Hyundai 15LC-7M 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 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19

Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-25

SECTION 4 BRAKE SYSTEM

Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8

Group 4 Connector Destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9

Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11

CONTENTS

Summary of Contents for Hyundai 15LC-7M

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 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 will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
Page 5 3. CONVERSION TABLE 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 D35ASF05...
Page 14 · Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. D35ASF09 · When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
Page 15 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 it.
Page 16 GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS 15LC7MOM57 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 15LC7MSP01 Model Unit 15LC-7M 18LC-7M 20LC-7M Capacity kg(lb) 1500(3000) 1800(3500) 2000(4000) ← ← Load center mm(in) 500(24") Weight(Unloaded) kg(lb) 2828(6235) 3027(6673) 3170(6989) mm(ft · in) Lifting height ← ← 3300(10' 10") Free lift ← mm(in) 115(4.5") 120(4.7") ←...
Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item Specification Unit Model MMC 2.0L Type 4-cycle, vertical Cooling Method Water cooled Number of cylinders and arrangement 4 cylinders, In line Firing order 1-3-4-2 Cylinder bore X stroke mm(in) 85×88(3.35×3.46) cc(cu in) Piston displacement 1997(121.9) Compression ratio Rated gross horse power...
Page 19 STEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev Max. inpact pressure kg/cm Max. back pressure kg/cm 0.15±0.02 Input torque kgf·m POWER TRAIN DEVICES Item Specification Model KAPEC 280DB Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type...
Page 20 4. TIGHTENING TORQUE OF MAJOR COMPONENTS kgf·m lbf·ft ITEMS SIZE M12×1.25 Engine mounting bolt, nut 12.5±2.5 90±18 M 8×1.25 Engine Radiator mounting bolt, nut 2.5±0.5 18.1±3.6 M10×1.25 Torque converter mounting bolt 6.9±1.4 50±10 M10×1.5 MCV mounting bolt, nut 4.0±0.5 29±3.6 Hydraulic system 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 2.0 ~ 3.0 M 8×1.25 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" PIPE 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. 。 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) (1.24) Torque ATF DEXRON III...
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 degrees of wear at time of periodic maintenance;...
Page 25 SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
Page 26 SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE 12 13 15LC7MOM23 Mast 10 Transmission 19 Radiator Lift cylinder 11 Torque converter 20 Muffler Steering unit 12 Engine 21 LPG tank Tilt cylinder 13 Air cleaner 22 Overhead guard Main control valve 14 Exhaust pipe 23 Seat...
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 Pull the knob up and slide one fork at a time toward the center of the carriage Knob where a notch has been cut in the bottom...
Page 28 ② While supporting lift chains, remove the nuts and split pin from the chain anchors Lift chain of stationary upright. Outer mast Split pin 20D7RE05 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. 15L7RE06 ④...
Page 29 Piping ① Remove the return hoses and clamps attached to the cylinder. ② Remove the return hoses from the connector. Band clamp Hose ③ Remove hose assembly, connector, clamp Return down safety valve from the lift cylinder. hose ④ Disconnect hose assembly from the flow regulator.
Page 30 Inner mast ① Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Inner mast Be careful the mast not to swing or fall. Outer mast 15L7RE10 Tilt cylinder pin Mast support cap 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. ① Mast support cap ② Check the mast support cap and spring pin for wear. Jack up the machine so that the front is raised and then using an overhead hoist assemble outer ③...
Page 32 2. POWER TRAIN ASSEMBLY REMOVAL D503RE04 Mast Refer to section on mast (Page 2-2)
Page 33 Brake piping Disconnect the brake piping from the brake housing of drive axle. Brake valve Brake pipe Drive axle 15L7MRE12 Parking brake cable Disconnect parking brake cable from the drive axle. Parking brake cable Drive axle 15LC7MRE13...
Page 34 Drive axle Crane ① Attach a crane to the tilt cylinder notches on the dashboard and raise the machine. ② Loosen hexagonal bolts (1) connection drive axle to the transmission. ③ Put the block under the drive axle and support under the drive axle with a truck. Tilt cylinder notch ④...
Page 35 Torque converter ① Remove the cover on top face of the torque converter housing then remove Cover the 8 mounting bolts installed on the engine flywheel. To rotate the flywheel, remove 1 mounting bolt, then insert a turning tool in the mounting hole. One man must turn the engine fan by hand while the other turns the flywheel.
Page 36 INSTALLATION Installation is the reverse order to removal, Bolt(1) but be careful of the following points. Tightening torque Bolt(2) ·Bolt (1) : 5.5~8.3kgf·m (39.8~60lbf·ft) ·Bolt (2) : 2.7~4.1kgf·m (19.5~29.7lbf·ft) ·Bolt (3) : 5.5~8.3kgf·m (39.8~60lbf·ft) Bolt(5) ·Bolt (4) : 62~68kgf·m (449~491lbf·ft) ·Bolt (5) : 7.5kgf·m (54.2lbf·ft) Bolt(4) Bolt(3)
Page 37 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL D503RE25 Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and flasher lamp on the stay of the overhead guard and then raise it together with the bonnet.
Page 38 Remove the torque converter housing cover, mounting bolts installed to flywheel housing. For details, see page 2-10. 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 39 INSTALLATION Installation is the reverse order of removal, but be careful of the following points. Tighten the engine mounting bolts and nuts. Tighten the engine mounting bracket bolts. ※ Do not remove the bolts unless necessary. Loctite is coated over the threads of bolt. So, once the bolts were removed, coat them with loctite (#243) when installing.
Page 40 15LC7MRE27 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) 15LC-7M : 810kg(1785lb) 18LC-7M : 1005kg(2215lb) 20LC-7M : 1140kg(2510lb) 2-15...
Page 41 Rear wheel Oil seal Rear wheel Remove cap, split pin and castle nut and then carefully take out the tire assembly. Castle nut Split pin Taper roller bearing 15LC7MRE28 Hose Drain hydraulic oil in the hoses and Steering axle cylinder before removing them. Loosen connector and then disconnect the hoses.
Page 42 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-25...
Page 43 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN DIAGRAM STRUCTURE 15LC7MPT26 Engine Drive shaft Brake Transmission Drive axle...
Page 44 SPECIFICATION Item Specification Model KAPEC 280DB Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick down system 1 : 1 Gear ratio 1 : 1 Type Front-wheel drive type, fixed location Axle...
Page 45 2. TORQUE CONVERTER 11 21 15L7APT03 Hexagon bolt Plug Air breather Plain washer O-ring Magnetic plug Flexible plate Torque converter housing Temperature sensor Torque converter assembly Hexagon bolt Inner oil strainer Shaft Torque converter cover Oil strainer spring Snap ring O-ring O-ring Gear...
Page 46 OPERATION The torque converter is connected with a flywheel by a flexible plate, engine output is delivered from the flywheel to the flexible plate. The exterior of the torque converter is protected by the torque converter housing. The torque converter housing forms the oil path for the oil pump, it includes the oil strainer filtering sucked oil through this oil path and the oil level gauge measuring oil level of the transmission inside.
Page 47 3. TRANSMISSION STRUCTURE 15L7APT28 Control valve Output gear Torque converter Temperature sensor Turbine wheel Oil strainer Impeller wheel Idle gear Stator wheel Forward clutch pack Forward clutch gear Input shaft Oil pump Reverse clutch pack Reverse clutch gear...
Page 48 INSTALLATION VIEW 15L7APT05 1 Torque converter 5 Air breather 2 Temperature sensor 6 Transmission oil filter 3 Control valve 7 Transmission output (Universal joint link part) 4 Oil level pipe and dipstick OPERATION The torque converter is an automatic fluid drive. It transmits engine torque by means of hydraulic force.
Page 49 OPERATING MODES Forward → Torque converter → Clutch shaft → Input Forward clutch gear → Output gear → Output 15L7APT29 Reverse Input → Torque converter → Clutch shaft → Reverse clutch gear → Output gear → Output 15L7APT30...
Page 50 TRANSMISSION CASE AND CONTROL VALVE 15L7APT07 Transmission case 12 Socket bolt Cylinder gear Plug 13 Oil gauge Idle gear Oil seal 14 Clamp Output gear Ball 15 Socket bolt Socket bolt Spring 16 Flange bolt Lock pin O-ring 17 Control valve O-ring Plug 18 Solenoid valve...
Page 51 Operation The transmission case includes the function of a control valve, an oil filter and a parking brake. The oil filter is charge of filtering sucked oil by an oil pump before transmitting sucked oil to a control valve and a torque converter. Oil transmitted through an oil filter delivers oil pressure to the piston of the forward and reverse clutch through the solenoid valve.
Page 52 CONTROL VALVE Operation 15L7APT08 Modulation Inching valve pressure check port Solenoid valve Forward clutch pressure check port Inching spool Reverse clutch pressure check port Main relief valve Main pressure check port The control valve consists of the main relief valve, solenoid valve, modulation valve and inching valve.
Page 53 Structure Main relief valve Modulation Forward clutch pressure check port Inching valve pressure check port Main pressure check port Reverse clutch pressure check port Inching spool Solenoid valve 15L7APT22 1 Plug 11 Spring 21 Stopper 2 O-ring 12 Solenoid valve 22 Spring 3 Spring 13 Seal...
Page 54 CLUTCH Operation Reverse Forward 15L7APT31 Forward clutch plugging pressure delivery line ( Reverse clutch plugging pressure delivery line ( Clutch pack lubrication line ( When (forward/reverse) mode is selected through the solenoid valve of control valve, the flux flowed by the oil pump flows into forward (reverse) clutch pack in 9~14.2 kgf/cm (128~202 psi) of pressure through the oil path of transmission inside.
Page 55 Structure 15L7APT11 21 Wire ring 1 Shaft 11 Seal ring 22 Plate 2 Seal ring 12 Piston 23 Clutch drum 3 Needle bearing 13 Quad ring 24 Spacer 4 Ring 14 Quad ring 5 Seal ring 15 Plate 25 Snap ring 26 Ball bearing 6 Bushing 16 Friction plate...
Page 56 OUTPUT GEAR Operation The output gear is engaging the forward clutch gear and reverse clutch gear together. If a driver selects forward, the forward clutch gets plugging, the forward clutch gear revolves and the power of forward clutch gear is delivered to output gear. If a driver selects reverse, the reverse clutch gets plugging, the reverse clutch gear revolves and the power of reverse clutch gear is delivered to output gear.
Page 57 4. DRIVE AXLE INSTALLATION VIEW Carrier assembly Traveling brake Oil level gage Drive axle housing STRUCTURE Pinion shaft Axle shaft Ring gear Traveling brake Differential device Hub reduction The drive axle is connected with the transmission output gear and universal joint. The power transferred by the universal joint is connected to the pinion shaft of drive axle, the pinion shaft delivers the power to the differential device through the ring gear.
Page 58 CARRIER ASSEMBLY Operation Carrier sub assy includes differential device and parking brake. The pinion shaft is supported by the taper roller bearing in the carrier case and the bolt at the end of pinion shaft and transfers the power which is delivered from the drive shaft assy to the ring gear assembled from bolts at a differential device.
Page 59 Structure 15L7APT18 1 Parallel pin 5 Actuator 9 Eccentric shaft 2 Parking plate 6 Push pin 10 Lever 3 Friction plate-parking 7 Parking spline 4 Cone spring 8 Carrier case cover 3-17...
Page 60 DIFFERENTIAL DEVICE Operation Since the ring gear is linked with the right of the differential case and the bolt, the power transferred to the ring gear makes the differential device revolve. And also, the left and right of the differential case are connected with the left and right of the axle shaft and the spline respectively, it delivers the power to the final drive.
Page 61 GROUP 2 TROUBLESHOOTING 1. TRANSMISSION Trouble symptom Probable cause Remedy 1. Output does not go up 1) Torque converter - Torque converter oil ·The oil is in short supply. ·Replenish oil. ·The oil that is not regulated is used. ·Change the oil to regular oil. ·The air has mixed into oil.
Page 62 Trouble symptom Probable cause Remedy 2. Power is not transmitted. ·The flexible plate is broken. ·Change the flexible plate. 1) Torque converter ·The oil is in short supply. ·Replenish oil. ·The shaft and spline are worn. ·Change the shaft and the spline. ·The gear is broken.
Page 63 Trouble symptom Probable cause Remedy 4. Clutch or converter oil pressure is too high 1) Torque converter ·Viscosity of oil is too high (at cold · Warm up the torque converter if the time). temperature of torque converter oil is below outside air temperature.
Page 64 2. DRIVE AXLE Trouble symptom Probable cause Remedy 1. Noise and vibration 1) Drive axle ·Lubricating oil shortage. ·Check oil level and refill lubricating oil. ·Using different lubricating oil. ·Change lubricating oil. ·Maladjustment or detect of wheel ·Change wheel bearing. bearing.
Page 65 Trouble symptom Probable cause Remedy 2. Oil leakage 1) External leakage ·Excess of oil. ·Check oil level. Set of oil amount. ·Using different oil. ·Change oil. ·Blocking air breather. ·Washing or change air breather. ·Damaged of hub oil seal. ·Disassemble, check and change. ·Leakage at pinion shaft.
Page 66 Trouble symptom Probable cause Remedy 4. Brake does not apply 1) Service brake. ·Empty fluid reservoir. ·Fill reservoir to correct level with specified - Low or no pressure to fluid. brake. ·Damaged hydraulic system. ·Check hydraulic system. ·Leakage of brake actuation fluid. ·Refer to "Brake leaks actuation fluid"...
Page 67 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF TRANSMISSION DISASSEMBLING OF TRANSMISSION ASSY Drain the transmission oil. Remove the drain plug at T/C housing. Lay the wood plate (or plastic plate) on the workshop's table (bottom). And put the T/M assy on the wood plate (or plastic plate) : For an (dis)assembly at the time of damage prevent.
Page 68 Remove the socket gear. Next remove the snap-ring at socket gear. 15L7ATM005 Removal the oil pump sub assy. ① Remove the hexagon bolt (M8×1.25P×38L), and then remove the copper washer. 15L7ATM006 ② Remove the plug. (PT 1/8) 15L7ATM007 ③ Remove the pump sub assy + gasket using the plug hole for pulling out from the T/C housing.
Page 69 Removal the control valve sub assy. ① Remove the hexagon bolt (M8×1.25P×60L). 15L7ATM010 ② Remove the part slowly with hit the end side softly. ※ Using a plastic hammer . Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.
Page 70 (10) Remove the cooler (in/out) plug.(PT 3/8) 15L7ATM015 (11) Remove the air breather. 15L7ATM016 (12) Remove the hexagon bolt, and then remove the T/C cover. 15L7ATM017 (13) Remove the oil level gauge. 15L7ATM018 (14) Remove the socket bolt, and then remove the clamp.
Page 71 (15) Remove the socket bolt, and then remove the pipe. Next remove the O-ring at the pipe. 15L7ATM020 (16) Remove the temperature sensor. 15L7ATM021 (17) Lay the T/M assy without damage to the T/C housing.(engine mounting surface) 15L7ATM022 (18) Remove the plug, and then remove the spring, oil strainer.
Page 72 (19) Remove the plug.(PT 1/8) 15L7ATM024 (20) Remove the socket bolt (T/M case + T/C housing fastening bolt) 4 socket bolt exclusions. 15L7ATM025 15L7ATM026 (21) To turn over T/M assy without damage to the T/M case.(main pump mounting surface) Next remove the 4 socket bolt. 15L7ATM027 3-30...
Page 73 Remove the part slowly with hit the end side softly. (22) ※ Using a plastic hammer. 15L7ATM028 (23) Remove the T/C housing. 15L7ATM029 (24) Gear assemblies arrangements. 15L7ATM030 (25) Remove the O-ring. 15L7ATM031 (26) Remove the output gear assy. 15L7ATM032 3-31...
Page 74 (27) Remove the idle gear assy. 15L7ATM033 (28) Remove the clutch gear assy. ※ Store each gear assembly in separate box. 15L7ATM034 (29) Remove the oil seal. 15L7ATM035 3-32...
Page 75 DISASSEMBLING OF GEAR ASSEMBLIES Disassembling clutch gear assy. 15L7ATM036 ① Remove the seal ring. 15L7ATM037 ② Pull out the bearing(#6207) and spacer from the shaft. 15L7ATM038 ③ Pull out the forward clutch sub assy. 15L7ATM039 ④ Pull out the bearing(#6911) from the shaft. 15L7ATM040 3-33...
Page 76 ⑤ Pull out the reverse clutch sub assy. 15L7ATM041 ⑥ Forward clutch sub assy. 15L7ATM042 ⑦ Remove the forward clutch gear sub, and then remove the spacer. 15L7ATM043 ⑧ Remove the snap ring, and then remove the bearing. 15L7ATM044 3-34...
Page 77 ⑨ Remove the snap ring, and then remove the back plate, friction disk, and steel plate. 15L7ATM045 ⑩ Remove the wire ring, and then remove the back plate and spring. When you remove the wire-ring, it might be shot out by impact of spring. Certainly fixing the spring, will have to remove.
Page 78 ⑭ Remove the snap ring, and then remove the bearing. 15L7ATM049 ⑮ Remove the snap ring, and then remove the back plate, friction disk, and steel plate. 15L7ATM050 Remove the wire ring, and then remove the back plate and spring. When you remove the wire-ring, it might be shot out by impact of spring.
Page 79 Disassembling of Idle gear assy. 15L7ATM052 ① Pull out the bearing, and then remove the idle gear upper(lower). 15L7ATM053 Disassembling of output gear assy. 15L7ATM054 3-37...
Page 80 ① Remove the seal ring, oil seal and sealing cap. 15L7ATM055 ② Pull out the bearing. 15L7ATM056 3-38...
Page 81 2. ASSEMBLY OF TRANSMISSION ASSEMBLING OF GEAR ASSEMBLIES ※ Assemble the part with reverse the aforementioned disassemble procedure. · Assembling of clutch gear assembly. Forward clutch drum sub assembly. ① In drum internal groove tefron seal assembly. ※ Spread grease on seal ring. 15L7ATM057 ②...
Page 82 ⑤ First insert steel plate, and then insert friction disk alternately. Next insert the back plate, and then assemble the snap ring. 15L7ATM061 ⑥ Assemble the bearing, and then assemble the snap ring alternately. 15L7ATM062 ⑦ Arrange serration of the friction disk, and then assemble the spacer, clutch gear sub.
Page 83 Reverse clutch drum sub assembly. ① Do work as the same way like forward clutch drum ① ~ ⑤. sub assembly procedure 1) ② Assemble the bearing, and then assemble the snap ring alternately. 15L7ATM065 ③ Arrange serration of the friction disk, and then assemble the clutch gear sub.
Page 84 ③ Assemble the forward clutch drum sub assy at the shaft sub assy. 15L7ATM070 ④ Assemble the spacer and bearing. - Used method of heating bearing. 15L7ATM071 ⑤ Assemble the seal ring. ※ Spread grease on seal ring 15L7ATM072 ⑥ Clutch gear assy.
Page 85 Assembling of output gear assembly. ① Assemble the bearing. - Used method of heating bearing ※ All bearings should never be heated above 120。 C 15L7ATM074 ② Assemble the oil seal, seal ring and sealing cap. ※ Spread loctite #609 on the out wheel of oil seal, spread grease on inside wheel of oil seal.
Page 86 Assembling of idle gear assembly. ① Press the idle gear upper and idle gear lower at the idle gear shaft, and then assemble the bearing. - Used method of heating bearing ※ All bearings should never be heated above 120。 C 15L7ATM077 ②...
Page 87 ASSEMBLING OF TRANSMISSION ASSY Press the oil seal. ※ Spread loctite #592 on the out wheel of oil seal, spread grease on inside wheel of oil seal. 15L7ATM079 Assemble the clutch gear assy. ※ When you insert the shaft after install the seal ring in the shaft, please insert the shaft with turning it into the shaft side and hole side of shaft for prevent the damage of shaft.
Page 88 Press the lock-pins. ※ After the assembling, please check whether you can turn the input(output) gear lightly by your hand. 15L7ATM084 Spread loctite #5127 on T/C housing space. 15L7ATM085 Assemble the T/C housing. 15L7ATM086 Assemble the part slowly with hit the end side softly. ※...
Page 89 (11) Turn over T/M assy without damage to the T/C housing.(engine mounting surface) Next assemble the socket bolts. ·Socket bolt (M10×1.5p×40mm) ×16EA ·Tightening torque : 5.5~6.5 kgf·m(40~47 lbf·ft) ※ Spread loctite #277 on socket bolt. 15L7ATM089 (12) Assemble the socket bolts. ·Socket bolt (M10×1.5p×25mm) ×2EA ·Tightening torque : 5.5~6.5 kgf·m(40~47 lbf·ft) ※...
Page 90 (15) Assemble the O-ring at the plug. Insert the oil strainer, spring ,and then assemble O- ring+plug assy. ·Plug tightening torque : 8~10 kgf·m(58~72 lbf·ft) ※ Spread grease on O-ring. 15L7ATM093 (16) Assemble the temperature sensor. ·Tightening torque : 3.0~4.0 kgf·m(22~29 lbf·ft) ※...
Page 91 (20) Assemble the T/C cover and hexagon bolts. ·Hexagon bolt (M8×1.25p×16mm) ×2EA ·Tightening torque : 2.0~3.0 kgf·m(14.5~21.7 lbf·ft) ※ Spread loctite #277 on socket bolt. 15L7ATM098 (21) Assemble the air breather. ·Tightening torque : 1.0~1.5 kgf·m(7.0~11 lbf·ft) ※ Spread loctite #577 on air breather. 15L7ATM099 (22) Assemble the O-ring at the plug, and then insert...
Page 92 (25) Assemble the hex bolt. ·Hexagon bolt (M8×1.25p×60mm) ×10EA ·Tightening torque : 3.0~3.3 kgf·m(22~24 lbf·ft) 15L7ATM103 (26) Assemble the o-ring at the charging pump assy. ※ Spread grease on O-ring. 15L7ATM104 (27) Install the gasket at the T/C housing, and then install the charging pump assy.
Page 93 (30) Install the flexible plate at the torque converter, and then install the hexagon bolt and washer. ·Hexagon bolt (3/8-24UNF-2B) ×6EA ·Tightening torque : 3.0~3.5 kgf·m(21.6~25.3 lbf·ft) ※ Spread loctite #277 on hexagon bolt 15L7ATM108 (31) Insert the T/C sub assy at the T/M sub assy. 15L7ATM109 (32) Transmission assy.
Page 94 3. DISASSEMBLY OF DRIVE AXLE DISASSEMBLY Disassembling of drive axle assy. 15L7ADA001 Remove bolts of hub sub assembly. To avoid serious personal injury and possible damage to components, be very careful when using lifting devices during removal and disassembly procedures. Inspect to make sure that neither lifting strap is damaged.
Page 95 Remove pins. 15L7ADA005 → return spring. Disassemble in order of special bolt 15L7ADA006 Detach brake piston. 15L7ADA007 After remove retaining ring, pull out left axle shaft. (Do work as the same way like right axle shaft) Use a brass, leather or rubber mallet for assembly and disassembly procedures.
Page 96 (10) Remove all snap rings. 15L7ADA010 → (11) Remove all each parts in order of thrust washer planet gear → needle bearing → thrust washer. 15L7ADA011 (12) Loose lock nut by using jig. 15L7ADA012 (13) Extract planet carrier. 15L7ADA013 (14) Extract carrier housing with bearing.
Page 97 (15) Remove bolts fixing flange hub and wheel shaft. 15L7ADA015 (16) Remove bolts fixing carrier assy. 15L7ADA016 (17) Extract the bracket. 15L7ADA017 (18) Extract carrier assembly. 15L7ADA018 (19) Fix carrier assembly to a jig. 15L7ADA019 3-55...
Page 98 (20) Remove carrier cap bolt. 15L7ADA020 (21) Extract the carrier cap (apply marking a match). 15L7ADA021 (22) Remove adjusting ring of both sides bearing cup. 15L7ADA022 (23) Extract differential assembly. 15L7ADA023 (24) After turn over carrier assy and fix it, remove nut. 15L7ADA024 3-56...
Page 99 (25) Remove U-joint flange. 15L7ADA025 (26) Remove carrier case cover bolts. 15L7ADA026 (27) Extract carrier case cover assembly. 15L7ADA027 (28) Extract push pins and actuator. 15L7ADA028 (29) Remove O-ring and spline parking. 15L7ADA029 3-57...
Page 100 (30) Remove parking friction plates and separate plates. 15L7ADA030 (31) Finish disassembling of carrier assembly. 15L7ADA031 3-58...
Page 101 ASSEMBLY Carrier sub assembly Thrust washer Differential device assembly Differential gear ① Prepare parts for assembly of differential. Spider Differential Differential case-RH case-LH Bearing 15L7MDA032 ② Fix differential case RH and LH with bolt. After paste loctite #277 on spiral of bolt. Confirm torque : 350~380 kgf·cm 15L7ADA033 ③...
Page 102 Adjusting shim and pinion shaft assembly ① Fix carrier case to the jig. ※ Read the following information before installing new gearset in the carrier. Always inspect the gearset for correct marks to make sure the gears are a matched set. 15L7ADA036 The locations of the gearset marks are shown in right figure.
Page 103 ② Decide thickness of shim by gauge and measuring apparatus (Standard gap between bearing and carrier case step : A) (Mounting distance(MD) of pinion shaft : B) ※ Thickness of shim · X = A - B + Carrier case bearing step depth ex1) A= 0.35, B= -0.1, Bearing step depth= +0.1 ·...
Page 104 ⑦ Set a ball. 15L7ADA043 ⑧ Equip jig for fixing. 15L7ADA044 ⑨ Fasten the ball. 15L7ADA045 ⑩ Revolve carrier case 180。 . 15L7ADA046 ⑪ Put into spacer. 15L7ADA047 3-62...
Page 105 ⑫ Decide thickness of shim by gauge and measuring apparatus (thickness : B) ※ Thickness of shim · X = B - End play (0.03~0.06) ex 1) B = 0.45, · X = 0.45 - (0.03~0.06) = 0.42~0.39mm 15L7ADA048 ⑬ Remove pinion shaft.
Page 106 Assemble bearing cone. Assemble after paste grease on bearing cone roller. 15L7ADA053 Assemble of parking sub assembly ① Assemble pin into carrier case. 15L7ADA054 ② → cone spring Assemble in order of separate plate → friction plate. But assemble separate plate lastly. ·Separate plates : 4EA ·Friction plates : 3EA 15L7ADA055...
Page 107 ⑤ Assemble push pin into actuator. 15L7ADA058 ⑥ Assemble O-ring on groove of pinion shaft. Assemble after paste grease on O-ring grease. 15L7ADA059 ⑦ Assemble pin into the carrier case. 15L7ADA060 Assemble of carrier case cover assemble ① Assemble oil seal into carrier case cover. Paste #592 on outside of oil seal and grease on inside of oil seal.
Page 108 ③ Assemble cover by first putting small O-ring on eccentric shaft, and then put big O-ring on collor. 15L7ADA063 ④ Assemble set screw. Assemble paste loctite #277. Confirm torque : 200~250 kgf·cm 15L7ADA064 ⑤ After complete assembling of axle when pull parking lever.
Page 109 ⑦ Assemble cap. Assemble after paste loctite #609. 15L7ADA067 ⑧ Assemble carrier cover assy. Assemble after paste loctite #277. Confirm torque : 304~405 kgf·cm Paste loctite #5127 on assembling side of carrier case cover and carrier case. 15L7ADA068 ※ Applying liquid gasket material. ※...
Page 110 ⑨ Assemble flange U-joint. 15L7ADA070 ⑩ Fasten nut. Assemble paste loctite #242. Confirm torque : 2600~2950 kgf·cm ※ Preload : 10~19 kgf·cm 15L7ADA071 ⑪ Calking. (2 EA) 15L7ADA072 ⑫ Assemble differential sub in carrier case. 15L7ADA073 ⑬ Fit carrier cap with steel ball. Bolt : paste loctite #277 Confirm torque : 1170~1130 kgf·cm...
Page 111 Adjusting the gearset backlash ① Assemble bearing adjust ring. 15L7ADA076 ② Adjust bearing adjust ring. 15L7ADA077 ③ Measure backlash. 15L7ADA078 ④ Fasten bearing adjust ring. 15L7ADA079 ⑤ Measure again backlash. ※ Backlash of pinion and ring gear : 0.15~0.20mm ※ If backlash is wrong, carry out adjusting work.
Page 112 ※ Backlash is increased by moving the ring gear away from the pinion shaft. Backlash is decreased by moving the ring gear toward the pinion shaft. Refer to figure DA076 and DA077. ⑥ Loosen one bearing adjusting ring one notch, then tighten the opposite ring the same amount.
Page 113 ② Rotate ring gear forward and backward so that the 6 marked teeth go past the drive pinion six time to get a good contact pattern. ③ Compare the contact patterns to figure DA086, DA087 and DA088. ※ In new gearsets, a good contact pattern is toward the toe of the tooth, and centered between the top and bottom of the tooth.
Page 114 ④ If the contact patterns require adjustment along the ⓐ-ⓑ. width of tooth (top/bottom), follow steps If the contact patterns require adjustment along the length of tooth (toe/heel), follow steps ⓒ-ⓓ. ⓐ High pattern : A high contact pattern indicates that the pinion was installed too shallow into the carrier.
Page 115 ⑤ Fix spring pin with ring bearing adjust. And assemble them. 15L7ADA094 15L7ADA095 3-73...
Page 116 Assemble of carrier assembly ① Pressurize lock pin into axle housing. 15L7ADA096 ② Paste sealant on axle housing. (Loctite #5127) 15L7ADA097 ③ Assemble carrier assembly on axle housing. 15L7ADA098 ④ Fasten bolt. Assemble bolt after spread loctite #277. Confirm torque : 610~650 kgf·cm 15L7ADA099 3-74...
Page 117 Traveling brake system assembly Axle shaft assembly ① Insert snap ring on the axle shaft. 15L7ADA100 ② After put the ball bearing, fix it with snap ring. 15L7ADA101 ③ After put axle shaft into axle housing fix with snap ring. 15L7ADA102 Piston assembly ①...
Page 118 ※ When assembling the shim, you calculate the value of the shim ad then assemble it. · "L" : Piston assembling part axle housing stage depth (standard : 56.9mm) · "C":Carrier housing stage height (standard : 9mm) · "F" : The total thickness of friction plate and separate plate (standard : 20.5mm) ·...
Page 119 ⑥ → friction plate Assemble in order of separate plate → cone spring. But Assemble separate plate lastly. (Separate plate : 4EA , friction plate : 3EA) 15L7ADA109 Hub assembly Hub sub assembly ① Pressurize hub bolt. 15L7ADA110 ② Pressurize oil seal with loctite #592. Spread grease inside of oil seal.
Page 120 ⑤ Assemble flange hub and wheel shaft. ※ Paste loctite #5127 Confirm torque : 600~700kgf·cm Bolt : Spread loctite #277 15L7ADA114 ⑥ Fix spacer. 15L7ADA115 ⑦ Assemble oil seal at carrier housing. Oil seal with loctite #592. 15L7ADA116 ⑧ Assemble bearing cup at carrier housing. 15L7ADA117 ⑨...
Page 121 ⑩ Put carrier housing on assembled flange hub and wheel shaft. Before assembling, spread grease inside of flange hub. ·Grease : Shell retinax 0434 - 60~80% spread 15L7ADA119 ⑪ Adjust preload for fix shim. ·Preload : 40~50kgf·cm 15L7ADA120 ⑫ Put into shim. ※...
Page 122 ⑮ Fasten lock nut. Confirm torque : 2800~3200kgf·cm, calke after assembling. ·Preload : 40~50kgf·cm 15L7ADA124 Assemble in order of washer → needle bearing → planet gear → washer . Before assembling washer, paste oil, spread grease on needle bearing. 15L7ADA125 Fix snap ring.
Page 123 The rest part assembly ① Assemble O-ring and fitting bleeder for LH and RH. Confirm torque : 380~420kgf·cm 15L7ADA129 ② Assemble bleeder and cap. Screw : Assemble after spread loctite #577. Confirm torque : 150~200kgf·cm 15L7ADA130 ③ Assemble air breather. 15L7ADA131 ④...
Page 124 ⑥ Put in dipstick. ※ Fill axle oil as much as standard. Standard between the upper limit and the lowest limit. Figure DA134. 15L7ADA134 15L7ADA135 ⑦ Assemble bracket. Bolt : Paste loctite #277. Confirm torque : 610~650kgf·cm 15L7ADA136 ⑧ Finish drive axle assembly. 15L7ADA137 3-82...
Page 125 Functional test of hydraulic apply brake ※ The following procedure describes how to test the hydraulic apply brake system only. To perform this test, use a device that allows you to observe possible leaks through oil seals and that also allows you to verify that the piston return system works correctly .
Page 126 SECTION 4 BRAKE SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8 Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10...
Page 127 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. The foot brake adopts the brake system of oil type at drive axle. kgf/cm 2 Oil pressure is generated in maximum 60 through brake oil input path of the left and right drive axle housing, this pressure allows the piston brake to advance and compresses a friction plate and a...
Page 128 3. BRAKE PEDAL AND PIPING STRUCTURE T/M control valve Drive axle 15LC7MBS01 Brake pedal Reservoir tank assembly Parking lever assembly Brake master cylinder...
Page 129 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the drive axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force.
Page 130 5. WET DISK BRAKE STRUCTURE 15L7APT20 Drive axle housing Piston brake Socket gear Square ring Plate Snap ring Square ring Friction plate Flange shaft OPERATION Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
Page 131 6. BRAKE VALVE CYLINDER STRUCTURE 25L7MBS04 Body O-ring 11 Union Piston Snap ring 12 Head Secondary cup Boot 13 Nut Primary cup Spacer 14 Rod Piston 10 Elbow 15 Cap DISASSEMBLY Remove the master cylinder boot(8) and remove the rod(14). Remove the snap ring(7) and take out the spacer(9), the piston(2), the piston primary cup(4), and piston spring(5).
Page 132 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS BRAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. PARKING BRAKE Operating force of parking lever is 35~40 ·...
Page 133 2. TROUBLESHOOTING Problem cause 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 134 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 Air vent plug on the ground and removes cap from air vent plug on wheel cylinder.
Page 135 Micro switch for parking brake (if equipped) Lever stroke 40mm ① After assembling parking brake and parking cable, put the parking brake lever ② released. Loosen the nut for parking brake plate to Micro switch ③ play up and down. Move up the plate so that the stopper can Rachet be contacted with the pin and then...
Page 136 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 137 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Steering cylinder Steering unit Hydraulic tank Pump priority valve "LS" Pump priorty valve "CF" 15L7MSS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and pipings.
Page 138 2. HYDRAULIC CIRCUIT 15L7MSS02 Hydraulic gear pump with priority valve Suction strainer Steering unit 12 Hydraulic tank Steering cylinder...
Page 139 NEUTRAL 15L7MSS03 The steering wheel is not being operated so control spool(G) does not move. The oil from hydraulic gear pump(1) enters port P of priority valve(1) which is included in the pump and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(12).
Page 140 LEFT TURN 15L7MSS04 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) within the steering unit(4) through the spool(D) of priority valve in the pump and flows to the gerotor(H).
Page 141 RIGHT TURN 15L7MSS05 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) within the steering unit(4) through the spool(D) of priority valve in the pump and flows to the gerotor(H).
Page 142 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 143 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 144 4. STEERING AXLE STRUCTURE 1-35 15LC7MSS07 Steering axle 14 Retaining ring 26 Clevis pin Knuckle-RH 15 Cover 27 Grease nipple Knuckle-LH 16 Needle bearing 28 Thrust washer Oil seal 17 Thrust bearing 29 Steering cylinder Taper roller bearing 18 Shim 30 Hex bolt Taper roller bearing 19 Thrust cap...
Page 145 TIGHTENING TORQUE AND SPECIFICATION Stroke 15LC7MSS08 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 81.7 / 55.3 Tread mm(in) 853 (33.6)
Page 146 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) 15LC-7M 1892mm (74in) 18LC-7M 1920mm (75in) 20LC-7M 1940mm (76in) Hydraulic pressure of power Remove plug from outlet port of flow divider and install oil pressure gauge.
Page 147 Problem Cause 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 148 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 149 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 150 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 151 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 152 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool.
Page 153 Take ring, bearing races and thrust bearing from sleeve and spool. The outer (Thin) bearing race can sometimes "stick" in the housing, therefore check that it has come out. 5-74(1) (10) Press out the cross pin. Use the special screw from the end cover. 5-74(2) ※...
Page 154 (12) Press the neutral position springs out of their slots in the spool. 5-75(1) (13) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (14) Screw out the plug using an 8mm hexagon socket spanner. Remove seal washers. D353SE10 (15) Unscrew the setting screw using an 8mm...
Page 155 (16) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (17) The pressure relief valve is now disassem- bled. D353SE13 5-19...
Page 156 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 5-76(1) slots.
Page 157 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 158 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) ※ Assembly pattern for standard bearings 1 Outer bearing race 2 Thrust bearing 3 Inner bearing race 4 Spool 5 Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
Page 159 (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 160 (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 161 (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 162 (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 163 (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 164 (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 ±...
Page 165 (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 166 2. STEERING CYLINDER STRUCTURE 15L7SS11 Tube assembly Gland O-ring DU bushing 10 Lock washer Piston seal Rod seal 11 Spacer Wear ring Dust wiper 12 O-ring 5-30...
Page 167 DISASSEMBLY ※ Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in a vice. Remove the gland by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube.
Page 168 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Set a special tool the cylinder, gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland assembly, and tighten it with torque 45±4.5 kgf·m(325±33lbf·ft).
Page 169 3. STEERING AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 1-35 15L7CMSS07 Steering axle 14 Retaining ring 26 Clevis pin Knuckle-RH 15 Cover 27 Grease nipple Knuckle-LH 16 Needle bearing 28 Thrust washer Oil seal 17 Thrust bearing 29 Steering cylinder Taper roller bearing 18 Shim...
Page 170 CHECK AND INSPECTION A1,A2 15LC7MSS10 unit : mm(in) Criteria Remarks Check item Standard size Repair limit 49.954~49.985 49.8 OD of shaft (1.966~1.968) (1.960) Shaft 50.1~50.3 50.5 ID of bushing (1.972~1.980) (1.988) 29.975~29.991 29.96 Replace OD of king pin (1.180~1.181) (1.179) 16.973~16.984 16.958 OD of steering cylinder pin...
Page 171 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 Tire weight part of the truck. Taper roller bearing Remove Hub cap. Castle nut Split pin Pull out split pin and remove slotted nut.
Page 172 ASSEMBLY ※ In reassembling, have all parts washed, grease applied to lubricating parts, and all expendable items such as oil seal and spring washers replaced by new ones. Perform the disassembly in reverse order. Tighten the special bolt (21) and washer (22) of king pin (20).
Page 173 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 174 SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 3A 3B 4A 4B 19MPa CF EF LIFT TILT AUX1 AUX2 15MPa 15LC7MHS02 Hydraulic gear pump with priority valve Suction strainer Main control valve Down control valve Steering unit 10 Down safety valve Steering cylinder 11 Return filter...
Page 175 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION With OPSS only 3A 3B 4A 4B Steering system 19MPa LIFT TILT AUX1 AUX2 15MPa Return line 15LC7MHS03 When the lift control lever is pulled back, the spool on the first block moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(3) through the priority valve(1) and then goes to the large chamber of lift cylinder(7) by pushing the load check valve of the spool.
Page 176 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION With OPSS only 3A 3B Steering system 19MPa LIFT TILT AUX1 AUX2 15MPa Return line 15LC7MHS04 When the lift control lever is pushed forward, the spool on the first block moves to lower position. The work port(1A) and the small and the large chamber of lift cylinder are connected to the return passage, so the fork will be lowered due to its own weight.
Page 177 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION With OPSS only 3A 3B Steering system 19MPa LIFT TILT AUX1 AUX2 15MPa Return line 15LC7MHS05 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
Page 178 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION With OPSS only 3A 3B 4A 4B Steering system 19MPa LIFT TILT AUX1 AUX2 15MPa Return line 15LC7MHS06 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
Page 179 2. HYDRAULIC GEAR PUMP STRUCTURE 15L7MHS06A Housing 11 Back-up ring 21 Spring 22 Plug Body 12 Side plate Body-priority v/v 13 Oil seal 23 O-ring Bushing 14 Snap ring 24 Adjust screw O-ring 15 Bold 25 O-ring 16 Washer 26 Bolt 27 Poppet Drive gear 17 Plug...
Page 180 3. MAIN CONTROL VALVE STRUCTURE (4 SPOOL - TRAVEL WITH MAST OPSS) 15L7HS57 Port name Size Inlet port 7/8-14UNF Outlet port 7/8-14UNF Work port 3/4-16UNF 11 Inlet block assy 15 Auxiliary block assy 12 Lift block assy 16 Long bolt 13 Tilt block assy 17 Nut 14 Outlet block assy...
Page 181 INLET SECTION OPERATION (TRAVEL WITH MAST OPSS) Operation INLET WORK 19MPa SECTION SOL V/V 15L7HS58 When the operator is not seated, the solenoid valve is in the normally open position, which helps divert flow from the pump directly to the outlet to tank. In this manner, oil pressure and flow are not able to reach the portions of the valve which control the vehicle functions, so their operation is prevented.
Page 182 LIFT SECTION OPERATION (TRAVEL WITH MAST OPSS) Lift position LIFT NEEDLE LIFT LOCK V/V SOL V/V "B" 15L7HS59 When the operator shifts the lever backwards, the spool is extended out of the valve, and this opens the internal fluid passages that lift the mast. Oil flows through the high pressure parallel cavity, past the load check valve, through the spool metering notches, past the lift lock check valve, and to the head side of the lift cylinder.
Page 183 Lower position LIFT NEEDLE LIFT LOCK V/V SOL V/V "B" 15L7HS60 When the seated operator shifts the lever forwards, the spool retracts into the valve, and the oil is directed from the cylinder, past the lift lock check valve, past the spool metering notches, and to the common tank cavity.
Page 184 Secondary lower position LIFT NEEDLE V/V NEEDLE LIFT LOCK V/V SOL V/V "B" 15L7HS61 Secondary lowering method : A secondary lowering method is available in the event of the loss of engine power that is needed to energize the normally closed solenoid valve. ·...
Page 185 OUTLET SECTION OPERATION Operation OUTLET 150k 15L7HS62 The outlet section contains the tank port and the secondary relief valve (with built-in anti-cavitation feature). 6-12...
Page 186 4. LIFT CYLINDER D155HS13 Tube assembly Wear ring 11 O-ring Retaining ring 12 Guide Piston Gland 13 Du bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 5. TILT CYLINDER 19,20,21 13,14 18 17 16 3 4 6 5 11,12 15LC7MHS14...
Page 187 6. FREE LIFT CYLINDER D155HS15 Tube assembly Check valve 11 Dust wiper Ring retaining 12 Snap ring Piston Set screw 13 O-ring Piston seal Gland 14 Back up ring Wear ring 10 Rod seal 6-14...
Page 188 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1m from ground. Wait for 10 minutes and measure hydraulic drift(amount forks move down and amount mast tilts forward). ·Check condition 15LC7MHS18 - Hydraulic oil : Normal operating temp...
Page 189 2. TROUBLESHOOTING SYSTEM Problem Cause 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 190 HYDRAULIC GEAR PUMP Problem Cause 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 191 LIFT CYLINDER Problem Cause 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 192 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY CLAMPING PUMP Clamping pump in a vice with pump shaft facing up. (Do not chuck the aluminum parts such as body and housing.) Mark V by permanent marker pen. This will assure proper reassembly. PUMP101 HOUSING Loosen 8 bolts and remove housing.
Page 193 BODY AND REAR COVER Loosen the vice and remove body and bronze side plate from rear cover. Remove O-ring from rear cover. Disassemble pin from body. PUMP105 PRIORITY VALVE Loosen the plug at the side of drive gear, be careful not to bounce out spring. Take out spring.
Page 194 2. ASSEMBLY PREPARATION Clean all parts and dry them with compressed air thoroughly. Check the permanent mark. Apply grease O-ring, oil seal, E-type ring and side plate lightly. PRIORITY VALVE Suction Discharge · Relief valve : if disassembled Fit O-ring on plug and adjust screw. Tighten plug for port of gage mounting.
Page 195 REAR COVER AND BODY Assemble pin into body. Suction Discharge Assemble O-ring on the groove of rear cover. Place the bronze face of side plate contact with gear on rear cover. Insert side plate into body and adjust pin by pressing after adjusting pin hole of rear PUMP108 cover and pin of body.
Page 196 HOUSING Press fit oil seal with same direction as drawing carefully and fit snap ring. Fit O-ring into groove of housing. Insert drive gear into housing and combine housing with body pressing lightly after confirmed pin position. Tighten bolt with washer zigzag lightly, be careful not to leave O-ring its place.
Page 197 The formal Bills of Material, descriptions, and views are found in the attached documentation. ⑤ Additional auxiliary valve sections may be added to the main control valve in a similar manner as indicated below, as approved by the Hyundai. Block subassembly 2.4~2.9kgf m 15L7HS31 ①...
Page 198 Inlet section LIFT LOAD CHECK V/V SOLENOID V/V COIL SPRING LOAD CHECK SOLENOID V/V CATRIDGE (NORMALLY CLOSED) PLUG NEEDLE VALVE MAIN RELIEF VALVE SEAL DUST WIPER SOLENOID V/V CATRIDGE (NORMALLY OPEN) SOLENOID V/V COIL SECONDARY RELIEF VALVE SEAL PLATE 15L7HS34 ①...
Page 199 Lift section LIFT LOAD CHECK V/V SOLENOID V/V COIL SPRING LOAD CHECK SOLENOID V/V CATRIDGE (NORMALLY CLOSED) PLUG NEEDLE VALVE MAIN RELIEF VALVE SEAL DUST WIPER SOLENOID V/V CATRIDGE (NORMALLY OPEN) SOLENOID V/V COIL SECONDARY RELIEF VALVE SEAL PLATE 15L7HS34 ①...
Page 200 Tilt section LIFT LOAD CHECK V/V SOLENOID V/V COIL SPRING LOAD CHECK SOLENOID V/V CATRIDGE (NORMALLY CLOSED) PLUG NEEDLE VALVE MAIN RELIEF VALVE SEAL DUST WIPER SOLENOID V/V CATRIDGE (NORMALLY OPEN) SOLENOID V/V COIL SECONDARY RELIEF VALVE SEAL PLATE 15L7HS34 ①...
Page 201 Auxiliary sections LIFT LOAD CHECK V/V SOLENOID V/V COIL SPRING LOAD CHECK SOLENOID V/V CATRIDGE (NORMALLY CLOSED) PLUG NEEDLE VALVE MAIN RELIEF VALVE SEAL DUST WIPER SOLENOID V/V CATRIDGE (NORMALLY OPEN) SOLENOID V/V COIL SECONDARY RELIEF VALVE SEAL PLATE 15L7HS34 (Same procedure for all aux sections, but spool assembly components may vary) ①...
Page 202 DISASSEMBLY INSTRUCTIONS General ① Subassemblies (such as relief valves, check valves, and spools) may be removed without having to loosen the tie rods and disassembling the entire valve. ② Disassemble the valve sections on a flat working surface. ③ Ensure that the disassembly area will be clean and free of contamination. ④...
Page 203 4. LIFT CYLINDER STRUCTURE · I.D×O.D×Stroke : 45×55×1245mm (1.7×2.2×49~108in) · Rod O.D : 35mm (1.4 in) D155HS16 Tube assy Wear ring 11 O-ring Rod assy Retaining ring 12 Guide Piston Gland 13 Du bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring...
Page 204 DISASSEMBLY Hold the cylinder tube in a vice, loosen the Guide 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 205 5. TILT CYLINDER STRUCTURE I.D O.D Stroke : 70 80 85mm (2.8 3.1 3.3in) Rod O.D : 30mm(1.2in) 15LC7MHS21 Tube assy Dust wiper 16 Rod eye 10 DU bushing 17 Spherical bearing Piston 11 Rod seal 18 Grease nipple Piston seal 12 Back up ring 19 Hex bolt Wear ring...
Page 206 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 207 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 208 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 13 14 15 16 15LC7MEL01 Battery Rear lamp 15 Switch assembly Flasher lamp Combination lamp 16 Fuse box Work lamp 10 Beacon lamp 17 Flasher unit Combination switch 11 Forward-reverse lever 18 OPSS unit Horn assembly 12 Operating panel 19 Buzzer...
Page 209 GROUP 2 ELECTRICAL CIRCUIT CR-11 310-R 210-G G1-B FLASHER UNIT CR-5 220-L 320-Y 350-Gr G1-B RELAY NEUTRAL CR-13 FUEL SENDER(LPG) CN-24 330-G CD-29 230-Br 450-W 360-G RH SPEAKER G1-B S/W TM TEMP CN-23 RELAY HEADLAMP CR-50 CN-2 420-Y LH SPEAKER 322-W 205-R CL-1...
Page 210 GROUP 3 COMPONENT SPECIFICATION Specification Remark Part name Battery 12V, CCA : 550A 5HR : 48AH CMF 60(230×168×220) 12V, 55W Working lamp 12V, 10W License lamp 12V, 21W(T/S) 12V, 10W(Back) Combination lamp 12V, 5W (Tail) 12V, 21W(Stop) 12V, 55W Head lamp 12V, 23/8W Flasher lamp 12V, (23W+23W)×2+3W×2...
Page 211 GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Dashboard harness-frame harness) 1743059-2 1743062-2 CN-4 I/conn (Dashboard harness-head guard harness) MG610346 MG640348 CN-5 Support harness-RH S810-004201 CN-6 PACKARD Fuel system interface connection-1 15326863 CN-8 PACKARD Engine fuel system interface connection-2...
Page 212 Connector part No. Connector No. of Type Destination number Female Male Lamp Head lamp S822-014000 S822-114000 CL-3 CL-7 Beacon lamp S822-014000 S822-114000 CL-15 DAEDONG Combination lamp-LH 110-6PR CL-16 DAEDONG Combination lamp-RH 110-6PR CL-17 Flasher lamp S822-014000 S822-114000 CL-21 License lamp ST750018-3 ST750036-3 CL-23...
Page 213 GROUP 5 TROUBLESHOOTING Trouble symptom Probable 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 ·Charge lamp defective.
Page 214 MOBILE ENGINE LPG FUEL SYSTEM SCHEMATIC Liquid Fuel Supply Fuel Supply Vapor Fuel Supply Filtered Air Regulated Fuel Pressure Fuel Air & Fuel Shut-Off Exhaust 2-STAGE CONVERTOR Pressure Feedback IEPR / Can+ DEPR Air Cleaner Mixer Throttle Speed Control TMAP Crank Engine Timing...
Page 215 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(12,13,14,15)] Start switch[CS-2(3)] Fuse box[CN-36] (No.1) Cab[CN-17(1)]...
Page 216 POWER CIRCUIT CL-16 CS-2 CN-36 CN-17 HORN/STOP LAMP TURN LAMP OPS-UNIT 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR (CABIN) - ACC TRAVEL 4 BR - ACC SPEED CONTROL 2 R2 R/COMBI RH - ST START KEY CLUSTER CL-15 WORK/BEACON LAMP...
Page 217 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] I/conn[CN-1(12,13,14,15)] Start switch[CS-2(3)] ※The 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[CN-36(5)] ILLUM relay[CR-15(30)] Combi switch[CS-12(5)] Headlamp relay[CR-13(30)] When start key switch is START position...
Page 218 STARTING CIRCUIT CS-2 CN-36 HORN/STOP LAMP TURN LAMP CR-5 OPS-UNIT 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR - ACC TRAVEL 4 BR - ACC SPEED CONTROL 2 R2 - ST START KEY CLUSTER RELAY NEUTRAL WORK/BEACON LAMP FOR CABIN OPSS SYSTEM...
Page 219 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10...
Page 220 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) TILT CYLINDER LIFT CYLINDER CARRIAGE 15L7MS01 Outer mast Chain sheave 13 Clamp Inner mast Chain 14 Back up liner Roller Anchor bolt 15 Shim(0.5, 1.0t) Tilt cylinder pin 10 Roller 16 Shim(0.5, 1.0t) Mast support cap 11 Retaining ring...
Page 221 2. 3 STAGE MAST(TF MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE 15L7MS02 Outer mast Bushing 13 Clamp Middle mast Chain sheave 14 Back up liner Inner mast Chain 15 Shim(0.5, 0.1Ton) Roller 10 Anchor bolt 16 Shim(0.5, 0.1Ton) Tilt cylinder pin 11 Retaining ring 17 Sheave bracket...
Page 222 3. CARRIAGE, BACKREST AND FORK 15L7MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...
Page 223 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. ℓ=900mm(35.4in) EX : mm(in) STD Fork assy Applicable model Standard Limit 64FY-12030 15/18LC-7M 35(1.4) 32(1.3) 64HM-11010 20LC-7M 40(1.6)
Page 224 2. TROUBLESHOOTING MAST Problem Cause 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 225 FORKS Problem Cause 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 226 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V 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 227 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 15L7MS06...
Page 228 CARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, lower rollers after loosen the adjust screws from the side rollers. Shift the carriage to one side to bring the roller into contact with the inner mast, and measure the clearance between the roller side face and mast at...
Page 229 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are Knob approximately 25mm(1inch) from the floor. Pull the knob up and slide forks, one by one, toward the center of the carriage Spring where a notch has been cut in the bottom plate for easy fork removal.
Page 230 SIDE ROLLER Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. ※...
Page 231 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) ① Remove the carriage assembly and move them to one side. ② Loosen and remove hexagon bolts and washers securing lift cylinders to inner Inner mast. mast Stud ③ Loosen and remove hexagon bolts and bolt nuts securing lift cylinders to inner mast.
Page 232 3 stage mast(TF mast) ① Remove the carriage assembly and move it to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. ③ Loosen and remove hexagon bolt and special washers securing lift cylinders to middle mast.
Page 233 ELEVATING MAST Inner mast (V 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 234 CHAIN Chain sheave(V 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 235 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 236 ② 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 237 ⑧ 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 238 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 Adjustment 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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Hyundai 15LC-7M Operating Manual

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