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Hyundai 15LC-7A Operating Manual
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Hyundai 15LC-7A 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-15
Group 3 Test and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23
SECTION 4 BRAKE SYSTEM
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-26
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Group 4 Connector Destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
CONTENTS

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Summary of Contents for Hyundai 15LC-7A

  • 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( 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 = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
  • Page 8 m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
  • Page 11 SECTION 1 GENERAL Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13...
  • Page 12 GROUP 1 SAFETY HINTS 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. 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 15LC7AGE01 Mast Forks 12 Bonnet Lift chain Overhead guard 13 Counterweight Lift cylinder Turn signal lamp 14 Rear wheel Backrest 10 Head lamp 15 Front wheel Tilt cylinder 11 Operator's seat 16 Rear combination lamp Carriage...
  • Page 17 2. SPECIFICATIONS 15LC7SP01 Model Unit 15LC-7A 18LC-7A 20LC-7A Capacity 1500 1750 2000 Load center Weight(Unloaded) 2710 2920 3080 Lifting height 3325 Free lift Lifting speed(Unload/Load) Fork mm/sec 680/650 Lowering speed(Unload/Load) mm/sec 450/500 L W T L,W,T 900 100 35 900 100 40 Tilt angle (Forward/Backward) C/C’...
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS 5LC/18LC/20LC-7A ENGINE Item Specification Unit Model HYUNDAI beta, L4GC 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) 82 93.5(3.2 3.7)
  • Page 19 TEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev Max. input pressure 17.5 Back pressure Input torque 1.5 0.2 POWER TRAIN DEVICES Item Specification Model KAPEC 280-D1 Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type...
  • Page 20 4. TIGHTENING TORQUE OF MAJOR COMPONENTS Item Size kgf m lbf ft Engine mounting bolt, nut Engine M 8 1.25 Radiator mounting bolt, nut 2.5 0.5 18.1 3.6 Torque converter mounting bolt M10 1.25 6.9 1.4 50 10 M10 1.5 MCV mounting bolt, nut 4.0 1.4 29 3.6...
  • 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 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7...
  • Page 22 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat kgf m lbf ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" IPE AND HOSE(ORFS TYPE) Thread size(UNF) Width across flat mm kgf m lbf ft 9/16-18 28.9 11/16-16 36.2 13/16-16 68.7 1-3/16-12...
  • Page 23 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Capacity (U.S.gal) Ambient temperature Service Kind of point fluid 1.5~2.0 (-4) (14) (32) (50) (68) (86) (104) Engine oil Engine oil SAE 10W-30(API SL class or better) (1.0) 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 15 16 17 15LC7ARE01 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 Lower the fork carriage until the forks are Knob approximately 25mm(1in) from the floor. Spring Turn knob up and slide one fork at a time toward the center of the carriage where a notch has been cut in the bottom plate for easy removal.
  • Page 28 While supporting lift chains, remove the nuts and split pin from the chain anchors Lift chain of stationary upright. Outer mast Split pin 20D7RE05 Pull the chains out of the sheaves and drape them over the front of the carriage. 15L7RE06 Slowly raise inner mast upright until mast clears top of fork carriage.
  • Page 29 Piping Remove the return hoses and clamps attached to the cylinder. Remove the return hoses from the connector. Band clamp Hose Remove hose assembly, connector, clamp Return down safety valve from the lift cylinder. hose Disconnect hose assembly from the flow regulator.
  • Page 30 Inner mast 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 Attach a crane to the stay at the top of the outer mast, and raise enough to sustain jacked up machine.
  • 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 support cap 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 mast to drive axle unit.
  • Page 32 2. POWER TRAIN ASSEMBLY REMOVAL B153RE00 Mast Refer to section on mast(Page 2-2). Brake piping and T/M cooling piping Disconnect the brake pipes and T/M cooling pipes from powerline assembly. L15C5RE13 Parking brake cable Disconnect parking brake cable from the Parking brake wheel brake assembly.
  • Page 33 Powerline assembly Crane Mounting bolt Attach a crane to the tilt cylinder notches on the dashboard and raise the machine enough for truck to slide under powerline Powerline assembly assembly. Put the block between the truck and Frame powerline assembly. Support cap Truck Remove drive axle mounting bolts from...
  • Page 34 3. ENGINE Lever the torque converter, transmission and drive axle inside the frame, the remove the engine assembly. REMOVAL Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and Crane flasher lamp on the stay of the overhead guard and then raise it together with the bonnet.
  • Page 35 Engine accessory Remove all wiring harnesses, cables and hoses among the engine and, the Engine dashboard and frame. Wiring harness to alternator and starter. Wiring harness for oil pressure and engine water, temperature gauges. Hoses to fuel tank and air cleaner. Exhaust pipe.
  • Page 36 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 37 4. WHEEL BRAKE REMOVAL Front wheel Put a block under the mast and tilt forward, or jack up the bottom of the frame to raise the front wheels off the ground, then loosen the hub nuts to remove wheels. Hub nut 15LC7RE24 Brake, drum assembly The oil seal inside the hub acts as a seal...
  • Page 38 Wipe the inside of the brake drum clean, coat the lip of the seal with grease, and assemble the brake and drum assembly. Adjust a spring balance to the hub bolt Spring balance and adjust the nut to give a starting force of 12 to 20kgf(27~44lbf).
  • Page 39 15LC7ARE29 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-7A : 810kg(1786lb) 18LC-7A : 1005kg(2216lb) 20LC-7A : 1115kg(2458lb) 2-14...
  • Page 40 Rear wheels Before removing rear wheels, lift up the rear side with a crane or jack up. Rear wheel Remove cap, split pin and then loosen castle nut. Taper Take out rear wheel assembly with taper roller roller bearing and oil seal. bearing Frame Castle nut...
  • Page 41 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. 20D7RE28 Hose Drain hydraulic oil in the hoses and cylinder before removing them. Loosen connector and then disconnect the hoses. 15L7RE29 Mounting bolt Put a block under the steering axle, support on a truck, and raise the frame...
  • Page 42 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-15 Group 3 Test and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19 Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23...
  • Page 43 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN DIAGRAM The TORQFLOW transmission uses one-speed forward and one-speed reverse transmission. The torque converter, differential, and final drives are strengthened to match them with increased engine output and machine traveling performance. 15LC7APT26 Brake drum Drive axle...
  • Page 44 2. INSTALLATION VIEW L15C5PT05 Control valve Oil filter Temperature sender Dipstick Air breather...
  • Page 45 3. TRANSMISSION TORQUE CONVERTER The torque converter is directly bolted to the engine flywheel housing. Engine output is delivered from the flywheel to the flexible plate. Structure Ball bearing Output pressure adjusting valve spring Gear pump assembly Inlet relief valve spring Converter Input guide D153PT27...
  • Page 46 Hydraulic circuit Torque converter assy Torque converter Outlet port Inlet port To control valve Inlet pressure Outlet pressure detector port detector port Main relief valve To cooler Gear pump Drain Drain Strainer L15C3TC11 T/C input pressure T/C output pressure measurement port(PT 1/4) measurement port(PT 1/4) Drain holes Torque converter...
  • Page 47 TORQFLOW TRANSMISSION SECTION A - A Hydraulic clutch Gear 2.744 2.818 ratio Center line Gear forward of engine Hypoid pinion Clutch Hypoid pinion Gear forward Gear Center line of differential D153PT01 Torque converter Hydraulic clutch Hypoid gear set Pump Forward shaft 10 Differential Torque converter housing Forward gear...
  • Page 48 OPERATION The torque converter consists of three elements; an impeller wheel connected to the input side and a turbine wheel and stator wheel connected to the output side. The torque converter is filled with oil. The engine rotates the impeller wheel and the impeller blade will give the fluid energy. Oil flows out along the path by centrifugal force, and this energy will give the turbine wheel torque.
  • Page 49 TRANSMISSION OPERATING MODES Forward INPUT OUTPUT D153PT02 In forward the torque converter is turned by the engine. The torque converter turbine shaft turns the forward/reverse clutch pack shaft(1) and clutch packs at turbine speed. The piston in the forward clutch pack(2) is pressurized by transmission fluid from the control valve. The piston applies pressure to the discs in the clutch pack, causing the clutch to engage.
  • Page 50 Reverse INPUT OUTPUT D153PT04 In reverse the torque converter is turned by the engine. The torque converter turbine shaft turns the forward/reverse clutch pack shaft(1) and clutch packs. The piston in the reverse clutch pack(2) is pressurized by transmission fluid from the control valve. The piston applies pressure to the discs in the reverse clutch pack, causing the clutch to engage.
  • Page 51 4. CONTROL VALVE STRUCTURE (From COOLER) (To COOLER) SECTION A-A D153PT28 Body 14 Spring 27 Snap ring Plug 15 Plug 28 Valve Piston 16 Piston 29 Spring Valve 17 Stopper 30 Stopper Stopper 18 Spring 31 Nut Valve 19 Spring 32 Screw Plate 20 O-ring...
  • Page 52 HYDRAULIC CIRCUIT Reverse clutch Forward clutch Control valve Directional Valve Accumulator valve Pedal Inching valve Main relief Engine valve 13.2 cc/rev 10.8~14.9 kgf/cm To torque converter D153PT11 OPERATION The control valve mainly consists of the main relief valve, inching valve, accumulator valve and directional valve.
  • Page 53 5. HYDRAULIC CLUTCH STRUCTURE(Reverse and forward 1st) Center line of Hydraulic clutch Center line of engine Clutch Hypoid pinion D153PT12 T/Plug 12 Spacer 23 Spring Seal ring 13 Ring 24 Washer Snap ring 14 Disc 25 Snap ring Spacer 15 Plate 26 Gear Spring 16 Piston...
  • Page 54 CLUTCH PACKS The clutch packs have a driving side and a driven side for each gear selection, a total of two(1 forward, 1 reverse). One clutch pack assembly has two selections on the same shaft, forward and reverse, and the clutches are back to back with a spur gear in the middle. The forward reverse clutch pack is driven by the turbine shaft of the torque converter.
  • Page 55 OPERATION Forward Reverse Reverse (From control valve) From T/M cooler Seal ling Forward (From control valve) D153PT24 When a gear is selected by the operator, the following happens. The clutch pack shaft is being driven by the torque converter. The spur gear and clutch pack body is attached to shaft and rotates with it. The clutch piston is pressurized by transmission fluid from the control valve.
  • Page 56 6. DRIVE AXLE STRUCTURE L15C5-PT25 Housing 12 Hub drum 21 Bolt 13 Stud bolt 22 Oil seal Plug 14 Retainer 23 Bolt Plug 15 O-ring 24 Spring washer O-ring 16 Bearing 25 Brake assy(RH) 17 Oil seal 26 Brake assy(LH) Gasket 18 Axle tube 27 Bolt...
  • Page 57 G G ROUP 2 TROUBLESHOOTING Problem Probable cause Remedy . Excessive oil temperature rise Improper oil level. Check oil level. Add or drain oil as 1) Torque converter necessary. Impeller interfering with surroundings. After draining oil from oil tank and transmission, check and replace interfering parts.
  • Page 58 Problem Probable cause Remedy 3. Low output power 1) Torque converter Insufficient hydraulic pressure : Low oil level. Check oil level and add oil Air sucked in. Check joints and pipes. If necessary, retighten joint or replace packing. Oil filter clogging. Check and replace Oil pump worn.
  • Page 59 Problem Probable cause Remedy 4. Unusual oil pressure 1) Oil pressure is high Control valve malfunctioning. (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair. Cold weather. (high oil viscosity) When atmospheric temp is below freezing point(when normal oil pressure is recovered if heated to...
  • Page 60 Problem Probable cause Remedy . Power is not transmitted Low oil level. Check oil level and add oil. 2) Transmission Inching valve and link lever improper- Check measure and adjust. ly positioned. Forward/reverse spool and link lever Check and adjust. improperly positioned.
  • Page 61 This check raises the temperature of the oil in the torque converter, so do not run this test for a long period. Model Stall speed HYUNDAI beta 1680 100rpm 4. DIFFERENTIAL Fitting differential assembly Install the differential assembly and fit adjust screw gear(1).
  • Page 62 To adjust the backlash, loosen one adjustment screw gear 1 notch and tighten the other screw gear 1 notch. Gradually move the differential case in this way, and watch the indicator of the dial gauge to adjust to the correct value. Backlash between ring gear and pinion gear : 0.18~0.23mm(0.007~0.009in).
  • Page 63 If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows. (See next page for details) Adjust shims at pinion shaft. Adjust backlash of bevel gear. Adjust backlash of bevel gear side bearing. Tooth contact should be checked with no load on the bevel pinion.
  • Page 64 Increase the shim thickness at the pinion shaft to move the pinion in direction A. Then move the bevel gear away from the pinion gear in direction B. Adjust the backlash again. L15C3TH06 3-22...
  • Page 65 GROUP 4 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY Disassemble torque converter assembly Drain the transmission fluid and disconn- ect the torque converter assembly from the engine and the transmission. Disassemble input side of torque converter Remove the input plate bolts and the input L15C3TC01 plate, input guide, and O-rings.
  • Page 66 Extract pump Remove the inner turbine shaft snap ring and all bolts holding the pump. Tool(s) required : 12mm socket wrench L15C3TC05 Extract turbine shaft Remove the two snap rings. Tool(s) required : 12mm socket wrench L15C3TC06 Extract the turbine shaft. L15C3TC07 3-24...
  • Page 67 Extract valves Remove the two plugs. Tool(s) required : 24mm wrench. L15C3TC08 Remove the springs and pistons. Level the two sets-the springs especially- so that they do not get confused. Tool(s) required : 24mm wrench. L15C3TC09 Disassemble oil pump Remove the O-ring and phillips screws and disassemble the pump.
  • Page 68 ASSEMBLY The assembly procedure is the reverse of the disassembly procedure above, but requires additional care as noted below. Assembly oil pump Return the gears and stator support to their positions before disassembly. Check the gear action. If the gears do not rotate smoothly, disassemble the pump and start over.
  • Page 69 TORQUE CONVERTER ASSEMBLY DRAWING L15C3TC12 T/C input pressure T/C output pressure measurement port(PT 1/4) measurement port(PT 1/4) Drain holes Torque converter input To cooler Pump intake Pump output L255PT24 3-27...
  • Page 70 CHECK AND INSPECTION Turbine Impeller Torque converter Stator Input plate Gear pump H, I Turbine shaft Housing Engine side Transmission side L15C3TC14 L15C3TC15 3-28...
  • Page 71 Unit : mm(in), kg(lb) Criteria Check item Remedy Standard size Repair limit Clearance between piston 0.015-0.025 0.065 Replace and housing hole (0.0006-0.001) (0.0025) piston Free 89.9 87.3 length (3.54) (3.43) Torque converter Installed inlet relief valve Torque length (2.48) (2.48) spring converter Installed...
  • Page 72 AINTENANCE STANDARDS Hydraulic pressure Location Pressure (kgf/cm Cracking pressure (kgf/cm Torque converter input 3 ~ 7 Torque converter output 2 ~ 5.5 Cracking pressure means the pressure at which the valve begins to open. Tightening torques Tightening torque in kgf m(lbf ft) Location Thread specifications Target...
  • Page 73 2. TRANSMISSION Keep all parts in order as disassembly progresses. Take care to properly identify each part and its order of removal. If necessary, keep notes and put markings on parts using a non-destructive marker such as a felt-tipped pen. ISASSEMBLY Differential, torque converter, control valve...
  • Page 74 Pinion shaft Remove pinion shaft bolt(1). Fit a dolly block(copper rod) and tap the pinion shaft with a hammer to remove. L15C3TM03 Seal ring cap Remove bolt(2) and fit the bolt to the tapped hole. Remove the seal ring cap. Pull out the cap straight without twisting it.
  • Page 75 Disassembly of components of clutch pack assembly The number shows the sequence of disassembly. L15C3CL01 Sealing 13 Spring 25 Snap ring Spring 14 Piston 26 Disc Spacer 15 Sealing 27 Plate Washer 16 Sealing 28 Ring Gear 17 Needle bearing 29 Ball Spacer 18 Shaft assembly...
  • Page 76 ASSEMBLY Cleanliness is of extreme importance in the repair and overhaul of this assembly. Perform all disassembly work in a clean area. Overhaul the transaxle only in a clean, dust-free location, using clean tools and equipment. Dirt or grit will damage the highly-machined surfaces and result in premature failure of components.
  • Page 77 Idler shaft assembly Profit gear(1) in the case. Fit bearing(2) on the idler shaft and install in the case. Fix bearing(3) fix it with plate(4) and bolt (5). Tightening torque : 2.8 ~ 3.5kgf m (20 ~25lbf ft) L15C3TM09 Clutch pack assembly Fit bearing(1) in the case.
  • Page 78 TORQUE FLOW TRANSMISSION ASSEMBLY DRAWING Loctite #271 (screw hole side) Loctite #271(screw hole side) G2-L1(Lip portion) (Loctite #271 : Screw hole side) Match the stamps on the 18 ~ 20 kgf m (130 ~ 144lbf ft) inner and outer rings L15C3TM13 3-36...
  • Page 79 CHECK AND INSPECTION E2, H2 E1, H1 L15C3TM14 3-37...
  • Page 80 Unit : mm(in) Criteria Check item Remedy Standard size Repair limit 3.13-3.27 Thickness of drive plate (0.123-0.129) (0.114) Plate Replace 2.6(0.102) 2.90-3.05 Thickness of driven plate (Oil groove depth (0.114-0.120) Min0.2)(0.008) Clearance of abutment when 0.36-0.56 piston is inserted (0.014-0.002) Replace 0.15-0.35 Sealing...
  • Page 81 3. DIFFERENTIAL STRUCTURE TRANSMISSION Loctite #271 18~20 kgf m (130~144 lbf ft) 5~7.5 kgf m (36~54 lbf ft) Loctite #271(Hole side) (Run out : Max, 0.1 with dial guage reading) Adjust with item 12 9~16 kgf m (65~116 lbf ft) Loctite #271(Hole side) Starting torque : 35~43.5 kgf m (253~325 lbf ft)
  • Page 82 DIFFERENTIAL ASSEMBLY DRAWING Backlash : 0.18-0.23 mm (0.007-0.009 in) Runout is Max 0.1 5-7.5 kgf m (36-54.4 lbf ft) Loctite#271(screw portion) Starting torque : 3.1-5.7 kgf m Loctite#271(screw portion) (22-41 lbf ft) 9-16 kgf m (65.3-116 lbf ft) Loctite#271(screw hole side) Loctite#271(screw hole side) 0.8-1.2 kgf m 18-20 kgf m...
  • Page 83 CHECK AND INSPECTION L15C3DF07 Unit : mm(in) Criteria Check item Remedy Standard size Repair limit Differential pinion gear and Scratches on the Replace (Replace bevel side gear teeth gear and pinion) 19.959-19.980 19.75 O.D of spider (0.785-0.787) (0.777) 20.0-20.021 20.1 I.D of differential pinion gear (0.787-0.788) (0.791)
  • Page 84 4. DRIVE AXLE DISASSEMBLY AND ASSEMBLY 15~21 kgf m (108~152 lbf ft) Loctite #1215 6~8kgf m All face of (43~58 lbf ft) 11~13 kgf m (80~94 lbf ft) Starting torque 0.6~1.5 kgf m (4.3~10.8 lbf ft) 6~8 kgf m (43~58 lbf ft) L15C5DA01 Housing 12 Hub drum...
  • Page 85 ASSEMBLY OF DRIVE AXLE 6-8 kgf m (43-58 lbf ft) Three Bond #1215 Loctite #271 (All face of flange) Starting torque : 0.6-1.5 kgf m (4.3-10.8 lbf ft) 6-8 kgf m (43-58 lbf ft) Loctite #271 G2,L1 11-13 kgf m (79.2-93.6 lbf ft) G2,L1 Grease by 1/2-2/3 of space...
  • Page 86 INSTALLATION Perform installation in the reverse order to removal, paying attention to the following. Tightening torque converter case mounting bolt. Mounting bolt Tightening torque : 5.5~8.3kgf m (39.8~60lbf ft) 15LC7TIN01 Tightening flexible plate mounting bolt. Tightening torque : 2.7~4.1kgf m (19.5~29.7lbf ft) 15LC7TIN02 Pedal assembly brake piping.
  • Page 87 SECTION 4 BRAKE SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6 Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9...
  • Page 88 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 89 3. BRAKE PEDAL AND PIPING The brake system provides two systems, a foot brake and a parking brake. In the foot brake system, the oil pressure which is generated in the master cylinder when the brake pedal is depressed is transmitted to the wheel cylinders. The piston of the wheel cylinder presses the brake shoes and then moves outward causing contact with the drums and braking force is obtained.
  • Page 90 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 are applied.
  • Page 91 5. WHEEL BRAKE STRUCTURE The wheel brake assembly mounts to the flange on the drive axle housing casting and is basically contained within the hub assembly. The inside of the hub is machined and acts as the brake drum. 15LC7BS03 Back plate-LH/RH Shoe hole down spring 15 Adjuster guide...
  • Page 92 6. BRAKE MASTER CYLINDER 15LC7BS04 Body Spring 11 Union Piston Spring seat 12 Union bolt Primary cup Plate 13 Washer Secondary cup Retaining ring 14 Cap Spacer 10 Boot 15 Cap DISASSEMBLY Remove the master cylinder boot(10). Take out the retaining ring(9), plate(8) and secondary cup(4). Take out the piston(2), spacer(5), primary cup(3), spring seat(7) and spring(6).
  • Page 93 6. BRAKE MASTER CYLINDER 6. BRAKE MASTER CYLINDER STRUCTURE STRUCTURE 15LC7BS04 Body Spring 11 Union Piston Spring seat 12 Union bolt Primary cup Plate 13 Washer Secondary cup Retaining ring 14 Cap Spacer 10 Boot 15 Cap DISASSEMBLY DISASSEMBLY Remove the master cylinder boot(10). Take out the retaining ring(9), plate(8) and secondary cup(4).
  • Page 94 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS B B RAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal is depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. WHEEL BRAKE Compact wheel base chassis Measure lining at point with most wear, and check that lining thickness is at least 2.0mm(0.08in).
  • Page 95 . TROUBLESHOOTING Problem cause Remedy Insufficient braking force Hydraulic system leaks oil. Repair and add oil. Hydraulic system leaks air. Bleed air. Lining surface soiled with water or oil. Clean or replace. Lining surface roughened or in poor Repair by polishing or replace. contact with drum.
  • Page 96 Problem cause Remedy Brake squeaks Lining surface roughened. Repair by polishing or replace. Lining worn. Replace. Poor shoe to lining contact. Replace. Excessively large friction between Clean and apply brake grease. shoe and back plate. Foreign matter on drum sliding surfa- Clean Drum sliding surface damaged or di- Replace.
  • Page 97 GROUP 3 TESTS AND ADJUSTMENTS 1. ADJUSTMENT OF WHEEL BRAKE Adjust with engine stopped. Jack up truck. Extend adjustment screw by Adjustment wheel clicking adjustment wheel teeth with a Lever screwdriver until wheel(mounted on brake drum being adjusted) offers a light resistance when turned by hand.
  • Page 98 3. ADJUSTMENT OF PEDAL 1 1 ) BRAKE PEDAL 10~15mm Play Adjust with rod of master cylinder. Play : 10~15mm (0.4~0.6 in) Pedal height 174-184mm ( ( 2) Pedal height from floor plate Adjust with stopper bolt. Floor plate Pedal height : 174~184mm (6.9~7.2 in) 15LC7BS15 Micro switch for parking brake Lever stroke 12.1...
  • Page 99 INCHING PEDAL Pedal height from floor plate Inching stroke Adjust with stopper bolt. 15~35mm Pedal height : 174~184mm (6.9~7.2 in) Adjust bolt so that the brake pedal Pedal height 174-184mm interconnects with inching pedal at inching pedal stroke 15~35mm (0.6~1.4in) Floor plate 15LC7BS12 Inching spool protrusion...
  • Page 100 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 101 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Priority valve Steering cylinder Steering unit Hydraulic tank 15LC7SS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and pipings. The steering force given to the steering wheel enters the steering unit through the steering column.
  • Page 102 2. HYDRAULIC CIRCUIT 15L7SS02 Hydraulic gear pump Steering cylinder Priority valve Suction strainer Steering unit 12 Hydraulic tank...
  • Page 103 NEUTRAL 15L7SS03 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(2) and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(12). So, the pump flow is routed to the main control valve.
  • Page 104 LEFT TURN 15L7SS04 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(2) and flows to the gerotor(H).
  • Page 105 RIGHT TURN 15L7SS05 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(2) and flows to the gerotor(H).
  • Page 106 3. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 15LC7SS06 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 107 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 108 4. STEERING AXLE STRUCTURE 1-29 1-27 1-25 1-13 1-24 1-14 1-15 1-28 1-12 1-24 1-27 1-16 1-23 1-19 1-26 1-10 1-28 1-17 1-20 1-34 1-35 1-22 1-21 1-10 1-13 1-18 1-12 1-19 1-16 1-27 1-17 1-12 1-26 1-15 1-10 1-32 1-14 1-11 1-33...
  • Page 109 TIGHTENING TORQUE AND SPECIFICATION Stroke 73mm Apply loctite #243 49.5~66.5 kgf m(358~481 lbf ft) 15LC7SS09 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...
  • Page 110 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-7A 1900mm(75in) 1930mm(76in) 18LC-7A 1945mm(77in)
  • Page 111 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 steering wheel is turned fully Faulty.
  • Page 112 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 15LC7SS06 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 113 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 114 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1kgf (0~54.4lbf ft) 13mm socket spanner 6, 8mm and 12mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 5-70(2) TIGHTENING TORQUE L : Left port R : Right port T : Tank...
  • Page 115 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 116 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 117 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) A small mark has been made with a pumice stone on both spool and sleeve...
  • Page 118 (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 119 (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 120 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 121 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 122 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 123 (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 124 (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 125 (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 126 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20 5-82(2) (23) Place the distributor plate so that the channel holes match the holes in the...
  • Page 127 (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 128 (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 : 3.0 0.6kgf m (21.7...
  • Page 129 (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 130 2. STEERING CYLINDER STRUCTURE 15LC7SS11 Tube assembly Spacer Rod seal O-ring 10 Dust wiper Piston seal Gland 11 O-ring Wear ring Du bushing 12 Lock washer 5-30...
  • Page 131 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. Check wear condition of the sealing parts.
  • Page 132 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 40 4kgf m (289 29lbf ft).
  • Page 133 3. STEERING AXLE STRUCTURE Do not remove the stopper bolt unless necessary. 1-29 1-27 1-25 1-13 1-24 1-14 1-15 1-28 1-12 1-24 1-27 1-16 1-23 1-19 1-26 1-10 1-28 1-17 1-20 1-34 1-35 1-22 1-21 1-10 1-13 1-18 1-12 1-19 1-16 1-27 1-17...
  • Page 134 CHECK AND INSPECTION 15LC7SS10 unit : mm(in) Criteria Remarks Check item Standard size Repair limit 50(1.9) 50.5(1.9) Shaft ID of bushing 30(1.2) 29.8(1.2) OD of king pin Replace OD of steering cylinder pin 17(0.6) 16.8(0.6) OD of pin 17(0.6) 16.8(0.6) Knuckle Adjust with shims Vertical play...
  • Page 135 DISASSEMBLY Servicing work on the knuckle part can be Tire carried out without removing the axle assy from chassis. Taper roller bearing The work can be done by jacking up the Castle nut balance weight part of the truck. Split pin Plain washer Remove wheel cap.
  • Page 136 Loosen special bolt(1-21) and spring washer(1- 1-13 1-14 22). 1-15 Pry out the retaining ring(1-14) and remove oil 1-12 1-16 seal(1-12). (10) Push out the king pin(1-20) without damaging 1-20 the knuckle(1-3). 1-23 (11) Pull out the needle bearing(1-16). 1-19 If defect is observed in needle bearing(1-16), pull 1-27 1-17...
  • Page 137 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-26...
  • Page 138 SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT (NON OPSS / TRAVEL OPSS) 15LC7AHS01 Hydraulic gear pump Lift cylinder Priority valve Suction strainer Main control valve Down control valve Steering unit 10 Down safety valve Steering cylinder 11 Return filter Tilt cylinder 12 Hydraulic tank...
  • Page 139 HYDRAULIC CIRCUIT (TRAVEL WITH MAST OPSS) 15LC7AHS02 Hydraulic gear pump Lift cylinder Priority valve Suction strainer Main control valve Down control valve Steering unit 10 Down safety valve Steering cylinder 11 Return filter Tilt cylinder 12 Hydraulic tank...
  • Page 140 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION Steering system Return line 15LC7AHS03 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) and then goes to the large chamber of lift cylinder(7) by pushing the load check valve of the spool.
  • Page 141 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION Steering system Return line 15LC7AHS04 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 142 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION Steering system Return line 15LC7AHS05 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large chamber of tilt cylinder(6) by pushing the load check valve of the spool.
  • Page 143 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION Steering system Return line 15LC7AHS06 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position. The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the small chamber of tilt cylinder(6) by pushing the load check valve of the spool.
  • Page 144 2. HYDRAULIC GEAR PUMP STRUCTURE D155HS06 Front cover Bushing block 11 Lip seal Rear cover Dry bearing 12 Snap ring Gear housing Channel seal 13 Socket head bolt Drive shaft gear Square seal 14 Plain washer Driven gear 10 Dowel pin OPERATION This pump comprises of an end cover, a body, bushings and a mounting flange bolted together.
  • Page 145 3. MAIN CONTROL VALVE STRUCTURE (4 Spool - NON OPSS / TRAVEL OPSS) 15L7HS07 Port name Size Inlet port 7/8-14UNF Outlet port 7/8-14UNF Work port 3/4-16UNF Inlet block assy Auxiliary block assy Long bolt Lift block assy Tilt block assy Outlet block assy...
  • Page 146 INLET SECTION OPERATION Operation INLET WORK SECTION 19MPa 15L7HS08 The inlet section contains the pump inlet connection as well as a diagnostic inlet pressure gage port (new feature to be included).
  • Page 147 LIFT SECTION OPERATION Lift position LIFT 15L7HS09 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 148 Lower position LIFT 15L7HS10 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 149 TILT SECTION OPERATION Tilt forward position TILT 2A 2B 15L7HS11 When the seated operator shifts the level forward, pressure is applied to the head of the tilt cylinder, and the forks tilt forward. Oil is past the spool metering notches, and towards the cylinder head. Simultaneously, the high pressure acts upon the end of the tilt lock plunger to move it towards the spring end of the spool.This plunger movement opens additional spool metering notches which control oil flow from the rod end of the cylinder to the tank return line.
  • Page 150 Tilt backward position TILT 2A 2B 15L7HS12 When the seated operator shifts the lever back, the high pressure oil from the parallel passage is directed past the load check valve, past the spool metering notches, and to the rod side of the cylinder.
  • Page 151 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 6-14...
  • Page 152 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 153 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 154 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 155 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. Important Note : Before opening the secondary needle valve, make sure personnel and equipment are safely positioned to avoid accidents.
  • Page 156 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). 6-19...
  • Page 157 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 18 17 20,21,22 14,15 12,13 L15C5HS14 Tube assembly...
  • Page 158 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 6-21...
  • Page 159 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). heck condition 15LC7HS18 - Hydraulic oil : Normal operating temp...
  • Page 160 . 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 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. HYDRAULIC GEAR PUMP Tools required Metric socket set Internal snap ring pliers Shaft seal sleeve Torque wrench It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
  • Page 164 Lift and remove end cover. PUMP 03 Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts. PUMP 04 (10) Remove rear bearing block from drive and idler shafts. PUMP 05 (11) Remove idler shaft from bearing block.
  • Page 165 (12) Remove drive shaft from mounting flange. There is no need to protect the shaft seal as it will be replaced as a new item. PUMP 07 (13) Remove the front bearing block. PUMP 08 (14) Turn mounting flange over, with shaft seal up, and remove the retaining ring with proper snap ring pliers.
  • Page 166 (17) Remove seals from both bearing blocks and discard. PUMP 11 INSPECT PARTS FOR WEAR Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be replaced as new items. Check drive shaft spline for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway.
  • Page 167 Inspect bearing blocks for excessive wear or scoring on the surfaces which are in contact with the gears. Also inspect the bearings for excessive wear or scoring. Inspect the area inside the gear housing. It is normal for the surface inside the gear housing to show a clean "wipe"...
  • Page 168 ASSEMBLY New seals should be installed upon reassembly of pump. Install new shaft seal in mounting flange with part number side facing outboard. Press the seal into the seal bore until the seal reaches the bottom of the bore. Uniform pressure must be used to prevent misalignment or damage to the seal.
  • Page 169 Insert the drive end of the drive shaft through the bearing block with the seal side down, and the open side of the E- seal pointing to the intake side of the pump. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal.
  • Page 170 (13) Gently slide the gear housing over the rear bearing block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place with hands, do not force or use any tool. Check to make sure the intake port in the housing in on the same side as the open end of the E-seal and that the marked lines on the mounting flange and gear...
  • Page 171 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. Tighten torque : 6~7kgf m (43.4~50.6lbf ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
  • Page 172 The formal Bills of Material, descriptions, and views are found in the attached documentation. Additional auxiliary valve sections may be added to the main control valve in a similar manner as indicated below, as approved by the Hyundai. lock subassembly 2.4~2.9kgf m...
  • Page 173 nlet 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 Install the main relief valve assembly into the lower side cavity of the inlet section, as illustrated.
  • Page 174 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 The spool assembly should already consist of the lift spool, the return spring, one spring seat on either end of the spring, the seal plate, a spool seal, and a dust wiper.
  • Page 175 ilt 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 The spool assembly should already consist of the tilt spool (with tilt plunger and spring inserted into the bore on the spring end), the return spring, one spring seat on either end of the spring, the seal plate, a spool seal, and a dust wiper.
  • Page 176 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) The spool assembly should already consist of the proper aux spool, the return spring, one spring seat on either end of the spring, the seal plate, a spool seal, and a dust wiper.
  • Page 177 DISASSEMBLY INSTRUCTIONS General Subassemblies (such as relief valves, check valves, and spools) may be removed without having to loosen the tie rods and disassembling the entire valve. Disassemble the valve sections on a flat working surface. Ensure that the disassembly area will be clean and free of contamination. Keep the disassembly area neat to avoid loss or damage of parts.
  • Page 178 3. 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...
  • Page 179 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 180 4. TILT CYLINDER STRUCTURE I.D O.D Stroke : 70 80 85mm (2.7 3.1 3.3in) Rof O.D : 30mm(1.2in) L15C5HS17 Tube assy Gland 17 Rod eye Du bushing 10 Dust wiper 18 Spherical bearing 11 Du bushing 19 Grease nipple Piston 12 Rod seal 20 Hex bolt Piston seal...
  • Page 181 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 182 SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2 Group 3 Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 Group 4 Connector Destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10...
  • Page 183 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 9 10 11 12 HOURS HYUNDAI 1/10 15LC7AEL02 Flasher lamp Back buzzer 11 Switch assembly Work lamp Forward-reverse lever 12 Fuse box Combination switch Operating panel 13 OPSS unit Horn assembly Start switch...
  • Page 184 GROUP 2 ELECTRICAL CIRCUIT DASHBOARD PART FRAME/ENGINE PART CN-17 F/COMBI H/LAMP CLUSTER FOR CABIN CR-11 FLASHER UNIT CR-5 RELAY NEUTRAL START KEY CS-73 CS-2 CR-13 SWITCH SEAT 4 BR - ACC CN-131 1 R1 CUTOFF SOL1 4 BR - ACC (TILT/LIFT) RELAY HEADLAMP 4 BR...
  • Page 185 HMC 2.0 LPG ENGINE CIRCUIT HDGCP90 15L7AEL07...
  • Page 186 MEMORANDUM...
  • Page 187 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)] Start switch[CS-2(3)] Fuse box[CN-36] (No.1) Cab[CN-17(1)]...
  • Page 188 POWER CIRCUIT CL-16 CS-2 CN-36 HORN/STOP LAMP TURN LAMP OPS-UNIT 4 BR START RELAY - ACC CN-17 1 R1 ILL/HEAD LAMP 4 BR TRAVEL - ACC 4 BR - ACC 2 R2 R/COMBI RH - ST CLUSTER START KEY CL-15 WORK/BEACON LAMP (CABIN) FOR CABIN...
  • Page 189 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)] 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] I/conn[CN-1(19)] Fuel system interface[CN-6(1)] When start key switch is START position...
  • Page 190 STARTING CIRCUIT CS-2 CN-36 HORN/STOP LAMP TURN LAMP OPS-UNIT CR-5 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR TRAVEL - ACC 4 BR - ACC 2 R2 - ST RELAY NEUTRAL START KEY CLUSTER WORK/BEACON LAMP FOR CABIN OPSS FUSE BOX...
  • Page 191 GROUP 3 COMPONENT SPECIFICATION Part name Specification Remark Battery CCA : 550 20HR : 60AH CMF 60(223 168 220) Working lamp 12V, 55W 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 2 Flasher lamp Flasher &...
  • Page 192 GROUP 4 CONNECTOR DESTINATION Connector part No. No. of Connector 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 Fuel system interface connection 368050-1 CN-17 Power output for cabin S810-004201 CN-25...
  • Page 193 Connector part No. Connector No. of Type Destination number Female Male Sensor and pressure switch CD-2 Fuel level sensor S810-002201 CD-4 Brake switch S822-014000 CD-10 Air cleaner switch ST730057-2 CD-29 T/M temp switch S819-010122 7-11...
  • Page 194 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 195 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 196 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 197 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 198 3. CARRIAGE, BACKREST AND FORK 15L7MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...
  • Page 199 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. EX : =900mm(35.4in) mm(in) STD Fork assy Applicable model Standard Limit 64FP-12030 15LC/18LC-7A 35(1.4) 32(1.3) 64FD-11010 20LC-7A 40(1.6)
  • Page 200 . 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 201 ORKS 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 202 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 203 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 204 ARRIAGE 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 205 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1inch) from the floor. Knob Turn the knob up and slide forks, one by Spring one, toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 206 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. Adjustment Once carriage is properly installed, loosen nuts and adjust screws, (if not...
  • Page 207 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Remove the carriage assembly and move them to one side. Loosen and remove hexagon bolts and washers securing lift cylinders to inner Inner mast. mast Stud Loosen and remove hexagon bolts and bolt nuts securing lift cylinders to inner mast.
  • Page 208 3 stage mast(TF mast) Remove the carriage assembly and move it to one side. Loosen and remove hexagon bolt securing bottom cylinder from outer mast. Loosen and remove hexagon bolt and special washers securing lift cylinders to middle mast. Remove the spring pin. Attach chains or sling to the inner and middle mast section at top crossmember.
  • Page 209 ELEVATING MAST Inner mast (V mast) After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. Lift inner mast upright straight up and out of outer mast section. Replace and reverse above procedure to install.
  • Page 210 CHAIN Chain sheave(V mast) Place a sling around carriage and attach to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it. Remove the split pin securing the chain anchor pins and discard.
  • Page 211 Chain wheel bearing support(TF mast) Remove the carriage assembly and move to one side. After removing bolt to securing chain wheel bearing support assembly to free lift cylinder. After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 212 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 213 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 214 Adjustment Chain adjustments are important for the following reasons : Equal loading of chain. Proper sequencing of mast. Prevent over-stretching of chains. Prevent chains from jumping off sheaves if they are too loose. djustment procedure With mast in its fully collapsed and vertical position, lower the fork to the floor. Adjust the chain length by loosening or tightening nut on the chain anchor.

This manual is also suitable for:

18lc-7a20lc-7a