Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Operation and maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-31

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-58

Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-154

SECTION 4 BRAKE SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17

Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-22

SECTION 5 STEERING SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15

Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19

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

Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-16

CONTENTS

Table of Contents

Troubleshooting

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Summary of Contents for Hyundai 50DS-7E

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...
Page 3 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
Page 4 Revised edition mark(①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
Page 7 Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246...
Page 8 kgf·m to lbf·ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 11: Section 1 General
SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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 50DS7EOM54 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 Carrige 12 Bonnet...
Page 17 2. SPECIFICATIONS 50DS7ESP01 Model Unit 50DS-7E 60DS-7E 70DS-7E Capacity 5000 6000 7000 ← ← Load center Weight(Unloaded) 8602 9245 9871 ← ← Lifting height 3000 ← ← Free lift Lifting speed(Unload/Load) 480/450 480/440 480/430 Fork mm/sec ← ← Lowering speed(Unload/Load)
Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item Specification Unit Model MITSUBISHI S6S-T Type 4-cycle, in-line, Vertical OHV Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, in line Firing order 1-5-3-6-2-4 Combustion chamber type Indirect injection Cylinder bore X stroke mm(in) 94×120(3.7×4.7) cc(cu in)
Page 19 POWER TRAIN DEVICES Item Specification Model W280, 2.526/248 (TL, ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.526 Type Full auto, Power shift Gear shift(FR/RR) Transmission Control Electrical single lever type 1 : 4.446 2 : 2.341 3 : 0.974 Overhaul ratio 1 : 4.443...
Page 20 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS kgf·m lbf·ft ITEMS SIZE Engine mounting bolt, nut M16×2.0 Engine Radiator mounting bolt, nut 6.9±1.4 50±10 M10×1.5 6.9±1.4 50±10 Torque converter mounting bolt M10×1.5 12.8±3.0 93±22 MCV mounting bolt, nut M12×1.75 Hydraulic system Steering unit mounting bolt 6.9±1.4 50±10 M10×1.5...
Page 21 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT Coarse thread Bolt size kgf·m lbf·ft kgf·m lbf·ft 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7 4.0 ~ 6.0...
Page 22 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat(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(UNF) 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 FITTING Thread size(PF) Width across flat(mm)
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 16.5(4.3) 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 8 9 10 11 12 13 14 15 16 17 50DS7EOM21 Mast 10 Priority valve 19 Muffler Lift cylinder 11 Transmission 20 Silencer Tilt cylinder 12 Torque converter 21 Air cleaner Control valve 13 Engine 22 Overhead guard Fork 14 Exhaust pipe 23 Seat...
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 SHAFT TYPE FORKS Fork retainer ① Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Hanger bar ②...
Page 28 CARRIAGE Crane ① With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor.
Page 29 ④ Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage to work area and lower the mast. Make sure that carriage remains on floor and does not bind while mast is being raised. ※ Inspect all parts for wear or damage. Replace all worn or damaged parts.
Page 30 LIFT CYLINDER Set screw ① Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast. ② Bind the lift cylinder with overhead hoist Inner mast rope and pull up so that the rope has no slack or binding. Make sure the lift cylinder be tightened firmly for safety.
Page 31 TILT CYLINDER PIN MAST SUPPORT PIN Attach a crane to the stay at the top of the outer mast, and raise it. Outer mast Remove the mounting bolts and pins from drive axle, then slowly raise outer mast. ※ This operation is carried out under the machine, so use a pit, or if there is no pit, Tilt cylinder jack up the machine and loosen with an...
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 ① 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 wheel cylinder end. Brake valve Drive axle 80D7RE05 Parking brake cable Parking brake Disconnect parking brake cable from the lever wheel brake assembly. Parking brake cable Drive axle 80D7RE06 Drive axle ※...
Page 35 ④ Remove drive axle mounting bolts from the frame and then slowly pull out the truck with drive axle to the front. 50DS7ERE08 ⑤ Remove propeller shaft from the transmi- ssion by loosening the mounting bolts. 50DS7ERE81 Inching linkage Remove the nut, clevis pins and self locking pin.
Page 36 Transmission cooling piping ① Disconnect cooling hose and connector from the transmission. ※ Make sure that the coolant be drained from the hose. 50DS7ERE10 Torque converter ① Remove the cover on bottom face of the torque converter housing then remove the 4 mounting bolts installed on the engine flywheel.
Page 37 ② Using a moving truck slowly pull out transmission assembly to the front. 50DS7ERE13 INSTALLATION Installation is the reverse order to removal, but be careful of the following points. Tightening torque of mounting bolt for torque converter housing. ·6.0~8.9kgf·m(43~64lbf·ft) 50DS7ERE12 Tightening torque of mounting bolt for drive axle.
Page 38 Tightening torque of mounting bolt for transmission and propeller shaft. ·7±0.7kgf·m(50.6±5lbf·ft) 50DS7ERE15 2-13...
Page 39 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 40 Remove the torque converter housing cover, mounting bolts installed to flywheel housing. For details, see page 2-12. Engine accessory Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. ① Wiring harness to alternator and starter. ② Wiring harness for oil pressure and engine water temperature gauges.
Page 41 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 ·Engine end(MHI) : 60mm(2.36in) 50DS7ERE21...
Page 42 4. WHEEL BRAKE REMOVAL D503RE34 Front wheel Put a block under the mast and tilt forward, or jack up the bottom of the frame to raise the front wheels off the ground, then remove the front wheels. 50DS7ERE22 Brake, drum assembly. D503RE23 INSTALLATION Installation is in the reverse order to removal,...
Page 43 50DS7ERE30 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) 50DS-7E : 2,120kg(4,674lb) 60DS-7E : 2,680kg(5,908lb) 70DS-7E : 3,250kg(7,165lb) 2-18...
Page 44 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. D503RE31 Hose 50DS7ERE32 Mounting bolt Put a block under the steering axle, support on a truck, an raise the frame with a crane.
Page 45: Section 3 Power Train System
SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Operation and maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-31 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-58 Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-154...
Page 46: Group 1 Structure And Operation
SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION . POWER TRAIN COMPONENT OVERVIEW 50DS7EPT01 The power train consists of the following components : ·Torque converter ·Transmission ·Propeller shaft ·Drive axle Engine power is transmitted to the transmission through the torque converter. The transmission is a hydraulically engaged three speed forward, three speed reverse power shift type transmission.
Page 47 2. TORQUE CONVERTER D503TM01 Turbine Pump Input shaft Stator Transmission pump The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the characteristics, and with it the favorable efficiency of a fluid clutch. The converter will be defined according to the engine power so that the most favorable operating conditions for each installation case are given.
Page 48 If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the turbine moment becomes equal to that of the pump moment. From this point on, the converter is working similar to a fluid clutch. A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the conversion range the moment upon the housing, and is released in the coupling range.
Page 49 3. TRANSMISSION LAYOUT 50DS7ETM03 Flex plate for direct mount 12 Transmission housing - rear part Central shaft/input shaft PTO Converter 13 Transmission housing - front part Connection, PTO ; coaxial, Converter bell housing engine-dependent 14 Output flange Transmission pump 15 Output shaft Clutch shaft(KD) Clutch shaft(KV) 16 Screen sheet...
Page 50 INSTALLATION VIEW FRONT VIEW REAR VIEW 50DS7EPT26 Filter Converter Transmission mounting holes M16×1.5 Direct mount via flex plate 10 Oil filter tube with oil dipstick Converter bell housing 11 Oil drain plug 7/8"14 UNF 2B Transmission housing-front part 12 Output flange MECH 6C Transport bracket 13 Identification plate Transmission housing-rear part...
Page 51 OPERATION OF TRANSMISSION Gearbox diagram The multi-speed reversing transmission in countershaft design is power shiftable by hydraulically actuated multi-disk clutches. All gears are constantly meshing and carried on antifriction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 3-speed reversing transmission is equipped with 5 multi-disk clutches.
Page 52 Forward In forward, forward clutch and 1st, 2nd, 3rd clutch are engaged. Forward clutch and 1st, 2nd, 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston. Transmission diagram 1st gear forward AN/KR KR/PTO Legend: AN = Input KV = Clutch forward KR = Clutch reverse KC = Clutch 1st speed...
Page 53 Reverse In reserve, reserve clutch and 1st, 2nd, 3rd clutch are engaged. Reverse clutch and 1st, 2nd, 3rd are actuated by the hydraulic pressure applied to the clutch piston. Transmission diagram 1st gear reverse AN/KR KR/PTO Legend: AN = Input KV = Clutch forward KR = Clutch reverse KC = Clutch 1st speed...
Page 54 TRANSMISSION CONTROL Transmission control see measuring points and oil circuit diagram see page 3-10. The transmission pump which is necessary for the oil supply of the converter and for the transmission control is located within the transmission on the engine-dependent input shaft. The pump feed rate is Q=45ℓ/min, at n =1500min engine...
Page 55 Hydraulic circuit Gear-shift signal Turbine speed Output speed Engine speed Speed central gear chain Inch enable signal Inch pedal signal 1 Oil sump temperature (OPTION) Inch pedal signal 2 Oil temperature after the converter Converter Display Park brake feedback signal SKR WSV Lubrication Main pressure...
Page 56 GEAR SELECTOR(DW-3) The gear selector is designed for the mounting on the steering column left side. By a rotative motion, the positions(speeds) 1 to 3 are selected by tilting the lever, the driving direction(Forward (F) - Neutral(N) - Reverse(R)). For the protection from unintended start off, a neutral interlock is installed : Position "...
Page 57 Gear selector(DW-3) LEVER FOR MECHANICAL NEUTRAL INTERLOCK CODING GEAR SELECTOR OUTPUT FORWARD REVERSE NEUTRAL SPEED IN POSITION(NEUTRAL), F-R NOT SWITCHABLE TYPE PLATE CIRCUIT DIAGRAM SELECTOR GEAR POSITIONS A AD3(B3) B AD2(B2) C AD1(B1) C AD7(KD) F = Forward N = Neutral A ED1(+/VP) R = Reverse D = Mechanical neutral interlock...
Page 58 TRANSMISSION ERROR DISPLAY Function The display can be used with the gear selector. It indicates speed and driving direction as well as the activated inching. When driving in the automatic mode, a bar indicator gives additionally also information about the selected driving range;...
Page 59 isplay during operation Symbol Meaning Remarks Actual gear and direction F, N, R Central side shows actual gear 1, 2, 3 Right side shows actual direction Not neutral, waiting for neutral To engage a gear, first move shift selector to (Central and right side) after power up or a severse fault neutral position and again to F to R position...
Page 60 Display during AEB-Mode Symbol Meaning Remarks AEB-Starter is plugged at the diagnostic plug AEB-Starter-button is pressed KC, KD for 2 gear transmission Calibraiting clutch KC..KE, KV or KA..KE KC, KD, KE for 3 gear transmission KR resp. KV, KR Wait for start, initialization of _and Kx clutch Kx, x : C, D, E, V, R ≡and Kx...
Page 61 Definition of the error codes ① ① Introduction The error codes consists of two hexadecimal numbers. The first number shows the type of signal, the second number shows signal and the type of the error. ② Description of error codes First No.
Page 62 Number Meaning of error code 3A hex Short circuit to battery voltage or open circuit at output speed input 3B hex Short circuit to ground or open circuit at output speed input 3C hex Logical error at output speed input 71 hex Short circuit to battery voltage at clutch KC 72 hex...
Page 63 Number Meaning of error code Slippage at clutch KC B1 hex B2 hex Slippage at clutch KD B3 hex Slippage at clutch KE B5 hex Slippage at clutch KV Slippage at clutch KR B6 hex Short circuit to battery voltage at power supply for sensors D1 hex D2 hex Short circuit to ground at power supply for sensors...
Page 64 ELECTRONIC CONTROL FOR POWER TRANSMISSION Description of the basic functions The powershift transmission 3 WG-94 EC of series WG-90 is equiped with the electronic transmission control EST-65 specially developed for this purpose. The system process the driver command according to the follwing criteria: ·Gear determination depending on driving speed and load condition.
Page 65 50DS7EPT17 Inching pedal 11 Temperature measuring point after the Gear selector converter (No. 63) Display 12 Inductive sensor - turbine speed Optical warning 13 Inductive sensor - engine speed Switch for driving program 14 Temperature measuring point for the converter Manual/Automatic (No.
Page 66 Inching device This function is especially suitable for lift trucks. Without modifying the engine speed, it allows a continuously variable reduction of the driving speed to such a level that operation at a very low speed is possible. In this way, the driver can move the vehicle to a certain position with high accuracy.
Page 67 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS The measurement have to be carried out with hot transmission(about 80~95。 C) 11 21 21 68 57 67 AN/KR KV AN/KR 4661 401 059 4661 301 059 50DS7ETM04 3-22...
Page 68 easuring points for pressure oil and temperature Port Description Size 11 + 2 bar Before the converter - opening pressure M10x1 16 + 3 bar Reverse clutch M10x1 16 + 3 bar Forward clutch M10x1 16 + 3 bar Clutch M10x1 16 + 3 bar Clutch...
Page 69 5. DIFFERENTIAL CARRIER ASSEMBLY STRUCTURE 80D7AX02 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 70 6. DRIVE AXLE A. DRY TYPE STRUCTURE D503DR02 Axle housing 14 Side gear 27 Taper roller bearing Air breather 15 thrust washer 28 Shin set(0.15, 0.20, 0.25t) plug 16 Pinion gear 29 Dowel pin Gasket 17 Spider 30 Gasket Plug 18 Ring gear 31 Carrier housing assembly Plug...
Page 71 WHEEL HUB D503DR03 O-ring 12 C-ring S 23 Thrust washer Brake tube 13 Carrier 24 Needle bearing Washer 14 Ring gear 25 Planetary gear Bolt 15 Nut 26 Bolt Bushing 16 Washer 27 Planetary housing Hub cover 17 bolt 28 O-ring Oil seal 18 Snap ring 29 O-ring...
Page 72 B. WET TYPE STRUCTURE 80D7AX03 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 73 RIVE AXLE TIGHTENING TORQUE 80D7AX04 Item Specification Inner carrier 2.2±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 (116±3.6lbf·ft) Differential case 6±0.5kgf·m (43.4±3.6lbf·ft) Connection between differential carrier and drive axle Gasket Ring gear 13.5±0.5kgf·m (97.6±3.6lbf·ft) Differential carrier assembly 18.0±0.5kgf·m (130±3.6lbf·ft)
Page 74 DISK BRAKE 80D7AX05 Spindle Parking piston Parking lever Steel plate Parking piston mounting bolt 10 Parking lever shaft Disk plate Spline collar 11 Brake housing Service piston Drive shaft Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
Page 75 7. TIRE AND WHEEL B507AX68 Wheel rim Lock ring Valve assembly Tire Side ring Wheel nut The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with the ground to gain the power which drives the machine. Various types of tires are available to suit the purpose.
Page 76: Group 2 Operation And Maintenance
GROUP 2 OPERATION AND MAINTENANCE 1. OPERATION DRIVING PREPARATION AND MAINTENANCE Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filters as well as the pipes must get filled with oil.
Page 77 - Upshifting in overrunning condition. In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if the speed of the vehicle on a downgrade should not be further increased. - Downshifting in overrunning condition. Downshifting in overrunning mode will be then carried out if the vehicle should be related. If the vehicle will be stopped and is standing with running engine and engaged transmission, the engine cannot be stalled.
Page 78 Now, the temperature must drop quickly(in about 2-3minutes) to normal values. If this is not the case, there is a trouble pending, which must be eliminated prior to continue working. The monitoring of the oil temperature(behind the converter) is additionally on the temperature gauge which is located on the dashboard.
Page 79 2. MAINTENANCE TRANSMISSION Oil level check At the oil level check, the vehicle has to be secured against rolling with blocks. The oil level check must be carried out as follows : - Oil level check(weekly) - At horizontally standing vehicle - Transmission in neutral position "N"...
Page 80 Oil change and filter replacement intervals ※ First oil change after 100 operating hours in service. Every further oil change after 1000 operating hours in service, however at least once a year. At every oil change, the fine filter has to be replaced. ①...
Page 81 50DS7EPT19 Legend: 1 = Oil filler tube with oil dipstick 2 = Mounting provision for oil filler tube with oil dipstick(option) 3 = Oil drag plug 7/8" 14 UNF 2B 4 = Fine filter Oil dipstick MEASURED AT LOW COLD IDLING-NEUTRAL D507PT20 3-36...
Page 82 0.57kg(20 ounces) of low carbon steel. The drain plug must be checked for metal particles at every oil change interval. Hyundai recommends replacing the magnetic drain plug each time the oil is changed. Use the correct part. Pipe plugs will leak if used as a drain plug.
Page 83 ④ If oil flows from the hole when you loosen the plug : The oil level is high. Let the oil drain to the correct level. ※ Do not fill only through the axle housing bowl. ⑤ If the oil level is below the bottom of the hole of the fill/level plug : Fill the axle at each wheel end and the axle housing bowl to the bottom of the fill plug hole with the specified oil.
Page 84 3. TROUBLESHOOTING DRIVE AXLE BRAKE LEAKS ACTUATION FLUID Condition ossible cause Correction Internal leak : Fluid 1. Worn or damaged piston seal. 1. Replace piston seals. bypasses seals into axle 2. Melted or extruded piston seals. 2. Correct cause of overheating and replace and fills axle with fluid seals.
Page 85 BRAKE OVERHEATS Condition Possible cause Correction Overheating due to Inadequate coolant flow or heat 1. Install brake cooling system if not already excessive duty cycle. exchange. installed on vehicle. 2. Re-analyze and re-size brake cooling system if necessary. Inadequate coolant flow Low pump output, blocked filter or Check pump output at different operating coolant lines.
Page 86 BRAKE DOES NOT RELEASE Condition Possible cause Correction Vehicle does not move Damaged hydraulic system. Repair hydraulic system. Brakes dragging 1. More than 1.4bar(20psi) pressure 1. Repair hydraulic system so pressure is less applied when brakes released. than 1.4bar(20psi) when brakes released and while machine is operating in any mode.
Page 87 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 88 TRANSMISSION 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. 4) Oil pump damage or defect.
Page 89 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 90 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 91 PRESSURE TEST CHECK LIST Problem Cause Incorrect adjustment of inching valve linkage FR/RR clutch low pressure Inching spool sticked 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 92 Transmission fault codes Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Logical error at gear range signal TCU shifts transmission to Check the cables from TCU to neutral shift lever TCU detected a wrong signal combination...
Page 93 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction, TCU uses Check the cable from TCU to the S.C. to ground at retarder/torque default temperature sensor converter temperature sensor input ·...
Page 94 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · OP mode : Substitute clutch S.C. to ground at turbine speed input Check the cable from TCU to the control TCU measures a voltage less than 0.45V sensor...
Page 95 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Special mode for gear S.C. to ground at output speed input Check the cable from TCU to the selection TCU measures a voltage less than 1.00V sensor...
Page 96 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · TCU shifts to neutral S.C. to ground at clutch KC Check the cable from TCU to the OP mode : Limp home The measured resistance value of the valve gearbox ·...
Page 97 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to ground at clutch KE TCU shifts to neutral Check the cable from TCU to the The measured resistance value of the valve OP mode : Limp home gearbox ·...
Page 98 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Check the cable from TCU to the S.C. to ground at clutch KR TCU shifts to neutral gearbox The measured resistance value of the valve OP mode : Limp home ·...
Page 99 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · TCU shifts to neutral Check pressure at clutch KE Slippage at clutch KE · OP mode : Limp home Check main pressure in the TCU calculates a differential speed at If failure at another clutch...
Page 100 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Transmission output torque overload OP mode : Normal TCU calculates an transmission output torque above the defined threshold Transmission input torque overload programmable TCU calculates an transmission output reaction or shift to neutral...
Page 101 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage at display output Check the cable from TCU to the No reaction TCU sends data to the display and display OP mode : Normal ·...
Page 102 Measuring of resistance at actuator/sensor and cable ① ① Actuator 76043PT19 = ∞ Open circuit Short cut to ground = R; R = 0, R = R or R = R, R (For S.C. to ground, G is connected to vehicle ground) Short cut to battery = R;...
Page 103: Group 3 Disassembly And Assembly
GROUP 3 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY DISASSEMBLY Transmission 3 WG-94 EC 50DS7ETM11 ① Attach transmission to the assembly truck by means of clamping angles(1) and holding fixtures(2). (S) Assembly truck 5870 350 000 (S) Holding fixtures 5870 350 063 (S) Clamping angles 5870 350 124 50DS7ETM12...
Page 104 ③ Separate the fine filter(1) from the filter head by means of belt wrench. (S) Belt wrench 5870 105 005 50DS7ETM15 ④ Loosen the cylindrical screws(2) and separate the filter head(1) from the transmission housing. 50DS7ETM16 ⑤ Remove both O-rings(1) out of the annular groove of the filter head.
Page 105 DISASSEMBLY PRESSURE CONTROLLER (PROPORTIONAL VALVES), INDUCTIVE SENSOR, SPEED SENSOR(HALL SENSOR), TEMPERATURE SENSOR, BREATHER AND SCREW PLUGS ① Remove all screw plugs with O-ring(1 and 2). 50DS7ETM18 ② Loosen cylindrical screws(1) and remove pressure controller(proportional valves, 50DS7ETM19 ③ Remove positioned parts. 1 = Inductive sensor-n turbine 2 = Inductive sensor-n central gear chain 3 = Temperature sensor, measuring point...
Page 106 ④ Loosen cylindrical screw(1) and remove speed sensor(2). 2 = Speed sensor-n output(Hall sensor) ※ Remove O-rings. 50DS7ETM21 ⑤ Remove breather (1). 50DS7ETM22 3-61...
Page 107 DISASSEMBLY CONVERTER AND CENTRAL SHAFT(PTO SHAFT) ① Loosen cylindrical screws(1) and separate the flexplate(2) from the converter(3). 50DS7ETM23 ② Pull off converter(1) by hand. 50DS7ETM24 ③ Disengage the retaining ring(see arrow). 50DS7ETM25 ④ Pull the central shaft assy out of the housing hole.
Page 108 ⑤ Pull the toothed disk(1) from the central shaft. 50DS7ETM27 ⑥ Press the ball bearing(1) from the central shaft(2). 50DS7ETM28 3-63...
Page 109 DISASSEMBLY OF OUTPUT FLANGE ① Loosen the hexagon screws(1) and remove disk and O-ring(2 and 3). 50DS7ETM29 ② Pull output flange(1) off the output shaft by means of two-armed puller. 50DS7ETM30 ③ Remove shaft seal(see arrow) from the housing hole by means of assembly lever.
Page 110 DISASSEMBLY OF MAIN PRESSURE VALVE AND CONVERTER SAFETY VALVE ① Loosen screw plug(1) and remove main pressure valve(control pressure valve): Main pressure valve consists of: 1 = Screw plug with O-ring 2 = Piston 3 = Spacer rings 4 = Compression spring 50DS7ETM32 ②...
Page 111 REMOVAL OF CLUTCHES AND DISASSEMBLY OF OIL PRESSURE PUMP ① Force out cylindrical pins(1). ② Loosen bolted connection(2) of housing front and rear part. Make sure to leave 2 cylindrical screws crosswise in the bolted connection(2). Transmission rear part is not fixed to the clamping angle and could get 50DS7ETM35 loose when turning.
Page 112 ⑤ Use assembly lever to remove all bearing outer rings from the housing front part. ※ If, contrary to the ZF recommendation, the tapered roller bearings of clutches and output are not replaced, it is imperative to ensure the previous pair- ing(bearing outer ring/bearing inner ring).
Page 113 ⑩ Loosen bolted connection between converter bellhousing/transmission housing(1) and pressure oil pump/ transmission housing(2). 50DS7ETM42 ⑪ Press converter bellhousing off the housing equally by means of hexagon screws M10(1). ※ Difficult disassembly due to fixing by cylindrical pins. 50DS7ETM43 ⑫ If required, remove both cylindrical pins (1).
Page 114 ⑭ Remove filter(1). 50DS7ETM46 ⑮ Remove O-ring(1). Loosen cylindrical screws(2). 50DS7ETM47 ※ Check oil pressure pump : In case of wear marks in the pump housing, stator hollow shaft or on the inner outer rotor, complete oil pressure pump is to be replaced.
Page 115 ISASSEMBLY CLUTCHES : 1 = Clutch KV(Clutch-forward) 2 = Clutch KR(Clutch-reverse and input) 3 = Clutch KD(Clutch-2nd gear) 4 = Clutch KE(Clutch-3rd gear) 5 = Clutch KC(Clutch-1st gear) 6 = Output 50DS7ETM50 Clutch KR/input ① Disengage rectangular ring(1). 50DS7ETM51 ② Pull off bearing inner ring with inner disk carrier(1).
Page 116 ④ Remove needle cage(1). 50DS7ETM54 ⑤ Remove axial bearing assy(1). 50DS7ETM55 ⑥ Disengage snap ring(1). 50DS7ETM56 ⑦ Remove end plate(1), disk package(2) and plate with cup springs(3) from the disk carrier. 50DS7ETM57 3-71...
Page 117 ⑧ Remove retaining ring-contact position of axial bearing(1). 50DS7ETM58 ⑨ Preload compression spring and disengage retaining ring(1). (S) Assembly aid 5870 345 114 50DS7ETM59 ⑩ Remove cup spring(1) and compression spring(2). 50DS7ETM60 ⑪ By means of compressed air(see arrow), press piston(1) off the shaft/disk carrier (see arrow) and remove it.
Page 118 ⑫ Remove both O-rings(1 and 2). 50DS7ETM62 ⑬ Disengage rectangular rings(1). 50DS7ETM63 ⑭ Pull tapered roller bearing(inner ring) off the shaft. (S) Grab sleeve 5873 001 026 (S) Basic tool 5873 001 000 50DS7ETM64 ※ The clutch(1) cannot be disassembled. It is supplied by the spare par ts service only as a complete assy which consists of :...
Page 119 Clutch KV ① Snap out rectangular ring(1). 50DS7ETM66 ② Pull off bearing inner ring with inner disk carrier(1). 50DS7ETM67 ③ Remove bearing inner ring(1), axial bearing assy(2) and inner disk carrier(3). 50DS7ETM68 ④ Remove needle cage(1). 50DS7ETM69 3-74...
Page 120 ⑤ Remove axial bearing assy(1). 50DS7ETM70 ⑥ Remove snap ring(1). 50DS7ETM71 ⑦ Remove end plate(1), disk package(2) and plate(3) from the disk carrier. 50DS7ETM72 ⑧ Remove retaining ring-contact position of axial bearing(1). 50DS7ETM73 3-75...
Page 121 ⑨ Preload compression spring and remove retaining ring(1). (S) Assembly aid 5870 345 114 50DS7ETM74 ⑩ Remove cup spring(1) and compression spring(2). 50DS7ETM75 ⑪ By means of compressed air(see arrow), press piston(1) off the shaft/disk carrier and remove it. 50DS7ETM76 ⑫...
Page 122 ⑬ Snap out rectangular ring(1). 50DS7ETM78 ⑭ Pull tapered roller bearing(inner ring) off the shaft. (S) Grab sleeve 5873 000 029 (S) Basic tool 5873 000 000 50DS7ETM79 ※ The clutch(1) cannot be disassembled. It is supplied by the spare parts ser- vice only as a complete assy which consists of : 1A = Retaining ring...
Page 123 Clutch KD ① Snap out rectangular ring(1). 50DS7ETM81 ② Pull tapered roller bearing(inner ring) off the shaft. (S) Grab sleeve 5873 000 029 (S) Basic tool 5873 000 000 50DS7ETM82 ③ Remove axial bearing assy(1) and inner disk carrier. 50DS7ETM83 ④...
Page 124 ⑤ Remove axial bearing assy(1). 50DS7ETM85 ⑥ Remove snap ring(1). 50DS7ETM86 ⑦ Remove end plate(1), disk package(2) and cup spring(3) from the disk carrier. 50DS7ETM87 ⑧ Remove retaining ring-contact position of axial bearing(1). 50DS7ETM88 3-79...
Page 125 ⑨ Preload compression spring and remove snap ring(1). (S) Assembly aid 5870 345 114 50DS7ETM89 ⑩ Remove spring cup(1) and compression spring(2). 50DS7ETM90 ⑪ By means of compressed air(see arrow), press piston(1) off the shaft/disk carrier and remove it. 50DS7ETM91 ⑫...
Page 126 ⑬ Snap out rectangular ring(1). 50DS7ETM93 ⑭ Pull tapered roller bearing(inner ring) off the shaft. (S) Rapid grip 5873 011 011 (S) Extractor set 5870 026 100 50DS7ETM94 ※ The clutch(1) cannot be disassembled. It is supplied by the spare parts ser- vice only as a complete assy which consists of : 1A = Retaining ring...
Page 127 Clutch KE ① Snap out rectangular ring(1). 50DS7ETM96 ② Pull tapered roller bearing(inner ring) off the shaft. (S) Grab sleeve 5873 000 029 (S) Basic tool 5873 001 000 50DS7ETM97 ③ Remove retaining ring(1). 50DS7ETM98 ④ Remove bearing inner ring(1) and inner disk carrier(2).
Page 128 ⑤ Remove tapered roller bearing(1) and inner disk carrier(2). 50DS7ETM100 ⑥ Pull off bearing inner ring(1) and running disk(2). 50DS7ETM101 ⑦ Remove bearing inner ring(1) and running disk(2). 50DS7ETM102 ⑧ Disengage snap ring(1). 50DS7ETM103 3-83...
Page 129 ⑨ Remove end plate(1), disk package(2) and cup spring(3) from the disk carrier. 50DS7ETM104 ⑩ Preload compression spring and remove snap ring(1). (S) Assembly aid 5870 345 114 50DS7ETM105 ⑪ Remove spring cup(1) and compression spring(2). 50DS7ETM106 ⑫ By means of compressed air(see arrow), press piston(1) off the shaft/disk carrier and remove it.
Page 130 ⑬ Remove both O-rings(1 and 2). 50DS7ETM62 ⑭ Snap out rectangular ring(1). 50DS7ETM109 ⑮ Pull tapered roller bearing(inner ring) off the shaft. (S) Rapid grip 5873 011 011 (S) Basic tool 5873 001 000 50DS7ETM110 ※ The clutch(1) cannot be disassembled. It is supplied by the spare parts ser- vice only as a complete assy which consists of :...
Page 131 Clutch KC ① Snap out rectangular ring(1). 50DS7ETM112 ② Pull off bearing inner ring with inner disk carrier(1). 50DS7ETM113 ③ Remove bearing inner ring(1), axial bearing assy(2) and inner disk carrier (3). 50DS7ETM114 ④ Remove needle cage(1) and bush(2). 50DS7ETM115 3-86...
Page 132 ⑤ Remove axial disk(1) and axial needle cage(2). 50DS7ETM116 ⑥ Disengage snap ring(1). 50DS7ETM117 ⑦ Remove end plate(1) and disk package (2) from the disk carrier. 50DS7ETM118 ⑧ Preload compression springs and remove snap ring(1). (S) Assembly aid 5870 506 128 50DS7ETM119 3-87...
Page 133 ⑨ Remove disk(1) and cup springs(2). 50DS7ETM120 ⑩ By means of compressed air(see arrow), press piston(1) off the shaft/disk carrier and remove it. Remove both O-rings. 50DS7ETM121 ⑪ Snap out rectangular ring(1). 50DS7ETM122 ⑫ Pull tapered roller bearing(inner ring) off the shaft.
Page 134 ※ The clutch(1) cannot be disassembled. It is supplied by the spare parts ser- vice only as a complete assy which consists of: 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM124 3-89...
Page 135 Output shaft ① Pull the bearing inner ring off the output shaft. (S) Grab sleeve 5873 000 029 (S) Basic tool 5873 000 001 50DS7ETM125 ② Rotate output shaft 180°and pull off bearing inner ring. (S) Grab sleeve 5873 002 035 (S) Rapid grip 5873 012 011 (S) Basic tool...
Page 136 2. TRANSMISSION ASSEMBLY REASSEMBLY OF CLUTCHES : Clutch KR/input ※ The clutch(1) is supplied by the spare parts service only as a complete assy which consists of: 1A = Ball 1B = Helical gear 1C = Disk carrier 50DS7ETM65 1D = Input shaft ①...
Page 137 ④ Insert piston(1) into the disk carrier. ※ Pay attention to the installation position, see Figure. 50DS7ETM131 ⑤ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. (S) Assembly aid 5870 345 114 50DS7ETM132 ⑥...
Page 138 ⑧ Mount plate assy with cup springs(1), with the open side showing towards the piston(see arrow). ※ Installation position plate-see below figure. 50DS7ETM135 ⑨ Fit plate(1) according to sketch(see arrow). 1 = Plate with cup springs 2 = Compression spring with spring cup and retaining ring 3 = Piston with O-rings...
Page 139 ⑫ Equally press on end plate with F (approx. 100N = 10kg) and set dial indicator to "zero". 50DS7ETM139 ⑬ Then press end plate against the snap ring(upwards) and read the disk clearance. ※ Disk clearance : 2.2 to 2.6mm ※...
Page 140 Mount needle cage 40×45×17(1) and oil it. 50DS7ETM143 Mount inner disk carrier until contact is obtained. Install inner disks by short ccw/cw rotations of the inner disk carrier(1). 50DS7ETM144 Mount axial washer 40×60×1(1), axial needle cage 40×60×3(2) and running disk(3) 40×60×3.5 and oil them. ※...
Page 141 Mount bearing inner ring(1) until contact is obtained. Fit rectangular ring 30×2(2). Wear protective gloves. ※ Adjust bearing inner ring after cool- ing-down. 50DS7ETM147 ※ Check closing and opening of the clutch by means of compressed air at the hole(see arrow). Closing and opening of the clutch must be clearly audible.
Page 142 Clutch KV The clutch(1) is supplied by the spare parts service only as a complete assy which consists of : 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM149 ① Heat up bearing inner ring(approx. 120°...
Page 143 ④ Insert piston(1) into the disk carrier. ※ Pay attention to the installation posi- tion, see figure. 50DS7ETM76 ⑤ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. (S) Assembly aid 5870 345 114 50DS7ETM154 ⑥...
Page 144 ⑧ Mount plate assy with cup springs(1), with the open side showing towards the piston(see arrow). ※ Installation position plate-see below figure. 50DS7ETM157 ⑨ Fit plate (1) according to sketch(see arrow). 1 = Plate with cup springs 2 = Compression spring with cup spring and retaining ring 3 = Piston with O-rings 4 = Clutch assy...
Page 145 ⑫ Equally press on end plate with F (approx. 100N = 10kg) and set dial indicator to "zero". 50DS7ETM161 ⑬ Then press end plate against the snap ring(upwards) and read the disk clearance. ※ Disk clearance : 2.2 to 2.6mm ※...
Page 146 Mount needle cage 40×45×17(1) and oil it. 50DS7ETM69 Mount inner disk carrier until contact is obtained. Install inner disks by short ccw/cw rotations of the inner disk carrier(1). 50DS7ETM166 Mount axial washer 40×60×1(1), axial needle cage 40×60×3(2) and running disk(3) 40×60×3.5 and oil them. ※...
Page 147 Mount bearing inner ring(1) until contact is obtained. Fit rectangular ring 30×2(2). Wear protective gloves. ※ Adjust bearing inner ring after cooling-down. 50DS7ETM169 ※ Check closing and opening of the clutch by means of compressed air at the hole(see arrow). Closing and opening of the clutch must be clearly audible.
Page 148 Clutch KD ※ The clutch(1) is supplied by the spare parts service only as a complete assy which consists of : 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM95 ① Heat up bearing inner ring(approx. 120°...
Page 149 ④ Insert both O-rings(1 and 2) into the piston grooves and oil them. 1 = 40×3 2 = 104.5×3 50DS7ETM62 ⑤ Insert piston(1) into the disk carrier. ※ Pay attention to the installation position, see figure. 50DS7ETM91 ⑥ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid.
Page 150 ⑧ By means of the assembly aid, preload compression spring under a hand- operated press until the retaining ring 40 ×1.75(1) can be snapped in. (S) Assembly aid 5870 345 114 50DS7ETM89 ⑨ Cup spring(1) into the disk carrier. ※ Pay attention to the installation position, see next page TM177.
Page 151 ⑫ Cap spring(1) according to sketch(see arrow). 1 = Cup spring 2 = Compression spring with spring cup and retaining ring 3 = Inner clutch- and outer clutch disc 4 = End shim 5 = Piston with O-rings 6 = Clutch assy. 50DS7ETM177 ⑬...
Page 152 Mount running disk 40×60×3.5(1), axial needle cage 40×60×3(2) and axial washer 40×60×1(3) and oil them. ※ Fit running disk(1), with the chamfer showing towards the retaining ring. 50DS7ETM181 Mount needle cage 40×45×17(1) and oil it. 50DS7ETM84 Mount inner disk carrier until contact is obtained.
Page 153 Heat up bearing inner ring(approx. 120° C). 50DS7ETM128 Mount bearing inner ring(1) until contact is obtained. Fit rectangular ring 30×2(2). Wear protective gloves. ※ Adjust bearing inner ring after cooling-down. 50DS7ETM184 ※ Check closing and opening of the clutch by means of compressed air at the hole(see arrow).
Page 154 Clutch KE ※ The clutch(1) is supplied by the spare parts service only as a complete assy which consists of : 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM111 ① Heat up bearing inner ring(approx. 120°...
Page 155 ④ Insert both O-rings(1 and 2) into the piston grooves and oil them. 1 = 40×3 2 = 104.5×3 50DS7ETM62 50DS7ETM107 ⑤ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. (S) Assembly aid 5870 345 114 50DS7ETM188 ⑥...
Page 156 ⑦ By means of the assembly aid, preload compression spring under a hand- operated press until the retaining ring 40 ×1.75(1) can be snapped in. (S) Assembly aid 5870 345 114 50DS7ETM105 ⑧ Cup spring(1) into the disk carrier. ※ Pay attention to the installation posi- tion, see next page TM192.
Page 157 ⑪ Cap spring(1) according to sketch(see arrow). 1 = Cup spring 2 = Compression spring with spring cup and retaining ring 3 = Inner clutch-and outer clutch disc 4 = End shim 5 = Piston with O-rings 6 = Clutch assy 50DS7ETM192 ⑫...
Page 158 ⑮ Press in both bearing outer rings into the inner disk carrier(1) until contact is obtained. Then mount the bearing inner rings. 50DS7ETM196 ※ Setting of axial play of the inner disk carrier bearing±0.05mm(see TM197 to TM202) : Determine dimension "X2" of the inner disk carrier →...
Page 159 Determine dimension "X1" from retaining ring(1) to running disk(2). → see below figure. Dimension X1 = 42.1mm 50DS7ETM200 Legend : 1 = Retaining ring 35×2.0 2 = Running disk 35×52×3.5 3 = Compression spring with cup spring and retaining ring 4 = Disk package with end plate and snap ring 5 = Piston with O-rings...
Page 160 Mount bearing inner ring(1) until contact is obtained. ※ → see page Different bearing sizes 3-124 TM198. Wear protective gloves. ※ Adjust bearing inner ring after cooling-down. 50DS7ETM203 Mount inner disk carrier until contact is obtained. Install inner disks by short ccw/cw rotations of the inner disk carrier(1).
Page 161 Heat up bearing inner ring(approx. 120° C). 50DS7ETM128 Mount bearing inner ring(1) until contact is obtained. Fit rectangular ring 30×2(2). Wear protective gloves. ※ Adjust bearing inner ring after cooling-down. 50DS7ETM206 ※ Check closing and opening of the clutch by means of compressed air at the hole(see arrow).
Page 162 Clutch KC ※ The clutch(1) cannot be disassembled. It is supplied by the spare parts service only as a complete assy which consists of : 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM124 ①...
Page 163 ④ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. (S) Assembly aid 5870 345 114 50DS7ETM210 ⑤ Mount cup spring package(1) and disk (2). ※ Installation position of the cup springs, see below figure.
Page 164 ⑧ Install outer and inner disks alternately into the disk carrier(3) as shown in figure. Starting with an outer disk and ending with an inner disk. 1 = Outer disks(10 pcs) 2 = Inner disks(10 pcs) 3 = Clutch assy 50DS7ETM212 ⑨...
Page 165 ⑫ Mount axial needle cage 35×52×2 (1) and axial disk 35×52×1(1) and oil them. 50DS7ETM116 ⑬ Mount needle cage 35×42×18(1) and bush(2) and oil it. 50DS7ETM115 ⑭ Mount inner disk carrier until contact is obtained. Install inner disks by short ccw/cw rotations of the inner disk carrier(1).
Page 166 Heat up bearing inner ring(approx. 120° C). 50DS7ETM128 Mount bearing inner ring(1) until contact is obtained. Fit rectangular ring 30×2(2). Wear protective gloves. ※ Adjust bearing inner ring after cooling-down. 50DS7ETM218 ※ Check closing and opening of the clutch by means of compressed air at the hole(see arrow).
Page 167 Output ① Heat up bearing inner ring(approx. 120° C). 50DS7ETM128 ② Mount bearing inner ring(1) until contact is obtained. Wear protective gloves. ※ Adjust bearing inner ring after cooling-down. 50DS7ETM220 ③ Heat up bearing inner ring(approx. 120° C). 50DS7ETM128 ④ Mount bearing inner ring(1) until contact is obtained.
Page 168 ESSEMBLY OF OIL PRESSURE PUMP AND REINSTALLATION OF CLUTCHES Reassembly of oil pressure pump ※ In case of wear marks in the pump housing, stator hollow shaft, inner rotor, outer rotor and on the sliding bearing, the pump assy must be replaced.
Page 169 ③ Fit stator hollow shaft(1). 50DS7ETM224 ④ Fix stator hollow shaft radially with two cylindrical screws(1). ※ Do not tighten the cylindrical screws - just turn them in until contact is obtained and then turn them back by ½ rotation. approx.
Page 170 ⑦ Fit two adjusting screws(S) and position converter bellhousing(1) equally until contact is obtained. ※ Pay attention to the hole pattern. (S) Adjusting screws(M10) 5870 204 007 50DS7ETM228 ⑧ Force the cylindrical pins 12×24(1) into the holes(blind holes) until contact is obtained.
Page 171 ⑪ Position transmission pump with 3 cylindrical screws(1) M8×60(3×120° offset position) equally until contact is obtained. ※ Do not damage(shear off) the O-ring. 50DS7ETM232 ⑫ Fix transmission pump with cylindrical screws M8×60(1). Tightening torque (M8/8.8×60) - - - - - - M = 23Nm 50DS7ETM233 ⑬...
Page 172 ⑭ Fix suction tube(1) with cylindrical screws M8×16(2). Tightening torque M8/8.8×16 ------- M = 23Nm ※ When reusing the cylindrical screws, they must be secured with Loctite no. 243. ※ New cylindrical screws are already provided with adhesive (microcapsule). The microcapsule bursts when the 50DS7ETM236 screw is turned in, wets screw and nut thread and hardens.
Page 173 ② Align and grease rectangular ring 30×2 (1). Position clutch KD(2). 50DS7ETM240 ③ Align and grease rectangular rings 50× 2.5(1). Position clutch KR- input(2). 50DS7ETM241 ④ Align and grease rectangular ring 30×2 (1). Position clutch KV(2). 50DS7ETM242 ⑤ Position output shaft(1) together with screen sheet(2).
Page 174 ⑥ Align and grease rectangular ring 30×2 (1). Position clutch KE(2). 50DS7ETM244 ⑦ Align and grease rectangular rings(1). 50DS7ETM245 ⑧ Use the lifting device to carefully bring the transmission housing rear part into contact position. ※ Bolts(1) of screen sheet must be fixed into the pilot holes.
Page 175 ⑨ Hand-tighten the transmission housings crosswise with 2 cylindrical screws(1). Fit cylindrical pins 12×24(2) centrically to the mounting face. Tighten the transmission housing front and rear part crosswise with 4 cylindrical screws M10(1). Tightening torque --------------- M = 46Nm 50DS7ETM247 Transmission rear part is not fixed to the holding fixture and could get loose after turning.
Page 176 REASSEMBLY OF OUTPUT FLANGE ① Use driver tool to fit the shaft seal 70× 100×10(1) until contact position, with the sealing lip showing towards the oil sump. (S) Driver tool 5870 048 057 ※ Fill space between sealing lip and dust lip with grease.
Page 177 EASSEMBLY CONVERTER SAFETY VALVE AND MAIN PRESSURE VALVE Reassembly of converter safety valve ① Insert valve(1) with drift(S) into the housing until contact is obtained. (S) Drift 5870 705 012 50DS7ETM253 ② Place compression spring(1) into the transmission hole and fit screw plug M38 ×1.5(2) with O-ring 35×2(3).
Page 178 EASSEMBLY OF CENTRAL SHAFT (PTO) AND CONVERTER ① Press tapered bearing(1) onto the central shaft(2) until contact is obtained. 50DS7ETM254 ② Press the toothed disk(1) onto the pump shaft until contact is obtained. 50DS7ETM255 ③ Mount rectangular ring 50×2.5(1). Grease and centrically align rectangular ring.
Page 179 ⑤ Mount converter(1) until contact is obtained. 50DS7ETM24 ⑥ Position 1 washer/each/thickness= 1.0mm (4EA) (1) onto the flexplate mounting webs(4EA). Place flexplates(2). ※ Pay attention to the installation posi- tion. Spot-welded reinforcing disks of the flexplate to be arranged towards the outside-see arrows.
Page 180 REASSEMBLY OF PRESSURE CONTROLLER (PROPORTIONAL VALVES), INDUCTIVE SENSOR, SPEED SENSOR(HALL SENSOR), TEMPERATURE SENSOR, BREATHER AND SCREW PLUGS ① Mount breather (1). 50DS7ETM260 ② Mount output Hall sensor-(1) onto the speed sensor, install Oring 15.5×2.6(2) and fix it with cylindrical screws M8×16 (3).
Page 181 ④ Fix pressure controller-proportional valves-(1) with the cylindrical screws M6x12(2). Tightening torque(M6/8.8×12) - - - - - - M = 9.5Nm 50DS7ETM263 ⑤ Mount all screw plugs(1 and 2) with O- rings. 1 = Screw plug M10x1 with O-ring 8×1.5(24EA) Tightening torque(M10×1) - - - - - - - - M = 6Nm 2 = Screw plug 9/16-18 UNF with O-ring...
Page 182 REASSEMBLY OF FILTER, CLOSING COMPONENTS, OIL FILLER TUBE WITH OIL DIPSTICK AND OIL DRAIN PLUG ① Place O-rings 34.2×3(1) into the holes and grease them. 50DS7ETM265 ② Attach filter head(1) with cylindrical screws M8x30 (2). Tightening torque(M8/8.8×30) - - - - - - - M = 23Nm 50DS7ETM266 ※...
Page 183 ③ Install O-ring 30×3(1) onto the oil suction tube(2), grease it and fix it with cylindrical screws M8×16(3) to the transmission housing. Mount oil dipstick(4). Tightening torque (M8/8.8×16) - - - - - - M = 23 Nm 50DS7ETM268 ④ Fit oil drain plug 7/8-14 UN 2A(1).
Page 184 3. 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 185 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 3-140...
Page 186 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 187 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 188 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 189 (10) After loosening lock nut(9), remove yoke(11). (11) Remove drive bevel pinion shaft (10) by using a plastic hammer. ※ Be careful not to damage bevel pinion shaft. 80D7AX08 (12) Remove shim(12) and spacer(13) from pinion shaft. Using a bearing puller, disassemble inner race of taper roller bearing from the pinion shaft.
Page 190 . 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 191 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. 80D7AX10 Heat inner race of bearing to max 100。...
Page 192 ADJUSTMENT OF PINION SHAFT Assemble bearing cup. Assemble spacer to the pinion shaft and then install measured shims onto the spacer. 80D7AX11 80D7AX091 Insert pinion shaft into the carrier. Assemble bearing cone, yoke and lock nut. Apply loctite #271 or #277 on the thread of pinion and then tighten lock nut.
Page 193 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.
Page 194 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 195 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 11~13 (79.6~94.0 kgf·m lbf·ft 80D7AX17 ASSEMBLY OF WHEEL HUB Insert bearing into wheel hub. Confirm that the bearing and wheel hub contact completely.
Page 196 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 197 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 198 Assemble wheel hub and tighten plug(1). ·Tightening torque : 3.5~6.0 · · (25.3~43.4 D357DA47 3-153...
Page 199: Group 4 Adjustment
GROUP 4 ADJUSTMENT CHECKING RING GEAR BACKFACE RUNOUT Runout specification : 0.20mm(0.008-inch) maximum INDICATOR Attach a dial indicator on the mounting Rotate ring gear . flange of the carrier. Adjust the dial indicator so that the plunger or pointer is against the back surface of the ring gear.
Page 200 ADJUSTING THE GEARSET BACKLASH Backlash specification : 0.13~0.18mm (0.005-0.007inch) If the old gearset is installed, adjust the backlash to the setting that was measured before the carrier was disassembled. If a new gearset is installed, adjust the backlash to the correct specification for new gearsets.
Page 201 ADJUSTING TOOTH CONTACT PATTERN OF THE GEARSET Always check tooth contact pattern on the drive side of the gear teeth. Apply marking compound to approximately 12 teeth of the ring gear. HEEL BOTTOM DRIVE SIDE (CONVEX) D507AX57 D507AX58 Rotate ring gear forward and backward so that the 12 marked teeth go past the drive pinion six times to get a good contact pattern.
Page 202 LOW PATTERN D507AX61 GOOD PATTERN IN OPERATION (USED GEARS) D507AX62 High pattern : A high contact pattern Move pattern toward indicates that the pinion was installed too bottom shallow into the carrier. To correct, move the pinion toward the ring gear by decreasing the shim pack between pinion spigot and inner bearing cone.
Page 203 Heel pattern : Decrease the gearset Move pattern toward toe Move pattern toward toe backlash(within specified range) to move contact pattern toward toe and away from heel. Loosen adjusting ring this side Refer to "Adjusting the gearset backlash". Decrease backlash Tighten adjusting ring this side D507AX65 Toe pattern : Increase the gearset back-...
Page 204: Section 4 Brake System
SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17 Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-22...
Page 205: 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 (wheel) brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
Page 206 3. BRAKE PEDAL AND PIPING DRY TYPE 50DS7EBS03 Brake pedal & bracket assembly Reservoir tank assembly Parking lever assembly Brake master cylinder...
Page 207 WET TYPE Brake pipe Parking cable Disc brake Drive axle Disc brake 50DS7EBS40 Brake pedal & bracket assembly Reservoir tank assembly Parking lever assembly Brake master cylinder...
Page 208 DO AEB WORK Start engine after parking the machine on flat floor and blocking wheels. Release parking brake. With stepping on the service brake, operate T/M STALL(3 stage). (To avoid defect of clutch pack, repeat 10 sec of operation and 10 sec of placing neutral) When the T/M oil temperature reaches 75~80。...
Page 209 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. 122 - 128mm Pedal height Link assy...
Page 210 5. WHEEL BRAKE DRY TYPE D507BS02 Back plate(LH, RH) Air breather 15 Lock washer Adapter Spring washer 16 Return spring Washer 10 Cylinder bolt 17 Return spring Holder 11 Lever shoe assembly 18 Pressure spring Spring washer 12 Brake shoe assembly 19 Plug Holder bolt 13 Adjuster assembly...
Page 211 6. WET DISK BRAKE STRUCTURE D507TM238 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 212 7. BRAKE VALVE A. DRY TYPE STRUCTURE 39 40 D507BS07 Stop ring 16 Stop ring 31 Push rod Seal 17 Seal 32 Connector Booster housing 18 Seal 33 Dust cover Seal 19 Seal 34 Plug Cylindrical thorn 20 Guide plug 35 Spring Flow valve 21 Seal...
Page 213 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(43), in order to be able to separate the front housing(3) from the rear housing(30).
Page 214 By means of retaining ring pinces remove retaining ring(16), accurnulator fitting(32) and then the second retaining ring(16). Remove rubber cap(33). Unscrew guide cap(20) and then extract rod(31) and spring(8). After the extraction of the rod(31) remove pin(5) and disassemble parts(1, 2, 6, 7, 22~25). Remove piston(27), extracting it from the side opposite to the threaded hole.
Page 215 D507BS10 Unscrew rear cap completely(15) by making sure that it’s not being disconnected abruptly; remove then O-ring, spring(10) and the joints(9). In order to remove the piston(9), knock the cylinder body on a piece of wood. Only at last unscrew valve(13). Remove the O-ring and the lip seal still inside the pump body with the aid of an “L”...
Page 216 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. ※ Take the utmost care in assembling the components shown at stage 4, by assembling first of all valve(13), then piston(9), spring(10) and only afterwards the other components.
Page 217 B. WET TYPE STRUCTURE 25 26 D507BS42 Plug 11 Seal 21 Seal 31 Spring Seal 12 Ring 22 Seal 32 Seal Spring 13 Seal 23 Booster housing 33 Plug Screw 14 Ball 24 Relief valve body 34 Seal Seal 15 Spring 25 Spring 35 Push rod B/Cyl Housing...
Page 218 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(23), in order to separate the booster from the brake cylinder housing. Separate the two parts and remove the components that are inside from(25) to(36), in order to remove spring(26) and ball(27), you should remove seal(28) from piston containing the seal(25).
Page 219 Unscrew guide cap(37) and then remove O-ring(38), rod(39), spring(40) and the piston(50). Once rod(39) has been removed, take out pin(41) and all the components that are inside the rod from(42) to(49). Remove the lip seal inside the brake cylinder housing by means of on L-Iron. Remove all other seals from the disassembled components, namely drive(39), piston(50), O-ring housing(29) and valve(34).
Page 220 ASSEMBLY ※ The assembly procedure must be carried out by following the sequence described before in reverse order, taking great care not to fit the new seals back to front or upside down. In order to fit the valve inside the piston containing the seal(25) following these instructions. Fit the seal into the appropriate tool and press ball and spring into the seat;...
Page 221: Group 2 Operational Checks And Troubleshooting
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS A. DRY TYPE 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.
Page 222 B. WET TYPE 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 223 . TROUBLESHOOTING . DRY TYPE Problem ause Remedy Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil. ·Hydraulic system leaks air. ·Bleed air. ·Lining surface soiled with water or oil. ·Clean or replace. ·Lining surface roughened or in poor ·Repair by polishing or replace.
Page 224 Problem ause Remedy Brake squeaks ·Lining surface roughened. ·Repair by polishing or replace. ·Lining worn. ·Replace. ·Poor shoe to lining contact. ·Replace. ·Excessively large friction between ·Clean and apply brake grease. shoe and back plate. ·Foreign matter on drum sliding surfa- ·Clean ·Drum sliding surface damaged or di- ·Replace.
Page 225 . WET TYPE 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 226: Group 3 Tests And Adjustments
GROUP 3 TESTS AND ADJUSTMENTS 1. ADJUSTMENT OF WHEEL BRAKE (DRY TYPE) Adjust with engine stopped. Adjustment wheel Jack up truck. Extend adjustment screw by Lever clicking adjustment wheel teeth with a screwdriver until wheel(mounted on brake drum being adjusted) offers a light resistance when turned by hand.
Page 227 B. WET TYPE Air bleeding should be performed by two Vinyl tube persons : Air vent plug One rides on truck for depressing and releasing brake pedal : the other person is on the ground and removes cap from air vent plug on wheel cylinder.
Page 228 3. ADJUSTMENT OF PEDAL BRAKE PEDAL Pedal height from floor plate Adjust with stopper bolt. 122 - 128mm Pedal height ·Pedal height : 122~128mm(4.8~5.0in) dle stroke Adjust with rod of master cylinder ·Play : 4~6.5mm(0.16 ~ 0.25in) Micro switch for parking brake (if equipped) Stopper bolt D507BS04 ①...
Page 229: Section 5 Steering System
SECTION 5 STEERING SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13...
Page 230: Group 1 Structure And Function
SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1 Hydraulic gear pump 2 Priority valve 3 Steering unit 4 Steering cylinder 5 Steering wheel 50DS7ESE00 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, trail axle and piping.
Page 231 2. HYDRAULIC CIRCUIT 13.5MPa LS CF Brake valve 50DS7ESE01 Hydraulic gear pump Steering cylinder Priority valve 10 Suction filter Steering unit 14 Hydraulic tank...
Page 232 NEUTRAL 13.5MPa Brake valve 50DS7ESE02 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(3) and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(14), so the pump flow is routed to the main control valve through the EF port.
Page 233 LEFT TURN 13.5MPa LS CF Brake valve 50DS7ESE03 When the steering wheel is turned to the left, the spool(G) within the steering unit(4) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) the steering unit through the spool(D) of priority valve and flows the gerotor(H).
Page 234 RIGHT TURN 13.5MPa LS CF Brake valve 50DS7ESE04 When the steering wheel is turned to the right, the spool(G) within the steering unit(4) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool(G) the steering unit through the spool(D) of priority valve and flows the gerotor(H).
Page 235 3. STEERING UNIT STRUCTURE Hydraulic circuit 26-4 26-3 26-1 26-2 SECTION B-B 25-6 25-5 25-4 25-3 25-2 25-1 SECTION A - A D507SE32 Dust seal 10 O-ring 19 Plate 25-3 Spring seat Retaining ring 11 O-ring 20 Cap screw 25-4 Spring Cap seal 12 Rolled screw 21 Housing...
Page 236 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 237 4. PRIORITY VALVE STRUCTURE 1-1/16-12UNF HYDRAULIC CIRCUIT 7/16-20UNF 1-1/16-12UNF 3/4-16UNF 50DS7ESE06 Body 4 End plug 7 Orifice Spool 5 Spring Spring pulg 6 O-ring OPERATION The oil from the hydraulic gear pump flows to the priority valve. The priority valve supplies a flow of oil to the steering system and lift, tilt system. The steering flow is controlled by the steering unit to operate the steering cylinder.
Page 238 5. STEERING AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 50DS7ESE24 Steering axle 12 Gasket 23 Grease nipple 35 Cover Knuckle 13 Cover 24 Hub 36 Hexagon bolt Thrust bearing 14 Bolt w/washer 25 Hub bolt 38 Support Needle bearing 15 Grease nipple 26 Taper roller bearing...
Page 239 TIGHTENING TORQUE AND SPECIFICATION Stroke 150mm Hub nut 61.2 kgf.m(443 lbf.ft) 35.1 ~ 47.5 kgf.m (253 ~ 343 lbf.ft) 50DS7ESE07 Center pin support Type Unit single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of degree...
Page 240: 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) 50DS-7E 3270mm(128in) 60DS-7E 3315mm(130in) 70DS-7E 3360mm(132in) Hydraulic pressure of power Remove plug from outlet port of flow divider and install oil pressure gauge.
Page 241 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 242: Group 3 Disassembly And Assembly
GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 50DS7ESE05 Dust seal 10 O-ring 19 Plate Retaining ring 11 O-ring 20 Cap screw Cap seal 12 Rolled screw 21 Housing Thrust bearing 13 Gerotor set 22 Spool Ball 14 Bearing race 23 Sleeve 15 Bore screw 24 Plate spring...
Page 243 TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-14...
Page 244 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 245 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 246 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball and suction valve pins and balls. D353SE09 5-17...
Page 247 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 248 (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 249 (16) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (17) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (18) The pressure relief valve is now disassem- bled. D353SE13 5-20...
Page 250 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 251 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 252 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 253 (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 254 (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 255 (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 256 (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 257 (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 258 (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 259 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. ※ Do not use a hammer! 5-85(2) 5-30...
Page 260 2. PRIORITY VALVE STRUCTURE 50DS7ESE08 Body End plug Orifice Spool Spring Spring plug O-ring 5-31...
Page 261 DISASSEMBLY ※ Cleanliness is the primary means of assuring satisfactory the priority valve life. Select clean place. Before removing the piping, clean the surrounding area of valve ports. Fix the body(1) in a vise with copper or lead sheets. Do not over tighten jaws. Loosen plug(3) for LS port.
Page 262 Remove plug(4) and separate O-ring(6) and plug(3, 4) individually. D353SE17 ASSEMBLY ※ Clean all metal parts in clean solvent and blow dry with air and correct any damage, burrs and rust. ※ Do not wipe dry with cloth or paper towel. ※...
Page 263 Install the O-ring(6) onto plug(3, 4) and install the plug(3, 4) into the body(1). ·Tighten torque : 4.5kgf·m(32.5lbf·ft) D353SE20 5-34...
Page 264 3. STEERING CYLINDER STRUCTURE ※ Specifications ·Cylinder bore : 80mm ·Outer diameter : 94mm ·Stroke(half) : 150mm ·Rod diameter : 55mm D507SE21 1 Tube assy Rod seal 11 Back up ring 2 Rod Back up ring 12 O-ring 3 Piston seal Dust wiper 13 Lock washer 4 Gland...
Page 265 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 266 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 267 4. STEERING AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 50DS7ESE24 Steering axle 12 Gasket 23 Grease nipple 35 Cover Knuckle 13 Cover 24 Hub 36 Hexagon bolt Thrust bearing 14 Bolt w/washer 25 Hub bolt 38 Support Needle bearing 15 Grease nipple 26 Taper roller bearing...
Page 268 CHECK AND INSPECTION A1, A2 50DS7ESE25 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 60(2.4) 59.5(2.3) Shaft ID of bushing 60(2.4) 59.5(2.3) 50(2.0) 49.8(2.0) OD of king pin Replace 22(0.9) 21.9(0.9) OD of steering cylinder pin 22(0.9) 21.9(0.9) OD of pin...
Page 269 DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the balance weight part of the truck. Hub nut Loosen the hub nut and take off the steering wheel tire.
Page 270 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. Notch Tighten the set screw(10) of king pin(6). There is a notch in the middle of the king pin(6), make sure that this notch is on the set screw side.
Page 271: 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19...
Page 272: Group 1 Structure And Function
SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 1B 1A 2B 2A 3A 4B 18.5MPa 13.5 MPa 15MPa GAGE PORT 4 MPa To Axle From Axle 50DS7EHS01 Hydraulic gear pump Lift cylinder Priority valve Suction filter Main control valve 10 Return filter Steering unit...
Page 273 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 1B 1A 2B 2A 3A 4B 18.5MPa 15MPa Lift GAGE PORT Load check valve Steering system Steering return line Brake system Brake return line 50DS7EHS02 When the lift control lever is pulled back, the spool on the first block is moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large chamber of lift cylinder(8) by pushing the load check valve of the spool.
Page 274 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 1B 1A 2B 2A 3A 4B 18.5MPa Lower 15MPa GAGE PORT Steering system Steering return line Brake system Brake return line 50DS7EHS03 When the lift control is pushed forward, the spool on the first block is moved to lower position. The work port(1B) 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 275 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 1B 1A 2B 2A 3A 4B 18.5MPa Tilt forward 15MPa GAGE PORT Load check valve Steering system Steering return line Brake system Brake return line 50DS7EHS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
Page 276 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 1B 1A 2B 2A 3A 4B 18.5MPa 15MPa Tilt Backward GAGE PORT Load check valve Steering system Steering return line Brake system Brake return line 50DS7EHS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
Page 277 2. HYDRAULIC GEAR PUMP STRUCTURE 7 10 27 20 80D7HS06 Body 13 Screw 25 Antiextrusion Body 14 Screw 26 Antiextrusion ring Rear cover 15 Grub screw 27 Upper antiextrusion ring Cover 16 Washer 28 Sleeve bearing Thrust plate 17 Washer 29 Upper sleeve bearing Thrust plate 18 Seal...
Page 278 3. MAIN CONTROL VALVE STRUCTURE(4 Spool) Inlet SECTION B - B Outlet 3 Work ports Gauge port VIEW D - D Port name Size SECTION A - A Inlet port 1-5/16-12UNF Outlet port 1-5/16-12UNF Gauge port PF1/4 Work port 1-1/16-12UNF 50DS7EHS07 Solenoid valve 13 Wiper...
Page 279 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 280 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 281 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 282 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 283 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 284 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 285 4. LIFT CYLINDER 13 15 10 11 14 4,5 7,8 D507HS12 Tube assy Cushion seal 13 Dust wiper Retaining ring 14 O-ring Piston Retaining ring 15 O-ring Piston seal 10 Gland 16 Spacer Back up ring 11 Du bushing 17 O-ring Wear ring 12 Rod seal 5.
Page 286: 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 287 . 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 288 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 289 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 290: Group 3 Disassembly And Assembly
GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP STRUCTURE 7 10 27 20 80D7HS06 Body 13 Screw 25 Antiextrusion Body 14 Screw 26 Antiextrusion ring Rear cover 15 Grub screw 27 Upper antiextrusion ring Cover 16 Washer 28 Sleeve bearing Thrust plate 17 Washer 29 Upper sleeve bearing...
Page 291 GENERAL INSTRUCTION Cleanliness ① 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 292 Center section ① Remove through shaft(35) from driving 17 21 shaft(15). ② Loosen and remove the clamp bolt(17) with washer(21), and then remove the working section(2) with dowel pin(36). ※ Related parts Square ring(25). 80D7PMP03 ③ Remove driving gear(15), driven gear(14) with thrust plate parts (9, 23, 30), keeping gear as straight as possible, from first working body.
Page 293 REASSEMBLY ※ Information for assembly way of thrust plates It is important that all of thrust plate parts in this hydraulic pump should be assembled such as below picture during reassembly. Below figures show assembling sequence and direction. REAR DIRECTION OIL OUTLET OIL INLET FRONT...
Page 294 ② Locate the o-ring(24) on the groove 10 24 31 prearranged on the thrust plate(10). ③ Then, locate back-up ring(31) on the groove pre-arranged on the seals(10, 24) with plug(19). ※ Smear clean grease on the seal(24,31). (The front and rear thrust plates and seals and back-up ring are same.) 19 31 24 10 14 80D7PMP11...
Page 295 ⑨ Insert the driving shaft(15) and driven gear(14) including the completed thrust plate(9+23+30) into working section(3) while keeping the plate straight. 80D7PMP15 ⑩ Insert the through shaft(35) into driving shaft(15), and then locate the working body(2) after inserting the squaring ring (25) to body(2).
Page 296 ③ Locate the driving gear(11) and driven gear(12) with thrust plate parts(8+22+29) into working section(2). ④ Insert the dowel pin into the working section(2) and then, locate the rear working section(1) to working section(2) while keeping the gear straight. ※ Smear clean grease on the square ring (26) to avoid drifting away of square ring from the rear working section(1).
Page 297 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 298 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 299 3. LIFT CYLINDER STRUCTURE · I.D×O.D×stroke(standard) 85×98×1335mm (3.3×3.9×52.6in) · Rod O.D : 60mm(2.4in) D507HS19 Tube assy 10 Gland 11 Du bushing Piston 12 Rod seal Piston seal 13 Dust wiper Back up ring 14 O-ring Wear ring 15 O-ring Cushion seal 16 Spacer Retainning ring 17 O-ring...
Page 300 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 301 4. TILT CYLINDER STRUCTURE · I.D×O.D×stroke : 110×124×338mm (4.3×4.9×13.3in) · Rod O.D : 50mm(2.0in) D507HS22 Tube assy O-ring 17 Nylon nut 10 Back up ring 18 Rod eye Gland 11 Lock washer 19 Hexagon bolt DU bushing 12 O-ring 20 Hexagon nut Rod seal 13 Piston 21 Spring washer...
Page 302 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 303: 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 304: Group 1 Component Location
SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 13 6 5 50DS7EEL06 Work lamp Inching switch 17 Combination switch Operating panel 10 Auto/Manual switch 18 Backup alarm Glow timer 11 Hazard switch 19 Start switch Flasher lamp 12 T/M oil temp gauge 20 High horn Flasher unit 13 Relay 4P...
Page 305: Group 2 Electrical Circuit
SECTION 7 ELECTRICAL SYSTEM GROUP 2 ELECTRICAL CIRCUIT CLUSTER PARKING GLOW AUX. ILLUMINATION HEAD LAMP NEUTRAL BACK UP RELAY RELAY RELAY RELAY RELAY RELAY START KEY S/W HAZARD S/W FLASHER B BR R1 R2 C ACC AUTO/MANUAL S/W INCHING S/W REARWORK S/W BEACON S/W UNIT...
Page 306 MEMORANDUM...
Page 307 1. POWER CIRCUIT The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the off position, the current flows from the positive battery terminal. OPERATING FLOW Battery(+) Start motor[CN-45(B+)] Fusible link[CN-60] Glow relay[CR-24(1)] Start relay[CR-23] Fusible link[CN-95] Alternator[CN-74(B+)]...
Page 308 POWER CIRCUIT START KEY S/W FUSE BOX B BR R1 R2 C ACC CR-24 1.25BR GLOW RY 1.25B CN-74 CN-3 ALTERNATOR CN-60 FUSIBLE LINK CN-95 COMBI S/W FUSIBLE LINK CR-23 CS-11 START RY CN-45 CS-12 START MOTOR BATTERY CN-25 MASTER SW 12V X 2 HORN 50DS7EEL02...
Page 309 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] TCU[CN-50] ※ T he engine can be started only when the gearshift is in neutral position. The operator should be seated when starting. When start key switch is in ON position Fuse box[No.6 →5] Start switch ON [CS-2(4)] Gear selector switch[CS-15(A)]...
Page 310 STARTING CIRCUIT START KEY S/W B BR R1 R2 C ACC NEUTRAL RELAY CN-74 CN-3 ALTERNATOR CN-2 CN-95 GEAR SELECTOR S/W FUSIBLE LINK CR-23 CS-14 START RY CS-15 CN-45 START MOTOR BATTERY MASTER SW 12V X 2 50DS7EEL03...
Page 311 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 312 CHARGING CIRCUIT CN-2 CN-74 ALTERNATOR CN-56 GLOW LAMP(-) CN-95 GLOW LAMP(+) SEAT BELT OPS LAMP CN-3 FUSIBLE LINK WATER SEPARATOR BRAKE OIL LOW PARKING BRAKE ENGINE CHECK LAMP TURN SIGNAL RH CR-23 HEAD LAMP TURN SIGNAL LH AIR FILTER CHARGE LAMP START RY T/M OIL TEMP ENG.
Page 313 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[CS-2(3)] Start switch(B) Fusible link[CN-60] 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 314 PREHEATING CIRCUIT START KEY S/W B BR R1 R2 C ACC GLOW GLOW AUX TIMER RELAY GLOW TIMER CN-1 CN-80 GLOW PLUG CN-2 CR-24 1.25BR 1.25B GLOW RY CN-74 CN-3 ALTERNATOR CN-60 FUSIBLE LINK CN-95 FUSIBLE LINK CR-23 START RY CN-45 START MOTOR BATTERY...
Page 315: Group 3 Component Specification
GROUP 3 COMPONENT SPECIFICATION Specification Part name 12V×80AH RC : 130min Battery CCA : 630A Working lamp 24V, 70W License lamp 24V, 3W x 2 24V, 25/10W (Stop/Tail) 24V, 25W (Turn) Rear Combination lamp 24V, 25W (Back Up) Head lamp 24V, 70W Flasher lamp 24V, 25/10W...
Page 316: Group 4 Connector Destination
GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 S816-112002 I/conn(Dashboard harness-frame harness) S816-012002 CN-2 368301-1 I/conn(Frame harness-dashboard harness) 2-85262-1 CN-3 MG650943-5 I/conn(Frame harness-dashboard harness) MG640944-5 CN-4 LH support harness S810-004201 CN-5 Support harness S810-004201 CN-8 Transmission display...
Page 317 Connector part No. Connector No. of Type Destination number Female Male Switch CS-2 Start switch S810-004201 CS-11 Combination switch S810-004201 CS-12 Combination switch S810-003201 CS-14 PACKARD Gear selector switch 12010974 CS-15 PACKARD Gear selector switch 12015797 CS-17 Parking switch S810-003201 Beacon lamp switch 593757 CS-23...
Page 318 Connector part No. Connector No. of Type Destination number Female Male CD-81 PACKARD KR Solenoid 12162197 CD-82 PACKARD KD Solenoid 12162197 CD-83 PACKARD KE Solenoid 12162197 CD-84 PACKARD KC Solenoid 12162197 CD-90 Temp sensor 827551-3 7-15...
Page 319: 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 320 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...
Page 321 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) Outer master Inner master Lift cylinder Lift cylinder Drive axle Carriage 80D7MS01 Outer mast Lift chain Chain sheave bearing Roller bearing Anchor bolt 10 Side roller bearing Tilt cylinder pin Side roller bearing Mast mounting pin Inner mast...
Page 322 2. 3 STAGE MAST(TF MAST) Middle master Outer master Inner master Tilt cylinder Lift cylinder Lift cylinder Free Lift cylinder Drive axle Carriage 50DS7EMS011 Outer mast Mast mounting pin 11 Chain Shim Wear plug 12 Sheave bracket Roller bearing Middle mast 13 Inner mast Side roller bearing Sheave...
Page 323 3. CARRIAGE, BACKREST AND FORK HOOK ON TYPE(STD) Hook on type fork Extension fork 50DS7EMS03 Backrest Side roller Carriage Fork Roller Extension fork...
Page 324 SHAFT TYPE(OPTION) Shaft type fork Extension fork 80D7MS02 Carriage & backrest Side roller Hanger bar Fork Fork retaining Extension fork Roller...
Page 325 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 F14710011 50DS-7E 60(2.4) 54(2.1) F14710111 60DS-7E 65(2.6) 59(2.3) D507FK01 F14710111 70DS-7E 65(2.6) 59(2.3)
Page 326 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 damag-ed parts or replace complete mast assembly.
Page 327 FORKS roblem 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 328 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm(19in). Outer mast Inner mast Bring into Shift the inner mast to one side to bring contact the side roller into contact with the outer mast, and adjust the clearance between the end of inner beam and the outside of Side roller...
Page 329 CARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100mm from Outer mast Carriage the top of the inner mast. Adjust plate screw Measure the clearance at upper, middle and lower rollers after loosen the adjust Bring screws from the side rollers.
Page 330 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS HOOK ON TYPE Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Backrest Release fork anchor pins and slide one fork at a time toward the center of the carriage Anchor pin where a notch has been cut in the bottom Carriage...
Page 331 3. CARRIAGE ASSEMBLY CARRIAGE With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor.
Page 332 CARRIAGE LOAD ROLLER BEARING Carriage load Remove carriage as outlined in the roller bearing carriage removal paragraph. Using the plier, remove retaining rings Retaining ring from load roller bearing bracket. Using a plier, remove load roller bearings from load roller bearing bracket. Reverse the above procedure to assem- ble.
Page 333 3 STAGE MAST(TF MAST) Remove the carriage assembly and move it to one side. Loosen and remove hexagon bolt secur- Mast load roller ing bottom cylinder from outer mast. Loosen and remove set screws and nuts securing lift cylinders to middle mast. Attach chains or sling to the inner and Chain middle mast section at top crossmember.
Page 334 5. CHAIN CHAIN SHEAVE Place a sling around carriage and attach Outer mast Chain to an overhead hoist. Lift carriage high Sheave enough so that the tension on the chain Inner mast over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
Page 335 Sheave support(TF mast) Remove the carriage assembly and move to one side. After removing bolt to securing sheave support assembly to free lift cylinder. Attach a sling to the sheave support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder. Move assembly to work area. Remove retaining ring securing sheave to sheave support.
Page 336 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 337 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 338 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.

This manual is also suitable for:

60ds-7e 70ds-7e

Hyundai 50DS-7E Operation Manual

Section 1 General

Section 2 Removal and Installation of Unit

Section 3 Power Train System

Section 4 Brake System

Section 5 Steering System

Section 6 Hydraulic System

Section 7 Electrical System

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