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Hyundai 35L-7 Operating Manual

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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
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 Inspection and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-11
SECTION 5 STEERING SYSTEM
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-17
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
CONTENTS

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Summary of Contents for Hyundai 35L-7

  • Page 1 CONTENTS SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13 SECTION 2 REMOVAL AND INSTALLATION OF UNIT...
  • Page 2 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11...
  • Page 3 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
  • Page 4 Revised edition mark(①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 7 Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246...
  • Page 8 kgf·m to lbf·ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
  • Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
  • Page 11 SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13...
  • Page 12 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 1. MAJOR COMPONENTS 35L7OM57 Steering wheel Forks 15 LPG tank Mast Tilt cylinder 16 Clamp Lift chain 10 Front wheel 17 Overhead guard Lift cylinder 11 Bonnet 18 Rear combination lamp Cluster 12 Rear wheel 19 Turn signal lamp Backrest 13 Counterweight 20 Head lamp...
  • Page 17 2. SPECIFICATIONS 35L7SP01 Model Unit 35L-7 40L-7 45L-7 Capacity 3500 4000 4500 Load center ← ← Weight(Unloaded) 5671 6241 6663 Lifting height ← ← 3000 Free lift ← ← Lifting speed(Unload/Load) ← ← Fork 530/510 mm/sec Lowering speed(Unload/Load) ← ←...
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item Specification Unit Model GM, 4.3L Type 4-cycle, in-line, Vertical OHV Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, V6 Valve configuration Push rod actuated overhead valve mm(in) Cylinder bore X stroke 101.6×88.39(4×3.48) Piston displacement cc(cu in)
  • Page 19 POWER TRAIN DEVICES Item Specification Model DE 280 (KAPEC) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.25 : 1 Type Power shift Gear shift(FR/RR) Transmission Control Electrical single lever type 1 : 2.550 2 : 1.29 Overhaul ratio 1 : 2.550 2 : 1.29...
  • Page 20 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS kgf·m lbf·ft Item Size Engine mounting bolt, nut M16×2.0 Engine Radiator mounting bolt, nut 6.9±1.4 50±10 M10×1.5 Torque converter mounting bolt 6.9±1.4 50±10 M10×1.5 MCV mounting bolt, nut 19.6±2.9 142±21 M14×2.0 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. OLT AND NUT Coarse thread Bolt size kgf·m lbf·ft kgf·m lbf·ft × 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8 × 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8...
  • Page 22 PIPE AND HOSE(FLARE TYPE) Thread size Width across flat(mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" IPE AND HOSE(ORFS TYPE) Thread size Width across flat(mm) kgf·m lbf·ft 9/16-18 28.9 11/16-16 36.2 13/16-16 68.7 1-3/16-12 1-7/16-12 1-11/16-12 4 4 ) FITTING Thread size...
  • Page 23 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. 。 C (。 F) Ambient temperature Service Kind of Capacityℓ(U.S.gal) point fluid (-4) (14) (32) (50) (68) (86) (104) Engine oil Engine oil SAE 10W-30(API SL class or better) (1.1) Torque 12ℓ...
  • Page 24 GROUP 3 PERIODIC REPLACEMENT For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time of periodic maintenance;...
  • Page 25 SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
  • Page 26 GROUP 1 STRUCTURE 11 12 13 14 15 16 17 35L7OM23 Mast 10 Transmission 19 Radiator Lift cylinder 11 Torque converter 20 Muffler 21 LPG tank Steering unit 12 Engine Tilt cylinder 13 Air cleaner 22 Overhead guard Control valve 14 Exhaust pipe 23 Seat Fork...
  • Page 27 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Forks Backrest ① Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. ② Release fork anchor pins and slide one fork at a time toward the center of the Knob carriage where a notch has been cut in...
  • Page 28 ② While supporting lift chains, remove the Chain split pin and nuts from the anchor bolt. Outer mast Anchor bolt Split pin 35DS7RE06 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain...
  • Page 29 Piping ① Remove the return hoses and clamps attached to the cylinder. ② Remove the return hose from the tee. Return hose ③ Remove hose assembly, tee and down safety valve(1). ※ Put blind plugs in the piping immediately Hose clamp after removing hoses.
  • Page 30 Inner mast ① Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Inner Be careful the mast not to swing or fall. mast Outer mast 35DS7RE11 Tilt cylinder pin Mast mounting pin ①...
  • Page 31 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. ※ Installation procedure for each of mast component is the reverse of the removal procedure. Mast mounting pin ① Check the mast mounting pins for wear, then install pins into the mast support bracket. ②...
  • Page 32 2. POWER TRAIN ASSEMBLY REMOVAL D503RE04 Mast Refer to section on mast(Page 2-2)
  • Page 33 Brake piping Brake valve Disconnect the brake piping from the brake housing of drive axle unit. Brake pipe Drive axle 35DS7RE13 Parking brake cable Disconnect parking brake cable from the brake housing of drive axle unit. Parking brake lever Parking brake cable Drive axle 35DS7RE14...
  • Page 34 Inching linkage Inching pedal Remove the bolt fixing the linkage assembly to T/M control valve. Bolt T/M control valve 35DS7RE16 Transmission cooling piping ① Radiator Disconnect cooling hose and connector assy from the transmission. Hose ※ Make sure that the coolant be drained from the hose.
  • Page 35 Mounting bolts holding to flywheel housing ① Remove the transmission assembly from Mounting bolt the engine flywheel by loosening the mounting bolts. 35L7RE19 ② Using a moving truck slowly pull out transmission assembly to the front. Frame Block Truck 35DS7RE20 INSTALLATION Installation is the reverse order to removal, but be careful of the following points.
  • Page 36 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL D503RE25 Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and flasher lamp on the stay of the overhead guard and then raise it together with the bonnet.
  • Page 37 Remove the torque converter housing cover, mounting bolts installed to flywheel housing. For details, see page 2-9. Engine Engine accessory Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. ① Wiring harness to alternator and starter. ②...
  • Page 38 Radiator hoses ·Distance to insert hose : 42mm(1.65in) Engine ir cleaner hose ① Insert the air cleaner hose securely and fit a clamp. ② Distance to insert hose Air cleaner ·Air cleaner hose : 89mm(3.5in) Muffler Tail pipe ·Engine end : 60mm(2.36in) Loctite #243 Engine Exhaust pipe...
  • Page 39 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) 1820kg (4010lb) 35L-7 2200kg (4850lb) 40L-7 2550kg (5620lb) 45L-7 ·Tightening torque : 199±29.9 kgf·m (1440±216lbf·ft)
  • Page 40 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. 35DS7RE28 Hose Steering axle Hose 35DS7RE29 Mounting bolt Put a block under the steering axle, Steering axle support on a truck, an raise the frame with a crane.
  • Page 41 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Inspection and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19...
  • Page 42 GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN COMPONENT OVERVIEW STRUCTURE Engine From cooler Down regulator valve To cooler D357TA01 Torque converter T/M control valve Parking lever T/M oil level gauge Differential 10 Drive axle oil level gauge Transmission Drive axle 11 Disk brake T/M oil pump Drive wheel...
  • Page 43 2. SPECIFICATION Item Unit Specification Type 3 elements 2 phase 1 stage Torque converter Power transmit Torque converter Type/Gear shift POWER SHIFT / F2 : R2 2.550 FR/RR 1 stage Gear ratio 1.29 FR/RR 2 stage Transmission P.T.O system Included T/M oil DEXRON 3 ℓ...
  • Page 44 2. TORQUE CONVERTER STRUCTURE Turbine Input plate Impeller Torque converter Stator Pump gear Engine side Transmission side D357TA02 Item Specification Torque converter input plate 4.5±0.3kg·m (32.5±2.2lbf·ft) Torque converter pump gear 2.0±0.3kg·m (14.5±2.2lbf·ft) Pilot boss outer diameter 19.959 - 19.980mm(0.786 - 0.787in) Oil seal outer diameter 134.9 - 135.0mm(5.311 - 5.315in) Needle bearing outer diameter...
  • Page 45 According to the rate of inversion, the turbine wheel and with it also the output shaft, receives a more or less high reaction moment. The stator(Reaction member), following the turbine, has the task to inverse again the oil which is escaping out of the turbine and to delivery it under the suitable discharge direction to the pump wheel.
  • Page 46 3. TRANSMISSION STRUCTURE R2 R1 F1 F2 D357TA03 Torque converter Clutch piston 15 Output shaft Input shaft Valve assembly 16 Clutch drum (FR) 3 P.T.O gears 10 Clutch (RR, 1 stage) 17 Clutch (FR, 2 stage) Pump assembly 11 Gear (RR, 1 stage) 18 Gear (Output, 2 stage) Gear (RR, 2 stage) 12 Gear (FR, 1 stage)
  • Page 47 TRANSMISSION GEAR ARRAY T/C Input T/C Input relief T/C output (to cooler) From cooler INPUT T/C output relief COUNTER OUTPUT D357TA04 Cylinder clutch (RR) Gear(Output, 1st stage) Gear(FR, 2nd stage) Gear(RR, 2nd stage) Gear(Output, 2nd stage) Gear clutch(FR) Gear(RR, 1st stage) Gear(FR, 1st stage) ※...
  • Page 48 TRANSMISSION INPUT PORT D357TA05 T/C input port pressure RR 1st stage pressure Main line pressure RR 2nd stage pressure FR 2nd stage pressure T/C output port pressure FR 1st stage pressure ·Transmission pressure Engine Main line T/C input port T/C output port FR 1,2 stage RR 1,2 stage Unit...
  • Page 49 3. TRANSMISSION HYDRAULIC CIRCUIT Directional Modulation valve valve (Solenoid shift valve) Torque converter T/C in outlet relief valve 0.2~4.2 kgf/cm Main relief valve Pedal 7.0~15.0 kgf/cm Inching valve T/C out Oil filter cooler 20.6 cc/rev TRANSMISSION PUMP Torque converter TRANSMISSION inlet relief valve LUBRICATING 0.8~7.2 kgf/cm...
  • Page 50 4. DIFFERENTIAL CARRIER ASSEMBLY STRUCTURE D357TA07 Item Unit Specification Differential pinion gear inner diameter mm(in) 20.000 - 20.021(0.787~0.788) Spider outer diameter mm(in) 19.959 - 19.980(0.786~0.787) Pinion gear washer mm(in) 1.92 - 2.08(0.076~0.082) Side gear washer mm(in) 1.95 - 2.05(0.077~0.081) Side gear OPERATION Differential transmits the power from the transmission to drive wheel.
  • Page 51 5. DRIVE AXLE STRUCTURE D357TA08 Sun gear Hub assy 11 Pinion shaft Planetary gear Disk brake 12 Spider Inner gear Drive shaft 13 Differential pinion gear Inner gear carrier Differential carrier assy 14 Differential side gear Tapered bearing 10 Ring gear OPERATION Drive axle which consists of differential carrier assembly(9), drive shaft(8) and hub assembly(6) transmits the drive force from transmission to drive wheel.
  • Page 52 RIVE AXLE TIGHTENING TORQUE D357TA09 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 (115.7±3.6lbf·ft) Differential case 6±0.5kgf·m (43.4±3.6lbf·ft) Connection between differential carrier and drive axle LOCTITE #5127 Connection between differential carrier and T/M LOCTITE #17430 Ring gear 13.5±0.5kgf·m (97.6±3.6lbf·ft)
  • Page 53 DISK BRAKE D357TA10 Spindle Service piston Parking lever Steel plate Parking piston mounting bolt 10 Parking lever shaft Disk plate Spline collar 11 Brake housing Parking piston Drive shaft Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 54 G G ROUP 2 INSPECTION AND TROUBLESHOOTING 1. INSPECTION To check the problems of transmission, operate the machine and test its performance. Check and record the abnormal noise and if the machine doesn't operate perfectly, refer to problem and possible cause in the troubleshooting table. VISUAL CHECK Start engine and check T/M oil level at the neutral gear shift.
  • Page 55 2. TROUBLESHOOTING GENERAL INSPECTION WHILE DRIVING Problem Cause Failure at the specific gear 1. Low oil pressure or no pressure. stage 1) No oil, low level or high oil viscosity. 2) Loose inching control valve connection, incorrect adjustment or damage. 3) Inching valve spool sticked or open.
  • Page 56 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 57 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 58 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 59 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 60 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF DRIVE AXLE 1) REMOVAL AND DISASSEMBLY OF WHEEL HUB Loosen drain plug with a torque wrench(1) and drain oil. D357DA01 Loosen 4 socket head bolts(2) and a plug(3) from the housing of planetary. D357DA02 Fit socket head bolt(2) into the 2 tap holes(4) and remove housing of planetary.
  • Page 61 Remove snap ring(5) from the housing of planetary. D357DA04 Remove 3 pins(6) with a plastic hammer. D357DA05 Remove needle bearing(8), planet gear(7) and thrust washer(9). D357DA06 Remove sun gear(10) and drive shaft(11). D357DA07 3-20...
  • Page 62 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 63 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 64 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 65 (10) Remove lock nut(9). (11) Remove drive bevel pinion shaft (10) by using a plastic hammer. ※ Be careful not to damage bevel pinion shaft. D357DA19 (12) Remove shim(11) and spacer(12) from pinion shaft. Using a bearing puller, disassemble inner race of taper roller bearing from the pinion shaft.
  • Page 66 2 2 . REASSEMBLY OF DRIVE AXLE Clean all of the parts with cleaner and then remove remained loctite. ※ Be careful not to spill cleaner on your body. Avoid drinking cleaner or breathing its fumes. Wear protective clothing, glasses and gloves. If spilled on the skin, flush your skin with water immediately.
  • Page 67 Using different kinds of shims, adjust shim thickness as measured by previous equation. Place shims at the bearing place. Using a jig, assemble drive bearing so that the outer race contact with the bearing place. D357DA241 Heat inner race of bearing to max 100。...
  • Page 68 ADJUSTMENT OF PINION SHAFT Assemble bearing cup. Assemble spacer to the pinion shaft and then install measured shims onto the spacer. D357DA281 D357DA29 Insert pinion shaft into the carrier. Assemble bearing cone and lock nut. Apply grease on the outer bearing(1). Apply loctite #271 or #277 on the thread of pinion and then tighten lock nut.
  • Page 69 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 70 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 71 ASSEMBLY OF CARRIER Assemble carrier assembly into the axle housing. Apply loctite #271 or #277 to thread of bolt and then assemble at the tightening torque of 11~12 (79.6~86.8 kgf·m lbf·ft D357DA37 ASSEMBLY OF WHEEL HUB Insert bearing into wheel hub. Confirm that the bearing and wheel hub contact completely.
  • Page 72 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 73 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 74 Assemble wheel hub and tighten plug(1). ·Tightening torque : 4~5 · · (28.9~36.1 D357DA47 3-33...
  • Page 75 3. DISASSEMBLY OF TRANSMISSION Remove torque converter from the housing. Loosen 6 bolt(3) from torque converter and then remove adaptor(2) and flexible plate(1). D357TM01 Loosen 6 socket bolts(6) and remove Gear P.T.O Input(5). D357TM02 Remove oil seal(8), 4 bolts(9, 10) and washer individually, from the housing(7).
  • Page 76 Remove plug(11), O-ring, spring(12) and ball(13) from cover. Remove nipple(14) from the housing. Remove plug(15), O-ring, spring(16) and 12 11 valve(17). Remove plug(18). D357TM04 ※ Bearing cup(19) and shim(20) are located in the cover or at the shaft in the transmission case.
  • Page 77 Remove 4 socket bolts(23) from the bearing plate(14) and disassemble flange pump(24). Remove 1 socket bolt(25) and 4 socket bolts(26) from the flange pump to remove charging pump(27) and pump gasket(27) and then disassemble gear P.T.O output(29) and ball bearing. Remove elbow(30).
  • Page 78 · Disassembly of transmission control valve Remove transmission control valve ① Remove valve gasket(2-2). ② Remove stop bolt(19) and pin(18) from the valve body(1). ③ Remove spool(14), spring(18), spring (16), plunger(17), oil seal(20) and plug(21). ④ Remove plug(4), spring(3) and spool(2). ⑤...
  • Page 79 Using a plastic hammer push out tube(45) from transmission case. Remove output shaft assembly(43), input shaft assembly(44) and counter shaft assembly(45). D357TM14 Disassemble output gear(46) from the transmission case. D357TM15 3-38...
  • Page 80 Disassemble bearing cone(47) for high speed which locates in front side of clutch assembly with a gear puller. D357TM16 Remove 2 thrust washers(48) and gear(49). Remove needle bearing and washer from the shaft in front side of high speed clutch. D357TM17 Using a driver remove snap ring(50) from the cylinder.
  • Page 81 Remove clutch pressure plate, 7 clutch disks and 7 clutch plates(51) from the cylinder. D357TM19 Pressing the retainer(52) downward and then remove snap ring(53) with a driver while reducing the tension of spring assembly. Remove retainer(52) and spring assembly from the cylinder. Remove piston(54) using pressurized air and remove O-ring from the shaft.
  • Page 82 After removing snap ring(50) and then disassemble 7 disks and 7 plates from the cylinder. D357TM22 Remove 2 thrust washers(57) and a pin(59). By pressing the retainer(52), remove snap ring(53). Carefully reducing tension of spring assembly, remove retainer and spring. Using a air compressor, remove piston(54) and pull out O-ring.
  • Page 83 Remove 3 kinds of bearings(62) from the transmission case. ※ Mark on the bearing. D357TM25 Remove lip shaped oil seal (63) from the transmission. D357TM26 3-42...
  • Page 84 4. ASSEMBLY OF TRANSMISSION After cleaning all of the parts completely, apply T/M oil. Install inner seal(63) in order lip side to face the inner side and outer seal to face the outer side. D357TM27 Assemble 3 kinds of bearing cups(62) into the transmission case at their original positions.
  • Page 85 Assemble gear(61) and bearing(60) to the output shaft. D357TM29 Install seal ring on the piston(54). Apply T/M oil to seal ring. Assemble seal ring and piston into the cylinder. ※ Be careful not to damage seal ring when assembling piston. D357TM23 Install spring assembly and retainer(52) inside the cylinder.
  • Page 86 Apply clean T/M oil to the clutch disk and plate and then assemble 7 clutch disks and plates in the order of ; At first, install clutch plate which has teeth on the outer race. Install clutch disk which has teeth on the inner race.
  • Page 87 Assemble gear(49), thrust washer(48) and install bearing cone(47). ※ Do not apply compulsory force when assembling gears. Move gear forward and backward until spline of gear and teeth side of clutch disk mesh with each other. D357TM35 Assembly order of input shaft is the same as that of counter shaft assembly.
  • Page 88 Place the T/M case in the right position and then install counter shaft assembly(45) carefully. Install input shaft(44) carefully on its own place. Assemble output shaft assembly(43) into the output gear assembly(46) and then rotate the gear until teeth meshed. Install tube(42) into the case with a plastic hammer.
  • Page 89 After adhering valve gasket(34), assemble valve plate with 9 bolts(35) and 2 bolts(36). ·Tightening torque (35) : 1.4kgf·m (10.1 lbf·ft) ·Tightening torque (36) : 2.8kgf·m (20.3 lbf·ft) D357TM10 T/M control valve assembly ① Adhere valve gasket on the control valve body.
  • Page 90 Assemble the gear P.T.O output(23) and 2 ball bearings to the flange pump(25) with a jig and then assemble them to bearing plate with 4 bolts(26). Install charging pump(29) and gasket (27) to the flange pump(25) with bolts(28, 30x4). Assemble elbow(24) and then connect tube(31) to the elbow(24).
  • Page 91 In case of using new items calculate the shim thickness as below. Shaft assembly. (Including tapered bearing cone and cup) Install shaft assembly into the T/M case. Measure distance from the surface of bearing cup to that of T/M case, "X". ※...
  • Page 92 Install Gear P.T.O Input(5) on the torque converter(4) and fasten with 6 socket bolts(6). ·Tightening torque : 1.7~2.3 kgf·m (12.3~16.6 lbf·ft D357TM51 With 6 bolts(3) and 6 washers, assemble adaptor(2) and flexible plate(1) into torque converter. And then put together torque converter and housing.
  • Page 93 SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9 Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-11...
  • Page 94 SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE There are two brake systems, the foot brake system and the hand brake system. In the foot brake system, oil pressure is generated in the master cylinder by treading on the brake pedal.
  • Page 95 3. BRAKE PEDAL AND PIPING STRUCTURE T/M control valve Drive axle 35DS7BS03 Brake pedal & bracket assembly Reservoir tank assembly Parking lever assembly Brake valve...
  • Page 96 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. 130~140mm(Pedal height) T/M control valve Inching spool...
  • Page 97 5. WET DISK BRAKE STRUCTURE D357TA10 Spindle Service piston Parking lever Steel plate Parking piston fixing bolt 10 Parking lever shaft Disk plate Spline collar 11 Brake housing Parking piston Drive shaft OPERATION Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 98 6. BRAKE VALVE STRUCTURE 29-1 29-2 29-3 29-4 29-5 29-6 29-7 29-8 29-9 14 15 D357BS07 Dust cover 16 Nut 29-2 Spool plug Guide plug 17 Plug 29-3 Spool Seal 18 Seal 29-4 Stop ring Seal 19 Ring 29-5 Washer Push rod 20 Seal 29-6 Seal...
  • Page 99 DISASSEMBLY All operations must be carried out with the greatest care, following the instructions carefully. The disassembly instructions are being provided in chronological. Unscrew the 4 screws(33), in order to be able to separate the front housing(7) from the rear housing(31).
  • Page 100 Remove ring(25), seal(26), spring(27) and piston(28). Disassemble valve assembly(29), spring guide(30) and seal(32). Remove the O-ring and the lip seal still inside the pump body with the aid of an “L” iron. Remove all of the other gaskets from the disassembled components, namely the push rod(5), the piston(11).
  • Page 101 ASSEMBLY ※ The assembly must be carried out by following the so far described sequence but in reverse order, taking great care not to assemble the new gaskets back to front or upside down. 29-1 29-2 29-3 29-4 29-5 29-6 29-7 29-8 29-9...
  • Page 102 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS RAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. PARKING BRAKE Operating force of parking lever is 35 - 40 ·...
  • Page 103 . TROUBLESHOOTING Problem ause Remedy Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil. ·Hydraulic system leaks air. ·Bleed air. ·Disk worn. ·Replace. ·Brake valve malfunctioning. ·Repair or replace. ·Hydraulic system clogged. ·Clean. Brake acting unevenly. ·Tires unequally inflated. ·Adjust tire pressure.
  • Page 104 GROUP 3 TESTS AND ADJUSTMENTS 1. AIR BLEEDING OF BRAKE SYSTEM Air bleeding should be performed by two persons : One rides on truck for depressing and releasing brake pedal : the other person is Vinyl tube on the ground and removes cap from air vent plug on wheel cylinder.
  • Page 105 Micro switch for parking brake (if equipped) Lever stroke 295mm ① After assembling parking brake and parking cable, put the parking brake lever released. ② Loosen the nut for parking brake plate to Knob play up and down. ③ Move up the plate so that the stopper can be contacted with the pin and then Parking cable reassemble nut.
  • Page 106 SECTION 5 STEERING SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12...
  • Page 107 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Steering cylinder Steering unit Steering axle Priority valve pump Hydraulic tank 35DS7SE01 The steering system for this machine is composed of steering wheel assembly, steering unit, priority valve steering cylinder, steering axle and piping.
  • Page 108 2. HYDRAULIC CIRCUIT 12.5MPa Brake valve 35DS7SE02 Hydraulic gear pump Steering cylinder Steering unit Suction filter Priority valve 14 Hydraulic tank...
  • Page 109 NEUTRAL 12.5MPa Brake valve 35DS7SE03 The steering wheel is not being operated, so control spool(G) does not move. The oil from hydraulic gear pump(1) enters the port P of priority valve(4) and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(14).
  • Page 110 LEFT TURN 12.5MPa Brake valve 35DS7SE04 When the steering wheel is turned to the left, the spool(G) within the steering unit(3) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through the spool(D) of priority valve(4) and flows the gerotor(H).
  • Page 111 RIGHT TURN 12.5MPa Brake valve 35DS7SE05 When the steering wheel is turned to the right, the spool(G) within the steering unit(3) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through the spool(D) of priority valve(4) and flows the gerotor(H).
  • Page 112 3. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing 14 Bearing race 24 Plate spring Ball 15 Bore screw 25 P-port check valve 16 Drive 25-1 Plug...
  • Page 113 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 114 4. STEERING AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 1-22 1-26 1-29 1-25 1-24 1-30 1-35 1-10 1-31 1-38 1-26 1-27 1-32 1-28 1-23 1-12 1-25 1-27 1-13 1-28 1-11 1-21 1-10 1-14 1-33 1-34 1-15 1-44 1-16 1-35...
  • Page 115 GREASING AND SPECIFICATION Stroke 91.5mm(3.6in) Stroke 91.5mm(3.6in) 35kgf m(253lb ft) Apply loctite #277. 16.7~22.5kgf m(121~163lb ft) 35DS7SE07 Type Unit Center pin support single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of wheels(Inside/Outside) degree 74.8/53.8 Tread...
  • Page 116 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) 35L-7 2770mm(109in) 40L-7 2830mm(111in) 45L-7 2890mm(114in) Hydraulic pressure of power Remove screw coupling from CF port of priority valve and install oil pressure gauge.
  • Page 117 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 118 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing 14 Bearing race 24 Plate spring Ball 15 Bore screw 25 P-port check valve...
  • Page 119 TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-13...
  • Page 120 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 121 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 122 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball and suction valve pins and balls. D353SE09 5-16...
  • Page 123 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 124 (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 125 (16) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (17) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (18) The pressure relief valve is now disassembled. D353SE13 5-19...
  • Page 126 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 127 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 128 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 129 (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 130 (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 131 (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 132 (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 133 (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 134 (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 135 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. ※ Do not use a hammer! 5-85(2) 5-29...
  • Page 136 2. STEERING CYLINDER STRUCTURE ※ Specifications ·Cylinder bore : 80mm ·Outer diameter : 94mm ·Stroke(half) : 180mm ·Rod diameter : 55mm D357SE21 1 Tube assy DU bushing 11 O-ring 2 Rod assy Rod seal 12 Back up ring 3 Piston seal Back up ring 13 O-ring 4 Wear ring...
  • Page 137 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 138 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Using a special tool, install gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland ass- embly, and tighten it with torque 60±6kgf·m (434±43lbf·ft).
  • Page 139 3. STEERING AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 1-22 1-26 1-29 1-25 1-24 1-30 1-35 1-10 1-31 1-38 1-26 1-27 1-32 1-28 1-23 1-12 1-25 1-27 1-13 1-28 1-11 1-21 1-10 1-14 1-33 1-34 1-15 1-44 1-16 1-35...
  • Page 140 CHECK AND INSPECTION A1,A2 35DS7SE08 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 55(2.2) 54.5(2.1) Shaft ID of bushing 55(2.2) 55.5(2.2) 35(1.4) 34.5(1.4) Replace OD of king pin OD of steering cylinder pin 20(0.8) 19.5(0.8) OD of pin 20(0.8)
  • Page 141 DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the counter weight part of the truck. Hub nut Hub nut Loosen the hub nut and take off the steering wheel tire.
  • Page 142 ASSEMBLY ※ In reassembling, have all parts washed, grease applied to lubricating parts, and all expendable items such as oil seal and spring washers replaced by new ones. Perform the disassembly in reverse order. 1-38 Tighten the special bolt(1-8) and washer(1-9) of king pin(1-3).
  • Page 143 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-17 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22...
  • Page 144 SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 35DS7HS01 Hydraulic gear pump Lift cylinder Main control valve Suction filter Steering unit 10 Return filter Priority valve 11 Down safety valve Brake valve 12 Down control valve Steering cylinder 13 Hydraulic oil tank Tilt cylinder...
  • Page 145 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION Steering syetem Lift Load check valve Steering return line Brake syetem Brake return line 35DS7HS02 When the lift control lever is pulled back, the spool on the first block is moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(2) through the priority valve(4) and then goes to the large chamber of lift cylinder(8) by pushing the load check valve of the spool.
  • Page 146 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION Lower Steering syetem Steering return line Brake syetem Brake return line 35DS7HS03 When the lift control is pushed forward, the spool on the first block is moved to lower position. The work port(B1) and the small chamber and the large chamber are connected to the return passage, so the lift will be lowered due to its own weight.
  • Page 147 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION Steering syetem Steering return line Brake syetem Brake return line 35DS7HS04 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
  • Page 148 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION Steering syetem Tilt backward Load check valve Steering return line Brake syetem Brake return line 35DS7HS05 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
  • Page 149 2. HYDRAULIC GEAR PUMP STRUCTURE 35DS7HS06 Body 10 Screw 19 Shaft seal Rear cover 11 Screw 20 Ring Front cover 12 Grub screw 21 Back-up ring Thrust plate 13 Washer 22 Antiextrusion Thrust plate 14 Washer 23 Sleeve bearing Drive gear 15 Seal 24 Hub Driven gear...
  • Page 150 3. MAIN CONTROL VALVE STRUCTURE (2 Spool) Port name Size Inlet port 1-5/16-12UN Outlet port 1-5/16-12UN Gauge port PF1/4 3 Work port 1-1/16-12UN Inlet port SECTION B - B Outlet port 3 Work ports Gauge port VIEW D - D SECTION A - A 35DS7HS07 Special nut...
  • Page 151 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 152 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 153 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 154 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 155 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 156 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 157 4. LIFT CYLINDER 9 10 8 14 6 4, 5 3 D357HS12 Tube assy Retaining ring 13 DU busing Gland 14 O-ring Piston Dust wiper 15 Spacer Piston seal 10 Rod seal 16 O-ring Back up ring 11 O-ring Wear ring 12 Guide 5.
  • Page 158 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 159 . 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 160 Problem Cause Remedy Actuator(cylinder or motor) · · Shortage of oil in oil tank. Check the oil level in the oil tank. works slowly or does not · · Decrease of relief valve pressure. Install pressure gauge on the circuit, operate.
  • Page 161 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 162 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 163 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP STRUCTURE 35DS7HS06 Body 10 Screw 19 Shaft seal Rear cover 11 Screw 20 Ring Front cover 12 Grub screw 21 Back up ring 13 Washer 22 Antiextrusion Thrust plate Thrust plate 14 Washer 23 Sleeve bearing Drive gear 15 Seal...
  • Page 164 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 165 ③ And remove drive gear(6), driven gear(7), thrust plate(4), keeping gears as straight as possible, and body(1) also. D357PMP03 Front section ① Loosen and remove the screw(10) from the body(27). ※ Coat the sharp edges of the drive shaft (8) with adhesive tape and smear a clean grease on the shaft end extension to avoid any damaging lip of the shaft seal when removing the cover(3).
  • Page 166 Cover assembly ① Remove snap ring(20) with proper tool(Only when it is needed to replace shaft seal). ② Remove the shaft seal(19) taking care not to give any damage on the surface of shaft hole(Only when it is needed to replace shaft seal).
  • Page 167 ③ Insert the steel bushing(26) into body(27). D357PMP10 ④ Insert the complete pressure plate (5+16+22) into body(27) while keeping the plate straight. ※ Seal side should face to the rear side, opposite side of gears. ※ Pay attention to the direction of seal. (opened side should face suction side always) D357PMP11...
  • Page 168 ⑦ Tighten the bolts(10) with washer(14) in a crisscross pattern to torque value of 14.3kgf·m(103lbf·ft). 10(x4) 14(x4) D357PMP14 ear section ① Smear clean grease on the seal(18) to avoid drifting away of seal from the body(1) and assemble temporarily rear cover(2).
  • Page 169 ④ Locate driving gear(4) and driven gear(5) while keeping the gears straight. Locate pressure plate(4+21+15) with care for the direction. D357PMP18 ⑤ Open rear cover(2) to locate hub(24) into rear section. Front section Rear section D357PMP19 ⑥ Tighten the bolts(11) with washer(13) in a crisscross pattern to torque value of Rear section 4.6kgf·m(33.3lbf·ft).
  • Page 170 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 171 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 172 4. LIFT CYLINDER STRUCTURE · I.D×O.D×stroke(standard) 73×65×1335mm (2.9×2.6×52.6in) · Rod O.D : 50mm(2.0in) D357HS19 Tube assy Dust wiper 10 Rod seal Piston 11 O-ring Piston seal 12 Guide Back up ring 13 DU busing Wear ring 14 O-ring Retaining ring 15 Spacer Gland 16 O-ring...
  • Page 173 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 174 5. TILT CYLINDER STRUCTURE · I.D×O.D×stroke : 90×102×220mm (3.5×4.0×8.7in) · Rod O.D : 45mm(1.8in) 35DS7HS16 Tube assy O-ring 17 Nylon nut 10 Back up ring 18 Rod eye Gland 11 Lock washer 19 Spherical bearing DU bushing 12 O-ring 20 Retaining ring Rod seal 13 Piston 21 Hexagon bolt...
  • Page 175 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 176 SECTION 7 ELECTRICAL SYSTEM Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2 Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8 Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9...
  • Page 177 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 12 13 14 0 0 0 0 HYUNDAI 35L7EL02 Work lamp Beacon lamp 13 Horn button Battery License lamp 14 Start switch Master switch 10 Forward-reverse lever 15 Work lamp switch(opt) Tilt alarm...
  • Page 178 GROUP 2 ELECTRICAL CIRCUIT REAR SUPPORT HARNESS REAR BEACON R/COMBI LH R/COMBI RH F/COMBI H/LAMP F/COMBI H/LAMP WORK (OP) CLUSTER START KEY S/W B BR R1 R2 C ACC 9 10 11 12 190 W CD-2 120 R 000 B 458 Y CN-19 FUEL SENDER...
  • Page 179 MEMORANDUM...
  • Page 180 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+)] I/conn [CN-1(2)] Start switch [CS-2(3)] Fuse box [CN-36] (No.1)
  • Page 181 POWER CIRCUIT START KEY S/W BR R1 R2 C ACC CN-74 ALTERNATOR FUEL SYSTEM HARNESS CN-45 CN-1 CN-17 260 RY START MOTOR OPTION(CABIN) CR-11 BATTERY MASTER SW 12V X 2 FLASHER UNIT CN-57 CN-113 E/G TEMP GAUGE OPSS BUZZER FUEL GAUGE ANTI RESTART EARTH(GAUGE) CN-55...
  • Page 182 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Start motor [CN-45(B+)] I/conn [CN-1(2)] Start switch [CS-2(3)] ※ T he engine can be started only when the gearshift is in neutral position. When start key switch is in ON position Start switch ON [CS-2(4)] Fuse box [No.5] Combination switch [CS-12(5)] When start key switch is START position...
  • Page 183 STARTING CIRCUIT START KEY S/W BR R1 R2 C ACC CN-74 FUEL ALTERNATOR SYSTEM HARNESS CN-45 CN-1 CN-57 START MOTOR WATER TEMP GAUGE FUEL GAUGE BATTERY MASTER SW 12V X 2 ANTI RESTART EARTH(GAUGE) CLUSTER MAIN EARTH CR-5 Or 320 CN-6 IG(VSW) RELAY NEUTRAL...
  • Page 184 GROUP 3 COMPONENT SPECIFICATION Specification Remark Part name 12V80AH, RC : 30min, CCA : 630 Battery 12V, 55W Working lamp 12V, 3.4W×2 License lamp 12V, 21W (T/S) 12V, 10W (Back) Combination lamp 12V, 5W (Tail) 12V, 21W (Stop) 12V, 55W Head lamp 85±10 C/M, (23W + 23W)×2 + 3W ×...
  • Page 185 GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Frame harness-dashboard harness) 2-85262-1 368301-1 CN-2 I/conn(Dashboard harness-frame harness) 368047-1 368050-1 CN-4 LH support harness S810-004201 CN-5 RH support harness S810-004201 CN-7 174264-2 I/conn(RR support harness-frame harness) 174262-2 CN-8 I/conn(RR support harness-frame harness)
  • Page 186 Connector part No. Connector No. of Type Destination number Female Male CL-23 S822-114000 Rear work lamp S822-014000 Relay CR-5 Neutral relay S810-004201 CR-11 Flasher unit relay S810-003702 CR-13 Head lamp relay S810-004201 CR-50 Travel cut relay S810-006202 CR-51 Attach cut relay S810-006202 Sensor and pressure switch CD-2...
  • Page 187 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 188 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11...
  • Page 189 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) Lift cylinder Carriage Frame 35DS7MS01 Outer mast Bearing 11 Roller bearing Shim(0.5, 1.0t) Inner mast 12 Back up liner Roller bearing Lift chain 13 Shim(0.5, 1.0t) Tilt cylinder pin Anchor bolt Mast mounting pin 10 Chain sheave bearing...
  • Page 190 2. 2 STAGE MAST(VF MAST) Outer mast Inner mast Lift cylinder Free lift cylinder Carriage Frame D357MS02 Outer mast Mast mounting pin 11 Chain Shim(0.5, 1.0t) Bearing 12 Sheave bracket Roller bearing Inner mast 13 Shim(0.5, 1.0t) Backup liner Chain sheave bearing Tilt cylinder pin 10 Anchor bolt...
  • Page 191 3. 3 STAGE MAST(TF MAST) Outer mast Inner mast Lift cylinder Free lift cylinder Middle mast Carriage Frame D357MS03 Outer mast Mast mounting pin 11 Chain Shim(0.5, 1.0t) Bearing 12 Sheave bracket Roller bearing Middle mast 13 Inner mast Backup liner Chain sheave bearing 14 Shim(0.5, 1.0t) Tilt cylinder pin...
  • Page 192 3. CARRIAGE, BACKREST AND FORK 35DS-7E ONLY 35DS7MS04 Backrest Fork Carriage Extension fork Roller Shim(0.5, 1.0t) Side roller...
  • Page 193 FORKS Measure thickness of root of forks and check that it is more than specified value. ℓ=1200mm(47in) EX : mm(in) STD Fork assy Applicable model Standard Limit Thickness S173896-02 35L-7 50(2.0) 45(1.7) F13710010 40L-7 50(2.0) 45(1.7) D507FK01 F17393603 45L-7 50(2.0) 45(1.7)
  • Page 194 2. TROUBLESHOOTING MAST Problem ause Remedy Forks fail to lower. ·Deformed mast or carriage. ·Disassemble, repair or replace. Fork fails to elevate ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. ·Deformed mast assembly. ·Disassemble mast and replace damaged parts or replace complete mast assembly.
  • Page 195 FORKS Problem ause Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear wear and reduces the thickness of the limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...
  • Page 196 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V, VF MAST) INNER/OUTER MAST ROLLER CLEAR- ANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the roller side face and mast at the closest position on the opposite side to the...
  • Page 197 2 2 . MAST LOAD ROLLER(TF MAST) INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast and the middle mast, and adjust the clearance between the roller side face and mast at the closest position on the...
  • Page 198 ARRIAGE LOAD ROLLER Outer mast Adjust Bring into Measure the clearance when the center of screw contact the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, middle Side and lower rollers after loosen the adjust roller Carriage screws from the side rollers.
  • Page 199 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. Release fork anchor pins and slide forks, one by one, toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 200 SIDE ROLLER Remove carriage as outlined in the carriage Side roller assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. ※...
  • Page 201 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Hexagon ① Remove the carriage assembly and bolt Chain move them to one side. ② Loosen and remove hexagon bolts and clamps securing lift cylinders to outer Backup liner mast.
  • Page 202 2 stage mast(VF mast) ① Remove free lift chain connected between carriage and free lift cylinder. ② Remove the carriage assembly and move them to one side. ③ Loosen and remove hexagon bolts and washers securing lift cylinders to inner Chain mast.
  • Page 203 3 stage mast(TF mast) ① Remove the carriage assembly and move to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. ③ Loosen and remove bolts and special washers securing lift cylinders to middle mast. ④...
  • Page 204 ELEVATING MAST Inner mast (V, VF mast) ① After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. ② Lift inner mast upright straight up and out of outer mast section. ③...
  • Page 205 CHAIN Chain sheave(V, VF mast) ① Place a sling around carriage and attach to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 206 Chain wheel bearing support(TF mast) ① Remove the carriage assembly and move to one side. ② After removing bolt to securing chain wheel bearing support assembly to free lift cylinder. After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 207 ② Rust and corrosion Chains used on lift trucks are highly stressed precision components. It is very important that the “as-manufactured” ultimate strength and fatigue strength be maintained throughout the chain service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or roller chain because corrosion causes side plate cracking.
  • Page 208 ⑧ Chain wear scale The chain can be checked for wear or stretching with the use of a chain wear scale. Stretching of a chain is due to the elongation of the pitch holes and wearing of the pin O.D. The greatest amount of stretching occurs at the areas of the chain that flex over the sheaves most frequently.
  • Page 209 ③ ③ Adjustment Chain adjustments are important for the following reasons : ·Equal loading of chain. ·Proper sequencing of mast. ·Prevent over-stretching of chains. ·Prevent chains from jumping off sheaves if they are too loose. ④ djustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor. ·Adjust the chain length by loosening or tightening nut on the chain anchor.

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40l-745l-7