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SECTION 1 GENERAL
Group 1 Safety Hints
Group 2 Specifications
Group 3 Periodic Replacement
SECTION 2 REMOVAL AND INSTALLATION OF UNIT
Group 1 Structure
Group 2 Removal and Installation of Unit
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and Operation
Group 2 Troubleshooting
Group 3 Tests and Adjustments
Group 4 Disassembly and Assembly
SECTION 4 BRAKE SYSTEM
Group 1 Structure and Function
Group 2 Operational Checks and Troubleshooting
Group 3 Tests and Adjustments
SECTION 5 STEERING SYSTEM
Group 1 Structure and Function
Group 2 Operational Checks and Troubleshooting
Group 3 Disassembly and Assembly
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and Function
Group 2 Operational Checks and Troubleshooting
Group 3 Disassembly and Assembly
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location
Group 2 Electrical Circuit
Group 3 Component Specification
Group 4 Troubleshooting
CONTENTS
1-1
1-5
1-13
2-1
2-2
3-1
3-15
3-19
3-23
4-1
4-6
4-9
5-1
5-10
5-12
6-1
6-19
6-23
7-1
7-2
7-9
7-11

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Summary of Contents for Hyundai HLF 15CIII

  • Page 1 CONTENTS SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications Group 3 Periodic Replacement 1-13 SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure Group 2 Removal and Installation of Unit SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Operation Group 2 Troubleshooting 3-15 Group 3 Tests and Adjustments...
  • Page 2 SECTION 8 MAST Group 1 Structure Group 2 Operational Checks and Troubleshooting Group 3 Adjustment Group 4 Removal and Installation 8-10...
  • Page 3 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
  • Page 4 Revised edition mark(①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 7 Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246...
  • Page 8 kgf・m to lbf・ft 1kgf・m = 7.233lbf・ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
  • Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
  • Page 11 SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications 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 L15C3GE01 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 Operator's seat 16 Rear combination lamp Carriage...
  • Page 17 2. SPECIFICATIONS L15C3SP01 Model Unit HLF 15CIII HLF 18CIII 1500 1750 Capacity ← Load center Weight(Unloaded) 2800 3000 ← 3300 Lifting height ← Free lift ← mm/sec 540/480 Fork Lifting speed(Unload/Load) ← mm/sec 500/400 Lowering speed(Unload/Load) ← 1050×100×40 L×W×T L,W,T ←...
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE ITEM SPECIFICATION UNIT Model MITSUBISHI 4G63-31HL Type 4 cycle, overhead camshaft type Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, In-line Firing order 1-3-4-2 Combustion chamber type Hemisphere mm(in) Cylinder bore X stroke 85×88(3.3×3.5) Piston displacement cc(cu in)
  • Page 19 POWER TRAIN DEVICES Item Specification Model OKAMURA MD14 Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.8 : 1 Type Full-automatic power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick-down system 13.720 : 1 Overhaul ratio 14.090 : 1 Type Front-wheel drive type, fixed location...
  • Page 20 4. TIGHTENING TORQUE OF MAJOR COMPONENTS ITEMS SIZE kgf・m lbf・ft Engine mounting bolt, nut M16×2.0 Engine Radiator mounting bolt, nut 6.9±1.4 50±10 M10×1.5 Torque converter mounting bolt 4.17 M10×1.25 Hydraulic MCV mounting bolt, nut 7.43±1.5 54±10.8 M10×1.25 system Steering unit mounting bolt 6.9±1.4 50±10 M10×1.5...
  • Page 21 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT Coarse thread Bolt size kgf・m lbf・ft kgf・m lbf・ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7 M10×1.5...
  • Page 22 PIPE AND HOSE Thread size Width across flat(mm) kgf・m lbf・ft 1/4" 21.7 3/8" 28.9 1/2" 36.2 3/4" 86.8 1" FITTING Thread size Width across flat(mm) kgf・m lbf・ft 1/4" 28.9 3/8" 36.2 1/2" 43.4 3/4" 94.0 1" 1-11...
  • Page 23 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature ° C (° F) Capacityℓ(U.S.gal) Service Kind of 1.5~ 2.0~ point fluid 1.8ton 3.0ton (-4) (14) (32) (50) (68) (86) (104) Engine oil Engine oil SAE 10W-30/API SG or over (For LPG ENG)
  • 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 Group 2 Removal and Installation of Unit...
  • Page 26 SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE L15C3RE01 Mast 10 Torque converter 19 Counterweight Lift cylinder Engine 20 LPG tank Steering unit 12 Air cleaner 21 Head guard Tilt cylinder 13 Rear tire 22 Seat Brake master cylinder 14 Steering axle 23 Parking brake lever Fork...
  • Page 27 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Forks ① Lower the fork carriage until the forks are approximately 25mm(1in) from the floor. ② Release fork anchor pins and slide one fork at a time toward the center of the carriage where a notch has been cut in the bottom plate for easy removal.
  • Page 28 ② While supporting lift chains, remove the split pins and slide out chain anchor pins from the chain anchors of stationary upright. L15C3RE05 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. L15C3RE06 ④...
  • Page 29 PIPING ① Remove the return hoses and clamps attached to the cylinder. ② Remove the return hoses from the connector. ③ Remove hose assembly, connector, down safety valve from the lift cylinder. ④ Disconnect hose assembly from the flow regulator. L15C3ER08 LIFT CYLINDER ①...
  • Page 30 INNER MAST ① Using an overhead hoist raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. L15C3RE10 TILT CYLINDER PIN MAST SUPPORT CAP ① 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 ① Check the mast support cap and spring pin for wear. ②...
  • Page 32 2. POWER TRAIN ASSEMBLY REMOVAL B153RE00 Mast Refer to section on mast. Brake piping and T/M cooling piping Disconnect the brake pipes and T/M cooling pipes from powerline assembly. L15C3RE13 Parking brake cable Disconnect parking brake cable from the wheel brake assembly. L15C3RE14 Flexible plate Remove the cover on the top face of the...
  • Page 33 Powerline assembly Crane ① Attach a crane to the filt cylinder notches Dashboard on the dashboard and raise the machine Powerline Mounting bolt assembly enough for truck to slide under powerline assembly. Frame ② Put the block between the truck and powerline assembly.
  • 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 Overflow Remove all wiring harnesses, cables and hose hoses between the engine and the Hose Reservoir Radiator dashboard and frame. tank ① Wiring harness to alternator and starter. Engine ② Wiring harness for oil pressure and assembly engine water. Hose L15C3RE20 Radiator hose...
  • Page 36 INSTALLATION Installation is in the reverse order to Loctite #243 removal, but be careful of the following points. 7.5kgf m(54.2lbf.ft) Tighten the engine mounting bolts and Mounting bolt nuts. 7.5kgf m(54.2lbf.ft) Tighten the engine mounting bracket bolts. ※ Do not remove the bolts unless necessary. Shim Loctite is coated on the thread of bolt.
  • 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 L15C3RE24 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 5. REAR AXLE REMOVAL Mounting bolt Counterweight L15C3RE29 Counterweight Install a lifting tool in the hole in the counterweight, and raise it with a crane. Remove the mounting bolts and raise the counterweight slightly and move it to the rear side. ・...
  • 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 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Operation Group 2 Troubleshooting 3-15 Group 3 Test and Adjustments 3-19 Group 4 Disassembly and Assembly 3-23...
  • Page 42 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. D153PT26 Brake drum Transmission...
  • Page 43 2. INSTALLATION VIEW D153PT05 Control valve Oil filter Temperature sender Dipstick Air breather...
  • Page 44 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. ① Structure Ball bearing Output pressure adjusting valve spring Gear pump assembly Inlet relief valve spring Converter Input guide D153PT27...
  • Page 45 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...
  • Page 46 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 47 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 48 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 49 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 50 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 51 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 52 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 53 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 54 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 55 6. DRIVE AXLE STRUCTURE D153PT25 Housing 10 O-ring 18 Taper roller bearing Plug Support drive (L) 19 Plate 12 Hub 20 Nut Gasket 13 Washer 21 Bolt Plug 14 Bolt 22 Oil seal Support drive (R) 15 Retainer 23 Drive shaft Axle tube 16 O-ring 24 Washer...
  • Page 56 GROUP 2 TROUBLESHOOTING Problem Probable cause Remedy 1. Excessive oil ・Improper oil level. ・Check oil level. Add or drain oil as temperature rise 1) Torque converter necessary. ・Impeller interfering with surroundings. ・After draining oil from oil tank and transmission, check and replace interfering parts.
  • Page 57 Problem Probable cause Remedy 3. Low output power ・Insufficient hydraulic pressure : 1) Torque converter - Low oil level. - Check oil level and add oil - Air sucked in. - Check joints and pipes. If necessary, retighten joint or replace packing.
  • Page 58 Problem Probable cause Remedy 4. Unusual oil pressure ・Control valve malfunctioning. 1) Oil pressure is high (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 59 Problem Probable cause Remedy ・Low oil level. ・Check oil level and add oil. 5. Power is not transmitted ・Inching valve and link lever improper- ・Check measure and adjust. 2) Transmission ly positioned. ・Forward/reverse spool and link lever ・Check and adjust. improperly positioned.
  • Page 60 GROUP 3 TESTS AND ADJUSTMENTS 1. INCHING PEDAL Depress inching pedal fully, and move gear shift lever to FORWARD or REVERSE. 132~142mm Check that machine does not move even when engine speed is increased slightly. Adjust stopper bolt so that pedal height is 132~142mm (5.2~5.6in).
  • Page 61 2. HYDRAULIC PRESSURE Block wheels of truck, and pull parking lever. Install oil pressure gauge at inlet of control valve. Move direction control lever to FORWARD or REVERSE, depress accelerator pedal and run engine at 1500rpm. Measure clutch pressure and torque converter pressure and check that they are within specified range.
  • Page 62 ADJUSTMENT OF THE SIDE BEARING PRELOAD Tighten adjust screw gear(1) uniformly at 20kgf・m(145lbf・ft) L15C3DF03 ADJUSTING TOOTH CONTACT Coat the tooth face of the bevel pinion lightly with red lead(minimum). Rotate the bevel gear forward and backward. Inspect the pattern left on the teeth. ・...
  • Page 63 INCORRECT TOOTH CONTACT Heel 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. L15C3TH03 Reduce the shim thickness at the pinion shaft to move the pinion in direction A.
  • Page 64 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 plate, input guide, and O-rings.
  • Page 65 ② Ease the torque converter out of the housing so as not to damage the pump oil seal. L15C3TC04 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 ①...
  • Page 66 Extract valves ① Remove the two plugs. Tool(s) required : 24mm wrench. L15C3TC08 ② 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 philips screws and disassemble the pump.
  • Page 67 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 68 TORQUE CONVERTER ASSEMBLY DRAWING L15C3TC12 L15C3TC13 3-27...
  • Page 69 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 70 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 71 MAINTENANCE 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...
  • Page 72 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. DISASSEMBLY Differential, torque converter, control valve ①...
  • Page 73 Pinion shaft ① Remove pinion shaft bolt(1). ② Fit a dolly block(copper rod) and tap the pinion shaft with a hammer to remove. L15C3TM03 Seal ring cap ① Remove bolt(2) and fit the bolt to the tapped hole. Remove the seal ring cap. ※...
  • Page 74 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 75 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 sufaces and result in premature failure of components.
  • Page 76 Idler shaft assembly ① Prefit gear(1) in the case. ② Fit bearing(2) on the idler shaft and install in the case. ③ 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 ①...
  • Page 77 TORQUEFLOW 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 78 CHECK AND INSPECTION E2, H2 E1, H1 L15C3TM14 3-37...
  • Page 79 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 80 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 81 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 (22-41 lbf ft) Loctite#271(screw portion) 9-16 kgf m (65.3-116.0 lbf ft) Loctite#271(screw hole side) Loctite#271(screw hole side) 0.8-1.2 kgf m 15-17 kgf m...
  • Page 82 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 83 4. DRIVE AXLE DISASSEMBLY AND ASSEMBLY 15~21 kgf m (108~152 lbf ft) 6~8kgf m (43~58 lbf ft) Loctite #1215 All face of 0.6~1.5 kgf m (4.3~10.8 lbf ft) 6~8 kgf m (43~58 lbf ft) L15C3DA01 Housing 10 O-ring 19 Plate Plug Support drive(LH) 20 Nut...
  • Page 84 ASSEMBLY OF DRIVE AXLE 6.0-8.0 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) 6.0-8.5 kgf m (43.2-61.2 lbf ft) Loctite #271 G2, L1 11.0-13.0 kgf m (79.2-93.6 lbf ft) G2,L1 Grease by 1/2-2/3 of space...
  • Page 85 INSTALLATION Perform installation in the reverse order to removal, paying attention to the following. Tightening torque converter case mounting bolt. ・Tightening torque : 6.0-7.5kgf・m (43-54lbf・ft) L15C3TIN01 Tightening flexible plate mounting bolt. ・Tightening torque : 2.8-3.5kgf・m (20-25lbf・ft) L15C3TIN02 Pedal assembly brake piping. ①...
  • Page 86 SECTION 4 BRAKE SYSTEM Group 1 Structure and Function Group 2 Operational Checks and Troubleshooting Group 3 Tests and Adjustments...
  • Page 87 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 88 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 89 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 90 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. L15C3BS03 Back plate-LH/RH Shoe hole down spring 15 Adjuster guide...
  • Page 91 6. BRAKE MASTER CYLINDER STRUCTURE L15C3BS04 Body Snap ring 13 Washer Piston Boot 14 Rod Secondary cup Spacer 15 Head Primary cup 10 Spring seat 16 Head pin Spring Union 17 Nut Plate 12 Union bolt 18 Cap DISASSEMBLY Remove the master cylinder boot(8) and remove the rod(14). Remove the snap ring(7) and take out the plate(6), the piston(2), the piston primary cup(4), and piston spring(5).
  • Page 92 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 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 93 2. TROUBLESHOOTING Problem cause Remedy ・Hydraulic system leaks oil. ・Repair and add oil. Insufficient braking force ・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 94 Problem cause Remedy ・Lining surface roughened. ・Repair by polishing or replace. Brake squeaks ・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 95 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 96 3. ADJUSTMENT OF PEDAL BRAKE PEDAL Pedal height from floor plate Adjust with stopper bolt. ・Pedal height : 138~148mm(5.4~5.8in) Play Adjust with rod of master cylinder ・Play : 10mm(0.4in) Micro switch for parking brake (if equipped) L15C3BS08 ① After assembling parking brake and parking cable, put the parking brake lever released.
  • Page 97 SECTION 5 STEERING SYSTEM Group 1 Structure and Function Group 2 Operational Checks and Troubleshooting 5-10 Group 3 Disassembly and Assembly 5-12...
  • Page 98 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1 Steering unit 2 Steering cylinder 3 Steering wheel 4 Trail axle L15C3SS01 To Hydraulic tank The steering system for this machine is composed of steering wheel assembly(3), steering unit(1), steering cylinder(2), trail axle(4) and pipings.
  • Page 99 2. HYDRAULIC CIRCUIT MCV spool 8.5MPa 8MPa 15MPa L15C3SS02 Hydraulic gear pump Steering cylinder MCV (Priority valve) Suction filter Steering unit Hydraulic tank...
  • Page 100 NEUTRAL MCV spool 8.5MPa 8MPa 15MPa L15C3SS03 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 MCV(Priority valve) and the inlet pressure oil moves the spool(D) to the left. Oil flow into LS port to the hydraulic tank(11).
  • Page 101 LEFT TURN MCV spool 8.5MPa 8MPa 15MPa L15C3SS04 When the steering wheel is turned to the left, the spool(G) within the steering unit(3) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit through the spool(D) of priority valve and flows to the gerotor(H).
  • Page 102 RIGHT TURN MCV spool 8.5MPa 8MPa 15MPa L15C3SS05 When the steering wheel is turned to the right, the spool(G) within the steering unit(3) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool(G) where it is directed out of the right work port(R).
  • Page 103 3. STEERING UNIT STRUCTURE L15C3SS06 Dust seal Spacer 21 Relief valve assembly Housing assembly 12 O-ring 22 Spring Ball 13 Distributor plate 23 Shock valve, Complete Thread bushing 14 Gear wheel set 24 Ball O-ring 15 O-ring 25 Suction valve pin Bearing assembly 16 End cover 26 Screw...
  • Page 104 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 105 4. TRAIL AXLE STRUCTURE 21(RH) 22(LH) L15C3SS07 Steering axle 15 Taper roller bearing 30 Hexagon bolt King pin 16 Taper roller bearing 31 Hexagon bolt Thrust bearing 17 Low castle nut 32 Hexagon bolt Bearing cap 18 Plain washer 33 Trunnion bolt Oil seal 19 Split pin 34 Bushing...
  • Page 106 TIGHTENING TORQUE AND SPECIFICATION Stroke 85.5 Apply loctite #277 29~32 kgf m(210~231 lbf ft) Greasing Fill 1/2 to 2/3 of the space in the hub with lithium grease Bearing end should be leveled with boss end Fix with split pin SECTION A-A L15C3SS09 Center pin support...
  • Page 107 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS Check item Checking procedure ・ Steering wheel Set rear wheels facing straight forward, then turn steering wheel to left and right. 30-60mm Measure range of steering wheel movement before rear wheel starts to move. (1.2-2.4 in) Range should be 30~60mm at rim of steering wheel.
  • Page 108 Problem Cause Remedy ・Lockout loosening. ・Retighten. Steering wheel turns unstea- ・Metal spring deteriorated. ・Replace. dily. ・Gear backlash out of adjustment. ・Adjust. Steering system makes abn- ・Lockout loosening. ・Retighten. ormal sound or vibration. ・Air in oil circuit. ・Bleed air. Abnormal sound heard when Valve ・Faulty.
  • Page 109 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE L15C3SS06 Dust seal Spacer 21 Relief valve assembly Housing assembly 12 O-ring 22 Spring Ball 13 Distributor plate 23 Shock valve, Complete Thread bushing 14 Gear wheel set 24 Ball O-ring 15 O-ring 25 Suction valve pin Bearing assembly...
  • Page 110 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 111 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 112 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 113 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Shake out the check valve ball and suction valve pins and balls. D353SE09 5-16...
  • Page 114 Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and thrust bearing will be pushed out of the housing together.
  • Page 115 (12) Carefully press the spool out of the sleeve. 5-74(4) (13) Press the neutral position springs out of their slots in the spool. 5-75(1) (14) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (15) Screw out the plug using an 8mm hexagon socket spanner.
  • Page 116 (16) Unscrew the setting screw using an 8mm hexagon socket spanner. D353SE11 (17) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (18) The pressure relief valve is now disassem- bled. D353SE13 5-19...
  • Page 117 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 118 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 119 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 120 (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 121 (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 122 (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 123 (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 124 (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 125 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ・Tightening torque : 4.0 ±...
  • Page 126 (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 127 2. STEERING CYLINDER STRUCTURE L15C3SS11 Tube assembly Glyd ring Bushing Ring 10 Rod seal O-ring Retaining ring Dust wiper Piston Gland 12 O-ring 5-30...
  • Page 128 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 129 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 130 3. TRAIL AXLE STRUCTURE ※ Do not remove the stopper bolt unless necessary. 21(RH) 22(LH) L15C3SS07 Steering axle 15 Taper roller bearing 30 Hexagon bolt King pin 16 Taper roller bearing 31 Hexagon bolt Thrust bearing 17 Low castle nut 32 Hexagon bolt Bearing cap 18 Plain washer...
  • Page 131 CHECK AND INSPECTION L15C3SS12 mm(in) Criteria Check item Remedy Standard size Repair limit Diameter of king pin 30(1.18) 29.8(1.17) Replace Vertical play of knuckle 0.2(0.008) Adjust with shims Diameter of center pin 50(1.96) 49.5(1.94) Replace Damage, wear Rear axle, hub, knuckle, bearing Replace Seizure, abnormal noise, defective rotation 5-34...
  • Page 132 DISASSEMBLY ※ Servicing work on the knuckle part can be carried Tire out without removing the axle assy from chassis. The work can be done by jacking up the balance Taper roller bearing weight part of the truck. Castle nut Loosen the castle nut and take off the steering Plain washer wheel tire.
  • Page 133 Loosen special bolt(11) and spring washer(38). Pry out the retaining ring(9) and remove oil seal(8). (10) Push out the king pin(2) without damaging the knuckle(12). (11) Pull out the needle bearing(6). If defect is observed in needle bearing(6), pull it out by using extractor.
  • Page 134 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and Function Group 2 Operational Checks and Troubleshooting 6-19 Group 3 Disassembly and Assembly 6-23...
  • Page 135 SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT 13MPa 8MPa 8MPa 15MPa L15C3HS01 Hydraulic gear pump Suction filter Main control valve Return filter Steering unit Down control valve Steering cylinder 10 Down safety valve Lift cylinder Hydraulic tank Tilt cylinder...
  • Page 136 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 13MPa 8MPa 15MPa Steering system Return line L15C3HS02 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(2) and then goes to the large chamber of lift cylinder(5) by pushing the load check valve of the spool.
  • Page 137 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 13MPa 8MPa 15MPa Steering system Return line L15C3HS03 When the lift control lever is pushed forward, the spool on the first block moves to lower position. The work port(1B) and the small chamber and the large chamber are connected to the return passage, so the lift will be lowered due to its own weight.
  • Page 138 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 13MPa 8MPa 15MPa Steering system Return line L15C3HS04 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(2) and then goes to the large chamber of tilt cylinder(6) by pushing the load check valve of the spool.
  • Page 139 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 13MPa 8MPa 15MPa Steering system Return line L15C3HS05 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(2) and then goes to the small chamber of tilt cylinder(6) by pushing the load check valve of the spool.
  • Page 140 2. HYDRAULIC GEAR PUMP STRUCTURE L15C3HS06 Front cover Bearing Oil seal Gear plate Square ring 12 Retainer ring Rear cover Wear plate 13 Bolt Drive gear Balance seal 14 Plain washer Idler gear 10 Back up ring OPERATION This pump comprises of an end cover, a body, bushings and a mounting flange bolted together. The gear journals are supported in plane bearings within pressure balanced bushings to give high volumetric and mechanical efficiencies.
  • Page 141 3. MAIN CONTROL VALVE STRUCTURE (3 Spool) 11,13 15 7 23,29 25,28 21,30 Lift Tilt 3 Work ports SECTION A - A SECTION B - B L15C3HS07 Port name Size Inlet port 1-5/16-12UN Outlet port 1-5/16-12UN Gauge port PF1/4 Work port 1-1/16-12UN Special nut 15 Wiper...
  • Page 142 INLET SECTION OPERATION Structure and description TO PS L15C3HS071 Connector assembly Oil passage Main relief valve Pilot passage PF port relief valve Damper EF passage(Main) Tank passage Orifice for control stand-by flow Chamber Orifice Damper orifice for 20 position Damper orifice for 2(Spool)
  • Page 143 Operation ① In case of not running the PF side circuit Part N Part M L15C3HS072 Position of spool and piston when PF port does not be operated when pump displacement is over the stand-by flow volume Q Oil flows from P(pump) port to PF side through passage H and orifice E. The pressure measured before orifice E is running through the passage I and acting on the head of spool 2, and the one measured after orifice E is running through the orifice G and acting on the tail of spool 2.
  • Page 144 ② When running PF side circuit L15C3HS073 Position of spool and piston when PF port operates when pump displacement is over the controlled flow Q For the pressure difference running type, K room flows to tank(T side). By the same reason, the piston 20 moves toward the direction of opened orifice E when the pressure of PF side reasoned to switching pressured P .
  • Page 145 LIFT SECTION OPERATION Lift position Load check valve(1) SECTION A-A L15C3HS08 When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flow into lift cylinder port(B1).
  • Page 146 Lower position L15C3HS09 When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (B1)→T. In lift lower position the fork drops due to its own weight.
  • Page 147 TILT SECTION OPERATION Tilt forward position Load check valve(1) SECTION A-A Tilt lock spool Low pressure passage L15C3HS10 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flow into tilt cylinder port(A2).
  • Page 148 Tilt backward position Load check valve(1) SECTION A-A Low pressure passage L15C3HS11 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve(1) and flows into tilt cylinder port(B2).
  • Page 149 MAIN RELIEF VALVE Pressure setting A good pressure gage must be installed in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit. Procedure ①...
  • Page 150 The loss of oil behind poppet C, effected by the opening of pilot poppet E. This shuts off the oil flow to the area behind relief valve poppet D, and causes a low pressure area internally. L15C3HS15 The imbalance of pressure on the inside as compared to that of the high pressure port HP, forces the relief valve poppet D to open and relieve the oil directly to the...
  • Page 151 4. LIFT CYLINDER L15C3HS18 Tube assy Wear ring O-ring Retaining ring 12 Stopper Piston Rod cover 13 Du bushing U-packing Dust wiper 14 Spacer Back up ring 10 U-packing 15 O-ring 5. TILT CYLINDER 18 17 20,21,22 16 12,13 14,15 L15C3HS19 Tube assy Rod cover...
  • Page 152 6. FREE LIFT CYLINDER 7,6 11,12,13 9,10 L15C3HS20 Tube assembly U-packing Steel ball Rod assembly Back up ring 12 Bleeder screw Ring Slyd ring 13 Set screw Gland nut O-ring Dust wiper 10 Back up ring 6-18...
  • Page 153 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Load maximum load, set mast vertical and raise 1m from ground. Wait for 2 minutes and measure hydraulic drift(amount forks move down and amount mast tilts forward).
  • Page 154 2. TROUBLESHOOTING SYSTEM Problem Cause Remedy ・Seal inside control valve defective. ・Replace spool or valve body. Large fork lowering speed. ・Oil leaks from joint or hose. ・Replace. ・Seal inside cylinder defective. ・Replace packing. ・Tilting backward : Check valve defec- ・Clean or replace. Large spontaneous tilt of mast.
  • Page 155 HYDRAULIC GEAR PUMP Problem Cause Remedy ・System relief valve set too low or ・Check system relief valve for proper Pump does not develop full pressure. leaking. setting. ・Oil viscosity too low. ・Change to proper viscosity oil. ・Pump is worn out. ・Repair or replace pump.
  • Page 156 LIFT CYLINDER Problem Cause Remedy ・Foreign matters on packing. ・Replace packing. Oil leaks out from gland ・Unallowable score on rod. ・Smooth rod surface with an oil stone. through rod. ・Unusual distortion of dust seal. ・Replace dust seal. ・Chrome plating is striped. ・Replace rod.
  • Page 157 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP ※ ※ Tools required ・Metric socket set ・Internal snap ring pliers ・Shaft seal sleeve ・Torque wrench : 13.8 kgf・m (100lbf・ft) It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
  • Page 158 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 159 (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 160 (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 161 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 162 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 163 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 164 (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 165 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. ・Tighten torque : 11.1~11.8kgf・m (80~85lbf・ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
  • Page 166 2. MAIN CONTROL VALVE Lay out valve components on a clean, flat working surface. The inlet assembly will include an O-ring, and the spool section(s) include an O-ring, a load check puppet and a load check spring. Tools required for basic valve assembly include 3/4 and 11/16 open or box end wrenches and a torque wrench with thin wall sockets.
  • Page 167 Position valve assembly with the mounting pads of the end sections on a flat surface. To obtain proper alignment of end sections relative to the spool sections apply downward pressure to the end sections ; Snug tie rod nuts to about 10lbf・ft. Final torque the two 11/16 nuts to 48±lbf・ft Final torque one 3/4 nut to 74±8lbf・ft.
  • Page 168 3. LIFT CYLINDER STRUCTURE Down control valve Down safety valve ・ I.D×O.D×Stroke : 50×58×1655mm (2.0×2.3×65.1 in) ・ Rod O.D : 40mm (1.6 in) L15C3HS24 Tube assy Wear ring O-ring Rod assy Retaining ring 12 Stopper Piston Rod cover 13 Du bushing U-packing Dust wiper 14 Spacer...
  • Page 169 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 170 4. TILT CYLINDER STRUCTURE ・ I.D×O.D×Stroke : 70×82×114mm (2.7×3.2×4.5 in) ・ Rod O.D : 30mm (1.2 in) L15C3HS27 Tube assy Rod cover 16 O-ring Du bushing 10 Dust wiper 17 Eye Rod assy Du bushing 18 Bushing Piston 12 U-packing 19 Grease nipple O-ring 13 Back up ring...
  • Page 171 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 172 SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location Group 2 Electrical Circuit Group 3 Component Specification Group 4 Troubleshooting 7-11...
  • Page 173 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION L15C3EL01 Flasher lamp Combination lamp 13 Head lamp relay Work lamp License lamp 14 Start switch Combination switch Back buzzer 15 Switch assembly Horn assy 10 Connector plate 16 Fuse box Connector plate Flasher relay 17 Battery Work lamp...
  • Page 174 SECTION 7 ELECTRICAL SYSTEM GROUP 2 ELECTRICAL CIRCUIT L15C3EL02...
  • Page 175 1. POWER CIRCUIT The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the off position, the current flows from the positive battery terminal. OPERATING FLOW Battery(+) Start motor[CN-45(B+)] Fusible link[CN-60] Start relay[CR-23(1)] Alternator[CN-74(B+)] I/conn[CN-3(2)] I/conn[CS-2(3)]...
  • Page 176 POWER CIRCUIT HORN START KEY CN-36 B BR R1 R2 C ACC OPERATING PANEL HEAD LAMP FLASHER LAMP F-R SWITCH FUEL CUT OFF OPTION 1 START RELAY HORN CN-1 DISTRIBUTOR CN-18 IG COIL CN-2 CN-87 FUEL SOL VALVE CN-74 CN-3 5-REV 4-FWD CS-11...
  • Page 177 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-60] Start switch[CS-2(3)] Start relay[CR-23] ※ ※ 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[No.
  • Page 178 STARTING CIRCUIT HORN START KEY CN-36 B BR R1 R2 C ACC OPERATING PANEL HEAD LAMP FLASHER LAMP F-R SWITCH FUEL CUT OFF OPTION 1 START RELAY HORN CN-1 DISTRIBUTOR CN-18 IG COIL CN-2 CN-87 FUEL SOL VALVE CN-74 5-REV 4-FWD CN-3 CS-11...
  • Page 179 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator release the start switch to the ON position. Charging current generated by operating alternator flows into the battery. The current also flows from alternator to each electrical component through the fusible link(CN-60) and the fuse box.
  • Page 180 CHARGING CIRCUIT START KEY CN-36 B BR R1 R2 C ACC OPERATING PANEL HEAD LAMP FLASHER LAMP F-R SWITCH FUEL CUT OFF OPTION 1 START RELAY HORN CN-1 CN-74 CN-3 CN-60 FUSIBLE LINK CN-45 START MOTOR OPTION BATTERY MASTER SW HEAD FLASHER UNIT/RELAY L15C3EL05...
  • Page 181 GROUP 3 COMPONENT SPECIFICATION Specification Remark Part name Battery 12V×30AH/5HR Reserve capacity : 152min -18° C Cold cranking ampere : 354A Working lamp 12V, 55W License lamp 12V, 3.4W×12 Combination lamp 12V, 21W(T/S) 12V, 10W(Back) 12V, 5W (Tail) 12V, 21W(Stop) Head lamp 12V, 55W Flasher lamp...
  • Page 182 Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Dashboard harness-frame harness) MG640341 MG610339 CN-2 I/conn(Dashboard harness-frame harness) MG640341 MG610339 CN-3 I/conn(Dashboard harness-frame harness) S813-130201 S813-030201 CN-4 DAEDONG Support harness-LH 110-4P-F CN-5 Support harness-RH 110-4P-F CN-18 Ignition coil ST730018-3 ST750036-3 CN-19...
  • Page 183 GROUP 4 TROUBLESHOOTING Trouble symptom Probable cause Remedy ・Faulty wiring. ・Check for loose terminal and discon- Lamps dimming even at maxi- mum engine speed. nected wire. ・Improper belt tension. ・Adjust belt tension. Lamps flicker during engine operation. ・Charge lamp defective. ・Replace.
  • Page 184 SECTION 8 MAST Group 1 Structure Group 2 Operational Checks and Troubleshooting Group 3 Adjustment Group 4 Removal and Installation 8-10...
  • Page 185 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) LIFT CYLINDER L15C3MS01 Outer mast Mast support metal Roller Shim(0.5, 1.0t) Inner mast 12 Back up liner Roller Lift chain 13 Shim(0.5, 1.0t) Tilt cylinder pin Anchor bolt Mast support cap 10 Chain wheel bearing...
  • Page 186 2. 3 STAGE MAST(TF MAST) L15C3MS02 Outer mast Chain Shim(0.5, 1.0t) Bushing 12 Sheave bracket Roller Middle mast 13 Inner mast Back up liner Sheave 14 Shim(0.5, 1.0t) Tilt cylinder pin 10 Anchor bolt 15 Mast up cylinder band...
  • Page 187 3. CARRIAGE, BACKREST AND FORK L15C3MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...
  • Page 188 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=1050mm(41.3in) EX : mm(in) STD Fork assy Applicable model Standard Limit 64FD-11040 HLF 15CII 40(1.6) 37(1.5) B153FK01 Set forks in middle and measure out of...
  • Page 189 2. TROUBLESHOOTING MAST Problem Cause Remedy ・Deformed mast or carriage. ・Disassemble, repair or replace. Forks fail to lower. ・Faulty hydraulic equipment. ・See troubleshooting hydraulic pump Fork fails to elevate and cylinders in section 6, hydraulic system. ・Deformed mast assembly. ・Disassemble mast and replace damaged parts or replace complete mast assembly.
  • Page 190 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 191 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V MAST) INNER/OUTER 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 adjust the clearance between the roller side face and mast at the closest position on the opposite side to the...
  • Page 192 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 L15C3MS06...
  • Page 193 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, middle and 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...
  • Page 194 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1inch) from the floor. Release fork anchor pins and slide forks, one by one, toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 195 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 196 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 mast. ③ Loosen and remove hexagon bolts and nuts securing lift cylinders to inner mast.
  • Page 197 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 band and special washers securing lift cylinders to middle mast.
  • Page 198 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 199 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. ②...
  • Page 200 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 201 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 202 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 203 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 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.

This manual is also suitable for:

Hlf 18ciii