 1. DISASSEMBLY OF TRANSMISSION DISASSEMBLING OF TRANSMISSION ASSY DISASSEMBLING OF TRANSMISSION ASSY 1) 1) Drain the transmission oil. Remove the drain plug at T/C housing. Lay the wood plate (or plastic plate) on the workshop's table (bottom).
  • Page 68 Remove the socket gear. Next remove the snap-ring at socket gear. 15L7ATM005 Removal the oil pump sub assy. ① Remove the hexagon bolt (M8×1.25P×38L), and then remove the copper washer. 15L7ATM006 ② Remove the plug. (PT 1/8) 15L7ATM007 ③ Remove the pump sub assy + gasket using the plug hole for pulling out from the T/C housing.
  • Page 69 Removal the control valve sub assy. ① Remove the hexagon bolt (M8×1.25P×60L). 15L7ATM010 ② Remove the part slowly with hit the end side softly. ※ Using a plastic hammer . Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.
  • Page 70 (10) Remove the cooler (in/out) plug.(PT 3/8) 15L7ATM015 (11) Remove the air breather. 15L7ATM016 (12) Remove the hexagon bolt, and then remove the T/ C cover. 15L7ATM017 (13) Remove the oil level gauge. 15L7ATM018 (14) Remove the socket bolt, and then remove the clamp.
  • Page 71 (15) Remove the socket bolt, and then remove the pipe. Next remove the O-ring at the pipe. 15L7ATM020 (16) Remove the temperature sensor. 15L7ATM021 (17) Lay the T/M assy without damage to the T/C housing.(engine mounting surface) 15L7ATM022 (18) Remove the plug, and then remove the spring, oil strainer.
  • Page 72 (19) Remove the plug.(PT 1/8) 15L7ATM024 (20) Remove the socket bolt (T/M case + T/C housing fastening bolt) 4 socket bolt exclusions. 15L7ATM025 15L7ATM026 (21) To turn over T/M assy without damage to the T/M case.(main pump mounting surface) Next remove the 4 socket bolt. 15L7ATM027 3-30...
  • Page 73 Remove the part slowly with hit the end side softly. (22) ※ Using a plastic hammer. 15L7ATM028 (23) Remove the T/C housing. 15L7ATM029 (24) Gear assemblies arrangements. 15L7ATM030 (25) Remove the O-ring. 15L7ATM031 (26) Remove the output gear assy. 15L7ATM032 3-31...
  • Page 74 (27) Remove the idle gear assy. 15L7ATM033 (28) Remove the clutch gear assy. ※ Store each gear assembly in separate box. 15L7ATM034 (29) Remove the oil seal. 15L7ATM035 3-32...
  • Page 75 2) 2) DISASSEMBLING OF GEAR ASSEMBLIES DISASSEMBLING OF GEAR ASSEMBLIES Disassembling clutch gear assy. 15L7ATM036 ① Remove the seal ring. 15L7ATM037 ② Pull out the bearing (#6207) and spacer from the shaft. 15L7ATM038 ③ Pull out the forward clutch sub assy. 15L7ATM039 ④...
  • Page 76 ⑤ Pull out the reverse clutch sub assy. 15L7ATM041 ⑥ Forward clutch sub assy. 15L7ATM042 ⑦ Remove the forward clutch gear sub, and then remove the spacer. 15L7ATM043 ⑧ Remove the snap ring, and then remove the bearing. 15L7ATM044 3-34...
  • Page 77 ⑨ Remove the snap ring, and then remove the back plate, friction disk, and steel plate. 15L7ATM045 ⑩ Remove the wire ring, and then remove the back plate and spring. When you remove the wire-ring, it might be shot When you remove the wire-ring, it might be shot out by impact of spring.
  • Page 78 ⑭ Remove the snap ring, and then remove the bearing. 15L7ATM049 ⑮ Remove the snap ring, and then remove the back plate, friction disk, and steel plate. 15L7ATM050 Remove the wire ring, and then remove the back plate and spring. When you remove the wire-ring, it might be shot When you remove the wire-ring, it might be shot out by impact of spring.
  • Page 79 Disassembling of Idle gear assy. 15L7ATM052 ① Pull out the bearing, and then remove the idle gear upper (lower). 15L7ATM053 Disassembling of output gear assy. 15L7ATM054 3-37...
  • Page 80 ① Remove the seal ring, oil seal and sealing cap. 15L7ATM055 ② Pull out the bearing. 15L7ATM056 3-38...
  • Page 81 2. ASSEMBLY OF TRANSMISSION 2. ASSEMBLY OF TRANSMISSION 1) 1) ASSEMBLING OF GEAR ASSEMBLIES ASSEMBLING OF GEAR ASSEMBLIES ※ Assemble the part with reverse the aforementioned disassemble procedure. · Assembling of clutch gear assembly. Assembling of clutch gear assembly. (1) (1) Forward clutch drum sub assembly.
  • Page 82 ⑤ First insert steel plate, and then insert friction disk alternately. Next insert the back plate, and then assemble the snap ring. 15L7ATM061 ⑥ Assemble the bearing, and then assemble the snap ring alternately. 15L7ATM062 ⑦ Arrange serration of the friction disk, and then assemble the spacer, clutch gear sub.
  • Page 83 (2) (2) Reverse clutch drum sub assembly. Reverse clutch drum sub assembly. ① Do work as the same way like forward clutch drum sub assembly procedure 1) ① ~ ⑤. ② Assemble the bearing, and then assemble the snap ring alternately. 15L7ATM065 ③...
  • Page 84 ③ Assemble the forward clutch drum sub assy at the shaft sub assy. 15L7ATM070 ④ Assemble the spacer and bearing. - Used method of heating bearing. 15L7ATM071 ⑤ Assemble the seal ring. ※ Spread grease on seal ring 15L7ATM072 ⑥ Clutch gear assy.
  • Page 85 Assembling of output gear assembly. Assembling of output gear assembly. ① Assemble the bearing. - Used method of heating bearing ※ All bearings should never be heated above 120°C 15L7ATM074 ② Assemble the oil seal, seal ring and sealing cap. ※...
  • Page 86 Assembling of idle gear assembly. Assembling of idle gear assembly. ① Press the idle gear upper and idle gear lower at the idle gear shaft, and then assemble the bearing. - Used method of heating bearing ※ All bearings should never be heated above 120°C 15L7ATM077 ②...
  • Page 87 2) 2) ASSEMBLING OF TRANSMISSION ASSY ASSEMBLING OF TRANSMISSION ASSY Press the oil seal. ※ Spread loctite #592 on the out wheel of oil seal, spread grease on inside wheel of oil seal. 15L7ATM079 Assemble the clutch gear assy. ※ When you insert the shaft after install the seal ring in the shaft, please insert the shaft with turning it into the shaft side and hole side of shaft for prevent...
  • Page 88 Press the lock-pins. ※ After the assembling, please check whether you can turn the input(output) gear lightly by your hand. 15L7ATM084 Spread loctite #5127 on T/C housing space. 15L7ATM085 Assemble the T/C housing. 15L7ATM086 Assemble the part slowly with hit the end side softly.
  • Page 89 (11) Turn over T/M assy without damage to the T/C housing.(engine mounting surface) Next assemble the socket bolts. ·Socket bolt (M10×1.5p×40 mm)×16EA ·Tightening torque : 5.5~6.5 kgf·m (40~47 lbf·ft) ※ Spread loctite #277 on socket bolt. 15L7ATM089 (12) Assemble the socket bolts. ·Socket bolt (M10×1.5p×25mm)×2EA ·Tightening torque : 5.5~6.5 kgf·m (40~47 lbf·ft) ※...
  • Page 90 (15) Assemble the O-ring at the plug. Insert the oil strainer, spring ,and then assemble O-ring+plug assy. ·Plug tightening torque : 8~10 kgf·m (58~72 lbf·ft) ※ Spread grease on O-ring. 15L7ATM093 (16) Assemble the temperature sensor. ·Tightening torque : 3.0~4.0 kgf·m (22~29 lbf·ft) ※...
  • Page 91 (20) Assemble the T/C cover and hexagon bolts. ·Hexagon bolt (M8×1.25p×16 mm) ×2EA ·Tightening torque : 2.0~3.0 kgf·m (14.5~21.7 lbf·ft) ※ Spread loctite #277 on socket bolt. 15L7ATM098 (21) Assemble the air breather. ·Tightening torque : 1.0~1.5 kgf·m (7.0~11 lbf·ft) ※...
  • Page 92 (25) Assemble the hex bolt. ·Hexagon bolt (M8×1.25p×60 mm)×10EA ·Tightening torque : 3.0~3.3 kgf·m (22~24 lbf·ft) 15L7ATM103 (26) Assemble the o-ring at the charging pump assy. ※ Spread grease on O-ring. 15L7ATM104 (27) Install the gasket at the T/C housing, and then install the charging pump assy.
  • Page 93 (30) Install the flexible plate at the torque converter, and then install the hexagon bolt and washer. ·Hexagon bolt (3/8-24UNF-2B) ×6EA ·Tightening torque : 3.0~3.5 kgf·m (21.6~25.3 lbf·ft) ※ Spread loctite #277 on hexagon bolt 15L7ATM108 (31) Insert the T/C sub assy at the T/M sub assy. 15L7ATM109 (32) Transmission assy.
  • Page 94 3. DISASSEMBLY OF DRIVE AXLE 3. DISASSEMBLY OF DRIVE AXLE 1) 1) DISASSEMBLY DISASSEMBLY Disassembling of drive axle assy. 15L7ADA001 Remove bolts of hub sub assembly. To avoid serious personal injury and possible To avoid serious personal injury and possible damage to components, be very careful when damage to components, be very careful when using lifting devices during removal and...
  • Page 95 Remove pins. 15L7ADA005 Disassemble in order of special bolt → return spring. 15L7ADA006 Detach brake piston. 15L7ADA007 After remove retaining ring, pull out left axle shaft. (Do work as the same way like right axle shaft) Use a brass, leather or rubber mallet for Use a brass, leather or rubber mallet for assembly and disassembly procedures.
  • Page 96 (10) Remove all snap rings. 15L7ADA010 Remove all each parts in order of thrust washer → (11) planet gear → needle bearing → thrust washer. 15L7ADA011 (12) Loose lock nut by using jig. 15L7ADA012 (13) Extract planet carrier. 15L7ADA013 (14) Extract carrier housing with bearing.
  • Page 97 (15) Remove bolts fixing flange hub and wheel shaft. 15L7ADA015 (16) Remove bolts fixing carrier assy. 15L7ADA016 (17) Extract the bracket. 15L7ADA017 (18) Extract carrier assembly. 15L7ADA018 (19) Fix carrier assembly to a jig. 15L7ADA019 3-55...
  • Page 98 (20) Remove carrier cap bolt. 15L7ADA020 (21) Extract the carrier cap (apply marking a match). 15L7ADA021 (22) Remove adjusting ring of both sides bearing cup. 15L7ADA022 (23) Extract differential assembly. 15L7ADA023 (24) After turn over carrier assy and fix it, remove nut. 15L7ADA024 3-56...
  • Page 99 (25) Remove U-joint flange. 15L7ADA025 (26) Remove carrier case cover bolts. 15L7ADA026 (27) Extract carrier case cover assembly. 15L7ADA027 (28) Extract push pins and actuator. 15L7ADA028 (29) Remove O-ring and spline parking. 15L7ADA029 3-57...
  • Page 100 (30) Remove parking friction plates and separate plates. 15L7ADA030 (31) Finish disassembling of carrier assembly. 15L7ADA031 3-58...
  • Page 101 2) 2) ASSEMBLY ASSEMBLY (1) (1) Carrier sub assembly Carrier sub assembly Thrust washer Differential device assembly Differential gear ① Prepare parts for assembly of differential. Spider Differential Differential case-RH case-LH Bearing 15L7MDA032 ② Fix differential case RH and LH with bolt. After paste loctite #277 on spiral of bolt.
  • Page 102 Adjusting shim and pinion shaft assembly Adjusting shim and pinion shaft assembly ① Fix carrier case to the jig. ※ Read the following information before installing new gearset in the carrier. Always inspect the gearset for correct marks to make sure the gears are a matched set.
  • Page 103 ② Decide thickness of shim by gauge and measuring apparatus (Standard gap between bearing and carrier case step : A) (Mounting distance (MD) of pinion shaft : B) ※ Thickness of shim · X = A - B + Carrier case bearing step depth ex1) A= 0.35, B= -0.1, Bearing step depth= +0.1 ·...
  • Page 104 ⑦ Set a ball. 15L7ADA043 ⑧ Equip jig for fixing. 15L7ADA044 ⑨ Fasten the ball. 15L7ADA045 ⑩ Revolve carrier case 180°. 15L7ADA046 ⑪ Put into spacer. 15L7ADA047 3-62...
  • Page 105 ⑫ Decide thickness of shim by gauge and measuring apparatus (thickness : B) ※ Thickness of shim · X = B - End play (0.03~0.06) ex 1) B = 0.45, · X = 0.45 - (0.03~0.06) = 0.42~0.39 mm 15L7ADA048 ⑬...
  • Page 106 Assemble bearing cone. Assemble after paste grease on bearing cone roller. 15L7ADA053 Assemble of parking sub assembly Assemble of parking sub assembly ① Assemble pin into carrier case. 15L7ADA054 ② Assemble in order of separate plate → cone spring → friction plate. But assemble separate plate lastly.
  • Page 107 ⑤ Assemble push pin into actuator. 15L7ADA058 ⑥ Assemble O-ring on groove of pinion shaft. Assemble after paste grease on O-ring grease. 15L7ADA059 ⑦ Assemble pin into the carrier case. 15L7ADA060 Assemble of carrier case cover assemble Assemble of carrier case cover assemble ①...
  • Page 108 ③ Assemble cover by first putting small O-ring on eccentric shaft, and then put big O-ring on collor. 15L7ADA063 ④ Assemble set screw. Assemble paste loctite #277. Confirm torque : 200~250 kgf·cm 15L7ADA064 ⑤ After complete assembling of axle when pull parking lever.
  • Page 109 ⑦ Assemble cap. Assemble after paste loctite #609. 15L7ADA067 ⑧ Assemble carrier cover assy. Assemble after paste loctite #277. Confirm torque : 304~405 kgf·cm Paste loctite #5127 on assembling side of carrier case cover and carrier case. 15L7ADA068 ※ Applying liquid gasket material. ※...
  • Page 110 ⑨ Assemble flange U-joint. 15L7ADA070 ⑩ Fasten nut. Assemble paste loctite #242. Confirm torque : 2600~2950 kgf·cm ※ Preload : 10~19 kgf·cm 15L7ADA071 ⑪ Calking. (2 EA) 15L7ADA072 ⑫ Assemble differential sub in carrier case. 15L7ADA073 ⑬ Fit carrier cap with steel ball. Bolt : paste loctite #277 Confirm torque : 1170~1130 kgf·cm 15L7ADA075...
  • Page 111 Adjusting the gearset backlash Adjusting the gearset backlash ① Assemble bearing adjust ring. 15L7ADA076 ② Adjust bearing adjust ring. 15L7ADA077 ③ Measure backlash. 15L7ADA078 ④ Fasten bearing adjust ring. 15L7ADA079 ⑤ Measure again backlash. ※ Backlash of pinion and ring gear : 0.15~0.20 mm ※...
  • Page 112 ※ Backlash is increased by moving the ring gear away from the pinion shaft. Backlash is decreased by moving the ring gear toward the pinion shaft. Refer to figure DA076 and DA077. ⑥ Loosen one bearing adjusting ring one notch, then tighten the opposite ring the same amount.
  • Page 113 ② Rotate ring gear forward and backward so that the 6 marked teeth go past the drive pinion six time to get a good contact pattern. ③ Compare the contact patterns to figure DA086, DA087 and DA088. ※ In new gearsets, a good contact pattern is toward the toe of the tooth, and centered between the top and bottom of the tooth.
  • Page 114 ④ If the contact patterns require adjustment along the width of tooth (top/bottom), follow steps ⓐ-ⓑ. If the contact patterns require adjustment along the length of tooth (toe/heel), follow steps ⓒ-ⓓ. ⓐ High pattern : A high contact pattern indicates that the pinion was installed too shallow into the carrier.
  • Page 115 ⑤ Fix spring pin with ring bearing adjust. And assemble them. 15L7ADA094 15L7ADA095 3-73...
  • Page 116 (2) (2) Assemble of carrier assembly Assemble of carrier assembly ① Pressurize lock pin into axle housing. 15L7ADA096 ② Paste sealant on axle housing. (Loctite #5127) 15L7ADA097 ③ Assemble carrier assembly on axle housing. 15L7ADA098 ④ Fasten bolt. Assemble bolt after spread loctite #277. Confirm torque : 610~650 kgf·cm 15L7ADA099 3-74...
  • Page 117 Traveling brake system assembly Traveling brake system assembly (3) (3) Axle shaft assembly ① Insert snap ring on the axle shaft. 15L7ADA100 ② After put the ball bearing, fix it with snap ring. 15L7ADA101 ③ After put axle shaft into axle housing fix with snap ring.
  • Page 118 ※ When assembling the shim, you calculate the value of the shim ad then assemble it. · "L" : Piston assembling part axle housing stage depth (standard : 56.9 mm) · "C" : Carrier housing stage height (standard : 9 mm) ·...
  • Page 119 ⑥ Assemble in order of separate plate → friction plate → cone spring. But Assemble separate plate lastly. (Separate plate : 4EA , friction plate : 3EA) 15L7ADA109 (4) (4) Hub assembly Hub assembly Hub sub assembly ① Pressurize hub bolt. 15L7ADA110 ②...
  • Page 120 ⑤ Assemble flange hub and wheel shaft. ※ Paste loctite #5127 Confirm torque : 600~700kgf·cm Bolt : Spread loctite #277 15L7ADA114 ⑥ Fix spacer. 15L7ADA115 ⑦ Assemble oil seal at carrier housing. Oil seal with loctite #592. 15L7ADA116 ⑧ Assemble bearing cup at carrier housing. 15L7ADA117 ⑨...
  • Page 121 ⑩ Put carrier housing on assembled flange hub and wheel shaft. Before assembling, spread grease inside of flange hub. ·Grease : Shell retinax 0434 - 60~80% spread 15L7ADA119 ⑪ Adjust preload for fix shim. ·Preload : 40~50 kgf·cm 15L7ADA120 ⑫ Put into shim.
  • Page 122 ⑮ Fasten lock nut. Confirm torque : 2800~3200 kgf·cm, calke after assembling. ·Preload : 40~50 kgf·cm 15L7ADA124 Assemble in order of washer → needle bearing → planet gear → washer . Before assembling washer, paste oil, spread grease on needle bearing. 15L7ADA125 Fix snap ring.
  • Page 123 The rest part assembly The rest part assembly (6) (6) ① Assemble O-ring and fitting bleeder for LH and RH. Confirm torque : 380~420 kgf·cm 15L7ADA129 ② Assemble bleeder and cap. Screw : Assemble after spread loctite #577. Confirm torque : 150~200 kgf·cm 15L7ADA130 ③...
  • Page 124 ⑥ Put in dipstick. ※ Fill axle oil as much as standard. Standard between the upper limit and the lowest limit. Figure DA134. 15L7ADA134 15L7ADA135 ⑦ Assemble bracket. Bolt : Paste loctite #277. Confirm torque : 610~650 kgf·cm 15L7ADA136 ⑧ Finish drive axle assembly.
  • Page 125 (7) (7) Functional test of hydraulic apply brake Functional test of hydraulic apply brake ※ The following procedure describes how to test the hydraulic apply brake system only. To perform this test, use a device that allows you to observe possible leaks through oil seals and that also allows you to verify that the piston return system works correctly .

  • Page 126: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and function -------------------------------------------------------------------------------------- 4-1 Group 2 Operational checks and troubleshooting -------------------------------------------------------- 4-5 Group 3 Tests and adjustments ------------------------------------------------------------------------------------- 4-7...

  • Page 127: Group 1 Structure And Function

    SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE There are two brake systems, the foot brake system and the hand brake system. The foot brake adopts the brake system of oil type at drive axle. kgf/cm 2 Oil pressure is generated in maximum 60 through brake oil input path of the left and right...
  • Page 128 3. BRAKE PEDAL AND PIPING 3. BRAKE PEDAL AND PIPING STRUCTURE STRUCTURE T/M control valve Drive axle 20DF7TBS01 Brake pedal Reservoir tank assembly Parking lever assembly Brake master cylinder...
  • Page 129 4. INCHING PEDAL AND LINKAGE 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the drive axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force.
  • Page 130 5. WET DISK BRAKE 5. WET DISK BRAKE STRUCTURE STRUCTURE 1) 1) 15L7APT20 Drive axle housing Piston brake Socket gear Square ring Plate Snap ring Square ring Friction plate Flange shaft 2) 2) OPERATION OPERATION Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.

  • Page 131: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS 1) 1) BRAKE PIPING 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.
  • Page 132 2. TROUBLESHOOTING 2. TROUBLESHOOTING Problem Cause Remedy ·Hydraulic system leaks oil. ·Repair and add oil. Insufficient braking force ·Hydraulic system leaks air. ·Bleed air. ·Disk worn. ·Replace. ·Brake valve malfunctioning. ·Repair or replace. ·Hydraulic system clogged. ·Clean. ·Tires unequally inflated. ·Adjust tire pressure.

  • Page 133: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS GROUP 3 TESTS AND ADJUSTMENTS 1. AIR BLEEDING OF BRAKE SYSTEM 1. AIR BLEEDING OF BRAKE SYSTEM Air bleeding should be performed by two persons : One rides on truck for depressing and releasing brake pedal : the other person is Air vent plug on the ground and removes cap from air vent plug on wheel cylinder.
  • Page 134 (3) (3) Micro switch for parking brake (if Micro switch for parking brake (if equipped) equipped) Lever stroke 12.1 ① After assembling parking brake and parking cable, put the parking brake lever released. ② Loosen the nut for parking brake plate to Micro switch play up and down.

  • Page 135: Section 5 Steering System

    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 136: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE ( 1. OUTLINE (NON BOOSTER BRAKE NON BOOSTER BRAKE) Steering wheel Steering unit Steering cylinder Hydraulic tank Gear pump 20DFSS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and pipings.
  • Page 137 2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT LIFT CYLINDER 20DFSS02 Hydraulic gear pump with priority valve Suction strainer Steering unit Hydraulic tank Steering cylinder...
  • Page 138 1) 1) NEUTRAL NEUTRAL LIFT CYLINDER 20DFSS03 The steering wheel is not being operated so control spool (G) does not move. The oil from hydraulic gear pump (1) enters priority valve and the inlet pressure oil moves the spool (D) to the left. Oil flow into LS port to the hydraulic tank (5).
  • Page 139 2) 2) LEFT TURN LEFT TURN LIFT CYLINDER 20DFSS04 When the steering wheel is turned to the left, the spool (G) within the steering unit (2) 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 (2) through the spool (D) of priority valve and flows to the gerotor (H).
  • Page 140 3) 3) RIGHT TURN RIGHT TURN LIFT CYLINDER 20DFSS05 When the steering wheel is turned to the right, the spool (G) within the steering unit (2) 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 141 3. STEERING UNIT 3. STEERING UNIT 1) 1) STRUCTURE STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing 14 Bearing race 24 Plate spring Ball 15 Bore screw...
  • Page 142 2) 2) OPERATION 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.
  • Page 143 4. 4. STEERING STEERING AXLE AXLE 1) 1) STRUCTURE STRUCTURE 20D7SS07 Steering axle 17 Hub 33 Thrust washer Knuckle-RH 18 Hub bolt 34 Pin Knuckle-LH 19 Hub nut 35 Spring washer Special bolt 20 Hub cap 36 Hardened washer King pin 21 Steering link 37 Upper cover Taper roller bearing...
  • Page 144 TIGHTENING TORQUE AND SPECIFICATION TIGHTENING TORQUE AND SPECIFICATION Stroke 86mm Stroke 86mm Apply loctite #277 49.5~66.5 kgf m(358~481 lbf ft) 20D7SS08 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...

  • Page 145: Group 2 Operational Checks And Troubleshooting

    Fit bar and a piece of chalk at outside edge of counterweight to mark line of turning radius. · If minimum turning radius is not within±100 mm (±4 in)of specified value, adjust turning angle stopper bolt. Min turning radius (Outside) 20DT-7 2248 mm (86 in) 30DT-7 2398 mm (94 in) 25DT-7 2302 mm (91 in)
  • Page 146 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 147: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT 1. STEERING UNIT 1) 1) STRUCTURE STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing...
  • Page 148 TOOLS 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 149 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1kgf·m (0~54.4lbf·ft) 13 mm socket spanner 6, 8 mm and 12 mm hexagon sockets 12 mm screwdriver 2 mm screwdriver 13 mm ring spanner 6, 8 and 12 mm hexagon socket spanners Plastic hammer Tweezers 5-70(2)
  • Page 150 DISASSEMBLY 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 151 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool.
  • Page 152 Take ring, bearing races and thrust bearing from sleeve and spool. The outer (Thin) bearing race can sometimes "stick" in the housing, therefore check that it has come out. 5-74(1) (10) Press out the cross pin. Use the special screw from the end cover. 5-74(2) ※...
  • Page 153 (12) Press the neutral position springs out of their slots in the spool. 5-75(1) (13) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve Disassembling the pressure relief valve (14) Screw out the plug using an 8mm hexagon socket spanner.
  • Page 154 (16) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (17) T h e p r e s s u r e r e l i e f v a l v e i s n o w disassem-bled.
  • Page 155 ASSEMBLY 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 156 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 157 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) ※ Assembly pattern for standard bearings Assembly pattern for standard bearings Outer bearing race Thrust bearing Inner bearing race Spool Sleeve 5-78(3) Installation instruction for O-ring Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 158 (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 159 (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 Installation instructions for lip seal (15) Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 160 (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 161 (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 162 (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 163 (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 164 (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! Do not use a hammer! 5-85(2) 5-29...
  • Page 165 2. STEERING CYLINDER 2. STEERING CYLINDER 1) 1) STRUCTURE 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 166 2) 2) DISASSEMBLY 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 167 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±6 kgf·m (434±43 lbf·ft).
  • Page 168 3. TRAIL AXLE 3. TRAIL AXLE 1) 1) STRUCTURE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 20D7SS07 Steering axle 17 Hub 33 Thrust washer Knuckle-RH 18 Hub bolt 34 Pin Knuckle-LH 19 Hub nut 35 Spring washer Special bolt 20 Hub cap 36 Hardened washer...
  • Page 169 2) 2) CHECK AND INSPECTION CHECK AND INSPECTION A1,A2 20D7SS10 unit : mm (in) Criteria Check item Remarks Standard size Repair limit OD of shaft 55(2.2) 54.5(2.1) Shaft ID of bushing 55(2.2) 55.5(2.2) OD of king pin 35(1.4) 34.5(1.4) Replace OD of steering cylinder pin 20(0.8) 19.5(0.8)
  • Page 170 3) 3) DISASSEMBLY DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the counter Hub nut weight part of the truck. Loosen the hub nut and take off the steering wheel tire.
  • Page 171 4) 4) ASSEMBLY ASSEMBLY ※ In reassembling, have all parts washed, grease applied to lubricating parts, and all expendable items such as oil seal and spring washers replaced by new ones. Perform the disassembly in reverse order. Tighten the special bolt (4) and washer (35) of king pin (5).

  • Page 172: Section 6 Hydraulic System

    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 173: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 1. HYDRAULIC CIRCUIT 4B 4A 3B 3A LIFT TILT AUX1 AUX2 20DFHS01S Hydraulic gear pump with Priority valve Tilt cylinder Main control valve Suction strainer Steering unit...
  • Page 174 1) 1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 3B 3A 4B 4A LIFT TILT AUX1 AUX2 Steering system Return line 20DFHS03S When the lift control lever is pulled back, the spool on the first block moves to lift position. The oil from hydraulic gear pump (1) flows into main control valve (2) and then goes to the large chamber of lift cylinder (5) by pushing the load check valve of the spool.
  • Page 175 2) 2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 3B 3A 4B 4A LIFT TILT AUX1 AUX2 Steering system Return line 20DFHS04 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 176 3) 3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 3B 3A 4B 4A LIFT TILT AUX1 AUX2 Steering system Return line 20DFHS05S When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
  • Page 177 4) 4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 4B 4A 3B 3A LIFT TILT AUX1 AUX2 Steering system Return line 20DFHS06S When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
  • Page 178 2. HYDRAULIC GEAR PUMP STRUCTURE 29,30 2 7 9 10 11 1 13 14 SECTION B - B" 20L7HS07 Housing 11 Back-up ring 21 Spring Body 12 Side plate 22 Plug Body-priority v/v 13 Oil seal 23 O-ring Bushing 14 Snap ring 24 Adjust screw O-ring 15 Bold...
  • Page 179 3. MAIN CONTROL VALVE 3. MAIN CONTROL VALVE 1) 1) STRUCTURE STRUCTURE (4- Spool) 16 15 SECTION H - H SECTION T - T SECTION E - E VIEW F - F VIEW G - G VIEW I - I Port name Size Inlet port...
  • Page 180 INLET SECTION OPERATION INLET SECTION OPERATION (1) (1) Structure and description Structure and description (Relief valve piston) 9 10 Relief valve piston 20D7HS08 Hydrostat plug 14 Relief plug O-ring 16 Relief spring 10 Hydrostat spring 17 Pilot poppet 11 Hydrostat sleeve 28 O-ring 12 Relief piston 29 System relief seat...
  • Page 181 (2) (2) Operation Operation Secondary relief valve To neutral passage To aux block 16.5MPa System relief valve 20.0MPa To neutral passage To load check valve 20D7HS15 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 182 LIFT SECTION OPERATION LIFT SECTION OPERATION (1) (1) Lift position Lift position Load check valve 20DEHS09 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 183 (2) (2) Lower position Lower position Load check valve 20DEHS10 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. In lift lower position the fork drops due to its own weight.
  • Page 184 TILT SECTION OPERATION TILT SECTION OPERATION (1) (1) Tilt forward position Tilt forward position Tilt lock spool Load check valve 20D7HS11 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed.
  • Page 185 (2) (2) Tilt backward position Tilt backward position Tilt lock spool Load check valve 20D7HS12 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flows into tilt cylinder port (2A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 186 5) 5) MAIN RELIEF VALVE MAIN RELIEF VALVE (1) (1) Pressure setting Pressure setting Seat Relief plug A good pressure gauge must be installed 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 Adjust bar pressure of the relief unit.
  • Page 187 4. LIFT CYLINDER 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 5. TILT CYLINDER 18 17 16 19,20,21 11,12 13,14...
  • Page 188 6. FREE LIFT CYLINDER 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 189: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS 1) 1) CHECK ITEM CHECK ITEM Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1m from ground.
  • Page 190 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) SYSTEM SYSTEM Problem Problem Cause Cause Remedy 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.
  • Page 191 2) 2) HYDRAULIC GEAR PUMP HYDRAULIC GEAR PUMP Problem Problem Cause Cause Remedy 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.
  • Page 192 4) 4) LIFT CYLINDER LIFT CYLINDER Problem Problem Cause Cause Remedy 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.

  • Page 193: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. Disassembly 1. Disassembly CLAMPING PUMP CLAMPING PUMP 1) 1) Clamping pump in a vice with pump shaft facing up. (Do not chuck the aluminum parts such as body and housing.) Mark V by permanent marker pen.
  • Page 194 4) 4) BODY AND REAR COVER BODY AND REAR COVER Loosen the vice and remove body and bronze side plate from rear cover. Remove O-ring from rear cover. Disassemble pin from body. PUMP105 5) 5) PRIORITY VALVE PRIORITY VALVE Loosen the plug at the side of drive gear, be careful not to bounce out spring.
  • Page 195 2. ASSEMBLY 2. ASSEMBLY 1) 1) PREPARATION PREPARATION Clean all parts and dry them with compressed air thoroughly. Check the permanent mark. Apply grease O-ring, oil seal, E-type ring and side plate lightly. 2) 2) PRIORITY VALVE PRIORITY VALVE Suction Discharge ·...
  • Page 196 3) 3) REAR COVER AND BODY REAR COVER AND BODY Assemble pin into body. Suction Discharge Assemble O-ring on the groove of rear cover. Place the bronze face of side plate contact with gear on rear cover. Insert side plate into body and adjust pin by pressing after adjusting pin hole of rear PUMP108 cover and pin of body.
  • Page 197 5) 5) HOUSING HOUSING Press fit oil seal with same direction as drawing carefully and fit snap ring. Fit O-ring into groove of housing. Insert drive gear into housing and combine housing with body pressing lightly after confirmed pin position. Tighten bolt with washer zigzag lightly, be careful not to leave O-ring its place.
  • Page 198 2. MAIN CONTROL VALVE 2. MAIN CONTROL VALVE Remove bolt (1) to separate the valve section. +0.6 ·Bolt torque (1) : 4.0 kgf·m 20D7MCV01 Divide the valve body. Aux2 Aux1 Tilt Lift T-cover 20D7MCV02 Remove dust cap (3) and bolt (2) from the valve body.
  • Page 199 Remove O-ring seals (5) from the valve body. 20D7MCV05 Remove tilt spool (6) from the valve body. 20D7MCV06 Remove lift spool (7) from the valve body. Remove lock poppet (8) from the valve body. Remove normal close solenoid valve (9, Opt) from the valve body.
  • Page 200 Remove relief plugs (15), springs (14) and poppets (13). ·Relief plugs torque (15) : 2.5 kgf·m 20D7MCV09 Remove normal open solenoid valve (16, Opt) from the valve body. 20D7MCV10 Assembly procedure of the main control valve is the reverse order of the removal procedure. 6-28...
  • Page 201 3. LIFT CYLINDER 3. LIFT CYLINDER 1) 1) STRUCTURE STRUCTURE Down safety valve 20D7HS19 Tube assy Wear ring 11 O-ring Rod assy Retaining ring 12 Guide Piston Gland 13 Du bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 6-29...
  • Page 202 2) 2) DISASSEMBLY DISASSEMBLY Hold the cylinder tube in a vice, loosen Guide the cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn.
  • Page 203 4. TILT CYLINDER 4. TILT CYLINDER 1) 1) STRUCTURE STRUCTURE D255HS27 Tube assy Rod cover 15 O-ring Dust wiper 16 Eye Piston 10 DU bushing 17 Spherical bearing Piston seal 11 Rod seal 18 Grease nipple Wear ring 12 Back up ring 19 Hexagon bolt O-ring 13 O-ring...
  • Page 204 2) 2) DISASSEMBLY 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 205: Section 7 Electrical System

    SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component location ----------------------------------------------------------------------------------------- 7-1 Group 2 Electrical circuit ------------------------------------------------------------------------------------------------- 7-2 Group 3 Component Specification --------------------------------------------------------------------------------- 7-10 Group 4 Connector Destination -------------------------------------------------------------------------------------- 7-11 Group 5 Troubleshooting ------------------------------------------------------------------------------------------------- 7-13...

  • Page 206: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 9 10 13 14 15 16 20D7EEL01 Flasher lamp Cluster 13 Glow controller Work lamp Start switch 14 OPSS unit Horn assembly 10 Head lamp switch 15 Flasher unit Beacon lamp(opt) Illumination lamp...

  • Page 207: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT EPACS CONTROLLER RS232C RXD RS232C SHIELD DASHBOARD PART LOADER SENSOR CABIN PART CAM_SHIELD CAN_SHIELD CAN HIGH(+) CN-27 CAN LOW(-) CN-17 F/COMBI H/LAMP 200-RW 290-LW S.R- 340-L CLUSTER S.L- RS232C TXD G1-B PROGRAM DUMP FOR CABIN FRAME/ENGINE PART ILL+...
  • Page 208 MEMORANDUM MEMORANDUM...
  • Page 209 1. POWER CIRCUIT 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 OPERATING FLOW Battery(+) Start motor[CN-45(B+)] Fusible link[CN-95A(1→2)] Alternator[CN-74(B+)]...
  • Page 210 POWER CIRCUIT POWER CIRCUIT CL-16 CS-2 CN-36 390 W 200 RW HORN/BRAKE LAMP 120 R TURN LAMP 210 Gr OPS-UNIT 212 Y 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR - ACC TRAVEL 4 BR - ACC FUEL CUT SOL/ALT 2 R2 R/COMBI RH...
  • Page 211 2. STARTING CIRCUIT 2. STARTING CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-95A] Alternator[CN-74(B+)] I/conn[CN-1] Start switch[CS-2(3)] Start relay[CR-23(87)] Glow relay[CR-24(30)] ※The engine can be started only when the gearshift is in neutral position. (1) (1) When start key switch is in ON position When start key switch is in ON position Start switch ON [CS-2(4)]...
  • Page 212 STARTING CIRCUIT STARTING CIRCUIT CS-2 CN-36 170 W HORN/BRAKE LAMP 120 R TURN LAMP CR-5 180 WR OPS-UNIT 4 BR 220 Br START RELAY 220 Br - ACC 1 R1 ILL/HEAD LAMP 320 YB 4 BR TRAVEL - ACC 4 BR - ACC 250 Or FUEL CUT SOL/ALT...
  • Page 213 3. CHARGING CIRCUIT 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 214 CHARGING CIRCUIT CHARGING CIRCUIT CS-2 CN-36 170 W HORN/BRAKE LAMP 120 R TURN LAMP 180 WR OPS-UNIT 4 BR START RELAY - ACC CN-56 1 R1 ILL/HEAD LAMP 4 BR GLOW LAMP(-) TRAVEL - ACC GLOW LAMP(+) 4 BR - ACC 250 Or FUEL CUT SOL/ALT 2 R2...

  • Page 215: Group 3 Component Specification

    GROUP 3 COMPONENT SPECIFICATION GROUP 3 COMPONENT SPECIFICATION Part name Specification Remark Battery 12V MF80CT RC : 130 min CCA : 630A Working lamp 12V, 55W License lamp 12V, 3.4W×2 Rear combination lamp 12V, 21W (T/S) 12V, 10W (Back) 12V, 5W (Tail) 12V, 21W (Stop) Head lamp 12V, 55W...

  • Page 216: Group 4 Connector Destination

    GROUP 4 CONNECTOR DESTINATION GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn (Dashboard harness-frame harness) 368047-1 CN-3 I/conn (Dashboard harness-frame harness) CN-4 I/conn (Head guard harness-dashboard harness) MG640348 CN-5 To support harness-RH S810-004201 CN-7 I/conn (Dashboard harness-frame harness)
  • Page 217 Connector part No. Connector No. of Type Destination number Female Male Lamp Lamp CL-3 Head lamp ST730018-3 ST750036-3 CL-7 Beacon lamp ST730018-3 ST750036-3 CL-15 DAEDONG Combination lamp-LH 110-6PR CL-16 DAEDONG Combination lamp-RH 110-6PR CL-21 License lamp S822-014000 S822-114000 CL-23 Working lamp ST730018-3 ST750036-3 Relay...

  • Page 218: Group 5 Troubleshooting

    GROUP 5 TROUBLESHOOTING GROUP 5 TROUBLESHOOTING Trouble symptom Trouble symptom Probable cause Probable cause Remedy 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.
  • Page 219 SECTION 8 MAST 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 220: Group 1 Structure

    SECTION 8 MAST SECTION 8 MAST GROUP 1 STRUCTURE GROUP 1 STRUCTURE 1. 2 STAGE MAST (V MAST) 1. 2 STAGE MAST (V MAST) TILT CYLINDER LIFT CYLINDER CARRIAGE 20D7MS01 Outer mast Anchor bolt 11 Bushing Inner mast Chain wheel bearing 12 Roller Roller Retaining ring...
  • Page 221 2. 2 STAGE MAST (VF MAST) 2. 2 STAGE MAST (VF MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE 20D7MS02 Outer mast Shim (0.5, 1.0t) 11 Bushing Inner mast Roller 12 Sheave Chain Shim (0.5, 1.0t) 13 Sheave bracket Anchor bolt Tilt cylinder pin 14 U-bolt...
  • Page 222 3. 3 STAGE MAST (TF MAST) 3. 3 STAGE MAST (TF MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE 20D7MS21 Outer mast Roller 11 Sheave Middle mast Shim (0.5, 1.0t) 12 Tilt cylinder pin Inner mast Back up liner 13 Support cap Chain Shim (0.5, 1.0t)
  • Page 223 4. CARRIAGE, BACKREST AND FORK 4. CARRIAGE, BACKREST AND FORK D255MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...

  • Page 224: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS 1) 1) FORKS FORKS Measure thickness of root of forks and check that it is more than specified value. EX :ℓ= 1050 mm (41.3 in) mm (in) STD Fork assy Applicable model Standard Limit Thickness...
  • Page 225 2. TROUBLESHOOTING 2. TROUBLESHOOTING MAST MAST 1) 1) Problem Problem Cause Cause Remedy 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.
  • Page 226 2) 2) FORKS FORKS Problem Problem Cause Cause Remedy Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear and reduces the thickness of the wear limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion...

  • Page 227: Group 3 Adjustment

    GROUP 3 ADJUSTMENT GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER (V, VF MAST) 1. MAST LOAD ROLLER (V, VF MAST) 1) 1) INNER/OUTER MAST ROLLER INNER/OUTER MAST ROLLER CLEAR-ANCE ADJUSTMENT CLEAR-ANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480 mm. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the...
  • Page 228 2. MAST LOAD ROLLER (TF MAST) 2. MAST LOAD ROLLER (TF MAST) 1) 1) INNER AND MIDDLE MAST ROLLER INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480 mm. 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...
  • Page 229 3) 3) CARRIAGE LOAD ROLLER CARRIAGE LOAD ROLLER Outer mast Adjust Bring into Measure the clearance when the center of screw contact the carriage upper roller is 100 mm from the top of the inner mast. Measure the clearance at upper, middle Side and lower rollers after loosen the adjust roller...

  • Page 230: Group 4 Removal And Installation

    GROUP 4 REMOVAL AND INSTALLATION GROUP 4 REMOVAL AND INSTALLATION 1. FORKS 1. FORKS Lower the fork carriage until the forks are Knob approximately 25 mm (1 inch) from the floor. Turn the knob up and slide forks, one by one, toward the center of the carriage Spring where a notch has been cut in the bottom...
  • Page 231 2) 2) SIDE ROLLER 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 232 4) 4) MAST LOAD ROLLER AND BACK UP MAST LOAD ROLLER AND BACK UP LINER LINER (1) (1) 2 stage mast (V mast) 2 stage mast (V mast) Chain ① Remove the carriage assembly and move them to one side. Stud bolt ②...
  • Page 233 (2) (2) 2 stage mast (TF mast) 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...
  • Page 234 (2) (2) 3 stage mast (TF mast) 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.
  • Page 235 5) 5) ELEVATING MAST ELEVATING MAST (1) (1) Inner mast (V, VF 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...
  • Page 236 6) 6) CHAIN CHAIN Chain sheave (V, VF mast) Chain sheave (V, VF mast) (1) (1) ① Place a sling around carriage and attach to an overhead hoist. Lift carriage high Chain Anchor enough so that the tension on the chain bolt Middle mast over sheaves is relieved after the...
  • Page 237 (3) (3) Chain wheel bearing support (TF mast) 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 238 ② ② Rust and corrosion 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 239 ⑧ ⑧ Chain wear scale 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 240 ③ Adjustment 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 Adjustment procedure Adjustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor.

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