Hyundai 35DS-7 Operation Manual
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Hyundai 35DS-7 Operation Manual

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SECTION 1 GENERAL
SECTION 1 GENERAL
Group 1 Safety hints --------------------------------------------------------------------------------------------------------
Group 2 Specifications ----------------------------------------------------------------------------------------------------
Group 3 Periodic replacement ----------------------------------------------------------------------------------------
Group 1 Structure ------------------------------------------------------------------------------------------------------------
Group 2 Removal and Installation of Unit ----------------------------------------------------------------------
Group 1 Structure and operation -----------------------------------------------------------------------------------
Group 2 Inspection and troubleshooting -----------------------------------------------------------------------
Group 3 Disassembly and assembly -----------------------------------------------------------------------------
Group 1 Structure and function --------------------------------------------------------------------------------------
Group 2 Operational checks and troubleshooting --------------------------------------------------------
Group 3 Tests and adjustments -------------------------------------------------------------------------------------
Group 1 Structure and function --------------------------------------------------------------------------------------
Group 2 Operational checks and troubleshooting --------------------------------------------------------
Group 3 Disassembly and assembly -----------------------------------------------------------------------------
Group 1 Structure and function --------------------------------------------------------------------------------------
Group 2 Operational checks and troubleshooting --------------------------------------------------------
Group 3 Disassembly and assembly -----------------------------------------------------------------------------
CONTENTS
CONTENTS
1-1
1-5
1-13
2-1
2-2
3-1
3-13
3-19
4-1
4-9
4-11
5-1
5-10
5-12
6-1
6-19
6-24

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  • Page 1: Table Of Contents

    CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints -------------------------------------------------------------------------------------------------------- Group 2 Specifications ---------------------------------------------------------------------------------------------------- Group 3 Periodic replacement ---------------------------------------------------------------------------------------- 1-13 SECTION 2 REMOVAL AND INSTALLATION OF UNIT SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure ------------------------------------------------------------------------------------------------------------ Group 2 Removal and Installation of Unit ---------------------------------------------------------------------- SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM...
  • Page 2 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component location ----------------------------------------------------------------------------------------- Group 2 Electrical circuit ------------------------------------------------------------------------------------------------- Group 3 Component specification --------------------------------------------------------------------------------- 7-22 Group 4 Connector destination -------------------------------------------------------------------------------------- 7-24 7-25 Group 5 Troubleshooting ------------------------------------------------------------------------------------------------ SECTION 8 MAST SECTION 8 MAST Group 1 Structure ------------------------------------------------------------------------------------------------------------ Group 2 Operational checks and troubleshooting -------------------------------------------------------- Group 3 Adjustment --------------------------------------------------------------------------------------------------------...
  • 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( Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 7 Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
  • Page 8 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...
  • 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 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. D50ASF09 When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
  • Page 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 1. MAJOR COMPONENTS D357OM54 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 Carriage 12 Bonnet...
  • Page 17 2. SPECIFICATIONS 35DS/40DS/45DS-7 (MHI ENGINE) D357SP01 Model Unit 35DS-7 40DS-7 45DS-7 Capacity 3500 4000 4500 Load center Weight(Unloaded) 5915 6460 6875 Lifting height 3000 Free lift Fork Lifting speed(Unload/Load) mm/sec 600/570 600/560 600/550 Lowering speed(Unload/Load) mm/sec 450/500 L W T...
  • Page 18 35D/40D/45D-7 (HMC ENGINE) D357SP01 Model Unit 35D-7 40D-7 45D-7 Capacity 3500 4000 4500 Load center Weight(Unloaded) 5890 6460 6875 3000 Lifting height Free lift 600/550 600/540 600/530 Fork Lifting speed(Unload/Load) mm/sec 450/500 Lowering speed(Unload/Load) mm/sec L,W,T 1070 122 50 1070 150 50 1220 150 50 L W T 8/10...
  • Page 19 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE ITEM 35DS/40DS/45DS-7 35D/40D/45D-7 UNIT Model MITSUBISHI S6S-DT HYUNDAI D4DA-C1 Type 4-cycle, in-line, Vertical OHV 4 cycle turbocharged diesel Cooling Method Water cooling Water cooling Number of cylinders and arrangement 6 cylinders, in line 4 cylinders, In-line...
  • Page 20 POWER TRAIN DEVICES Item Specification Model DE 280 (KAPEC) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.25 : 1 Type Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type 1 : 2.550 2 : 1.151 Overhaul ratio 1 : 2.550 2 : 1.151...
  • Page 21 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS ITEMS SIZE kgf m lbf ft Engine mounting bolt, nut Engine Radiator mounting bolt, nut M10 1.5 6.9 1.4 50 10 Torque converter mounting bolt M10 1.5 6.9 1.4 50 10 MCV mounting bolt, nut 19.6 2.9 142 21 M14 2.0...
  • Page 22 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT - Coarse thread Bolt size kgf m lbf ft kgf m lbf ft 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7...
  • Page 23 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 24 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 35DS/40DS/45DS-7 point fluid 35D/40D/45D-7 (104) (-4) (14) (32) (50) (68) (86) SAE 30 MHI : 17.5(4.6) SAE 10W (35DS/40DS/45DS-7) Engine oil...

  • Page 25: 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 26: Section 2 Removal And Installation Of Unit

    SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...

  • Page 27: Group 1 Structure

    GROUP 1 STRUCTURE 10 11 12 13 15 16 17 D357OM21 Mast Hydraulic pump 17 Rear wheel Lift cylinder 10 Transmission 18 Radiator Steering unit 11 Torque converter 19 Muffler Tilt cylinder 12 Engine 20 Silencer Control valve 13 Exhaust pipe 21 Overhead guard Fork 14 Air cleaner...

  • Page 28: 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 Backrest Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Release fork anchor pins and slide one Knob fork at a time toward the center of the Spring...
  • Page 29 While supporting lift chains, remove nuts Chain from the anchor bolt. Outer mast Anchor bolt D357RE54 Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain Block D357RE55 Slowly raise inner mast upright until mast clears top of fork carriage.
  • Page 30 PIPING Remove the bulk hoses and clamps attached to the cylinder. Remove the return hose from the down control valve. Bulk hose Put blind plugs in the piping immediately after removing hoses. This prevents the hydraulic oil from Lift cylinder flowing out and also prevents dust and dirt from getting in.
  • Page 31 INNER MAST 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 D357RE59 TILT CYLINDER PIN MAST SUPPORT PIN Attach a crane to the stay at the top of the outer mast, and raise it.
  • Page 32 INSTALLATION After assembling mast components tatally without piping connections, install mast assembly to the equipment. Installation procedure for each of mast component is the reverse of the removal procedure. MAST SUPPORT PIN Check the mast support pins for wear, then install pins into the mast support bracket and drive axle.
  • Page 33 2. POWER TRAIN ASSEMBLY REMOVAL D503RE04 Mast Refer to section on mast(Page 2-2)
  • Page 34 Brake piping Brake pipe Disconnect the brake piping from the brake housing of drive axle unit. Brake valve Drive axle D357RE05 Parking brake cable Disconnect parking brake cable from the Parking brake housing of drive axle unit. brake Parking brake lever cable Drive axle...
  • Page 35 Inching linkage Remove bolt fixing the linkage assembly Inching pedal to T/M control valve. Bolt control valve D357RE09 Transmission cooling piping Radiator assy Disconnect cooling hose and connector T/M cooling hose from the transmission. Make sure that the coolant be drained from the hose.
  • Page 36 Using a moving truck slowly pull out transmission assembly to the front. Truck Block D3573RE13 INSTALLATION Installation is the reverse order to removal, but be careful of the following points. Torque converter Tightening torque of mounting bolt for torque converter housing. 5.5~8.3kgf m(40~60lbf ft) Drive Bolt...
  • Page 37 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL D503RE25 Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and flasher lamp on the stay of the overhead guard and then raise it together with the bonnet.
  • Page 38 Torque converter housing cover, mounting bolts installed to flywheel housing. For details, see page 2-9. Engine Engine accessory Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. Wiring harness to alternator and starter. Wiring harness for oil pressure and engine water temperature gauges.
  • Page 39 Tightening torque of mounting bolt installing to torque converter housing. 6.0~8.9kgf m(43~64lbf ft) adiator hoses Distance to insert hose : 42mm(1.65in) Air cleaner hose Insert the air cleaner hose securely and fit a clamp. Distance to insert hose Air cleaner hose : 89mm(3.5in) Engine end(MHI) : 60mm(2.36in) Engine end(HMC) : 64mm(2.5in) D357RE21...
  • Page 40 D357RE30 Counterweight Hold the counterweight with hoist bars, and raise it with a crane. Remove the mounting bolts, raise slightly and move it slowly to rear side. Weight of counterweight(standard) 35DS-7/35D-7 : 1,820kg(4,010lb) 40DS-7/40D-7 : 2,200kg(4,850lb) 45DS-7/45D-7 : 2,550kg(5,620lb) 2-14...
  • Page 41 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. D357RE31 Hose D357RE32 Mounting bolt Steering axle Put a block under the steering axle, Support support on a truck, an raise the frame with a crane.

  • Page 42: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Inspection and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19...

  • Page 43: Group 1 Structure And Operation

    GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN COMPONENT OVERVIEW STRUCTURE Engine From cooler Down regulator valve To cooler D357TA01 Torque converter T/M control valve Parking lever T/M oil level gauge Differential 10 Drive axle oil level gauge Transmission Drive axle 11 Disk brake T/M oil pump Drive wheel...
  • Page 44 2. SPECIFICATION Item Unit Specification Type 3 elements 2 phase 1 stage Torque converter Power transmit Torque converter Type/Gear shift POWER SHIFT / F2 : R2 2.550 FR/RR 1 stage Gear ratio 1.151 FR/RR 2 stage Transmission P.T.O system Included T/M oil DEXRON 3 Oil quantity...
  • Page 45 2. TORQUE CONVERTER TRUCTURE Turbine Input plate Impeller Torque converter Stator Pump gear Engine side Transmission side D357TA02 Item Specification Torque converter input plate 0.3kg m (32.5 2.2lbf ft) Torque converter pump gear 2.0 0.3kg m (14.5 2.2lbf ft) Pilot boss outer diameter 19.959 - 19.980mm(0.786 - 0.787in) Oil seal outer diameter 134.9 - 135.0mm(5.311 - 5.315in)
  • Page 46 According to the rate of inversion, the turbine wheel and with it also the output shaft, receives a more or less high reaction moment. The stator(Reaction member), following the turbine, has the task to inverse again the oil which is escaping out of the turbine and to delivery it under the suitable discharge direction to the pump wheel.
  • Page 47 3. TRANSMISSION STRUCTURE R2 R1 F1 F2 D357TA03 Torque converter Clutch piston 15 Output shaft Input shaft Valve assembly 16 Clutch drum (FR) 3 P.T.O gears 10 Clutch (RR, 1 stage) 17 Clutch (FR, 2 stage) Pump assembly 11 Gear (RR, 1 stage) 18 Gear (Output, 2 stage) Gear (RR, 2 stage) 12 Gear (FR, 1 stage)
  • Page 48 TRANSMISSION GEAR ARRAY T/C Input T/C Input relief T/C output (to cooler) From cooler INPUT T/C output relief COUNTER OUTPUT D357TA04 Cylinder clutch (RR) Gear(Output, 1st stage) Gear(FR, 2nd stage) Gear(RR, 2nd stage) Gear(Output, 2nd stage) Gear clutch(FR) Gear(RR, 1st stage) Gear(FR, 1st stage) Selection of either forward or reverse gear makes all of the parts inside the T/M operate.
  • Page 49 TRANSMISSION INPUT PORT D357TA05 T/C input port pressure RR 1st stage pressure Main line pressure RR 2nd stage pressure FR 2nd stage pressure T/C output port pressure FR 1st stage pressure Transmission pressure Engine Main line T/C input port T/C output port FR 1,2 stage RR 1,2 stage Unit...
  • Page 50 3. TRANSMISSION HYDRAULIC CIRCUIT Directional Modulation valve valve (Solenoid shift valve) Torque converter T/C in outlet relief valve 0.2~4.2 kgf/cm Main relief valve Pedal 7.0~15.0 kgf/cm Inching valve T/C out Oil filter cooler 20.6 cc/rev TRANSMISSION PUMP Torque converter TRANSMISSION inlet relief valve LUBRICATING 0.8~7.2 kgf/cm...
  • Page 51 4. DIFFERENTIAL CARRIER ASSEMBLY STRUCTURE D357TA07 Item Unit Specification Differential pinion gear inner diameter mm(in) 20.000 - 20.021(0.787~0.788) Spider outer diameter mm(in) 19.959 - 19.980(0.786~0.787) Pinion gear washer mm(in) 1.92 - 2.08(0.076~0.082) Side gear washer mm(in) 1.95 - 2.05(0.077~0.081) Side gear OPERATION Differential transmits the power from the transmission to drive wheel.
  • Page 52 5. DRIVE AXLE STRUCTURE D357TA08 Sun gear Hub assy 11 Pinion shaft Planetary gear Disk brake 12 Spider Inner gear Drive shaft 13 Differential pinion gear Inner gear carrier Differential carrier assy 14 Differential side gear Tapered bearing 10 Ring gear OPERATION Drive axle which consists of differential carrier assembly(9), drive shaft(8) and hub assembly(6) transmits the drive force from transmission to drive wheel.
  • Page 53 RIVE AXLE TIGHTENING TORQUE D357TA09 Item Specification Inner carrier 0.3kgf m (15.9 2.2lbf ft) Spindle 12 0.5kgf m (86.8 3.6lbf ft) Parking piston 1.5 0.1kgf m (10.8 0.7lbf ft) Adjuster nut 1.0 0.2kgf m (7.2 1.4lbf ft) Differential cap 16 0.5kgf m (115.7 3.6lbf ft) Differential case 6 0.5kgf m (43.4 3.6lbf ft) Connection between differential carrier and drive axle...
  • Page 54 DISK BRAKE D357TA10 Spindle Service piston Parking lever Steel plate Parking piston mounting bolt 10 Parking lever shaft Disk plate Spline collar 11 Brake housing Parking piston Drive shaft Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.

  • Page 55: Group 2 Inspection And Troubleshooting

    G G ROUP 2 INSPECTION AND TROUBLESHOOTING 1. INSPECTION To check the problems of transmission, operate the machine and test its performance. Check and record the abnormal noise and if the machine doesn't operate perfectly, refer to problem and possible cause in the troubleshooting table. VISUAL CHECK Start engine and check T/M oil level at the neutral gear shift.
  • Page 56 2. TROUBLESHOOTING GENERAL INSPECTION WHILE DRIVING Problem Cause Failure at the specific gear 1. Low oil pressure or no pressure. stage 1) No oil, low level or high oil viscosity. 2) Loose inching control valve connection, incorrect adjustment or damage. 3) Inching valve spool sticked or open.
  • Page 57 Problem Cause Slow clutch meshing or failure 1. Low oil pressure. 2. Low converter oil pressure. 3. Air mixed with oil 1) Air mixed through the pump input port. 2) Low oil level 4. Abnormal adjustment of inching valve linkage. Reverse gear shift failure 1.
  • Page 58 ABNORMAL NOISE CHECK LIST Problem Cause Noise only at neutral 1. Gear or bearing wear inside the pump. 2.Torque converter stator wear. 3. Low oil level. 4. Gear parts of engine and T/M pump's misalignment with that of converter housing and pump. Pump noise 1.
  • Page 59 PRESSURE TEST CHECK LIST Problem Cause Incorrect adjustment of inching valve linkage FR/RR clutch low pressure Inching spool sitcked and open. Clutch and piston oil leakage. Regulator spring defect. Low oil pressure. Incorrect connection of cooler external line. High clutch and main pressure Pressure regulation valve does not move smoothly.
  • Page 60 DIFFERENTIAL Problem Cause Regular noise 1. Lubricating oil shortage. 2. Incorrect oil specification. 3. Wheel bearing adjustment failure or defect. 4. Drive gear and pinion adjustment failure. 5. Drive gear or pinion gear damage or wear. 6. Large or small gear backlash. 7.

  • Page 61: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF DRIVE AXLE 1) REMOVAL AND DISASSEMBLY OF WHEEL HUB Loosen drain plug with a torque wrench(1) and drain oil. D357DA01 Loosen 4 socket head bolts(2) and a plug(3) from the housing of planetary. D357DA02 Fit socket head bolt(2) into the 2 tap holes(4) and remove housing of planetary.
  • Page 62 Remove snap ring(5) from the housing of planetary. D357DA04 Remove 3 pins(6) with a plastic hammer. D357DA05 Remove needle bearing(8), planet gear(7) and thrust washer(9). D357DA06 Remove sun gear(10) and drive shaft(11). D357DA07 3-20...
  • Page 63 Remove snap ring(12) and then remove sun gear(10) from the shaft(11). D357DA08 After removing bolt(13), remove ring gear(14) and torque plate assembly from the axle tube. D357DA09 (10) Remove snap ring from the ring gear(14) and disassemble internal gear carrier. D357DA10 (11) Remove bearing cup from the wheel hub...
  • Page 64 2) REMOVAL AND DISASSEMBLY OF AXLE HOUSING Loosen 12 bolts(1) and then remove carrier from the housing by using a lifting machine. D357DA12 For the reassembly, check rolling resistance and record it. Remove backing plate(2). D357DA13 Before removing differential assembly from carrier(3), check the location of cap(4) and mark it for reassembly.
  • Page 65 Disassemble bearing(6) from the differential housing and remove 12 bolts (7). D357DA15 Remove differential assembly from the carrier. After removing 12 mounting bolts(8) from the housing and then disassemble ring gear. D357DA16 Check the mark on the housing and separate the housing from the differential. If there is no mark, be sure to mark on the housing.
  • Page 66 (10) Remove lock nut(9). (11) Remove drive bevel pinion shaft (10) by using a plastic hammer. Be careful not to damage bevel pinion shaft. D357DA19 (12) Remove shim(11) and spacer(12) from pinion shaft. Using a bearing puller, disassemble inner race of taper roller bearing from the pinion shaft.
  • Page 67 2 2 . REASSEMBLY OF DRIVE AXLE Clean all of the parts with cleaner and then remove remained loctite. Be careful not to spill cleaner on your body. Avoid drinking cleaner or breathing its fumes. Wear protective clothing, glasses and gloves. If spilled on the skin, flush your skin with water immediately.
  • Page 68 Using different kinds of shims, adjust shim thickness as measured by previous equation. Place shims at the bearing place. Using a jig, assemble drive bearing so that the outer race contact with the bearing place. D357DA241 Heat inner race of bearing to max 100 and then assemble it to the pinion shaft.
  • Page 69 ADJUSTMENT OF PINION SHAFT Assemble bearing cup. Assemble spacer to the pinion shaft and then install measured shims onto the spacer. D357DA281 D357DA29 Insert pinion shaft into the carrier. Assemble bearing cone and lock nut. Apply grease on the outer bearing(1). Apply loctite #271 or #277 on the thread of pinion and then tighten lock nut.
  • Page 70 ASSEMBLY OF DIFFERENTIAL ASSEMBLY Assemble thrust washer, side gear and spider with gear and then install them to the differential housing. Apply grease on the bevel gear and thrust washer. D357DA31 Assemble differential housing. heck marks on the housing. Match two marks at the same position. D357DA32 Tighten 12 bolts(7) to the differential housing.
  • Page 71 Install differential assembly onto the carrier. Place the bearing cup and screw into the housing. At this moment, using a screw adjust rotation backlash. Install the dial gauge on the gear tooth and measure the backlash while rotating bevel gear. Rotation backlash : 0.18~0.23 (0.007~0.009 D357DA35...
  • Page 72 ASSEMBLY OF CARRIER Assemble carrier assembly into the axle housing. Apply loctite #271 or #277 to thread of bolt and then assemble at the tightening torque of 11~12 (79.6~86.8 kgf m lbf ft D357DA37 ASSEMBLY OF WHEEL HUB Insert bearing into wheel hub. Confirm that the bearing and wheel hub contact completely.
  • Page 73 Assemble square ring(4, 5) with oil(MOBIL 1 2 3 #424) to the brake housing. Assemble piston(3) after applying oil sufficiently and apply loctite #271 to spring(6) and 4 bolts(4). Tightening torque : 1.4~1.6 kgf m (10.1~11.6l bf ft heck the status of square ring and replace if damaged.
  • Page 74 Assemble sun gear to axle shaft and fix it with snap ring. Assemble axle shaft to the axle assembly. Apply grease on the shaft where bushing contacts. Apply grease to teeth parts of planetary gear. D357DA43 Assemble internal components of planetary carrier in the reverse order to disassembly.
  • Page 75 Assemble wheel hub and tighten plug(1). Tightening torque : 4~5 kgf m (28.9~36.1 lbf ft D357DA47 3-33...
  • Page 76 3. DISASSEMBLY OF TRANSMISSION Remove torque converter from the housing. Loosen 6 bolt(3) from torque converter and then remove adaptor(2) and flexible plate(1). D357TM01 Loosen 6 socket bolts(6) and remove Gear P.T.O Input(5). D357TM02 Remove oil seal(8), 4 bolts(9, 10) and washer individually, from the housing(7).
  • Page 77 Remove plug(11), O-ring, spring(12) and ball(13) from cover. Remove nipple(14) from the housing. Remove plug(15), O-ring, spring(16) and 12 11 valve(17). Remove plug(18). D357TM04 Bearing cup(19) and shim(20) are located in the cover or at the shaft in the transmission case. Mark the location of the bearing cup(19) and shim(20) on the transmission cover or shaft in the transmission case.
  • Page 78 Remove 4 socket bolts(23) from the bearing plate(14) and disassemble flange pump(24). Remove 1 socket bolt(25) and 4 socket bolts(26) from the flange pump to remove charging pump(27) and pump gasket(27) and then disassemble gear P.T.O output(29) and ball bearing. Remove elbow(30).
  • Page 79 Disassembly of transmission control valve Remove transmission control valve Remove valve gasket(2-2). Remove stop bolt(19) and pin(18) from the valve body(1). Remove spool(14), spring(18), spring (16), plunger(17), oil seal(20) and plug(21). Remove plug(4), spring(3) and spool(2). Remove plug(7), spring(9) and then remove plug(11), filter(12), O-ring(13, 27) and piston(10).
  • Page 80 Using a plastic hammer push out tube(45) from transmission case. Remove output shaft assembly(43), input shaft assembly(44) and couter shaft assembly(45). D357TM14 Disassemble output gear(46) from the transmission case. D357TM15 3-38...
  • Page 81 Disassemble bearing cone(47) for high speed which locates in front side of clutch assembly with a gear puller. D357TM16 Remove 2 thrust washers(48) and gear(49). Remove needle bearing and washer from the shaft in front side of high speed clutch. D357TM17 Using a driver remove snap ring(50) from the cylinder.
  • Page 82 Remove clutch pressure plate, 7 clutch disks and 7 clutch plates(51) from the cylinder. D357TM19 Pressing the retainer(52) downward and then remove snap ring(53) with a driver while reducing the tension of spring assembly. Remove retainer(52) and spring assembly from the cylinder. Remove piston(54) using pressurized air and remove O-ring from the shaft.
  • Page 83 After removing snap ring(50) and then disassemble 7 disks and 7 plates from the cylinder. D357TM22 Remove 2 thrust washers(57) and a pin(59). By pressing the retainer(52), remove snap ring(53). Carefully reducing tension of spring assembly, remove retainer and spring. Using a air compresser, remove piston(54) and pull out O-ring.
  • Page 84 Remove 3 kinds of bearings(62) from the transmission case. Mark on the bearing. D357TM25 Remove lip shaped oil seal (63) from the transmission. D357TM26 3-42...
  • Page 85 4. ASSEMBLY OF TRANSMISSION After cleaning all of the parts completely, apply T/M oil. Install inner seal(63) in order lip side to face the inner side and outer seal to face the outer side. D357TM27 Assemble 3 kinds of bearing cups(62) into the transmission case at their original positions.
  • Page 86 Assemble gear(61) and bearing(60) to the output shaft. D357TM29 Install seal ring on the piston(54). Apply T/M oil to seal ring. Assemble seal ring and piston into the cylinder. Be careful not to damage seal ring when assembling pistion. D357TM23 Install spring assembly and retainer(52) inside the cylinder.
  • Page 87 Apply clean T/M oil to the clutch disk and plate and then assemble 7 clutch disks and plates in the order of ; At first, install clutch plate which has teeth on the outer race. Install clutch disk which has teeth on the inner race.
  • Page 88 Assemble gear(49), thrust washer(48) and install bearing cone(47). Do not apply compulsory force when assembling gears. Move gear forward and backward until spline of gear and teeth side of clutch disk mesh with each other. D357TM35 Assemby order of input shaft is the same as that of counter shaft assembly.
  • Page 89 Place the T/M case in the right position and then install counter shaft assembly(45) carefully. Install input shaft(44) carefully on its own place. Assemble output shaft assembly(43) into the output gear assembly(46) and then rotate the gear until teeth meshed. Install tube(42) into the case with a plastic hammer.
  • Page 90 After adhering valve gasket(34), assemble valve plate with 9 bolts(35) and 2 bolts(36). Tightening torque (35) : 1.4kgf m (10.1 lbf ft) Tightening torque (36) : 2.8kgf m (20.3 lbf ft) D357TM10 T/M control valve assembly Adhere valve gasket on the control valve body.
  • Page 91 Assemble the gear P.T.O output(23) and 2 ball bearings to the flange pump(25) with a jig and then assemble them to bearing plate with 4 bolts(26). Install charging pump(29) and gasket (27) to the flange pump(25) with bolts(28, 30x4). Assemble elbow(24) and then connect tube(31) to the elbow(24).
  • Page 92 In case of using new items calculate the shim thickness as below. Shaft assembly. (Including tapered bearing cone and cup) Install shaft assembly into the T/M case. Measure distance from the surface of bearing cup to that of T/M case, "X". The height of bearing cup should be higher than the height of T/M case so that depth gauge and block gauge can...
  • Page 93 Install Gear P.T.O Input(5) on the torque converter(4) and fasten with 6 socket bolts(6). Tightening torque : 1.7~2.3 kgf m (12.3~16.6 lbf ft D357TM51 With 6 bolts(3) and 6 washers, assemble adaptor(2) and flexible plate(1) into torque converter. And then put together torque converter and housing.

  • Page 94: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and function -------------------------------------------------------------------------------------- Group 2 Operational checks and troubleshooting -------------------------------------------------------- 4-11 Group 3 Tests and adjustments --------------------------------------------------------------------------------------...

  • Page 95: 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 96 3. BRAKE PEDAL AND PIPING STRUCTURE D357BS03 Brake pedal & bracket assembly Reservoir tank assembly Parking lever assembly Brake master cylinder...
  • Page 97 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the front axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force. By treading the pedal further, the brake is applied. 153~163mm(Pedal height) Inching spool Inching link assy...
  • Page 98 5. WET DISK BRAKE STRUCTURE D357TA10 Spindle Service piston Parking lever Steel plate Parking piston fixing bolt 10 Parking lever shaft Disk plate Spline collar 11 Brake housing Parking piston Drive shaft OPERATION Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 99 6. BRAKE VALVE STRUCTURE 29-1 29-2 29-3 29-4 29-5 29-6 29-7 29-8 29-9 14 15 D357BS07 Dust cover 16 Nut 29-2 Spool plug Guide plug 17 Plug 29-3 Spool Seal 18 Seal 29-4 Stop ring Seal 19 Ring 29-5 Washer Push rod 20 Seal 29-6 Seal...
  • Page 100 DISASSEMBLY All operations must be carried out with the greatest care, following the instructions carefully. The disassembly instructions are being provided in chronological. Unscrew the 4 screws(33), in order to be able to separate the front housing(7) from the rear housing(31).
  • Page 101 Remove ring(25), seal(26), spring(27) and piston(28). Disassemble valve assembly(29), spring guide(30) and seal(32). Remove the O-ring and the lip seal still inside the pump body with the aid of an “L” iron. Remove all of the other gaskets from the disassembled components, namely the push rod(5), the piston(11).
  • Page 102 ASSEMBLY The assembly must be carried out by following the so far described sequence but in reverse order, taking great care not to assemble the new gaskets back to front or upside down. 29-1 29-2 29-3 29-4 29-5 29-6 29-7 29-8 29-9 14 15...

  • Page 103: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS RAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. PARKING BRAKE Operating force of parking lever is 35 - 40 (253 - 290...
  • Page 104 . TROUBLESHOOTING Problem ause Remedy Insufficient braking force Hydraulic system leaks oil. Repair and add oil. Hydraulic system leaks air. Bleed air. Disk worn. Replace. Brake valve malfunctioning. Repair or replace. Hydraulic system clogged. Clean. Brake acting unevenly. Tires unequally inflated. Adjust tire pressure.

  • Page 105: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS 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 Vinyl tube on the ground and removes cap from air vent plug on wheel cylinder.
  • Page 106 INCHING PEDAL Pedal height from floor plate Adjust with stopper bolt. Pedal height : 153~163mm(6.0~6.4in) 153~163mm Adjust bolt so that brake pedal interconn- Pedal height ects with inching pedal at inching pedal stroke 32mm(1.26in). D357BS06 4-12...

  • Page 107: 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 108: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1 Main control vavle 2 Steering wheel 3 Steering unit FRAME ASSY (6010) 4 Steering cylinder D357SE00 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, trail axle and piping.
  • Page 109 2. HYDRAULIC CIRCUIT Brake valve D357SE011 Hydraulic gear pump Suction filter Steering unit Hydraulic tank Steering cylinder...
  • Page 110 NEUTRAL Brake valve D357SE02 The steering wheel is not being operated, so control spool(G) does not move. The oil from hydraulic gear pump(1) enters the port P of MCV and flow into steering unit(2) through priority valve of the MCV. The spool(D) of priority valve keeps downward position by spring force.
  • Page 111 LEFT TURN Brake valve D507SE03 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) the steering unit through the spool(D) of priority valve built in MCV and flows the gerotor(H).
  • Page 112 RIGHT TURN Brake valve D507SE041 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) the steering unit through the spool(D) of priority valve built in MCV and flows the gerotor(H).
  • Page 113 3. STEERING UNIT STRUCTURE 7/16-20UNF NAME PLATE O-RING BOSS 4-M10x1.5P DP15.2 4-3/4-16UNF O-RING BOSS SPLINE Hydraulic circuit 25-1 25-2 25-4 25-3 SECTION B-B SECTION A - A D357SE32 Dust seal 11 O-ring 21 Housing Retaining seal 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve...
  • Page 114 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 115 4. TRAIL AXLE STRUCTURE Do not remove the stopper bolt unless necessary. 1-24 1-31 1-28 1-27 1-32 1-26 1-33 1-13 1-12 1-28 1-29 1-34 1-11 1-30 1-25 1-27 1-29 1-22 1-35 1-30 1-23 1-27 1-36 1-26 1-10 1-37 1-27 1-36 1-10 1-35 1-37...
  • Page 116 GREASING AND SPECIFICATION 35 kgf.m (253 lbf.ft) Adjust gap with shims SECTION A-A Stroke 91.5mm (3.6in) Fill 70% of the space in the hub with lithium grease 16.7~22.5 kgf.m Greasing (121~163 lbf.ft) Fix with split pin SECTION B-B Greasing D357SE07 Type Unit Center pin support single shaft...

  • Page 117: Group 2 Operational Checks And Troubleshooting

    Fit bar and a piece of chalk at outside edge of counterweight to mark line of turning radius. If minimum turning radius is not within 100mm ( 4in)of specified value, adjust turning angle stopper bolt. Min turning radius(Outside) 35D-7, 35DS-7 2770mm(109in) 40D-7, 40DS-7 2830mm(111in) 45D-7, 45DS-7...
  • Page 118 Problem ause Remedy Steering wheel turns unstea- Lockout loosening. Retighten. dily. Metal spring deteriorated. Replace. Steering system makes abn- Gear backlash out of adjustment. Adjust. ormal sound or vibration. Lockout loosening. Retighten. Air in oil circuit. Bleed air. Abnormal sound heard when Valve steering wheel is turned fully Faulty.

  • Page 119: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 25-3 25-4 25-2 25-1 D357SE05 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 25 P-Port check valve...
  • Page 120 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 121 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1kgf (0~54.4lbf ft) 13mm socket spanner 6, 8mm and 12mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 5-70(2) TIGHTENING TORQUE L : Left port R : Right port T : Tank...
  • Page 122 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 123 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball and suction valve pins and balls. D353SE09 5-16...
  • Page 124 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 125 (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 126 (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 disassembled. D353SE13 5-19...
  • Page 127 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 128 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 129 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) Assembly pattern for standard bearings Outer bearing race Thrust bearing Inner bearing race Spool Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 130 (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 131 (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 132 (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 133 (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 5-82(2) (23) Place the distributor plate so that the channel holes match the holes in the...
  • Page 134 (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 135 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. Tightening torque : 4.0 0.5kgf m (28.9...
  • Page 136 (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 137 2. STEERING CYLINDER STRUCTURE Specifications Cylinder bore : 80mm Outer diameter : 94mm Stroke(half) : 180mm Rod diameter : 55mm D357SE21 1 Tube assy DU bushing 11 O-ring 2 Rod assy Rod seal 12 Back up ring 3 Piston seal Back up ring 13 O-ring 4 Wear ring...
  • Page 138 DISASSEMBLY Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in & vice. Remove the cover by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube. Check wear condition of the sealing parts(O-ring, oil seal, dust seal, U-packing, bush).
  • Page 139 Install the dust wiper(8) to the gland(4) using a special installing tool. Coat the dust wiper with grease slightly before installing. Using a special tool, install gland assembly into the cylinder tube(1). Special tool D507SE29 Using a hook spanner, install the gland(4) ass- Hook spanner embly, and tighten it with torque 60 6kgf m...
  • Page 140 3. TRAIL AXLE STRUCTURE Do not remove the stopper bolt unless necessary. 1-24 1-31 1-28 1-27 1-32 1-26 1-33 1-13 1-12 1-28 1-29 1-34 1-11 1-30 1-25 1-27 1-29 1-22 1-35 1-30 1-23 1-27 1-36 1-26 1-10 1-37 1-27 1-36 1-10 1-35 1-37...
  • Page 141 CHECK AND INSPECTION A1, A2 D507SE25 unit : mm(in) Criteria Remarks Check item 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) Replace OD of king pin 35(1.4) 34.5(1.4) 20(0.8) 19.5(0.8) OD of steering cylinder pin OD of pin 20(0.8) 19.5(0.8)
  • Page 142 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 weight part of the truck. Hub nut Loosen the hub nut and take off the steering wheel tire.
  • Page 143 ASSEMBLY In reassembling, have all parts washed, grease 1-13 1-12 applied to lubricating parts, and all expendable 1-11 items such as oil seal and spring washers replaced by new ones. Perform the disassembly in reverse order. Tighten the special bolt(1-7) and washer(1-8) of king pin(1-4).

  • Page 144: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24...

  • Page 145: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 35DS/40DS/45DS-7 13.5MPa 12.5MPa 21.0MPa 2 MPa D357SHS01 Hydraulic gear pump Lift cylinder Main control valve Suction filter Steering unit Return filter Brake valve 10 Down safety valve Steering cylinder 11 Hydraulic oil tank Tilt cylinder...
  • Page 146 35D/40D/45D-7 13.5MPa 12.5MPa 21.0MPa 2 MPa D357HS01 Hydraulic gear pump Tilt cylinder Brake pump Lift cylinder Main control valve Suction filter Steering unit 10 Return filter Brake valve 11 Down safety valve Steering cylinder 12 Hydraulic oil tank...
  • Page 147 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 12.5MPa 21.0MPa 13.5MPa Steering system Steering return line Brake system Brake return line 35D/40D/45D-7 ONLY D357HS02 When the lift control lever is pulled back, the spool on the first block is moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of lift cylinder(7) by pushing the load check valve of the spool.
  • Page 148 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 12.5MPa 21.0MPa 13.5MPa Steering system Steering return line Brake system Brake return line 35D/40D/45D-7 ONLY D357HS03 When the lift control is pushed forward, the spool on the first block is moved to lower position. The work port(B1) and the small chamber and the large chamber are connected to the return passage, so the lift will be lowered due to its own weight.
  • Page 149 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 12.5MPa 21.0MPa 13.5MPa Steering system Steering return line Brake system Brake return line 35D/40D/45D-7 ONLY D357HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
  • Page 150 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 12.5MPa 21.0MPa 13.5MPa Steering system Steering return line Brake system Brake return line 35D/40D/45D-7 ONLY D357HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
  • Page 151 2. HYDRAULIC GEAR PUMP 35DS/40DS/45DS-7 D357SHS06 Body 11 Screw 20 Ring Rear cover 12 Grub screw 21 Back up ring Front cover 13 Washer 22 Ring Thrust plate 14 Washer 23 Sleeve bearing Thrust plate 15 Seal 24 Hub Drive gear 16 Seal 25 Dowel pin Driven gear...
  • Page 152 35D/40D/45D-7 D357HS06 Flange Washer Channel seal Cover Bolt 10 Back up ring Body Lip seal 11 O-ring Set gear Bushing block assy 12 Dowel pin...
  • Page 153 3. MAIN CONTROL VALVE STRUCTURE (2 Spool) Port name Size Inlet port 1-1/16-12UNF Outlet port 1-1/16-12UNF Gauge port PF1/4 Work port 2-3/4-16UNF STEERING PORT LOAD SENSING PORT PUMP PORT CYLINDER PORT CYLINDER PORT SECTION F-F SECTION A-A D357HS07 Plug assy Orifice 39 Bolt Spring...
  • Page 154 OPERATION (2 Spool) Flow divider(Priority valve) Piston Steering relief valve To steering control unit D357MCV21 Oil flows from pump(P) line to steering(PS) line and control valve(CV) line. The control flow rate for steering line decides by the demand of steering control unit. Maximum pressure of steering line controls by steering relief valve.
  • Page 155 Inlet section Primary relief valve Unloading valve piston Max work port pressure line D357MCV22 At spool neutral position, oil flows from pump line to tank line through unloading valve piston. Also unloading valve piston controls flow rate work section. Maximum pressure of the system controls by primary relief valve. 6-11...
  • Page 156 Lift section Lift position Lift lock valve Return spring Load sensing passage D357MCV23 When the spool for lift section is pulled back, the oil supplied from the pump pushes up the lift lock valve and flow into lift cylinder port(B1). Flow rate is supplied to cylinder depends on opening area of the spool.
  • Page 157 Lower position Lift lock spring chamber Lift lock valve Lowering flow compensator D357MCV24 When the spool for lift section is pulled forward, the oil in lift cylinder is released to tank due to its own weight. First the pressure in the lift lock spring chamber is released. Therefore the lift lock valve is pushed up due to the difference pressure.
  • Page 158 Tilt section Tilt forward position Load check vavle Tilt lock valve D357MCV25 When the spool for lift section is pushed forward, the oil supplied from the pump pushes up the load check valve and flow into tilt cylinder port(A2). The return oil from cylinder port(B2) flows into the tank through the tilt lock valve. Flow rate is supplied to cylinder depends on opening area of the spool.
  • Page 159 Tilt backward position Load check vavle D357MCV26 When the spool for tilt section is pulled back, the oil supplied from the pump pushes up the load check valve and flow into tilt cylinder port(B2). The return oil from cylinder port(A2) flows into the tank. Flow rate is supplied to cylinder depends on opening area of the spool.
  • Page 160 MAIN RELIEF VALVE Pressure setting A good pressure gauge must be installed in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit.
  • Page 161 The loss of oil behind poppet C, effected by the opening of pilot poppet E, causes poppet C to move back and seat against pilot puppet E. This shuts off the oil flow to the area behind relief valve poppet D, and causes a low pressure area internally.
  • Page 162 4. LIFT CYLINDER 9 10 8 14 6 4, 5 3 D357HS12 Tube assy Retaining ring 13 DU busing Gland 14 O-ring Piston Dust wiper 15 Spacer Piston seal 10 Rod seal 16 O-ring Back up ring 11 O-ring Wear ring 12 Guide 5.

  • Page 163: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Load maximum load, set mast vertical and raise 1m from ground. Wait for 10 minutes measure hydraulic drift(amount forks move down and amount mast tilts forward).
  • Page 164 . TROUBLESHOOTING SYSTEM Problem ause 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 165 Problem Cause Remedy Actuator(cylinder or motor) Shortage of oil in oil tank. Check the oil level in the oil tank. works slowly or does not Decrease of relief valve pressure. Install pressure gauge on the circuit, operate. and check the pressure with it by handling the lever.
  • Page 166 HYDRAULIC GEAR PUMP Problem ause 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 167 LIFT CYLINDER Problem ause 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 168: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP(35DS/40DS/45DS-7) STRUCTURE D357SHS06 Body 11 Screw 20 Ring Rear cover 12 Grub screw 21 Back up ring Front cover 13 Washer 22 Ring Thrust plate 14 Washer 23 Sleeve bearing Thrust plate 15 Seal 24 Hub Drive gear 16 Seal...
  • Page 169 GENERAL INSTRUCTION Cleanliness Cleanliness is the primary means of assuring satisfactory hydraulic pump life. Components such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears should be washed in solvent, air dried, and oiled immediately. Certain cleaning solvents are flammable.
  • Page 170 And remove drive gear(6), driven gear(7), thrust plate(4), keeping gears as straight as possible, and body(1) also. D357PMP03 Front section Loosen and remove the clamp bolts(11) from the body(27). Coat the sharp edges of the drive shaft (8) with adhesive tape and smear a clean grease on the shaft end extension to avoid any damaging lip of the shaft seal when removing the cover(3).
  • Page 171 Cover assembly Remove snap ring(20) with proper tool(Only when it is needed to replace shaft seal). Remove the shaft seal(19) taking care not to give any damage on the surface of shaft hole(Only when it is needed to replace shaft seal). D357PMP07 EASSEMBLY Cover assembly...
  • Page 172 Insert the steel bushing(26) into body(27). D357PMP10 Insert the complete pressure plate (5+16+22) into body(27) while keeping the plate straight. Seal side should face to the rear side, opposite side of gears. Pay attention to the direction of seal. (opened side should face suction side always) D357PMP11 Locate driving gear(8) and driven gear(9)
  • Page 173 Tighten the bolts(10) with washer(14) in a crisscross pattern to torque value of 28.6kgf.m(207lbf.ft). 10(x4) 14(x4) D357PMP14 Rear section Smear clean grease on the seal(18) to avoid drifting away of seal from the body(1) and assemble temporarily rear cover(3). D357PMP15 Locate the seals(15) on the groove pre- arranged on the thrust plates(4).
  • Page 174 Locate driving gear(4) and driven gear(5) while keeping the gears straight. Locate pressure plate(4+21+15) with care for the direction. D357PMP18 Open rear cover(2) to locate hub(24) into rear section. Front section Rear section D357PMP19 Tighten the bolts(10) with washer(14) in a crisscross pattern to torque value of Rear section 4.6kgf.m(33.3lbf.ft).
  • Page 175 2. MAIN PUMP(35D/40D/45D-7) STRUCTURE D357HS06 Flange Washer Channel seal Cover Bolt 10 Back up ring Body Lip seal 11 O-ring Gear set Bushing block assy 12 Dowel pin 6-31...
  • Page 176 DISASSEMBLY Tools required Metric socket set Internal snap ring pliers Shaft seal sleeve Torque wrench : 13.8 kgf m (100lbf ft) It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
  • Page 177 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 178 (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 179 (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 180 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 181 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 182 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 183 (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 184 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. Tighten torque : 11.1~11.8kgf m (80~85lbf ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
  • Page 185 . MAIN CONTROL VALVE PRECAUTION Handling When carrying or installing valves, don't drop it and don't apply shock to the top of spools and caps of the valve. When storing the valve for long time, each port should be blinded and protected against dust or water.
  • Page 186 DISASSEMBLY AND REASSEMBLY Replacing O-ring on contract surface Loosen the M8 bolt, and then remove bolt and spring washer. D357MCV01 Remove valve body block from the mono-block. At this time, care must be taken not to damage machined contact surface. D357MCV02 Replace some O-ring on contact surface.
  • Page 187 Hand tighten M8 bolt. Tightening torque : 2.5kgf m(18.1lbf ft) D357MCV05 Tighten them up while making sure that spools of each block work smoothly. D357MCV06 Replacing O-ring and scraper, which are fitted in spool On the lever side Loosen mounting M5 hexagon screw on seal case, and remove seal case.
  • Page 188 Screw up seal case with M5 hexagon screw without damaging O-ring. Tighteing torque : 0.9kgf m(6.5lbf ft) D357MCV09 On the spring cap side Loosen M5 hexagon screw on spring cap, and remove spring cap. D357MCV10 Take out spool and O-ring plate from valve body, and renew O-ring(1AxP16) D357MCV11 After cleaning spool, fit O-ring and O-ring...
  • Page 189 During fitting O-ring to spool, care must be taken not to damage O-ring. D357MCV13 Replacing relief valve assy and O-ring Remove relief valve assy from mono block. Main relief valve : Valve aset assy(Breadth 36mm(1.4in)) Secondary relief valve : Relief valve assy(Breadth 21mm(0.8in)) D357MCV14 Steering relief valve is not cartridge type ;...
  • Page 190 Grease O-ring, fit them to mono-block. Tightening relief valve assy : 3.5kgf m(25.3lbf ft) Secondary relief valve assy : 2.8kgf m(20.3lbf ft) D357MCV17 Gasket should be replace if cap nut and rock nut on adjusting screw part are loosened in order to readjust relief valve set.
  • Page 191 4. LIFT CYLINDER STRUCTURE O.D stroke(standard) 73 65 1335mm (2.9 2.6 52.6in) Rod O.D : 50mm(2.0in) D357HS19 Tube assy Dust wiper 10 Rod seal Piston 11 O-ring Piston seal 12 Guide Back up ring 13 DU busing Wear ring 14 O-ring Retaining ring 15 Spacer Gland...
  • Page 192 DISASSEMBLY Hold the cylinder tube in a vice, loosen the cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn. Lever up the edge of the guide, then turn the guide in again and the guide can be removed.
  • Page 193 5. TILT CYLINDER STRUCTURE O.D stroke : 90 102 220mm (3.5 4.0 8.7in) Rod O.D : 45mm(1.8in) D357HS22 Tube assy O-ring 17 Nylon nut 10 Back up ring 18 Rod eye Gland 11 Lock washer 19 DU bushing DU bushing 12 O-ring 20 Hexagon bolt Rod seal...
  • Page 194 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 195 SECTION 7 ELECTRICAL SYSTEM Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-22 Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24...

  • Page 196: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. 35DS/40DS/45DS-7(MHI ENGINE) WITH OPSS WITHOUT OPSS D357EL06M DETAIL C(WITH OPSS) DETAIL A DETAIL B Fuse box Relay 5P 17 Monitor panel Start switch 10 Buzzer 18 Beacon lamp(opt) Work lamp switch(opt) 11 OPS unit 19 Rear work lamp(opt) Hazard switch(opt)
  • Page 197 2. 35D/40D/45D-7(HMC ENGINE) D357EL06H DETAIL A DETAIL B Fuse box Relay 5P 15 Combination switch Start switch High horn 16 Monitor panel Work lamp switch(opt) 10 Tilt alarm 17 Beacon lamp(opt) Hazard switch(opt) 11 Tilt switch 18 License lamp(opt) Relay 4P 12 Battery 19 Rear work lamp(opt) Relay 4P...

  • Page 198: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT 35DS/40DS/45DS-7 (MHI ENGINE) REAR WORK CLUSTER SEAT S.W LAMP BEACON START KEY S/W CONVERTER R/COMBI LH R/COMBI RH FRONT FRONT HEAD HEAD BR R1 R2 C ACC COMBI LH COMBI RH LAMP LAMP LICENCE LAMP CL-21 CN-65 BACK BUZZER CD-10...
  • Page 199 35D/40D/45D-7 (HMC ENGINE, -#1000) CLUSTER START KEY S/W R/COMBI LH R/COMBI RH HEAD FRONT HEAD FRONT BR R1 R2 C ACC R/WORK LAMP COMBI LH LAMP COMBI RH BEACON LAMP LICENSE LAMP CL-21 OPTION BACK-UP BUZZER CN-65 CN-20 TO:AIRCON HARNESS CD-10 CD-2 AIR CLEARNER...
  • Page 200 35D/40D/45D-7 (HMC ENGINE, #1001-) D357EL01T...
  • Page 201 MEMORANDUM...
  • Page 202 5DS/40DS/45DS-7 (MHI ENGINE) 1. POWER CIRCUIT 35DS/40DS/45DS-7 The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the off position, the current flows from the positive battery terminal. OPERATING FLOW Battery(+) Start motor[CN-45(B+)] Fusible link[CN-60] Glow relay[CR-24(3) (1)]...
  • Page 203 35DS/40DS/45DS-7 POWER CIRCUIT ( START KEY S/W BR R1 R2 C ACC CN-25 HORN CN-1 CD-4 BRAKE SW CN-80 GLOW PLUG CR-11 CR-24 1.25BR FLASHER UNIT 1.25B GEAR SELECTOR CN-2 GLOW RY CN-74 CS-11 2-FWD 1-REV ALTERNATOR CN-95 CN-60 6-ILL CS-12 FUSIBLE LINK FUSIBLE LINK...
  • Page 204 2. STARTING CIRCUIT 35DS/40DS/45DS-7 OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-95] Start switch[CS-2(3)] Start relay[CR-23] 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.6 Combi switch[CS-12(5)] When start key switch is START position...
  • Page 205 35DS/40DS/45DS-7 STARTING CIRCUIT ( CLUSTER START KEY S/W BR R1 R2 C ACC CN-1 CR-5 NEUTRAL & ANTI CN-74 RELAY ALTERNATOR CN-95 FUSIBLE LINK GEAR SELECTOR CS-11 2-FWD 1-REV CR-23 START RY 6-ILL CN-45 CS-12 7-Lo 8-Hi START MOTOR 1-TLH 2-TRH 3-HO 4-HO...
  • Page 206 3. CHARGING CIRCUIT 35DS/40DS/45DS-7 When the starter is activated and the engine is started, the operator release the start switch to the ON position. Charging current generated by operating alternator flows into the battery. The current also flows from alternator to each electrical component through the fusible link(CN-60) and the fuse box.
  • Page 207 35DS/40DS/45DS-7 CHARGING CIRCUIT ( CLUSTER START KEY S/W BR R1 R2 C ACC CN-1 DO-1 DIODE CN-74 ALTERNATOR CN-95 FUSIBLE LINK CR-23 START RY CN-45 START MOTOR BATTERY MASTER SW 12V X 2 D357EL04M 7-11...
  • Page 208 4. PREHEATING CIRCUIT 35DS/40DS/45DS-7 Combustion chamber glow plugs are used in order to give satisfactory starting of low ambient temperatures. OPERATING FLOW Battery(+) terminal Fusible link[CN-95] I/conn[CS-2(3)] Start switch(B) Fusible link[CN-60] Glow relay[CR-24(3)] When you turn the start switch to the ON position, the glow relay makes the glow plugs operated and the glow lamp of the cluster turned ON.
  • Page 209 35DS/40DS/45DS-7 PREHEATING CIRCUIT ( CLUSTER START KEY S/W BR R1 R2 C ACC CN-17 OPTION CR-45 CN-1 GLOW AUX. RELAY CN-80 CN-62 GLOW PLUG GEAR SELECTOR CR-24 CS-11 1.25BR 2-FWD 1.25B CN-2 1-REV GLOW RY CN-74 6-ILL CS-12 7-Lo ALTERNATOR 8-Hi CN-60 CN-95...
  • Page 210 5D/40D/45D-7 (HMC ENGINE) 1. POWER CIRCUIT (35D/40D/45D-7) The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the off position, the current flows from the positive battery terminal. OPERATING FLOW Battery(+) Start motor[CN-45(B+)] Glow relay[CR-24] Glow plug[CN-80] Start relay[CR-23]...
  • Page 211 35D/40D/45D-7 POWER CIRCUIT ( START KEY S/W BR R1 R2 C ACC 9 10 11 12 CN-25 CN-80 CR-24 HORN CD-4 GLOW PLUG GLOW RELAY BRAKE SW 8SQ(R) CN-1 CN-17 CN-74 CABIN CR-11 ALTERNATOR CN-95 FLASHER UNIT GEAR SELECTOR FUSIBLE LINK CN-2 CS-11 2-FWD...
  • Page 212 2. STARTING CIRCUIT 35D/40D/45D-7 OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-95] Start switch[CS-2(3)] Start relay[CR-23] 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.3 Engine stop relay[CR-47(2)] I/conn[CN-1(10)]...
  • Page 213 35D/40D/45D-7 STARTING CIRCUIT ( START KEY S/W BR R1 R2 C ACC CLUSTER 9 10 11 12 CN-17 CD-4 CABIN CR-11 BRAKE SW CN-1 FLASHER UNIT CR-5 RELAY NEUTRAL GEAR SELECTOR CS-11 CN-74 2-FWD 1-REV CN-2 ALTERNATOR CN-95 FUSIBLE LINK 6-ILL CS-12 CR-23...
  • Page 214 3. CHARGING CIRCUIT 35D/40D/45D-7 When the starter is activated and the engine is started, the operator release the start switch to the ON position. Charging current generated by operating alternator flows into the battery. The current also flows from alternator to each electrical component through the fusible link(CN-60) and the fuse box.
  • Page 215 35D/40D/45D-7 CHARGING CIRCUIT ( START KEY S/W CLUSTER BR R1 R2 C ACC 9 10 11 12 CN-1 CN-74 ALTERNATOR CN-95 FUSIBLE LINK CR-23 RELAY-START CN-45 START MOTOR 38SQ(B) 38SQ(R) 38SQ(B) BATTERY MASTER SW 12VX2 D357EL04H 7-19...
  • Page 216 4. PREHEATING CIRCUIT 35D/40D/45D-7 Combustion chamber glow plugs are used in order to give satisfactory starting of low ambient temperatures. OPERATING FLOW Battery(+) terminal Fusible link[CN-95] I/conn[CS-2(3)] Start switch(B) Fusible link[CN-60] Glow relay[CR-24(3)] When you turn the start switch to the ON position, the glow relay makes the glow plugs operated and the glow lamp of the cluster turned ON.
  • Page 217 35D/40D/45D-7 PREHEATING CIRCUIT ( START KEY S/W CLUSTER BR R1 R2 C ACC 9 10 11 12 CN-1 CN-2 CN-80 CR-24 GLOW PLUG GLOW RELAY 8SQ(R) CN-74 ALTERNATOR CN-95 FUSIBLE LINK CN-45 8SQ(R) START MOTOR 38SQ(B) 38SQ(R) 38SQ(B) BATTERY MASTER SW 12VX2 D357EL05H 7-21...

  • Page 218: Group 3 Component Specification

    GROUP 3 COMPONENT SPECIFICATION . 35DS/40DS/45DS-7(MHI ENGINE) Specification Part name 80AH 2EA Battery RC : 130min CCA : 630A Working lamp 24V, 70W License lamp 24V, 3W x 2 24V, 25/10W (Stop/Tail) 24V, 25W (Turn) Rear Combination lamp 24V, 10W (Back Up) Head lamp 24V, 70W...
  • Page 219 . 35D/40D/45D-7(HMC ENGINE) Specification Part name 80AH 2EA Battery RC : 130min CCA : 630A Working lamp 24V, 70W License lamp 24V, 3W x 2 24V, 25/10W (Stop/Tail) 24V, 25W (Turn) Rear Combination lamp 24V, 10W (Back Up) Head lamp 24V, 70W Flasher lamp 24V, 25/10W...

  • Page 220: Group 4 Connector Destination

    GROUP 4 CONNECTOR DESTINATION 1. 35DS/40DS/45DS-7(MHI ENGINE) Connector part No. Connector No. of Type Destination number Female Male CN-1 368301-1 I/conn(Dashboard harness-frame harness) 2-85262-1 CN-2 368050-1 I/conn(Dashboard harness-frame harness) 368047-1 CN-4 LH support harness S810-004201 CN-5 RH support harness S810-004201 CN-8 Rear and beacon lamp S810-003201...
  • Page 221 Connector part No. Connector No. of Type Destination number Female Male Lamp CL-15 DAEDONG Combination lamp-LH 110-6PR CL-16 DAEDONG Combination lamp-RH 110-6PR CL-21 License lamp S822-014000 S822-114000 Relay CR-5 Neutral relay S810-004201 CR-11 Flasher unit relay S810-003702 CR-13 Head lamp relay S810-004201 CR-23 S822-114000...
  • Page 222 2. 35D/40D/45D-7(HMC ENGINE) Connector part No. Connector No. of Type Destination number Female Male CN-1 368301-1 I/conn(Dashboard harness-frame harness) 2-85262-1 CN-2 I/conn(Dashboard harness-frame harness) 368047-1 368050-1 CN-4 LH support harness S810-004201 CN-5 RH support harness S810-004201 CN-8 Rear and beacon lamp S810-003201 CN-17 Option...
  • Page 223 Connector part No. Connector No. of Type Destination number Female Male Lamp CL-15 DAEDONG Combination lamp-LH 110-6PR CL-16 DAEDONG Combination lamp-RH 110-6PR CL-21 License lamp S822-014000 S822-114000 Relay CR-5 Neutral relay S810-004201 CR-11 Flasher unit relay S810-003702 CR-13 Head lamp relay S810-004201 CR-23 Start relay...

  • Page 224: Group 5 Troubleshooting

    GROUP 5 TROUBLESHOOTING Trouble symptom robable 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 225: 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 226: Group 1 Structure

    SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) Outer mast Lift cylinder Carriage Frame D357MS01 Outer mast Bearing 11 Roller bearing Shim Inner mast 12 Back up liner Roller bearing Inner mast 13 Shim Tilt cylinder pin Anchor bolt Mast mounting pin 10 Chain sheave bearing...
  • Page 227 2. 2 STAGE MAST(VF MAST) Outer mast Inner mast Lift cylinder Free lift cylinder Carriage Frame D357MS02 Outer mast Mast mounting pin 11 Chain Shim Bearing 12 Sheave bracket Roller bearing Inner mast 13 Shim Backup liner Chain sheave bearing Tilt cylinder pin 10 Anchor bolt...
  • Page 228 3. 3 STAGE MAST(TF MAST) Outer mast Inner mast Lift cylinder Free lift cylinder Middle mast Carriage Frame D357MS03 Outer mast Mast mounting pin 11 Chain Shim Bearing 12 Sheave bracket Roller bearing Middle mast 13 Inner mast Backup liner Chain sheave bearing 14 Shim Tilt cylinder pin...
  • Page 229 3. CARRIAGE, BACKREST AND FORK 3.5/4.0TON ONLY D357MS04 Backrest Fork Carriage Extension fork Roller Shim Side roller...

  • Page 230: Group 2 Operational Checks And Troubleshooting

    Measure thickness of root of forks and check that it is more than specified value. EX : =1200mm(47in) mm(in) STD Fork assy Applicable model Standard Limit Thickness S173896-02 35D-7, 35DS-7 50(2.0) 48(1.9) F13710010 40D-7, 40DS-7 50(2.0) 48(1.9) D507FK01 F18393603 45D-7, 45DS-7 50(2.0)
  • Page 231 2. TROUBLESHOOTING MAST Problem ause 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 232 FORKS Problem ause 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 233: Group 3 Adjustment

    GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V, VF MAST) INNER/OUTER MAST ROLLER CLEAR- ANCE 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 234 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 235 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 236: Group 4 Removal And Installation

    GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1in) 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 237 SIDE ROLLER Remove carriage as outlined in the carriage Side roller 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. Adjustment Once carriage is properly installed, loosen nuts and adjust screws, (if not...
  • Page 238 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Remove the carriage assembly and Chain move them to one side. Loosen and remove hexagon bolts and washers securing lift cylinders to inner Backup liner mast. Loosen and remove hexagon bolts and nuts securing lift cylinders to inner mast.
  • Page 239 2 stage mast(VF mast) Remove free lift chain connected between carriage and free lift cylinder. Remove the carriage assembly and move them to one side. Loosen and remove hexagon bolts and washers securing lift cylinders to inner Chain mast. Loosen and remove hexagon bolts and nuts securing lift cylinders to inner mast.
  • Page 240 3 stage mast(TF mast) Remove the carriage assembly and move to one side. Loosen and remove hexagon bolt securing bottom cylinder from outer mast. Loosen and remove bolts and special washers securing lift cylinders to middle mast. Attach chains or sling to the inner and middle mast section at top crossmember.
  • Page 241 ELEVATING MAST Inner mast (V, VF mast) 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. Lift inner mast upright straight up and out of outer mast section. Replace and reverse above procedure to install.
  • Page 242 CHAIN Chain sheave(V, VF mast) Place a sling around carriage and attach to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 243 Chain wheel bearing support(TF mast) Remove the carriage assembly and move to one side. 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 244 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 245 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 246 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. 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.

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