Hyundai 35D-7E Operation Manual
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Hyundai 35D-7E 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 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Inspection and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10
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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20
Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
CONTENTS

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  • Page 1: Table Of Contents

    CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13 SECTION 2 REMOVAL AND INSTALLATION OF UNIT...
  • Page 2 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 When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 7 Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246...
  • Page 8 kgf·m to lbf·ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
  • Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 11: Section 1 General

    SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13...

  • Page 12: Group 1 Safety Hints

    GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. · Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
  • Page 13 Be particularly careful when removing the radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using the machine, there is a danger that boiled oil may spurt out. · The procedure for releasing the hydraulic pressure is as follows : lower the fork to the ground, and stop the engine(Motor), move the control levers to each position two or three times.
  • Page 14 · Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. 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 35DS7EOM54 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 ENGINE AIR INTAKE KEEP WATER AND OTHER FOREIGN MATERIALS OUT. KEEP WATER AND OTHER FOREIGN MATERIALS OUT. 35DS7ESP01 Model Unit 35D-7E 40D-7E 45D-7E 50D-7AE Capacity 3500 4000 4500 5000 ← ← ← Load center Weight(Unloaded) 5832 6392 6807...
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item Specification Unit Model HYUNDAI D4DD Type 4 cycle turbocharged diesel type Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, In-line Firing order 1-3-4-2 Combustion chamber type Direct injection Cylinder bore X stroke mm(in) 104×115(4.1×4.5)
  • Page 19 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(FWD/REV) Transmission Control Electrical single lever type 1st : 2.550 2nd : 1.218 Overhaul ratio 1st : 2.550 2nd : 1.218...
  • Page 20 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS ITEMS SIZE kgf·m lbf·ft Engine mounting bolt, nut M16×2.0 Engine Radiator mounting bolt, nut 6.9±1.4 50±10 M10×1.5 MCV mounting bolt, nut M12×1.75 Hydraulic Steering unit mounting bolt 4±0.5 29±3.6 M10×1.5 system Hydraulic pump mounting bolt 21±3.1 152±22 M14×1.5...
  • Page 21 5. TORQUE CHART Use following table for unspecified torque. OLT AND NUT Coarse thread Bolt size kgf·m lbf·ft kgf·m lbf·ft × 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8 × 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8...
  • Page 22 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" IPE AND HOSE(ORFS TYPE) Thread size Width across flat(mm) kgf·m lbf·ft 9/16-18 28.9 11/16-16 36.2 13/16-16 68.7 1-3/16-12 1-7/16-12 1-11/16-12 4 4 ) FITTING Thread size...
  • Page 23 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature C F Service Kind of Capacity (U.S.gal) point fluid (104) (-4) (14) (32) (50) (68) (86) SAE 30 SAE 10W Engine oil Engine oil 8.5(2.2) SAE 10W-30...

  • Page 24: Group 3 Periodic Replacement

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

  • Page 25: 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 26: Group 1 Structure

    GROUP 1 STRUCTURE 9 10 11 12 13 15 16 17 35DEOM21 Mast 10 Transmission 19 Muffler Lift cylinder 11 Torque converter 20 Silencer Steering unit 12 Engine 21 Overhead guard Tilt cylinder 13 Exhaust pipe 22 Seat Control valve 14 Air cleaner 23 Control lever Fork...

  • Page 27: Group 2 Removal And Installation Of Unit

    GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Forks Backrest ① Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. ② Release fork anchor pins and slide one fork at a time toward the center of the Knob carriage where a notch has been cut in...
  • Page 28 ② While supporting lift chains, remove the Chain split pin and nuts from the anchor bolt. Outer mast Anchor bolt Split pin 35DS7RE06 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain...
  • Page 29 Piping ① Remove the return hoses and clamps attached to the cylinder. ② Remove the return hose from the tee. Return hose ③ Remove hose assembly, tee and down safety valve(1). ※ Put blind plugs in the piping immediately Hose clamp after removing hoses.
  • Page 30 Inner mast ① Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Inner Be careful the mast not to swing or fall. mast Outer mast 35DS7RE11 Tilt cylinder pin Mast mounting pin ①...
  • Page 31 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. ※ Installation procedure for each of mast component is the reverse of the removal procedure. Mast mounting pin ① Check the mast mounting pins for wear, then install pins into the mast support bracket. ②...
  • Page 32 2. POWER TRAIN ASSEMBLY REMOVAL D503RE04 Mast Refer to section on mast(Page 2-2)
  • Page 33 Brake piping Brake valve Disconnect the brake piping from the brake housing of drive axle unit. Brake pipe Drive axle 35D7ERE13 Parking brake cable Disconnect parking brake cable from the Parking brake housing of drive axle unit. brake lever Parking brake cable Drive axle 35D7ERE16...
  • Page 34 Inching linkage Inching pedal Remove the bolt fixing the linkage assembly to T/M control valve. Bolt T/M control valve 35DS7RE16 Transmission cooling piping ① Radiator Disconnect cooling hose and connector assy from the transmission. ※ Make sure that the coolant be drained Hose from the hose.
  • Page 35 Mounting bolts holding to flywheel housing Mounting bolt ① Remove the transmission assembly from the engine flywheel by loosening the mounting bolts. 35D7ERE12 ② Using a moving truck slowly pull out transmission assembly to the front. Frame Block Truck 35DS7RE20 INSTALLATION Installation is the reverse order to removal, Bolt(1)
  • Page 36 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 37 Remove the 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. ① Wiring harness to alternator and starter. ②...
  • Page 38 Tightening torque of mounting bolt installing to torque converter housing. ·5.5~8.3kgf·m adiator hoses Precleaner ·Distance to insert hose : 70mm(2.75in) Air cleaner hose ① Insert the air cleaner hose securely and fit a clamp. ② Distance to insert hose ·Air cleaner hose : 70mm(2.75in) ·Engine end : 60mm(2.36in) Air cleaner Muffler...
  • Page 39 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) 1820kg (4010lb) 2540kg (5600lb) 35D-7E 45D-7E 2190kg (4828lb) 2900kg (6390lb) 40D-7E 50D-7AE ·Tightening torque : 199±29.9 kgf·m (1440±216lbf·ft)
  • Page 40 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. 35DS7RE28 Hose Disconnect the hoses from the steering axle. Steering axle Hose 35DS7RE29 Mounting bolt Put a block under the steering axle, Steering axle support on a truck, an raise the frame with a crane.

  • Page 41: 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 42: Group 1 Structure And Operation

    GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN COMPONENT OVERVIEW STRUCTURE Engine 35D7ETA01 Torque converter T/M control valve Disk brake T/M oil level gauge Differential 10 Drive axle oil level gauge Transmission Drive shaft 11 Drive axle T/M oil pump Drive wheel OPERATION Power train system consists of engine , torque converter(1) , transmission(3) , drive shaft(7) , drive...
  • Page 43 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 1.218 FR/RR 2 stage Transmission P.T.O system Included T/M oil DEXRON 3 Oil quantity Type...
  • Page 44 2. TORQUE CONVERTER STRUCTURE Turbine Input plate Impeller Torque converter Stator Pump gear Engine side Transmission side D357TA02 Item Specification Torque converter input plate 4.5±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) Needle bearing outer diameter...
  • Page 45 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 46 3. TRANSMISSION STRUCTURE 35D7ETA03 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) 19 Gear (FR, 2 stage)
  • Page 47 TRANSMISSION GEAR ARRAY T/C input T/C input relief T/C output (to cooler) From cooler INPUT T/C output relief COUNTER OUTPUT 35D7ETA04 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) ※...
  • Page 48 TRANSMISSION INPUT PORT 35D7ETA05 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 49 TRANSMISSION INPUT PORT 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 Oil sump...
  • Page 50 4. DIFFERENTIAL CARRIER ASSEMBLY STRUCTURE 35D7ETA07 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 51 5. DRIVE AXLE STRUCTURE 35D7ETA08 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 52 RIVE AXLE TIGHTENING TORQUE 35D7ETA09 Item Specification Inner carrier 2.2±0.3kgf·m (15.9±2.2lbf·ft) Spindle 12±0.5kgf·m (86.8±3.6lbf·ft) Adjust bolt for service 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) Wheel hub 3.0±0.3kgf·m (21.7±2.2lbf·ft) Ring gear 13.5±0.5kgf·m (97.6±3.6lbf·ft) Differential carrier assembly 11.5±0.5kgf·m (83.2±3.6lbf·ft) Connection between differential carrier and drive axle...
  • Page 53 DISK BRAKE 35D7ETA10 Spindle Service piston Drive shaft Steel plate Service piston adjust bolt Parking brake Disk plate Spline collar Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the high humid or dusty area. Because it is possible to use the brake semi-permanently, there is no need to replace or change the lining as drum type brake do.

  • Page 54: 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 55 2. TROUBLESHOOTING TRANSMISSION Check list during operation list Condition Possible causes Correction Transmission does not Low oil pressure or no oil Check to oil level. operate in any speed or pressure caused by : Check to mix another oil. does not engage(slips) in Low oil, no oil, or thick oil.
  • Page 56 Check list from operation noises Condition Possible causes Correction Noise in NEUTRAL only. Worn bushing pump Changing is related with other assembly. componrent of charging. Worn one-way clutch in torque Charging to Torque Converter converter. Ass'y. Oil level low. Check to oil level. Converter housing or converter Should be alignment with engine tangs not in alignment with...
  • Page 57 Check list from pressure test Condition Possible causes Correction Low pressure to FORWARD Inching valve linkage adjustment Adjust to inching valve. and REVERSE clutches. is not correct. Inching valve spool held(stuck) Change to inching spool. open. Clutch piston seals cause Change to Clutch and Piston leakages.
  • Page 58 RIVE AXLE Condition Possible causes Correction · Constant noise Oil is not enough(Replace Refueling lubricating oil differential. interval : 50 hrs first, then every 500hrs ). · Wrong kind of oil. Exchange lubricating oil · Wheel bearings Exchange bearing adjustment or have a defect. ·...
  • Page 59 Condition Possible causes Correction Drive wheels do not rotate Broken axle shaft. · Loose wheel bearings. Re-assemble wheel bearings. · Axle shaft too short. Replace drive shaft · Loose flange studs or nuts. Tighten studs or nuts · Drive gear teeth have been Exchange damaged drive gear damaged.

  • Page 60: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF DRIVE AXLE 1) DISASSEMBLE WHEEL HUB SUB ASSEMBLY Loosen oil drain plug using torque wrench(1) in axle housing and drain oil.. 35DSEDA01 Loosen oil drain plug in planetary housing and drain oil. 35DSEDA02 Loosen 4 socket head bolts and remove the planetary carrier.
  • Page 61 Remove o-ring(2) and snap ring(3) from the housing of planetary. 35DSEDA04 Remove 3 pins(6) with a plastic hammer. 35DSEDA05 Remove needle bearings(6), planet gears(5) and thrust washers(7). 35DSEDA06 Remove sun gear(8) and drive shaft(9). 35DSEDA07 3-20...
  • Page 62 Remove snap ring(10) and then remove sun gear from the shaft(9). 35DSEDA08 After removing bolt(11), remove ring gear(13) and torque plate assembly(12) from the spindle. Must Measure the rolling resistance of tapered roller bearing. 35DSEDA09 (10) Remove c-ring(14) from the ring gear and pull the spindle(15) out of the ring gear.
  • Page 63 (12) Remove wheel hub from the axle housing after loosen 14 bolts and 2 nuts. 35DSEDA12 (13) Disassemble DRIVE SHAFT and DISC & PLATE assembly. 35DSEDA13 35DSEDA14 (14) After Roosing 4 BOLT-SELF ADJUST(18), disassemble SPRING-SELF ADJUST(20) from BUSHING-SELF ADJUST(19). Then disassemble PISTON(17) from AXLE HOUSING(16).
  • Page 64 (15) Remove bearing cup from the wheel hub by using jig and hamer. Shaft seal may be damaged. 35DSEDA16 DISASSEMBLY OF THE DIFFERENTIAL CARRIER ASSEMBLY Loosen 12 bolts(1) and then remove carrier from the housing by using a lifting machine. 35DSEDA17 For the reassembly, check rolling resistance and record it.
  • Page 65 Remove diffrential assembly(8) from the carrier. Disassemble bearing(9) from the differential housing and remove 12 bolts(10). 35DSEDA20 After removing 12 mounting bolts(11) from the housing and then disassemble the ring gear. 35DSEDA21 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) Loosen 4 bolts(12) and then remove Drum from the Parking Brake 35DSEDA24 (11) After removing lock nut(13) and then remove the yoke(14). (12) Loosen 4 bolts(15) and then remove Parking Brake(16) from the Carrier housing. (13) Remove the drive bevel pinion shaft (17) carefully by using a plastic hammer.
  • Page 67 (16) Remove outer race of taper roller bearing on the opposite side. 35DSEDA28 3-26...
  • Page 68 2. REDISASSEMBLY OF DRIVE AXLE Clean every parts with cleanser and then remove remained loctite. Be careful not to spill cleanser on your body. Avoid drinking cleanser or breathing its fumes. Wear protective clothing, glasses and gloves. If spilled on the skin, flush your skin with water immediately. If swallowed, get medical attention immediately.
  • Page 69 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. 35L7ADA03 Heat the inner race of bearing to max 100°...
  • Page 70 ADJUSTMENT OF PINION SHAFT Assemle bearing cup. Assemble spacer to the pinion shaft and then install measured shims onto the spacer. 35DSEDA28 35DSEDA26 Insert pinion shaft into the carrier. After assemble bearing cone and lock nut. Apply grease on the outer bearing. Apply loctite #271 or #277 on the thread of pinion and then tighten lock nut.
  • Page 71 ASSEMBLY OF DIFFERENTIAL ASSEMBLY Assemble thrust washer, side gear and spider with gears and then install them to the differential housing. Apply grease on the bevel gear and thrust washer. 35L7ADA05 Assemble differential housing. ※ heck marks on the housing. Match two marks at the same position.
  • Page 72 Install differential assembly into the carrier. Place the bearing cup and screw into the housing. At that moment, using a screw adjust rotation backlash. Install the dial gauge on the gear tooth and measure the backlash while rotating bevel gear. ※...
  • Page 73 ASSEMBLY OF CARRIER Assemble carrier assembly into the axle housing. Fix the carrier assembly with hexagon bolt(1). Apply loctite #271 or #277 to thread of bolt and then assemble it with tightening torque of 11~13 kgf·m 35L7ADA07 Assemble BRAKE DRUM to YOKE with tighting 4 bolts(1).
  • Page 74 ASSEMBLY WHEEL HUB ASSY Insert bearing into wheel hub. Confirm that the bearing and wheel hub contact completely. ※ Apply grease or oil to shaft seal and then assemble it with proper direction (Out side of wheel hub). D357DA38 Install wheel hub assembly to the spindle completely.
  • Page 75 Install the torque plate to fix the spindle. Apply loctite #5127 to axle housing surface which contact to the spindle. 35L7ADA13 35L7ADA14 Assemble square ring (2),(3) to the Axle housing(1) then apply oil(MOBILFLUID #424). Assemble bushing(5) to piston(2) and then assemble piston(2) to axle housing after applying oil sufficiently and then assemble the spring(6) to the bushing(5).
  • Page 76 Assembling plate and inspection ① Assemble 4 plates(9) and 3 disks(10) with spline collar(11) and then lock with snap ring(12). Disc must be assembled after the oil immersion during 12 hours(MOBILFLUID #424) ② Install assembled the spline collar to the axle housing with the drive shaft.
  • Page 77 After assemble sun gear to axle shaft and fix it with a snap ring. Apply grease on the shaft where bushing contacts. Apply grease on teeth of the planetary gear. D357DA43 (10) Assemble internal components of planetary carrier with the reverse order of disassembly.
  • Page 78 (12) Assemble the wheel hub and tighten the plug(14). ·Tightening torque : 3.5~6.0kg·m D357DA47 3-37...
  • Page 79 3. DISASSEMBLY OF TRANSMISSION Pull torque converter(1) straight forward and remove from the converter housing. Remove six bolts(3) and flexible plate(1), plate(2) from the torque converter. 35L7ADA22 Remove six socket bolts (3) and then gear P.T.O input from the the torque converter. D357TM02 Remove four bolts (9) and bolts(8), washes, oil seal(10) from the housing converter(7).
  • Page 80 ※ Bearing cups and their shims will be in cover or on the shafts in transmission case. Put identification on each of bearing cups and shims as to their location on transmission cover or shaft in transmission case. 35L7ADA25 Remove fasten five bolts(23) from fixed stator hub(24) and bearing plate.
  • Page 81 Separate to Two Thrust Washer's(34), Needle Bearing(35), Gear- P.T.O Idle(36) from Bearing Plate. 35L7ADA26 Remove two bolt's(38), nine bolt's(39), valve gasket(40). 35L7ADA27 Remove eight Bolt's(41), five Bolt.Soc(42), then separate valve plate from transmission case. 35L7ADA28 Remove O-ring, Plug(46) then Spring(47), Oil screen(48) from transmisson case.
  • Page 82 Use the plastic hammer to push tube (49) out of the transmission case. Remove the tube. Remove output shaft assembly (51), input shaft assembly (50), and counter shaft assembly (52). D357TM14 Remove the Output Gear (53) from the transmission case. D357TM15 3-41...
  • Page 83 For high speed forward clutch assembly, remove bearing cone (54) with gear pulley. 35L7ADA30 Remove two thrust washes (55) and gear (56). Remove needle bearings and thrust washer from the forward shaft of high speed clutch side. 35L7ADA31 Use a screwdriver and Remove snap ring (57) from the cylinder.
  • Page 84 Remove a five clutch discs and three 4T clutch plates(58), four 2T clutch plates (60), one bending plate (59) from the cylinder. 35L7ADA33 Push down on the retainer(61) by a press and remove snap ring(62) with a screwdriver. Slowly release the tension on the spring assembly.
  • Page 85 Remove snap ring (57), then remove a five clutch discs and three 4T clutch plates (58) and four 2T clutch plates (60), one bending plate (59) from the cylinder. 35L7ADA36 Remove two thrust washes and pin. Push down on the retainer (61) by a press and remove snap ring (62).
  • Page 86 Remove bearing cups (70) from the transmission case. ※ Put identification on bearing cups to use at assembly. D357TM25 Remove two lip type oil seals (71) from the transmission case. 35L7ADA38 3-45...
  • Page 87 4. ASSEMBLY OF TRANSMISSION Thoroughly clean all the parts of the transmission. Put clean transmission oil on all of the inner parts. Put lip type oil seal (71) in position on the case with the spring loaded lip of the inside seal toward the inside of the transmission case and with the lip of the outside seal (71) toward the outside of the transmission case.
  • Page 88 Install seal ring on the piston(60). Put clean transmission oil on the seal ring. Install piston with seal ring in cylinder. ※ Be extra careful during installation of the piston. Broken seal rings can be the result. 35L7ADA37 Put spring assembly and retainer(61) in position in the cylinder.
  • Page 89 Put clean transmission oil on each side of the clutch plates and clutch discs. Install four 2T clutch plates, three 4T clutch plates, five clutch discs and one bending plate in the cylinder with the following procedure. Install a clutch plate first, that has guide shape on its outside diameter.
  • Page 90 Use a screwdriver and install snap ring (57) that check all of them in position in the cylinder. Install three seal rings on the shaft. ※ Be careful not to cause damage to the seal rings. Install thrust washer and needle bearings on the counter shaft of high speed clutch side.
  • Page 91 Assemble input shaft assembly with the same procedure as counter shaft assembly. Install the gear assembly (53) into transmission case. D357TM15 Carefully put the counter shaft assembly (52) in position in the transmission case. Carefully put the input shaft assembly (50) in position in the transmission case.
  • Page 92 Install screen (48), spring (47) and plug, (46),o-ring in the transmission case. Install Temperature sensor (45) in the transmission case. Install plug (43) and washer (44) in the transmission case. 35L7ADA29 First, apply to Loctite 5172 on the transmiss case then, fixed. Install valve plate by using a eight bolts and an five socket bolt 35L7ADA41...
  • Page 93 Install a Gear-P.T.O Output(25), two ball bearings on the Flange Pump(28) by using the jig then, install four bolts on the bearing plate. Then, Charging pump(31) and Gasket(30) on the Flange Pump by install a Bolt(32) and four Bolt's(33). Install a 90 degree Elbow.
  • Page 94 When new parts are used, required shim thickness should be calculated as follows . Assemble shaft assembly (including taper bearing cone and cup). Insert shaft assembly into transmission case. ※ Use depth gage and block gage because the height of bearing cup is higher than surface of transmission case.
  • Page 95 Install torque converter housing in position. Install four bolts (9) and washes, oil seal (10), four bolts (8) that hold torque converter housing to the transmission. D357TM52 Install Gear P.T.O Input(5) to Torque converter, then tighten six socket bolts(6) in postion.

  • Page 96: 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 ------------------------------------------------------- 4-8 Group 3 Tests and adjustments -------------------------------------------------------------------------------------4-10...

  • Page 97: 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 98 3. BRAKE PEDAL AND PIPING STRUCTURE l v e n t r T / M Drive axle 35D7EBS03 Brake pedal & bracket assembly Reservoir tank assembly Parking lever assembly Brake valve...
  • Page 99 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. 155~163mm(Pedal height) T/M control valve Inching spool...
  • Page 100 5. WET DISK BRAKE STRUCTURE 35D7ETA10 Spindle Service piston Drive shaft Steel plate Service piston adjust bolt Parking brake Disk plate Spline collar Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the high humid or dusty area. Because it is possible to use the brake semi-permanently, there is no need to replace or change the lining as drum type brake do.
  • Page 101 6. BRAKE VALVE STRUCTURE 18 17 16 35D7EBV00 Front housing 11 U-cup seal 21 O-ring Rear housing 12 U-cup seal 22 Spring Push rod 13 U-cup seal 23 Gauge Bellows 14 U-cup seal 24 Air bent Master piston 15 Relief piston 25 Plug Lock washer 16 Relief spring...
  • Page 102 DISASSEMBLY 28 27 Remove push rod (3), bellows (4), air vent (24), bolt (27) and washer (28). 35D7EBV01 Remove front housing (1), rear housing (2), servo spring (10), servo piston (9) and master piston (5). 35D7EBV02 Remove relief plug (17) with O-ring (18), relief spring (16) and relief piston (15).
  • Page 103 INSPECTION AND ASSEMBLY Clean all parts thoroughly and lubricate the parts either with mineral or with hydraulic oil, according to their use destination. All single parts are to be checked for damage and replaced, if required. Assembly is in opposite order to disassembly. Seal kit : XKAU-00176 Use only brake fluid (Azola ZS10) into the compensation reservoirs.

  • Page 104: 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 ·...
  • Page 105 . 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 106: 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 Air vent plug vent plug on wheel cylinder.
  • Page 107 Micro switch for parking brake (if equipped) ① After assembling parking brake and parking cable, put the parking brake lever P/lever stroke released. Knob ② Loosen the nut for parking brake plate to play up and down. ③ Move up the plate so that the stopper can be contacted with the pin and then reassemble nut.

  • Page 108: 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 109: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Steering cylinder Steering unit Steering axle Priority valve pump Hydraulic tank 35DS7SE01 The steering system for this machine is composed of steering wheel assembly, steering unit, priority valve steering cylinder, steering axle and piping.
  • Page 110 2. HYDRAULIC CIRCUIT 12.5MPa Brake valve 35DS7SE02 Hydraulic gear pump Steering cylinder Steering unit Suction filter Priority valve 14 Hydraulic tank...
  • Page 111 NEUTRAL 12.5MPa Brake valve 35DS7SE03 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 priority valve(4) and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(14).
  • Page 112 LEFT TURN 12.5MPa Brake valve 35DS7SE04 When the steering wheel is turned to the left, the spool(G) within the steering unit(3) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through the spool(D) of priority valve(4) and flows the gerotor(H).
  • Page 113 RIGHT TURN 12.5MPa Brake valve 35DS7SE05 When the steering wheel is turned to the right, the spool(G) within the steering unit(3) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through the spool(D) of priority valve(4) and flows the gerotor(H).
  • Page 114 3. STEERING UNIT 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 25 P-port check valve 16 Drive 25-1 Plug...
  • Page 115 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 116 4. STEERING AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 1-22 1-26 1-29 1-25 1-24 1-30 1-35 1-10 1-31 1-38 1-26 1-27 1-32 1-28 1-23 1-12 1-25 1-27 1-13 1-28 1-11 1-21 1-10 1-14 1-33 1-34 1-15 1-44 1-16 1-35...
  • Page 117 GREASING AND SPECIFICATION Stroke 91.5mm(3.6in) Stroke 91.5mm(3.6in) 35kgf m(253lb ft) Apply loctite #277. 16.7~22.5kgf m(121~163lb ft) 35DS7SE07 Type Unit Center pin support single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of wheels(Inside/Outside) degree 74.8/53.8 Tread...

  • Page 118: 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-7E 2770mm(109in) 45D-7E 2890mm(114in) 40D-7E 2830mm(111in)
  • Page 119 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 ·Faulty.

  • Page 120: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT 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 25 P-port check valve...
  • Page 121 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 122 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1kgf·m (0~54.4lbf·ft) 13mm socket spanner 6, 8mm and 12mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 5-70(2) TIGHTENING TORQUE L : Left port R : Right port T : Tank P : Pump...
  • Page 123 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 124 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 125 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 126 (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 127 (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 128 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 129 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 130 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 131 (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 132 (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 133 (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 134 (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 135 (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 136 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ·Tightening torque : 4.0 ±...
  • Page 137 (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 138 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 139 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.
  • Page 140 Install the dust wiper to the gland 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. D353SE29 Using a hook spanner, install the gland ass- embly, and tighten it with torque 60±6kgf·m (434±43lbf·ft).
  • Page 141 3. STEERING AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 1-22 1-26 1-29 1-25 1-24 1-30 1-35 1-10 1-31 1-38 1-26 1-27 1-32 1-28 1-23 1-12 1-25 1-27 1-13 1-28 1-11 1-21 1-10 1-14 1-33 1-34 1-15 1-44 1-16 1-35...
  • Page 142 CHECK AND INSPECTION A1,A2 35DS7SE08 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) 35(1.4) 34.5(1.4) Replace OD of king pin OD of steering cylinder pin 20(0.8) 19.5(0.8) OD of pin 20(0.8)
  • Page 143 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 Hub nut Loosen the hub nut and take off the steering wheel tire.
  • Page 144 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. 1-38 Tighten the special bolt(1-8) and washer(1-9) of king pin(1-3).

  • Page 145: 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 ------------------------------------------------------- 6-15 Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 6-20...

  • Page 146: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT A2 B2 A3 B3 A4 B4 E/G T/M TO BRAKE 35D7EHS01 Hydraulic gear pump Tilt cylinder Main control valve Lift cylinder Steering unit 10 Suction filter Priority valve 11 Return filter Brake valve 12 Down safety valve...
  • Page 147 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION A2 B2 A3 B3 A4 B4 Steering syetem Lift Load check valve Steering return line Brake syetem E/G T/M Brake return line 35D7EHS02 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) through the priority valve(4) and then goes to the large chamber of lift cylinder(9) by pushing the load check valve of the spool.
  • Page 148 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION A2 B2 A3 B3 A4 B4 Lower Steering syetem Steering return line Brake syetem E/G T/M Brake return line 35D7EHS03 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 A2 B2 A3 B3 A4 B4 Steering syetem Steering return line Brake syetem E/G T/M Brake return line 35D7EHS04 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 A2 B2 A3 B3 A4 B4 Steering syetem Tilt backward Load check valve Steering return line Brake syetem E/G T/M Brake return line 35D7EHS05 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 STRUCTURE D353HS06 Bolt Seal Drive gear Spring washer Bushing Flange End cover Bushing Shaft seal O-ring Body Circlip Back up seal Driven gear OPERATION This pump comprised of an end cover, a body, bushings and a mounting flange bolted together with through bolts.
  • Page 152 3. MAIN CONTROL VALVE STRUCTURE (2 Spool) Port name Size Inlet port 1-5/16-12UN Outlet port 1-5/16-12UN Gauge port PF1/4 3 Work port 1-1/16-12UN Inlet port SECTION B - B Outlet port 3 Work ports Gauge port VIEW D - D SECTION A - A 35DS7HS07 Special nut...
  • Page 153 LIFT SECTION OPERATION Lift position D353HS08 When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flow into lift cylinder port(B1). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 154 Lower position D353HS09 When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (B1)→T. In lift lower position the fork drops due to its own weight.
  • Page 155 TILT SECTION OPERATION Tilt forward position D353HS10 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flow into tilt cylinder port(A2). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage.
  • Page 156 Tilt backward position D353HS11 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flows into tilt cylinder port(B2).
  • Page 157 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 158 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 159 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 160: 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 161 . 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 162 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.
  • Page 163 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 164 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 165: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP 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 6-20...
  • Page 166 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 167 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 168 (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 169 (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 170 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 171 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 172 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 173 (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 174 (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 175 2. MAIN CONTROL VALVE Lay out valve components on a clean, flat working surface. The inlet assembly will include an O-ring, and the spool section(s) include an O-ring, a load check poppet and a load check spring. Tools required for basic valve assembly include 3/4 and 11/16 open or box end wrenches and a torque wrench with thin wall sockets.
  • Page 176 Position valve assembly with the mounting pads of the end sections on a flat surface. To obtain proper alignment of end sections relative to the spool sections apply downward pressure to the end sections ; Snug tie rod nuts to about 10lbf·ft. Final torque the two 11/16 nuts to 48±...
  • Page 177 4. LIFT CYLINDER STRUCTURE · I.D×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 16 O-ring...
  • Page 178 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 179 5. TILT CYLINDER STRUCTURE · I.D×O.D×stroke : 90×102×220mm (3.5×4.0×8.7in) · Rod O.D : 45mm(1.8in) 35DS7HS16 Tube assy O-ring 17 Nylon nut 10 Back up ring 18 Rod eye Gland 11 Lock washer 19 Spherical bearing DU bushing 12 O-ring 20 Retaining ring Rod seal 13 Piston 21 Hexagon bolt...
  • Page 180 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 181: Section 7 Electrical System

    SECTION 7 ELECTRICAL SYSTEM Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2 Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12 Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13...

  • Page 182: Group 1 Component Location

    SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 13 14 15 0 0 0 0 HYUNDAI 35D7EEL01 Work lamp Combination lamp 15 Start switch Battery 10 Beacon lamp 16 Fuse box Master switch 11 Forward-reverse lever 17 Work lamp switch(opt)

  • Page 183: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT CLUSTER START KEY S/W SEAT S.W REAR SUPPORT HARNESS PARKING HEAD FRONT HEAD FRONT B BR R1 R2 C ACC BRAKE OIL SWITCH LAMP COMBI LH LAMP COMBI RH (OP) REAR BEACON R/COMBI LH R/COMBI RH WORK RELAY HEAD LAMP...
  • Page 184 MEMORANDUM...
  • Page 185 1. POWER CIRCUIT The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the off position, the current flows from the positive battery terminal. OPERATING FLOW Battery(+) Start motor[CN-45(B+)] Glow relay[CR-24] Glow plug[CN-80] Start relay[CR-23] Fusible link[CN-95] Alternator[CN-74(B+)]...
  • Page 186 POWER CIRCUIT START KEY S/W BR R1 R2 C ACC CN-1 CD-4 BRAKE SW CN-74 CR-11 ALTERNATOR CN-15 FLASHER UNIT GEAR SELECTOR CN-95 CN-2 CS-11 2-FWD FUSIBLE LINK 1-REV CR-24 GLOW RY CN-80 6-ILL GLOW PLUG CS-12 7-Lo CR-23 8-Hi CN-25 START RY 1-TLH...
  • Page 187 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-95] Start switch[CS-2(3)] Start relay[CR-23] ※ T he engine can be started only when the gearshift is in neutral position. When start key switch is in ON position Fuse box[No.4 →6] Start switch ON [CS-2(4)] Combi switch[CS-12(5)] When start key switch is START position...
  • Page 188 STARTING CIRCUIT CLUSTER START KEY S/W BR R1 R2 C ACC CN-1 CR-5 NEUTRAL & ANTI RELAY CN-74 ALTERNATOR CN-15 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 BATTERY...
  • Page 189 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator release the start switch to the ON position. Charging current generated by operating alternator flows into the battery. The current also flows from alternator to each electrical component through the fusible link(CN-60) and the fuse box.
  • Page 190 CHARGING CIRCUIT CLUSTER START KEY S/W BR R1 R2 C ACC CN-1 CN-74 ALTERNATOR CN-15 CN-95 FUSIBLE LINK CR-23 START RY CN-45 START MOTOR BATTERY MASTER SW 12V X 2 35D7EEL05...
  • Page 191 4. PREHEATING CIRCUIT Combustion chamber glow plugs are used in order to give satisfactory starting of low ambient temperatures. OPERATING FLOW Battery(+) terminal Fusible link[CN-95] I/conn[CN-15(1)] Alternator[CN-74(B+)] I/conn[CN-15(2)] I/conn[CN-1(8)] I/conn[CS-2(3)] Start switch Glow relay[CR-24] ※ When you turn the start switch to the ON position, the glow relay makes the glow plugs operated and the glow lamp of the cluster turned ON.
  • Page 192 PREHEATING CIRCUIT CLUSTER START KEY S/W BR R1 R2 C ACC CN-17 OPTION CR-46 CN-1 CN-20 GLOW AUX. TO.AIRCON HARNESS RELAY CR-24 GEAR SELECTOR GLOW RY CS-11 2-FWD CN-80 CN-2 GLOW PLUG 1-REV CN-74 6-ILL CS-12 7-Lo ALTERNATOR 8-Hi CN-15 CN-95 1-TLH 2-TRH...

  • Page 193: Group 3 Component Specification

    GROUP 3 COMPONENT SPECIFICATION Specification Part name 12V×96AH×2EA Battery RC : 130min CCA : 630A Working lamp 24V, 70W License lamp 24V, 3W×2 24V, 25/10W (Stop/Tail) 24V, 21W (Turn) Rear Combination lamp 24V, 10W (Back Up) Head lamp 24V, 70W Flasher lamp 24V, 25/10W Glow relay...

  • Page 194: Group 4 Connector Destination

    GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 368301-1 I/conn(Frame harness-dashboard 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-6 I/conn(Frame harness-dashboard harness) 368047-1 368050-1 CN-7...
  • Page 195 Connector part No. Connector No. of Type Destination number Female Male 1123340-1 CN-154 1123341-1 CN-155 CN-156 MOLEX ECU diagnostic 51115-1601 MG651026(L) CN-157 Switch Start switch S810-004201 CS-2 Horn GP140984 CS-5 RING TERM Gear selector switch S811-007002 CS-11 Combination switch S811-009002 CS-12 Parking switch S810-003201...

  • Page 196: 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 197 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 198: Group 1 Structure

    SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) Lift cylinder Carriage Frame 35DS7MS01 Outer mast Bearing 11 Roller bearing Shim(0.5, 1.0t) Inner mast 12 Back up liner Roller bearing Lift chain 13 Shim(0.5, 1.0t) Tilt cylinder pin Anchor bolt Mast mounting pin 10 Chain sheave bearing...
  • Page 199 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(0.5, 1.0t) Bearing 12 Sheave bracket Roller bearing Inner mast 13 Shim(0.5, 1.0t) Backup liner Chain sheave bearing Tilt cylinder pin 10 Anchor bolt...
  • Page 200 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(0.5, 1.0t) Bearing 12 Sheave bracket Roller bearing Middle mast 13 Inner mast Backup liner Chain sheave bearing 14 Shim(0.5, 1.0t) Tilt cylinder pin...
  • Page 201 3. CARRIAGE, BACKREST AND FORK 35D7EMS04 Backrest Fork Carriage Extension fork Roller Shim(0.5, 1.0t) Side roller...

  • Page 202: Group 2 Operational Checks And Troubleshooting

    FORKS Measure thickness of root of forks and check that it is more than specified value. ℓ=1200mm(47in) EX : mm(in) STD Fork assy Applicable model Standard Limit Thickness S173896-02 35D-7E 50(2.0) 45(1.7) F13710010 40D-7E 50(2.0) 45(1.7) D507FK01 F18393603 45D-7E 50(2.0) 45(1.7)
  • Page 203 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 204 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 205: 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 206 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 207 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 208: 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 209 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. ※...
  • Page 210 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Hexagon ① Remove the carriage assembly and bolt Chain move them to one side. ② Loosen and remove hexagon bolts and clamps securing lift cylinders to outer Backup liner mast.
  • Page 211 2 stage mast(VF mast) ① Remove free lift chain connected between carriage and free lift cylinder. ② Remove the carriage assembly and move them to one side. ③ Loosen and remove hexagon bolts and washers securing lift cylinders to inner Chain mast.
  • Page 212 3 stage mast(TF mast) ① Remove the carriage assembly and move to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. ③ Loosen and remove bolts and special washers securing lift cylinders to middle mast. ④...
  • Page 213 ELEVATING MAST Inner mast (V, VF mast) ① After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. ② Lift inner mast upright straight up and out of outer mast section. ③...
  • Page 214 CHAIN Chain sheave(V, VF mast) ① Place a sling around carriage and attach to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 215 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 216 ② Rust and corrosion Chains used on lift trucks are highly stressed precision components. It is very important that the “as-manufactured” ultimate strength and fatigue strength be maintained throughout the chain service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or roller chain because corrosion causes side plate cracking.
  • Page 217 ⑧ Chain wear scale The chain can be checked for wear or stretching with the use of a chain wear scale. Stretching of a chain is due to the elongation of the pitch holes and wearing of the pin O.D. The greatest amount of stretching occurs at the areas of the chain that flex over the sheaves most frequently.
  • Page 218 ③ ③ Adjustment Chain adjustments are important for the following reasons : ·Equal loading of chain. ·Proper sequencing of mast. ·Prevent over-stretching of chains. ·Prevent chains from jumping off sheaves if they are too loose. ④ djustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor. ·Adjust the chain length by loosening or tightening nut on the chain anchor.

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