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Hyundai 110D-7A Operating Manual
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Hyundai 110D-7A Operating Manual

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SECTION 1 GENERAL
SECTION 1 GENERAL
Group 1 Safety hints ------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications --------------------------------------------------------------------------------------------------- 1-5
Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-15
SECTION 2 REMOVAL & INSTALLATION
SECTION 2 REMOVAL & INSTALLATION
Group 1 Major components ------------------------------------------------------------------------------------------- 2-1
Group 2 Removal and installation of unit ---------------------------------------------------------------------- 2-2
SECTION 3 POWER TRAIN SYSTEM
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and operation ----------------------------------------------------------------------------------- 3-1
Group 2 Operation and maintenance --------------------------------------------------------------------------- 3-56
Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 3-68
Group 4 Adjustment ------------------------------------------------------------------------------------------------------- 3-186
SECTION 4 BRAKE SYSTEM
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function ------------------------------------------------------------------------------------- 4-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------- 4-24
Group 3 Tests and adjustments ------------------------------------------------------------------------------------- 4-32
Group 4 Disassembly and assembly ---------------------------------------------------------------------------- 4-35
SECTION 5 STEERING SYSTEM
SECTION 5 STEERING SYSTEM
Group 1 Structure and function ------------------------------------------------------------------------------------- 5-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------- 5-9
Group 3 Tests and adjustments ------------------------------------------------------------------------------------- 5-17
Group 4 Disassembly and assembly ---------------------------------------------------------------------------- 5-21
SECTION 6 HYDRAULIC SYSTEM
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function ------------------------------------------------------------------------------------- 6-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------- 6-31
Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 6-36
SECTION 7 ELECTRICAL SYSTEM
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component location ---------------------------------------------------------------------------------------- 7-1
Group 2 Electrical circuit ------------------------------------------------------------------------------------------------ 7-3
Group 3 Cluster -------------------------------------------------------------------------------------------------------------- 7-14
CONTENTS
CONTENTS

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Summary of Contents for Hyundai 110D-7A

  • Page 1 CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints ------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications --------------------------------------------------------------------------------------------------- 1-5 Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-15 SECTION 2 REMOVAL & INSTALLATION SECTION 2 REMOVAL & INSTALLATION Group 1 Major components ------------------------------------------------------------------------------------------- 2-1 Group 2 Removal and installation of unit ---------------------------------------------------------------------- 2-2 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM...
  • Page 2 Group 4 Transmission message indication ---------------------------------------------------------------- 7-27 Group 5 Switches ---------------------------------------------------------------------------------------------------------- 7-31 Group 6 Electrical component specification ---------------------------------------------------------------- 7-37 Group 7 Connectors ------------------------------------------------------------------------------------------------------ 7-46 Group 8 Troubleshooting ----------------------------------------------------------------------------------------------- 7-64 SECTION 8 MAST 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 -------------------------------------------------------------------------------- 8-9...
  • Page 3 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
  • Page 4 Revised edition mark(①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 7 Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246...
  • Page 8 kgf·m to lbf·ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
  • Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
  • Page 11 SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints ----------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-4 Group 3 Periodic replacement ------------------------------------------------------------------------------------- 1-15...
  • Page 12 GROUP 1 SAFETY HINTS GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. · Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
  • Page 13 Be particularly careful when removing the Be particularly careful when removing the radiator cap and the hydraulic oil tank filler radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using cap, if this is done immediately after using the machine, there is a danger that boiled the machine, there is a danger that boiled oil may spurt out.
  • Page 14 · Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. D50ASF09 · When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
  • Page 15 Way to use dipstick Push the dipstick fully into the guide, and then pull out. Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request the HYUNDAI Forklift distributor to carry out...
  • Page 16 GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS 160D7AOM54 Mast Tilt cylinder 13 Bonnet Lift chain Cabin 14 Counterweight Lift cylinder Head light-fender 15 Rear wheel Fork positioner cylinder 10 Work lamp-mast 16 Front wheel Carriage 11 Work lamp-cabin rear 17 Rear combination lamp Forks...
  • Page 17 2. SPECIFICATIONS 2. SPECIFICATIONS C' C 160D7ASP011 Model Unit 110D-7A 130D-7A 160D-7A Capacity kg (lb) 11,000 (25000) 13,000 (29000) 16,000 (36000) ← ← Load center mm (in) 600 (24") Weight(Unloaded) 15628 (34450) 16383 (36120) 19220 (42370) ← ← Lifting height mm (ft ·...
  • Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS 3. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) 110/130D-7A 110/130D-7A ENGINE ENGINE (1) (1) Item Unit Specification Model Cummins QSB6.7 Type 4 cycle turbocharged, charger air cooled diesel engine Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, In-line Firing order 1-5-3-6-2-4...
  • Page 19 (4) (4) STEERING UNIT STEERING UNIT Item Unit Specification Type Load sensing/Non load reaction/Dynamic signal Capacity cc/rev Rated flow 45.4 (5) (5) POWER TRAIN DEVICES POWER TRAIN DEVICES Item Specification Model F & S 300* OZG 040/18 (ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio...
  • Page 20 2) 2) 160D-7A 160D-7A (1) (1) ENGINE ENGINE Item Unit Specification Model Cummins QSB6.7 Type 4 cycle turbocharged, charger air cooled diesel engine Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, In-line Firing order 1-5-3-6-2-4 Combustion chamber type Direct injection Cylinder bore ×...
  • Page 21 (4) (4) STEERING UNIT STEERING UNIT Item Unit Specification Type Load sensing / Non load reaction / Dynamic signal Capacity cc/rev Rated flow 45.4 (5) (5) POWER TRAIN DEVICES POWER TRAIN DEVICES Item Specification Model F&S 300* OZG 040 / 18 (ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase...
  • Page 22 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Item Size kgf·m lbf·ft Engine mounting bolt, nut M24×3.0 100±15 723±109 Engine Radiator mounting bolt, nut M12×1.75 12.8±3.0 92±21.7 Hydraulic pump mounting bolt M12×1.75 9.0±0.5 65.1±3.6 Hydraulic MCV mounting bolt, nut M10×1.5 6.9±1.4 49.9±10.1...
  • Page 23 5. TORQUE CHART 5. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread Bolt size kg·m lb·ft kg·m lb·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...
  • Page 24 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size Width across flat (mm) kgf·m lbf·ft 9/16-18...
  • Page 25 6. RECOMMENDED LUBRICANTS 6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Capacityℓ (U.S. gal) Ambient temperature˚C (˚F) Service point Kind of fluid 110D-7A 160D-7A (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) 130D-7A ★...
  • Page 26 GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET ·Owner ·Date ·Hours ·Serial No. ·Technician ※ Use this sheet to record operational checkout results. Perform the operational check before installing any test equipment. 100D7GE02 Item Comments 1. Monitor indicator and gauge checks 1.
  • Page 27 4. Brake system and clutch cut off checks 4. Brake system and clutch cut off checks · Park brake capacity check · Park brake transmission lockout check · Service brake pump flow check · Service brake capacity check · Brake accumulator precharge check ·...
  • Page 28 7. Steering system checks 7. Steering system checks ·Steering valve check ·Steering system leakage check ·Priority valve (built in MCV) Low check pressure High check pressure 8. Accessory checks 8. Accessory checks ·Operating lights check ·Work light check ·Brake light check ·Cab light check ·Horn circuit check ·Windshield washer and wiper check...
  • Page 29 SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Major components -------------------------------------------------------------------------------------------- 2-1 Group 2 Removal and installation of unit ----------------------------------------------------------------------- 2-2...
  • Page 30 SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE GROUP 1 STRUCTURE 9 10 11 15 12 14 160D7AOM21 Mast Transmission 17 Counterweight Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder...
  • Page 31 GROUP 2 REMOVAL AND INSTALLATION OF UNIT GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST 1. MAST 1) 1) REMOVAL REMOVAL (1) (1) Forks Forks ① Lower the fork carriage until the forks are over approximately 25 mm (1 in) from the floor.
  • Page 32 ③ Pull the chains out of the sheaves and Inner mast drape them over the front of the carriage. Outer mast Work lamp assy Lift chain Block 110D7ERE55 ④ Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage to work area and lower the Inner mast mast.
  • Page 33 (3) (3) Piping Piping ① Remove the hoses and clamps attached to the cylinder. ※ Put blind plugs in the piping immediately after removing hoses. This prevents the hydraulic oil from Inner mast flowing out and also prevents dust and dirt from getting in.
  • Page 34 (4) (4) Lift cylinder Lift cylinder 110/130DF-7 160DF-7 ① Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast. ② Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no slack or binding.
  • Page 35 (5) (5) Inner mast 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. Be careful the mast not to swing or fall. Inner mast Outer...
  • Page 36 2) 2) INSTALLATION INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. ※ Installation procedure for each of mast component is the reverse of the removal procedure. (1) (1) Mast support pin Mast support pin Check the mast support pins for wear, then install pins into the mast support bracket and drive axle.
  • Page 37 2. POWER TRAIN ASSEMBLY 2. POWER TRAIN ASSEMBLY 1) 1) REMOVAL REMOVAL Mast Brake piping Drive axle Mounting bolts holding to engine flywheel Inching harness T/M & axle cooling Floor plate piping Flexible plate mount bolt 100D7RE04 (1) (1) Mast Mast Refer to section on mast (Page 2-2)
  • Page 38 (2) (2) Brake piping Brake piping Brake hose Brake hose Disconnect the brake hydraulic pipes from the brake housing of drive axle assy. Drive axle 110DERE05 (3) (3) Drive axle Drive axle ※ Before removing the drive axle assy, drain all of the oil from the axle. ①...
  • Page 39 (5) (5) Transmission and axle cooling piping Transmission and axle cooling piping ① Disconnect cooling hose and connector Radiator from the transmission. assembly ※ Make sure that the coolant has been drained from the line. Cooling hose Transmission assembly 160D7ARE10 ②...
  • Page 40 (6) (6) Flexible plate Flexible plate ① Remove the cover on the left side of the flywheel housing then remove the 8 Engine mounting bolts installed to the engine flywheel. Cover To rotate the flywheel, remove 1 Bolt mounting bolt, then insert a turning tool in Flexible plate the mounting hole.
  • Page 41 2) 2) INSTALLATION INSTALLATION Installation is the reverse order to removal, Bolt but be careful of the following points. Tightening torque of mounting bolts ① to Engine flywheel housing. ① : 5.5~8.3 kgf·m (39.8~60.0 lbf·ft) Socket bolt Tightening torque of mounting socket Transmission bolts ②...
  • Page 42 3. ENGINE 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly REMOVAL REMOVAL Mounting bolts T/C housing holding to engine cover flywheel Engine hood Engine accessory Shroud Mounting bolts Overhead Radiator guard hose Air cleaner...
  • Page 43 ② Engine cover (center) Engine cover (center) Radiator cover Pull upside the precleaner by loosening Precleaner the clamp and seal in the air intake hole Clamp of air cleaner. Remove engine cover and radiator cover upward. Engine cover 160D7ARE18 Flywheel housing cover and mounting bolts.
  • Page 44 (5) (5) Engine mounting bracket Engine mounting bracket Bolt Attach a crane to the engine hook and raise, then remove mounting bolts. Raise the engine slightly, slide towards the radiator, then lift up. Bolt ※ When sliding the engine, be careful of the collision of engine and radiator.
  • Page 45 Tightening torque of mounting bolt installed to torque converter housing. Air cieaner ·See page 2-12, 2)INSTALLATION. 2)INSTALLATION. (4) (4) Radiator hoses Radiator hoses ·Distance to insert hose : 50 mm (1.97 in) Engine (5) (5) Air cleaner hose Air cleaner hose ①...
  • Page 46 Remove the mounting bolts, raise slightly and move it slowly to rear side. ·Weight of counterweight (standard) Mode Counter weight (1) Counter weight (2) 110D-7A 2750 kg (6010 lb) 1390 kg (3065 lb) 130D-7A 3505 kg (7730 lb) 1390 kg (3065 lb)
  • Page 47 (2) (2) Rear wheel Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. 100D7RE31 (3) (3) Hose Hose Steering axle Hose 100D7RE32 (4) (4) Mounting bolt Mounting bolt Support Put a block under the steering axle, support on a truck, an raise the frame with a crane.
  • Page 48 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation ----------------------------------------------------------------------------------- 3-1 Group 2 Operation and maintenance --------------------------------------------------------------------------- 3-56 Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 3-68 Group 4 Adjustment ------------------------------------------------------------------------------------------------------- 3-186...
  • Page 49 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN COMPONENT OVERVIEW 1. POWER TRAIN COMPONENT OVERVIEW Drive axle Transmission Steering axle Propeller shaft Torque converter Engine 160D7APT01 The power train consists of the following components : ·Torque converter...
  • Page 50 · Hydraulic circuit Hydraulic circuit Pressure Temp reducing sensor valve 9 bar Main pressure valve 16+2.5bar Valve block control circuit Converter Filter Back pressure Con. valve 4.3+3 bar safety valve Bypass valve 11+2 bar 5.5 bar Pump 16+2 bar Main oil circuit Oil sump Lubrication D507PT31...
  • Page 51 2. TORQUE CONVERTER 2. TORQUE CONVERTER D503TM01 Turbine Pump Input shaft Stator Transmission pump The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the characteristics, and with it the favorable efficiency of a fluid clutch. The converter will be defined according to the engine power so that the most favorable operating conditions for each installation case are given.
  • Page 52 If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the turbine moment becomes equal to that of the pump moment. From this point on, the converter is working similar to a fluid clutch. A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the conversion range the moment upon the housing, and is released in the coupling range.
  • Page 53 3. TRANSMISSION 3. TRANSMISSION 1) 1) LAYOUT LAYOUT D507TM03 Input gear Clutch shaft (KR) Engine connection Clutch shaft 10 Clutch shaft (K1) Converter Power take-off 11 Output flange Input shaft Clutch shaft (KV) 12 Clutch shaft (K3/output) Transmission pump...
  • Page 54 2) 2) INSTALLATION VIEW NSTALLATION VIEW 21 20 11 10 FRONT VIEW REAR VIEW D507PT26 Converter 13 Breather Converter bell 14 Electro - hydraulic control Lifting lugs 15 Temperature sensor behind the converter Inductive transmitter n central gear train 16 Connection to the oil cooler Inductive transmitter n turbine 17 Filter head Gearbox housing - Front section...
  • Page 55 3) 3) OPERATION OF TRANSMISSION OPERATION OF TRANSMISSION Gearbox diagram Gearbox diagram (1) (1) The multi-speed reversing transmission in counter shaft design is power shiftable by hydraulically actuated multi-disk clutches. All gears are constantly meshing and carried on anti-friction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil.
  • Page 56 (2) (2) Forward Forward In forward, forward clutch and 1st, 2nd, 3rd clutch are engaged. Forward clutch and 1st, 2nd, 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston. 1st speed-forward Transmission diagram K3/AB Opinion direction of rotation Legend: AN = Input...
  • Page 57 (3) (3) Reverse Reverse In reserve, reserve clutch and 1st, 2nd, 3rd clutch are engaged. Reverse clutch and 1st, 2nd, 3rd are actuated by the hydraulic pressure applied to the clutch piston. 1st speed-reverse Transmission diagram K3/AB Opinion direction of rotation Legend: AN = Input K3/AB...
  • Page 58 4) 4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE SECTION A-A SECTION B-B D507PT03 Pressure reducing valve (9bar) Intermediate plate Main pressure valve (16 + 2bar) Duct plate Housing Vibration damper Plug (cable harness) 10 Follow - on slide Cover 11 Pressure regulator Valve block...
  • Page 59 Transmission control, see schedule of measuring points, Oil circuit diagram and Electro-hydraulic control unit see page 3-2, 3-10. The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is sitting in the transmission on the engine-dependent input shaft. The feed rate of the pump is Q = 85ℓ/min, at n = 2000 min...
  • Page 60 5) 5) GEAR SELECTOR (DW-3) GEAR SELECTOR (DW-3) The gear selector is designed for the mounting on the steering column left side. By a rotative motion, the positions (speeds) 1 to 3 are selected by tilting the lever, the driving direction (Forward (F) - Neutral (N) - Reverse (R)).
  • Page 61 Gear selector (DW-3) Gear selector (DW-3) LEVER FOR MECHANICAL CODING GEAR SELECTOR NEUTRAL INTERLOCK OUTPUT FORWARD REVERSE NEUTRAL SPEED ● ● ● AD1 B1 AD2 B2 ● ● ● ● ● ● AD3 B3 ● ● ● IN POSITION(NEUTRAL), ● ● ● F-R NOT SWITCHABLE ●...
  • Page 62 6) 6) TRANSMISSION ERROR DISPLAY TRANSMISSION ERROR DISPLAY (1) (1) Function Function The display can be used with the gear selector. It indicates speed and driving direction as well as the activated inching. When driving in the automatic mode, a bar indicator gives additionally also information about the selected driving range;...
  • Page 63 (3) (3) Display during operation Display during operation Symbol Meaning Remarks Actual gear and direction F, N, R Central side shows actual gear 1, 2, 3 Right side shows actual direction Not neutral, waiting for neutral To engage a gear, first move shift selector to (Central and right side) after power up or a reverse fault neutral position and again to F to R position...
  • Page 64 Transmission error codes Transmission error codes Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Logical error at gear range signal Logical error at gear range signal TCU shifts transmission to Check the cables from TCU to TCU detected a wrong signal combination...
  • Page 65 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage at load sensor S.C. to battery voltage at load sensor Retarder function is affected Check the cable from TCU to the input input...
  • Page 66 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to ground at retarder temperature S.C. to ground at retarder temperature N o r e a c t i o n , T C U u s e s Check the cable from TCU to the sensor input sensor input...
  • Page 67 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · OP mode : Substitute clutch Logical error at engine speed input Logical error at engine speed input Check the cable from TCU to the control sensor TCU measures a engine speed over a...
  • Page 68 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · OP mode : Substitute clutch Logical error at internal speed input Logical error at internal speed input Check the cable from TCU to the control sensor TCU measures a internal speed over a...
  • Page 69 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage at clutch K1 S.C. to battery voltage at clutch K1 TCU shifts to neutral Check the cable from TCU to the The measured resistance value of the valve OP mode : Limp home...
  • Page 70 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage at clutch K3 S.C. to battery voltage at clutch K3 TCU shifts to neutral Check the cable from TCU to the The measured resistance value of the OP mode : Limp home...
  • Page 71 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · O.C. at engine derating device O.C. at engine derating device No reaction Check the cable from TCU to the TCU detected a wrong voltage at the OP mode : Normal engine derating device...
  • Page 72 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to ground at clutch KR S.C. to ground at clutch KR TCU shifts to neutral Check the cable from TCU to the The measured resistance value of the valve OP mode : Limp home gearbox...
  • Page 73 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · No reaction Check the cable from TCU to the O.C. at relay reverse warning alarm O.C. at relay reverse warning alarm OP mode : Normal backup alarm device TCU detected a wrong voltage at the...
  • Page 74 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to ground at park brake solenoid S.C. to ground at park brake solenoid No reaction Check the cable from TCU to the TCU detected a wrong voltage at the OP mode : Normal park brake solenoid...
  • Page 75 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to battery voltage at converter lock S.C. to battery voltage at converter lock No reaction · Check the cable from TCU to the up clutch solenoid up clutch solenoid OP mode : Normal...
  • Page 76 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection S.C. to ground at difflock or axle S.C. to ground at difflock or axle No reaction · Check the cable from TCU to the connection solenoid connection solenoid OP mode : Normal...
  • Page 77 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · TCU shifts to neutral Check pressure at clutch K1 Slippage at clutch K1 Slippage at clutch K1 · OP mode : Limp home Check main pressure in the TCU calculates a differential speed at...
  • Page 78 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · TCU shifts to neutral Slippage at clutch KV Slippage at clutch KV Check pressure at clutch KV · OP mode : Limp home TCU calculates a differential speed at Check main pressure in the...
  • Page 79 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Slippage at converter lockup clutch Slippage at converter lockup clutch Check pressure at converter TCU calculates a differential speed at lockup clutch ·...
  • Page 80 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Overtemp converter output Overtemp converter output No reaction Cool down machine · TCU measured a oil temperature at the OP mode : Normal Check oil level ·...
  • Page 81 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage at power supply S.C. to battery voltage at power supply See fault codes No.21 to 2C Check cables and connectors to for sensors for sensors...
  • Page 82 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection ※ S.C. battery voltage at speedometer S.C. battery voltage at speedometer Not used output output ※ Not used S.C. to ground or O.C at speedometer S.C.
  • Page 83 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · General EEPROM fault General EEPROM fault No reaction Replace TCU ※ TCU can't read non volatile memory OP mode : Normal Often shown together with fault ·...
  • Page 84 (5) (5) Measuring of resistance at actuator/sensor and cable Measuring of resistance at actuator/sensor and cable ① Actuator Actuator 76043PT19 = ∞ Open circuit Short cut to ground = R; R = 0, R = R or R = R, R (For S.C.
  • Page 85 7) 7) ELECTRONIC CONTROL FOR POWER TRANSMISSION ELECTRONIC CONTROL FOR POWER TRANSMISSION (1) (1) Description of the basic functions Description of the basic functions The powershift transmission is equipped with TCU. ·The system is processing the desire of the driver according to the following criteria : ·Gear determination depending on gear selector position, driving speed and load condition.
  • Page 86 Legend Legend 2 = Display 3 = Gear selector DW - 3 4 = Power supply connection 5 = Switch for enable inched (Option) 6 = Switch for driving program manual/Auto 1/Auto 2 9 = TCU (EST-37A) 11 = Wiring 14 = Cable to inductive transmitter speed central gear train 15 = Cable to inductive speed engine 16 = Cable to inductive transmitter speed turbine...
  • Page 87 (2) (2) Inching device Inching device This function is especially suitable for lift trucks. It allows to reduce the driving speed infinitely variable without modification of the engine speed in such a way that driving with a very low speed will be possible.
  • Page 88 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS The measurement have to be carried out with hot transmission (about 80~95˚C) D50TM04 3-40...
  • Page 89 1) 1) OIL PRESSURE AND TEMPERATURE OIL PRESSURE AND TEMPERATURE Port Description Size In front of converter - Opening pressure 11+2 bar M10×1 Behind converter - Opening pressure 4.3 + 3 bar M14×1.5 Clutch Forward 16 + 2 bar M10×1 Clutch reverse 16 + 2 bar M10×1...
  • Page 90 5. DRIVE AXLE (DIC) 5. DRIVE AXLE (DIC) 1) 1) STRUCTURE 1 STRUCTURE 1 21-1 21-2 110DEDR02 Taper roller bearing 15 Oil seal 29 Hexagon bolt Spacer 16 Differential flange 30 Differential case-RH Taper roller bearing 17 Hexagon bolt 31 Differential case-LH Bevel gear assy 18 Spring washer 32 Side gear...
  • Page 91 2) 2) STRUCTURE 2 STRUCTURE 2 38 39 110DEDR03 Brake disc 14 Snap ring 27 Sun gear Brake plate 15 O-ring 28 Snap ring 16 Taper roller bearing 29 Stopper Brake cover Wheel hub 30 Snap ring Magnetic plug 18 O-ring 31 Thrust washer O-ring 19 C-ring...
  • Page 92 3) 3) STRUCTURE 3 STRUCTURE 3 27 28 10 11 16 17 110DEDR04 Dowel pin 11 O-ring 22 Adjust bolt Axle housing 12 Spacer 23 Piston Gasket 13 O-ring 24 Quad ring Air breather 15 Axle tube 25 Quad ring Plug 16 Magnetic plug 26 Bushing...
  • Page 93 4) 4) SYSTEM OPERATION SYSTEM OPERATION General specification General specification (1) 1) 110DEDA01 Differential Service brake Drive shaft Parking brake Drive wheel OPERATION OPERATION The drive axle is composed of differential carrier assy (1), drive shaft (2), and drive wheel (3). The power is transmitted from the engine fly wheel to the transmission.
  • Page 94 (2) (2) Powertrain specification Powertrain specification Classify 110/130D-7A 160D-7A Drive shaft Reduction Differential 2.93 (41/11) 3.73 (41/11) gear ratio Plenatary gear 3.60 (52/20) 10.548 13.428 Axle oil Differential Cooling oil Differential Cooling oil SAE 80W/90 Mobil 424 SAE 80W/90 Mobil 424 Oil capacity 15ℓ...
  • Page 95 5) 5) DIFFERENTIAL DIFFERENTIAL 110DEDA02 Ø27.110 ~ Ø27.131 Differential pinion gear inner diameter Ø26.980 ~ Ø26.959 Spider out diameter Pinion gear washer thickness 1.52 ~ 1.68 mm Side gear washer thickness 2.94 ~ 3.06 mm Ø50.00 ~ Ø50.04 Side gear (Inner diameter) OPERATION OPERATION Differential transmits the power from the transmission to drive wheel.
  • Page 96 6) 6) DRIVE SHAFT DRIVE SHAFT (1) (1) General standards General standards 110DEDA03 Sun gear Hub assembly 11 Pinion shaft Plenatary gear Disc brake 12 Spider Internal gear Drive shaft 13 Pinion gear Internal gear carrier Differential carrier 14 Side gear Taper roller bearing 10 Ring gear OPERATION...
  • Page 97 (2) (2) Driving axle tightening torque specifications Driving axle tightening torque specifications 110DEDA04 Wheel hub pre-load 330~400kg·cm Plenatary housing tightening torque 250~400kg·cm Spline hub tightening torque 3200±50kg·cm Brake cover tightening torque 2100±50kg·cm Self-adjust bolt tightening torque 300~350kg·cm Axle tube tightening torque 3200±50kg·cm Diff carrier cap tightening torque 5500±100kg·cm...
  • Page 98 (3) (3) Disc brake (110/130D-7A) Disc brake (110/130D-7A) 110DEDA05 Collar spline hub Brake housing Self adjust bolt Wheel hub Service brake piston Drive shaft Disc brake Brake plate Brake cover 10 Parking brake OPERATION OPERATION Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 99 (4) (4) Disc brake (160D-7A) Disc brake (160D-7A) 110DEDA06 Collar spline hub Brake housing Self adjust bolt Wheel hub Service brake piston Drive shaft Disc brake Brake plate Brake cover 10 Parking brake OPERATION OPERATION Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 100 6. DRIVE AXLE (KESSLER) 6. DRIVE AXLE (KESSLER) 1) 1) STRUCTURE 1 STRUCTURE 1 419 528 402 425 538 535 530 529 531 100D7DR02 400 Differential & carrier 412 Bearing bushing 422 Hexagon screw 401 Drive pinion 413 Hexagon screw 423 Hexagon screw 402 Ring gear 414 Hexagon screw...
  • Page 101 2) 2) STRUCTURE 2 STRUCTURE 2 100D7DR03 250 Inner disk 263 O-ring 280 Bleeder valve 251 Outer disk 266 Hexagon screw 281 Pipe 252 Piston 269 Hex sockets crew 282 Hexagon screw with flange 258 Gasket 271 Face seal 283 Compression spring 259 Gasket 272 Screw plug 260 Brake carrier...
  • Page 102 3) 3) STRUCTURE 3 STRUCTURE 3 100D7DR04 300 Planetary housing 314 Sun gear 335 Ring gear 304 O-ring 316 Circlip 336 Ring gear carrier 306 Sealing ring 320 Thrust ring 337 Retainer 307 Screw plug 322 Planetary gear 338 Hexagon socket screw 308 Sealing ring 324 Thrust washer 340 O-ring...
  • Page 103 7. TIRE AND WHEEL 7. TIRE AND WHEEL D507AX68 Wheel rim Lock ring Valve assembly Tire Side ring Wheel nut The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with the ground to gain the power which drives the machine. Various types of tires are available to suit the purpose.
  • Page 104 GROUP 2 OPERATION AND MAINTENANCE GROUP 2 OPERATION AND MAINTENANCE 1. OPERATION 1. OPERATION 1) 1) DRIVING PREPARATION AND MAINTENANCE DRIVING PREPARATION AND MAINTENANCE Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity.
  • Page 105 - Upshifting in overrunning condition. Upshifting in overrunning condition. In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if the speed of the vehicle on a downgrade should not be further increased. - Downshifting in overrunning condition. Downshifting in overrunning condition.
  • Page 106 Now, the temperature must drop quickly (in about 2~3 minutes) to normal values. If this is not the case, there is a trouble pending, which must be eliminated prior to continue working. The monitoring of the oil temperature(behind the converter) is additionally on the temperature gauge which is located on the dashboard.
  • Page 107 2. MAINTENANCE 2. MAINTENANCE 1) 1) TRANSMISSION TRANSMISSION (1) (1) Oil level check Oil level check At the oil level check, the vehicle has to be secured against rolling with blocks. At the oil level check, the vehicle has to be secured against rolling with blocks. The oil level check must be carried out as follows : - Oil level check (weekly) - At horizontally standing vehicle...
  • Page 108 (2) (2) Oil change and filter replacement intervals Oil change and filter replacement intervals ※ First oil change after 100operating hours in service. Every further oil change after 1000operating hours in service, however at least once a year. At every oil change, the fine filter has to be replaced. ①...
  • Page 109 D507PT19 Legend: Legend: 1 = Oil filter tube with oil dipstick 2 = Oil drain plug M38×1.5 3 = Attachment possibility oil level tube with oil dipstick(converter side) 4 = Filter head 5 = Fine filter Oil dipstick MEASURED AT LOW COLD IDLING-NEUTRAL D507PT20...
  • Page 110 2) 2) DRIVE AXLE DRIVE AXLE (1) (1) Important remarks Important remarks ① For safety reasons, the operator should verify and service at regular intervals all of the bolted assemblies and all of the important safety locks such as : Wheel nuts Nuts of axle mounting bolts Bolts on the steering components and the brake system parts : if the screws are tightable, the...
  • Page 111 (3) (3) Lubrication points (DIC) Lubrication points (DIC) 1 2 , The binding lubrication points has to be taken from the according installation drawing of the axle. ① Single drive assembly ※ The position is dependent from the respective axle version. ※...
  • Page 112 3. TROUBLESHOOTING 3. TROUBLESHOOTING 1) 1) BRAKE LEAKS ACTUATION FLUID BRAKE LEAKS ACTUATION FLUID Condition Condition Possible cause Possible cause Correction Correction Internal leak : Fluid 1. Worn or damaged piston seal. 1. Replace piston seals. bypasses seals into axle 2.
  • Page 113 3) 3) BRAKE OVERHEATS BRAKE OVERHEATS Condition Condition Possible cause Possible cause Correction Correction Overheating due to Inadequate coolant flow or heat 1. Install brake cooling system if not already excessive duty cycle. exchange. installed on vehicle. 2. Re-analyze and re-size brake cooling system if necessary.
  • Page 114 5) 5) BRAKE DOES NOT RELEASE BRAKE DOES NOT RELEASE Condition Condition Possible cause Possible cause Correction Correction Vehicle does not move Damaged hydraulic system. Repair hydraulic system. Brakes dragging 1. More than 1.4bar (20 psi) pressure 1. Repair hydraulic system so pressure is less applied when brakes released.
  • Page 115 7) 7) DIFFERENTIAL DIFFERENTIAL Condition Condition Possible causes Possible causes Correction Correction · Constant noise in differential. Oil is not enough(Replace Refueling lubricating oil interval : 50 hrs first, then every 500hrs ). · Wrong kind of oil. Exchange lubricating oil ·...
  • Page 116 Condition Condition Possible causes Possible causes Correction Correction Drive wheels do not rotate Broken axle shaft. · Loose wheel bearings. Re-assemble wheel bearings. · Axle shaft too short. Replace drive shaft · Loose flange studs or nuts. Tighten studs or nuts ·...
  • Page 117 GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY 1. TRANSMISSION DISASSEMBLY ELECTRO-HYDRAULIC CONTROL ELECTRO-HYDRAULIC CONTROL 1) 1) AND FILTER (EXCHANGE FILTER) AND FILTER (EXCHANGE FILTER) ① Mount the transmission to the assembly truck. (S) Assembly truck 5870 350 000 (S) Holding fixture 5870 350 124...
  • Page 118 (2) (2) Removal of the electric shift system Removal of the electric shift system ① Remove the shift system (1). Loosen the Torx screws (2) and separate the gearshift housing from the intermedi-ate sheet. (S) Socket spanner TX-27 5873 042 002 (S) Adjusting screw M6 5870 204 063 D507TM14...
  • Page 119 ⑤ Separate the duct plate (3), and inter- mediate sheet (2) from the valve block (1). D507TM18 ⑥ Remove the retaining clamp (1). D507TM19 ⑦ Loosen the cap screws (1) and remove the cover. Remove the opposite cover. (S) Socket spanner TX-27 5873 042 002 D507TM20 ⑧...
  • Page 120 ⑨ Loosen the cap screws, remove the fixing plates and the pressure regulators (1). (S) Socket spanner TX-27 5873 042 002 D507TM22 ⑩ Loosen two cap screws (1) and fasten the adjusting screws (S) preliminarily (housing is spring-loaded). Following to this loosen the remaining cap screws.
  • Page 121 ⑬ Remove the single parts on the opposite side analogously: 1 = Main pressure valve 2 = Vibration damper 3 = Follow-on slide D507TM26 2) 2) INDUCTIVE TRANSMITTERS, VALVES, INDUCTIVE TRANSMITTERS, VALVES, OIL FILTER AND OIL DRAIN PLUG, OIL FILTER AND OIL DRAIN PLUG, SCREW PLUGS SCREW PLUGS ①...
  • Page 122 ④ Remove the positioned parts. 1 = Inductive transmitter n - Internal speed input 2 = Inductive transmitter n - Turbine 3 = Speed transmitter n - Output 4 = Cover (mounting possibility for oil filler tube) D507TM30 3) 3) ENGINE CONNECTION, PRESSURE ENGINE CONNECTION, PRESSURE OIL PUMP AND REMOVAL OF THE...
  • Page 123 ③ By means of the lifting equipment the converter bell (1) with pressure oil pump (5) are commonly to be separated from the transmission housing rear section (4). Remove the intermediate sheet (3) and the stator hollow shaft (2). (S) Eyebolts assortment 5870 204 002 (S) Lifting chain 5870 281 047 D507TM33...
  • Page 124 ⑦ Remove the tab washer (2) and loosen the hexagon screws (1). D507TM37 ⑧ Pull off the input shaft (1). Remove the shaft seal. (S) Two-armed puller 5870 970 003 D507TM38 ⑨ Unsnap the retaining ring (1) from the power take-off and remove the O-ring (2).
  • Page 125 ⑪ By means of the lifting equipment separate the transmission housing rear section (1) from the transmission housing front section (2). (S) Eyebolts 2×(M20) 0636 804 003 (S) Ring nut (M12) 0664 462 774 (S) Lifting chain 5870 281 047 D507TM41 ⑫...
  • Page 126 ⑮ Remove the pipes (system pressure from the electro-hydraulic control to the respective clutch). Remove the holding segment (6). The pipes are to disassembled in the following sequence: 1 = Pipe 2 = Pipe 3 = Pipe D507TM45 4 = Pipe 5 = Pipe Remove all bearing outer rings (see arrows).
  • Page 127 4) 4) CLUTCHES KV/KR/K1/K2/K3 AND CLUTCHES KV/KR/K1/K2/K3 AND INPUT INPUT See figure on the right. D507TM51 (1) (1) Clutch KV Clutch KV ① Remove the stud (1) and unsnap the piston ring (2). D507TM52 ② Pull the taper roller bearing (inner ring) from the shaft.
  • Page 128 ④ Unsnap the retaining ring (1). (S) Set of external pliers 5870 900 015 D507TM55 ⑤ Press the clutch shaft (1) out of the idler (2). (S) Parting tool 5870 300 028 D507TM56 ⑥ Unsnap the retaining ring (2) from the idler (1) and remove the ball bearing (3).
  • Page 129 ⑧ Rotate the shaft (2) by 180°and unsnap the piston ring (1). D507TM59 ⑨ Pull the taper roller bearing (inner ring) from the shaft. (S) Gripping insert 5873 001 057 (S) Back-off insert 5870 026 100 (S) Rapid grip 5873 011 011 D507TM60 (2) (2) Clutch KR...
  • Page 130 ③ Pull the clutch (1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM63 ④ Unsnap the retaining ring (1). (S)Set of external pliers 5870 900 015 D507TM64 ⑤ Press the clutch shaft (1) out of the idler (2). (S)Parting tool 5870 300 028 D507TM65 ⑥...
  • Page 131 ⑦ Unsnap the retaining ring (2) from the idler (1) and remove the ball bearing. (S) Set of internal pliers 5870 900 013 D507TM67 ⑧ Remove the needle cage (1) from the shaft (2). D507TM68 Shaft (2) and gear (1) cannot be separa- ted (shrink fit).
  • Page 132 ⑩ Pull the taper roller bearing (inner ring) from the shaft. (S) Gripping insert 5873 001 057 (S) Back-off insert 5870 026 100 (S) Rapid grip 5873 011 011 D507TM71 (3) (3) Clutch K1 Clutch K1 ① Remove the stud (1) and unsnap the piston ring (2).
  • Page 133 ④ Remove the complete axial bearing (1). D507TM75 ⑤ Take off idler (1), remove the needle cage (2) and the complete axial bea-ring (3). D507TM76 ⑥ Pull the clutch (1) from the shaft. (S)Two-armed puller 5870 970 003 D507TM77 ⑦ Rotated the shaft (2) by 180°and unsnap the piston ring (1).
  • Page 134 ⑧ Pull the taper roller bearing (inner ring) from the shaft. (S) Gripping insert 5873 001 057 (S) Back-off insert 5870 026 100 (S) Rapid grip 5873 011 011 D507TM79 (4) (4) Clutch K1 Clutch K1 ① Remove the stud (1) and unsnap the piston ring (2).
  • Page 135 ④ Remove the complete axial bearing (1). D507TM83 ⑤ Take off idler (1), remove the needle cage (2) and the complete axial bea-ring (3). D507TM84 ⑥ Pull the clutch (1), front the shaft. (S) Two-armed puller 5870 970 003 D507TM85 ⑦...
  • Page 136 ⑧ Pull the taper roller bearing (inner ring) from the shaft. (S)Gripping insert 5873 001 057 (S)Back-off insert 5870 026 100 (S)Rapid grip 5873 011 011 D507TM87 (5) (5) Clutch K3 Clutch K3 ① Unsnap the piston ring (1). D507TM88 ②...
  • Page 137 ④ Take off idler (1), remove the needle cage (2) and the complete axial bea-ring (3). D507TM91 ⑤ Pull the clutch (1) from the shaft. (S) Two-armed puller 5870 970 003 D507TM92 ⑥ Rotated the shaft (2) by 180°and unsnap the piston ring (1). D507TM93 ⑦...
  • Page 138 Input ① Unsnap the piston ring (1). The turbine wheel shaft (2) and the input gear (3) are attached with a snap ring. ※ The components are destroyed at separ- ation D507TM95 ② Pull the taper roller bearing (inner ring) from the input gear.
  • Page 139 2. TRANSMISSION ASSEMBLY 2. TRANSMISSION ASSEMBLY CLUTCHES KV/KR/K1/K2/K3 AND INPUT CLUTCHES KV/KR/K1/K2/K3 AND INPUT 1) 1) ※ In the EST-37A (electronic transmission control)the gear change (filling times and pressure level) are controlled via the drive program of the transmission electronics. Additionally, the EST-37A monitors the disc clearance (clearance) of the clutches and if exceeded, a fault message is given in the transmission error display.
  • Page 140 ④ Put the ball bearing (2) into the idler (1) until contact is obtained and fasten it by means of retaining ring (3). (S) Set of internal pliers D507TM104 ⑤ Press in preassembled idler (1) until contact. D507TM105 ⑥ Fasten the idler (1) by means of retaining ring (2).
  • Page 141 ⑧ Mount the clutch (1) until contact is obtained. Wear safety gloves. Wear safety gloves. D507TM108 ⑨ Press the taper roller bearing (inner ring) (1) until contact is obtained. D507TM109 ⑩ Install the piston ring (1). D507TM110 ⑪ Install the stud (1). Tightening torque -------------- M =1.7 kg·...
  • Page 142 (2) (2) Clutch KR Clutch KR ① Press the taper roller bearing (inner ring) (1) onto the shaft (2) until contact is obtained. D507TM112 ② Install the piston ring (1). D507TM113 ③ Heat up the inner diameter of the gear (1)(approx.
  • Page 143 ⑤ Fasten the gear (1) by means of retaining ring (2). (S) Set of internal pliers 5870 900 015 D507TM116 ⑥ Mount the needle bearing (1) onto the shaft (2). D507TM117 ⑦ Put the ball bearing (2) into the idler (1) until contact is obtained and fasten it by means of retaining ring (3).
  • Page 144 ⑨ Fasten the idler (1) by means of retaining ring (2). (S) Set of internal pliers 5870 900 015 D507TM120 ⑩ Heat up the inner diameter of the clutch (1) (approx. 120˚C). (S) Hot- air blower 220V 5870 221 500 (S) Hot- air blower 110V 5870 221 501 D507TM121 ⑪...
  • Page 145 ⑬ Install the piston ring (1). D507TM124 ⑭ Install the stud (1). Tightening torque -------------- M =1.7 kg· m ※ Check closing respective opening of the clutch by means of compressed air at the bore (2). Closing respective opening of the clutch must be clearly audible.
  • Page 146 ③ Install the sealing cap (1). ※ Wet the contact surface with (Loctite Type No. 262). D507TM128 ④ Heat up the inner diameter of the clutch (1) (approx. 120˚C). (S) Hot- air blower 220V 5870 221 500 (S) Hot- air blower 110V 5870 221 501 D507TM129 ⑤...
  • Page 147 ⑦ Mount the needle cage (1). D507TM132 ⑧ Install the idler (1). D507TM133 ⑨ Mount the axial washer (1), axial cage Chamfer (2) and running disc (3). ※ Install chamfer (see arrow) of the running disc (3) showing towards the axial cage D507TM134 ⑩...
  • Page 148 ⑪ Press the taper roller bearing (inner ring) (1) until contact is obtained. D507TM136 ⑫ Install the piston ring (1). D507TM137 ⑬ Install the stud (1). Tightening torque -------------- M =1.7kg· m ※ Check closing respective opening of the clutch by means of compressed air at the bore (2).
  • Page 149 ② Install the piston ring (1). D507TM140 ③ Heat up the inner diameter of the clutch (1) (approx. 120˚C). (S) Hot- air blower 220V 5870 221 500 (S) Hot- air blower 110V 5870 221 501 D507TM141 ④ Mount the clutch (1) until contact is obtained.
  • Page 150 ⑥ Mount the needle cage (1). D507TM144 ⑦ Install the idler (1). D507TM145 ⑧ Mount the axial washer (1), axial cage Chamfer (2) and running disc (3). ※ Install chamfer (see arrow) of the running disc (3) showing towards the axial cage. D507TM146 ⑨...
  • Page 151 ⑩ Press the taper roller bearing (inner ring) (1) until contact is obtained. D507TM148 ⑪ Install the piston ring (1). D507TM149 ⑫ Install the stud (1). Tightening torque -------------- M =1.7kg· m ※ Check closing respective opening of the clutch by means of compressed air the bore(2).
  • Page 152 ② Install the piston ring (1). D507TM152 ③ Install the sealing cap (1). Wet the contact surface with loctite type No.262. D507TM153 ④ Heat up the inner diameter of the clutch (1) (approx. 120˚C). (S) Hot- air blower 220V 5870 221 500 (S) Hot- air blower 110V 5870 221 501 D507TM154 ⑤...
  • Page 153 ⑥ Mount the running disc (1), axial cage (2) and axial washer (3). Chamfer ※ Install chamfer (see arrow) of the running disc (3) showing toward the axial cage. D507TM156 ⑦ Mount the needle cage (1). D507TM157 ⑧ Install the idler (1). D507TM158 ⑨...
  • Page 154 ⑩ Press the taper roller bearing (inner ring) (1) until contact is obtained. D507TM160 ⑪ Install the piston ring (1). D507TM161 ⑫ Install the screw plug (1). (S) Lever riveting tongs 5870 320 016 D507TM162 ※ Check closing respective opening of the clutch by means of compressed air at the bore (1).
  • Page 155 (6) (6) Input Input ① Press the taper roller bearing (inner ring) (1) until contact is obtained. D507TM164 ② Press the taper roller bearing (inner ring) (1) until contact is obtained. D507TM165 ③ Have the snap ring (1) engaged into the annular groove of the turbine wheel shaft (2).
  • Page 156 2) 2) ENGINE CONNECTION, PRESSURE OIL PUMP AND INSTALLATION OF THE ENGINE CONNECTION, PRESSURE OIL PUMP AND INSTALLATION OF THE CLUTCHES CLUTCHES Install all bearing outer rings into the bearing bores of both transmission housing sections. ※ Should contrary to the recommendations the taper roller bearing of the clutches as well as of the input not be replaced, the assignment (bearing inner and outer rings) has to be kept at least .
  • Page 157 ② Fasten the screen sheet (1) by means of cap screws (2). Tightening torque (M8/8.8) -- M =2.3 kg· m D507TM174 ③ The clutch is to be put into the transmiss- ion housing front section as described in the legend. 1 = Input shaft 2 = Clutch KV 3 = Clutch KR...
  • Page 158 ⑥ Install the O-rings (3) and fasten the suction pipe (1) by means of cap scre-ws (2). Tightening torque (M8/8.8) -- M =2.3 kg· m D507TM178 ⑦ Grease the rectangular rings (see arrows) and align them, centrically. ※ Wet the mounting face with sealing com- pound loctite (Type No.574) D507TM179 ⑧...
  • Page 159 ⑩ Install the shaft seal (1) with the sealing lip showing to the oil sump. ※ The exact installation position is obtained by using the specified mounting tool (S). ※ Fill the shaft seal between dust lip and sealing lip with grease. Wet the outer diameter with spirit.
  • Page 160 ⑭ Install the retaining ring (1) and the O-ring (2). ※ Grease the O-ring D507TM186 ⑮ Install two adjusting screws and mount the stator hollow shaft (1). ※ Observe the radial installation position. (S) Adjusting screws 5870 204 007 D507TM187 Install the converter safety valve (1) until contact.
  • Page 161 Cautiously place the converter bell (1) by means of the lifting equipment to the tran-smission until contact is obtained. (S) Eyebolts assortment 5870 204 002 (S) Lifting chain 5870 281 047 D507TM190 (3) (3) Pressure oil pump Pressure oil pump ※...
  • Page 162 (4) (4) Installation of the external and internal Installation of the external and internal rotor rotor ※ Install the external rotor. Chamfer shows to the pump base (cannot be seen in the picture). ※ Install the internal rotor. Gearing (arrow) shows downwards. D507TM194 ①...
  • Page 163 ③ Fasten the converter bell, pressure oil pump and stator hollow shaft together by means of cap screws. ※ Different bolted connections. 1 = Bolted connection converter bell/tran- smission housing rear section. Tightening torque (M10/8.8) ---------------------- ----------------------------------------------- M =4.7 kg· m 2 = Bolted connect.
  • Page 164 3) 3) INDUCTIVE TRANSMITTERS, VALVES, INDUCTIVE TRANSMITTERS, VALVES, OIL FILTERS AND OIL DRAIN PLUG, OIL FILTERS AND OIL DRAIN PLUG, SCREW PLUGS SCREW PLUGS ① Install the converter pressure back-up valve. 1 = Piston 2 = Compression spring 3 = O-ring (27×2) 4 = Screw plug (30×1.5) D507TM201 ※...
  • Page 165 ④ Installation of: 1 = Inductive transmitter - n Internal speed input 2 = Inductive transmitter - n Turbine 3 = Breather ※ =3.1 kg · m Tightening torque (1 and 2) - M Tightening torque (3) ---------- M =1.2 kg· m Fasten the cove replate (4) by means of hexagon screws (5).
  • Page 166 ELECTRO-HYDRAULIC CONTROL UNIT WITH PROPORTIONAL VALVES ELECTRO-HYDRAULIC CONTROL UNIT WITH PROPORTIONAL VALVES ※ Different versions as to the positions of the wiring harness are possible. · The following sketches shows the sections of the electro-hydraulic control unit. Pressure reducing valve (9 bar) Main pressure valve Housing...
  • Page 167 (1) (1) Mounting of the electric control unit Mounting of the electric control unit ※ All single parts are to be checked for damaged and replaced, if required. Prior to installation check the mobile parts in the housing for functionality. Piston can be replaced individually.
  • Page 168 ④ Install two adjusting screws. Assembly flat gasket (1) and housing cover. Then place the housing cover by means of adjusting screws equally until contact. (S) Adjusting screws 5870 204 036 D507TM217 ⑤ Preload the pistons with cap screws and remove the cyl.
  • Page 169 · Preassemble the opposite side Preassemble the opposite side ⑧ The figure on the right shows the followi- ng single parts: 1 = Main pressure valve (1×, piston a. compr. spring) 2 = Vibration damper (3×, piston a. compr. spring) 3 = Follow-on slide (3×, piston a.
  • Page 170 ⑪ Mount the pressure regulators (1) and fasten them by means of fixing plates and cap screws. ※ Install the fixing plate with the neck showing downwards Observe radial installation position of the pressure regulators. Tightening torque ------------- M =0.56 kg· m D507TM224 ⑫...
  • Page 171 ⑮ Install two adjusting screws. (S) Adjusting screws 5870 204 063 D507TM228 Screens (1) are to be flush mounted into the bores of the intermediate sheet, see arrows. Observe the installation position-the screens are showing upwards (to the duct plate). D507TM229 Put on the intermediate sheet (1) ※...
  • Page 172 Provide the screw plugs (1) with new O-rings and install them. ※ Tightening torque ------------ M =0.61 kg· m D507TM232 Insert the pressure relief valve (1) and lock it with the indented ring (2). (S) Drive mandrel 5870 705 012 D507TM233 Mount the gasket (1) and the cpl.
  • Page 173 (2) (2) Mounting of the filter (pressure filter) Mounting of the filter (pressure filter) ① Fasten the filter head (1) with new O-rings by means of cap screws (2) to the trans-mission housing. =2.4 kg · m Tightening torque(M8) ------ M (S) Torque spanner 5870 203 034 (S) Socket spanner TX-40 5870 042 004...
  • Page 174 Loctite. (16) The bolted or keyed assemblies safeties are to be checked according to instructions ; in case of doubt, consult Hyundai dealer. (17) Refill the oil after assembly. (18) Repair weldment is only allowed after consultation with Hyundai. 3-125...
  • Page 175 2) 2) REMOVAL AND DISASSEMBLE THE WHEEL HUB REMOVAL AND DISASSEMBLE THE WHEEL HUB Loosen the drain plug of the axle housing by using a torque wrench, and drain the oil. 110DEDA10 Loosen the drain plug of planetary housing, then drain the oil. 110DEDA11 L o o s e n t h e f o u r b o l t s ( 1 ) a n d disassemble the planetary housing.
  • Page 176 Disassemble four planetary pin (3) using the tool. 110DEDA14 Disassemble planetary gear (4), needle bearing (5) and thrust washers (6). 110DEDA15 Disassemble drive shaft assembly (8) with sun gear (7). 110DEDA16 Disassemble retaining ring (9) by using tool and disassemble sun gear (10) from drive shaft (8).
  • Page 177 Loosen the bolts (11) and nut (12). (11) (13) Disassemble the internal gear carrier (12) assembly (13) from spindle (A). Mark the installation position of the nut (12) and the internal gear carrier before disassembling. Check for position during assembly. 110DEDA18 (10) Disassemble the gear (15) from ring gear...
  • Page 178 (12) Slowly disassemble the wheel hub assy and the internal gear carrier by using the extraction tab of the brake housing as loosen the nut. A strong shock may be damaged the oil seal. 110DEDA22 110DEDA23 110DEDA24 (13) Disassemble bearing of the carrier internal gear using two M8 bolts.
  • Page 179 (14) Disassemble disk (17) and plate (18) and (18) then disassemble six brake pin (19) from the disassembled wheel hub assembly. Disassemble the brake cover (20) and wheel hub assembly (21). (19) (17) 110DEDA26 (20) (21) 110DEDA27 (15) Disassemble hub spline (23) and wheel hub (24) (24) after untightening tweenty bolts (25).
  • Page 180 (16) Disassemble bearing (26) and O-ring (27) (26) from wheel hub. (27) 110DEDA30 (17) Disassemble brake housing assembly (28), (28) (30), (31) axle tube (29), after untightening tweenty bolts that connect axle housing (30) and tweenty washers (31). Detach O-ring (32) on both joints sides of tube after disassemble brake housing and tube.
  • Page 181 (33) (34, 35) 110DEDA34 3) 3) REMOVAL AND DISASSEMBLE THE CARRIER HOUSING ASSY REMOVAL AND DISASSEMBLE THE CARRIER HOUSING ASSY Disassemble parking disc (3) and brake assembly (4) after untightening six bolts (1) and four bolts (2). 110DEDA35 Loosen thirteen bolts (5) that connect the axle housing and the carrier housing and then disassemble the carrier from the axle housing.
  • Page 182 Check and record the rotational torque measurements of the carrier assy and then disassemble cotter pin (6). Disassemble two nuts (8) and two differential caps (9), after untightening four bolts (7). Check and record the direction of the cap Check and record the direction of the cap before removing bearing cup.
  • Page 183 Loosen sixteen bolt (13) then disassemble differential assembly. (13) 110DEDA42 Disassemble side gear (14), pinion gear (15), thrust washers (16), (17) and spider (18) (18) from differential assembly. (14) (16) (15) (17) 110DEDA43 Disassemble differential flange assembly (21) and shim (22) from carrier housing after loosen snap ring (19) and ten bolts (20).
  • Page 184 (22) 110DEDA46 Loosen nut (23) and disassemble the york (24) from differential flange assembly. (23) (24) 110DEDA47 (10) Disassemble the pinion shaft (25) from the differential flange (29) by using tools. Be careful imprints on the pinion shaft and oil seal damage. 110DEDA48 3-135...
  • Page 185 (25) 110DEDA49 (11) Disassemble shim (26) and spacer (27) from (29) pinion shaft (25). Disassemble both of tapered roller bearings (28) from the pinion shaft by using a bearing puller. Do not reuse shim. 110DEDA50 (28) (25) (26) (27) 110DEDA51 3-136...
  • Page 186 4. REASSEMBLY OF THE DRIVE AXLE 4. REASSEMBLY OF THE DRIVE AXLE Clean every parts with cleaner and then remove remained loctite. ※ Be careful not to spill cleaner on your body. Avoid drinking cleaner or breathing its fumes. Wear protective clothing, glasses and gloves. If spilled on the skin, flush your skin with water immediately.
  • Page 187 How to adjust the shim between differential carrier and the differential flange Measurements(A) Measurements(B) Pinion Shaft PMD Value Defeat vaule Taper Roller Bearing depth variation Carrier depth variation Shim thickness Flange depth variation 110DEDA53 ※ If gear is damaged, replace a set of the bevel gear shaft and bevel gear. Do not reuse deformed shim or damaged bearing.
  • Page 188 2) 2) ASSEMBLY THE PINION SHAFT ASSEMBLY THE PINION SHAFT Inner ring of bearings should be heated up to 100˚C by a preheater. Assemble the bevel pinion shaft and set the preload with the ring and the shim. 110DEDA54 110DEDA55 110DEDA56 3-139...
  • Page 189 Adjust the shim thickness by combinations of the different shims. Add the shims between the differential flange and differential carrier. Apply loctite on them and assemble the differential flange and differential carrier. The bolt tighten torque, see below. ·Short bolts (4ea) : 10.0~10.5 kgf·m ·Long bolts (6ea) : 12.0~12.5 kgf·m 110DEDA57 110DEDA58...
  • Page 190 3) 3) ASSEMBLE THE DIFFERENTIAL ASSY ASSEMBLE THE DIFFERENTIAL ASSY Assemble the thrust washer, side gear and spider with gears and then install them to the differential housing. Assemble the differential housing. C h e c k m a r k s o n t h e d i f f e r e n t i a l C h e c k m a r k s o n t h e d i f f e r e n t i a l assembly and housing.
  • Page 191 Assemble the bearing cap. ※ Fix the bearing cap with hex bolt. ·Tightening torque : 50.0~65.0 kgf·cm Measure the rolling resistance of the taper roller bearing. The following table shows the relation between the preload of the bevel pinion shaft(measured at the adjustment, page 3-130) and the rolling resistance.
  • Page 192 ASSEMBLE CARRIER TO AXLE HOUSING Assemble the carrier assy into axle housing. Fix the carrier assy to axle housing with the hex bolt. ·Tightening torque : 28.0~32.0 kgf·cm. 110DEDA64 Assemble brake disc to yoke (1) with hex bolt. Apply loctite #271 or #277 on the thread of the bolt and tighten them.
  • Page 193 110DEDA68 Assemble the oil seal into the brake cover. 110DEDA69 Assemble the internal gear carrier into the ring gear and fit the C-ring. Heat the bearing and assemble it into the carrier. Cool down the bearing sufficiently and then assemble them into wheel hub. 110DEDA70 110DEDA71 3-144...
  • Page 194 Assemble the preassembled wheel hub and spline collar with the brake cover assy. Assemble the disc, plate and 6 brake pins and apply loctite #5217 on the assemble surface. Disc 4 piece 110/130D-7A Plate 7 piece Disc 5 piece 160D-7A Plate 6 piece 110DEDA72...
  • Page 195 Fit the square ring (large, 36), square ring (36) (36, 37) (small, 38), backup ring (large, 37) and (38, 39) backup ring (small, 39) into the brake housing and apply oil (MOBIL #424) on them. Assemble the bushing (35) into the piston (36) and assemble the piston into brake housing.
  • Page 196 Mount the axle tube into the axle housing and assemble the brake housing to axle housing. Tighten the 20 bolts. ·Tightening torque : 31.5~32.5 kgf·cm ※ Be careful not to damage the O-ring of the axle tube when assembling the brake housing.
  • Page 197 110DEDA82 Place the wheel hub to the axle tube until seated completely and tighten the nut. Tighten the nut to the marks that marked when disassembling. 110DEDA83 (10) Apply loctite #271 or #277 on the bolts and tighten them. ·Tightening torque : 1.8~2.0 kgf·cm Assemble the ring gear and fix it with the C-ring.
  • Page 198 (12) Assemble the internal components of the planetary carrier with the reverse order of disassembling. 110DEDA86 110DEDA87 (13) Assemble the planetary carrier assy to the wheel hub. Tighten the bolts. ·Tightening torque : 2.5~4.0 kgf·cm 110DEDA88 (14) Assemble the wheel hub and tighten the plug (1).
  • Page 199 Loctite. (16) The bolted or keyed assemblies safeties are to be checked according to instructions ; in case of doubt, consult Hyundai dealer. (17) Refill the oil after assembly. (18) Repair weldment is only allowed after consultation with Hyundai. 3-150...
  • Page 200 2) 2) USING OF LOCTITE AND OPERATING SUPPLIES USING OF LOCTITE AND OPERATING SUPPLIES Kind Type Color Application Loctite Blue Lightly locked screws Middle locked screws Green Highly locked screws Green Increased coefficient of friction in contact surfaces Orange Surface gasket White Special gasket Light-green...
  • Page 201 4) 4) UTILIZATION OF LOCTITE AND OPERATING SUPPLIES UTILIZATION OF LOCTITE AND OPERATING SUPPLIES (1) (1) Hub assembly Hub assembly Safety blocked parts Joint Loctite Operating supplies Spacer ring Contact surface Axle spindle Screws Axle spindle Contact surface Grommet In planetary housing Disk In axle spindle Adjusting screw with nut...
  • Page 202 5) 5) TIGHTENING TORQUES TIGHTENING TORQUES Unit : N·m Metric standard thread Screw Screw Screw Thread 10.9 12.9 1050 1220 1100 1550 1800 1450 2100 2450 Unit : N·m Metric fine thread Screw Screw Screw Thread 10.9 12.9 M 8×1 M10×1 M10×1.25 M12×1.25...
  • Page 203 (1) (1) Tightening torques of wheel nuts Tightening torques of wheel nuts Wheel nut with spring lock Wheel nut with clamp Wheel nut with thrust collar washer (For clamp fixation) (For rims with centering) ① Wheel nut with spring lock washer Dimensions Phosphorus darkened Galvanized...
  • Page 204 Tightening torques for castle nuts on ball joints for track rods and ram cylinders The tightening torques of the different thread dimensions of the joints are applicable for nuts of quality S6. Cone size Thread Torque d1 (mm) d2 (mm) (Nm) M20×1.5 200~220...
  • Page 205 6) 6) SERVICE TOOLS SERVICE TOOLS When ordering service tools please provide order number (Installation drawing no), respective fabrication number→see identification plate. (The illustrations are not binding for the design) Spanner for wheel safety nut 100D7XL14 100D7XL15 Spanner for splined nut (hub assembly) 100D7XL16 3-156...
  • Page 206 Seal ring sleeve driver. 100D7XL17 Spanner for thread rings. (Differential bearing) 100D7XL18 Spanner for counter nut. (Planetary gear drive) 100D7XL19 Assembly cone for O-ring. (Differential lock) 100D7XL82 3-157...
  • Page 207 Centering tool for discs. 100D7XL20 Installation tool for face seal. 100D7XL21 3-158...
  • Page 208 7) 7) ASSEMBLY DRIVE ASSEMBLY ASSEMBLY DRIVE ASSEMBLY (1) (1) Adjustment of gear meshing of gleason gears Adjustment of gear meshing of gleason gears ① Perfect marking Perfect marking To become a perfect gear meshing is only possible, if the fabrication number of the drive pinion (marked on the end face) and the ring gear(marked on the circumference) are corresponding.
  • Page 209 (2) (2) Securing of the striking nut Securing of the striking nut The brim of the striking nut has to be sheared only along the slot flank and the corner has to be bent on the slot ground. 100D7XL26 100D7XL25 ①...
  • Page 210 ③ Drive assembly D 51 Drive assembly D 51 100D7XL27 3-161...
  • Page 211 (3) (3) Adjustment drive pinion distance Adjustment drive pinion distance To obtain the proper tooth flank contact, adjust the axial position of the drive pinion with the thickness of the adjustment disk. T h e n e c e s s a r y t h i c k n e s s o f t h e adjustment disk for first time assembly can be obtained by measurement (see calculation example).
  • Page 212 (4) (4) Assembly of drive pinion bearing Assembly of drive pinion bearing ① Insert the two outer rings of the taper roller bearings into the differential carrier. ② Calculate the thickness C of the spacer ring. Place the two inner rings of the taper roller bearings in their outer rings.
  • Page 213 8) 8) ASSEMBLY OF THE DIFFERENTIAL ASSEMBLY OF THE DIFFERENTIAL Before assembly all of the bevel gears and the thrust rings should be well oiled. Place one differential side gear with the side gear thrust washer in the differential case. Install the spider with differential gears and differential pinion thrust washers in the differential case.
  • Page 214 9) 9) ASSEMBLY OF DRIVE ASSEMBLY ASSEMBLY OF DRIVE ASSEMBLY Place the differential with the outer rings of the taper roller bearings on the differ- ential carrier which is in a vertical position, with mounted drive pinion. Mount the differential straps and align them with the thread rings.
  • Page 215 ASSEMBLY OF HUB ASSEMBLY ASSEMBLY OF HUB ASSEMBLY Assembly of the spacer ring Assembly of the spacer ring (1) (1) Coat the seat of the spacer ring on the steering knuckle respective axle spindle with Loctite 572. Heat the spacer ring to about 100˚C and push it by gently striking onto the steering knuckle respective axle spindle.
  • Page 216 ASSEMBLY OF THE DRIVE ASSEMBLY ONTO THE AXLE HOUSING ASSEMBLY OF THE DRIVE ASSEMBLY ONTO THE AXLE HOUSING 100D7XL39 100D7XL40 Coat the contact surface of the axle housing with Epple 33 (at version through drive with Loctite 510), and mount the complete drive assembly. The axle housing being placed in a horizontal position, secure the screws with Loctite 262.
  • Page 217 (7) (7) Mount wheel hub Mount wheel hub ① Push the pre-assembled wheel hub (9) parallel onto the axle spindle respective steering knuckle. ※ Be carefully do not damage the seal rings. 100D7XL41 (8) (8) Adjustment of wheel bearings Adjustment of wheel bearings ①...
  • Page 218 (9) (9) Assembly of the face seal Assembly of the face seal 1 Seal ring 2 Rubber toric ring 3 Housing retaining lip 4 Housing ramp 5 Seal ring housing 100D7XL46 ① Seal rings, torics, and housings must be clean and free of any oil film, dust, or other foreign matter.
  • Page 219 ⑦ Put the installation tool (9) onto the seal ring (1) with toric ring (2). Lower the rings into a container with lsopropanol until all surfaces of the toric (2) are wet. 100D7XL50 ⑧ Toric sliding on retainer ramp. 100D7XL51 ⑨...
  • Page 220 ⑪ After dipping the seal assembly in the solvent, shake the excess solvent from the seal assembly and immediately "pop" the seal into the housing with a firm push of the installation tool. Remove the installation tool and check the seal standout height at several places around the circumference of the ring to verify an accurate installation.
  • Page 221 Be sure there is no visible debris on either of the seal faces even a small piece of lint can hold the seal faces apart and cause leakage. 100D7XL57 After successful installation, wait one minute for the lsopropanol to dry before assembling the two seal halves in the final loaded position.
  • Page 222 After the unit to be sealed is assembled, a post-assembly leakage test can be performed to insure the seal is properly installed. A vacuum check is recommended rather than a pressure check as vacuum checks are more sensitive. Many users find this an easy check to combine with a vacuum fill technique for the lubricant.
  • Page 223 ASSEMBLY OF PLANETARY GEAR DRIVE ASSEMBLY OF PLANETARY GEAR DRIVE Prepare the ring gear and the ring gear Prepare the ring gear and the ring gear (1) (1) carrier carrier Heat the taper roller bearing inner ring with cage (1) to about 100˚C and install it onto the ring gear carrier (2).
  • Page 224 (5) (5) Assembly of planetary gear Assembly of planetary gear ① Prepare planetary gear : Install the needle bearing (10, 11) into the planetary gear (12, 13). 100D7XL63 ② Insert the preassembled planetary gears (12, 13) with needle bearings (10, 11), rings(16) (if present) and thrust disks (14 , 15) into the planetary housing (22, 23) (planetary housing in horizontal position).
  • Page 225 (6) (6) Disassembly of planetary gear Disassembly of planetary gear ① Knock the locking pin (20, 21) completely to the inner side of the planetary pin. 100D7XL66 ② Press the planetary pin in direction of arrow out of the planetary housing. ※...
  • Page 226 Assembly / disassembly cageless needle bearing(planetary gear bearing) Assembly / disassembly cageless needle bearing(planetary gear bearing) 100D7XL39 100D7XL40 (1) (1) Assembly Assembly ① Version 1 Version 1 Install the needle bearing with mounting bushings into the planetary gear, thereby the outer mounting bushing will be stripping.
  • Page 227 Assembly of the planetary housing Assembly of the planetary housing Place O-ring (30) into the slot of the planetary housing. Install the planetary housing and bolt it. Adjustment of the axial clearance Adjustment of the axial clearance 100D7XL72 The axial clearance between axle shaft respective universal joint and adjusting screw must be 0.3~0.7 mm.
  • Page 228 Assembly of service brake Assembly of service brake 100D7XL83 Brake carrier Seal ring 17 Seal ring Brake housing 10 Seal ring 18 Screw plug 19 O-ring Piston 11 Connection piece Inner disk 12 Breather 20 Face seal Outer disk 13 Sealing ring 21 Screw O-ring 14 Sealing ring...
  • Page 229 (2) (2) Assembly of the piston seals Assembly of the piston seals Place piston with the larger diameter downwards. Note succession of the sealing parts at fitting. Install O-rings free of torsion and loops. (3) (3) Assembly of O-ring and supporting ring Assembly of O-ring and supporting ring Install the supporting rings to the averting side of pressure.
  • Page 230 (5) (5) Assembly of the piston Assembly of the piston 100D7XL86 Lubricate cylinder bore, apply the thread holes at wet disk brakes of dimension X270 and X340 with Loctite 243, at wet disk brakes of dimension X460 and X650 with Loctite 262 and install and screw the bushing (if present).
  • Page 231 ① Prepare housing and check the air gap Prepare housing and check the air gap 100D7XL87 Lay discs into the housing. ② Check the air gap Check the air gap Air gap = measure A-measure B (measured without pressure) Rated size about 0.5 mm smaller than the air gap pressurized (see table). Install O-ring (brake housing / brake carrier) free of torsion and loops.
  • Page 232 (6) (6) Finish assembly Finish assembly Place the brake carrier onto the brake housing and bolt it. Mount breather with connection piece and seal ring, screw plugs with seal rings. Check brake hydraulic system for leaks (see tightness checking instruction). Install O-ring (Brake carrier / axle spindle respective steering knuckle) free of torsion and loops.
  • Page 233 Is the measured dimension bigger than the marked dimension and max. wear dimension, unconditional consult Hyundai dealer. 100D7XL76 After working at the brake, bleed the brake hydraulic system and check for tightness. 3-184...
  • Page 234 (9) (9) Brake disk Brake disk 100D7XL78 Network - like formation of cracks admissible Radially shaped crack not admissible Uneven brake surface characteristics below 1.0 mm admissible Continuous cracks not admissible (10) (10) Spring - loaded sliding caliper brakes Spring - loaded sliding caliper brakes Safety notes : Safety notes : ·Warning...
  • Page 235 GROUP 4 ADJUSTMENT GROUP 4 ADJUSTMENT 1. CHECKING THE RING GEAR BACKFACE RUNOUT 1. CHECKING THE RING GEAR BACKFACE RUNOUT Runout specification : 0.20 mm (0.008-inch) maximum Attach a dial indicator on the mounting INDICATOR flange of the carrier. Rotate ring gear . Adjust the dial indicator so that the plunger or pointer is against the back surface of the ring gear.
  • Page 236 2. ADJUSTING THE GEARSET BACKLASH 2. ADJUSTING THE GEARSET BACKLASH Backlash specification : 0.13~0.18 mm (0.005-0.007 inch) If the old gearset is installed, adjust the backlash to the setting that was measured before the carrier was disassembled. If a new gearset is installed, adjust the backlash to the correct specification for new gearsets.
  • Page 237 3. ADJUSTING TOOTH CONTACT PATTERN OF THE GEARSET 3. ADJUSTING TOOTH CONTACT PATTERN OF THE GEARSET Always check tooth contact pattern on the drive side of the gear teeth. Apply marking compound to approximately 12 teeth of the ring gear. HEEL BOTTOM DRIVE SIDE...
  • Page 238 LOW PATTERN D507AX61 GOOD PATTERN IN OPERATION (USED GEARS) D507AX62 High pattern : A high contact pattern Move pattern toward indicates that the pinion was installed too bottom shallow into the carrier. To correct, move the pinion toward the ring gear by decreasing the shim pack between pinion spigot and inner bearing cone.
  • Page 239 4. ADJUSTMENT OF GEAR MESHING OF GLEASON GEARS 4. ADJUSTMENT OF GEAR MESHING OF GLEASON GEARS To become a perfect gear meshing is only possible, if the fabrication number of the drive pinion (marked on the end face) and the ring gear (marked on the circumference) are corresponding.
  • Page 240 SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------- 4-1 Group 2 Operational checks and troubleshooting ------------------------------------------------------- 4-24 Group 3 Tests and adjustments ------------------------------------------------------------------------------------ 4-32 Group 4 Disassembly and assembly ---------------------------------------------------------------------------- 4-35...
  • Page 241 SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE ※ The brakes are operated by a pressure compensated, closed center hydraulic system. Flow is supplied by a fixed displacement, gear type brake pump. BRAKE SYSTEM BRAKE SYSTEM The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit and...
  • Page 242 FULL POWER HYDRAULIC BRAKE FULL POWER HYDRAULIC BRAKE SYSTEM SYSTEM Response time Response time ADVANTAGES - The full power hydraulic Full power brake actuation VS Full power brake actuation VS brake system has several advantages over Air/Hydraulic brake actuation Air/Hydraulic brake actuation traditional brake actuation systems.
  • Page 243 2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT 10.5MPa 17MPa 12.5MPa ~ 15MPa Steering unit Return 3MPa ~ 4MPa line 6MPa EF CF TO THE AXLE 14MPa 17.5MPa TILT POSITIONER LIFT FROM THE AXLE 160D7ABS01 Main pump 11 RCV 23 Strainer Brake pump 17 Pressure switch 24 Return filter Cut off valve...
  • Page 244 SERVICE BRAKE RELEASED SERVICE BRAKE RELEASED 10.5MPa 17MPa 12.5MPa ~ 15MPa Steering unit Return 3MPa ~ 4MPa line 6MPa EF CF TO THE AXLE 14MPa 17.5MPa TILT POSITIONER LIFT FROM THE AXLE 160D7ABS02 When the pedal of brake valve (8) is released, the operating force is eliminated by the force of the spring, and the spool is returned.
  • Page 245 SERVICE BRAKE OPERATED SERVICE BRAKE OPERATED 10.5MPa 17MPa 12.5MPa ~ 15MPa Steering unit Return 3MPa ~ 4MPa line 6MPa EF CF TO THE AXLE 14MPa 17.5MPa LIFT TILT POSITIONER FROM THE AXLE 160D7ABS03 When the pedal of brake valve (8) is depressed, the operating force overcomes the force of the spring, and is transmitted to the spool.
  • Page 246 PARKING BRAKE RELEASED PARKING BRAKE RELEASED 10.5MPa 17MPa Parking brake switch 12.5MPa ~ 15MPa Parking brake solenoid valve Steering unit Return 3MPa ~ 4MPa line 6MPa EF CF TO THE AXLE 14MPa 17.5MPa LIFT TILT POSITIONER FROM THE AXLE 160D7ABS04 When the parking brake switch is pressed B position, the solenoid valve is energized and the hydraulic oil controlled the pressure level by the cut-off valve enters the parking brake.
  • Page 247 PARKING BRAKE OPERATED PARKING BRAKE OPERATED 10.5MPa 17MPa Parking brake switch 12.5MPa ~ 15MPa Parking brake solenoid valve Steering unit Return 3MPa ~ 4MPa line 6MPa EF CF TO THE AXLE 14MPa 17.5MPa TILT POSITIONER LIFT FROM THE AXLE 160D7ABS05 When the parking brake switch is pressed A position, the solenoid valve is deenergized and the valve open the drain port.
  • Page 248 3. BRAKE PUMP 3. BRAKE PUMP STRUCTURE STRUCTURE 1) 1) 110D7EBS06 Body 10 Driven gear 19 Snap ring Body 11 Driven gear 20 Back up ring Body 12 Driven gear 21 Middle flange Mounting flange 13 Nut 22 Middle flange Rear cover 14 Washer 23 Middle flange...
  • Page 249 2) 2) PRINCIPLE OF OPERATION PRINCIPLE OF OPERATION Mechanism for delivering oil Mechanism for delivering oil (1) (1) T h e d r a w i n g a t r i g h t s h o w s t h e operational principle of an external gear pump in which two gears are rotating in mesh.
  • Page 250 (2) (2) Internal oil leakage Internal oil leakage Oil leaks from a place under higher pressure to a place under lower pressure, provided that a gap or a clearance exists in between. In the gear pump, small clearances are provided between the gear and the case and between the gear and the side plate to allow the oil to leak out and to serve as a lubricant so that the pump will be...
  • Page 251 (3) (3) Forces acting on the gear Forces acting on the gear The gear, whose outer surface is subjected to oil pressure, receives forces jointing towards its center. Due to the action of the delivery pressure, the oil pressure in higher on the delivery side of the pump, and due to suction pressure, is lower on the suction side.
  • Page 252 4. BRAKE VALVE 4. BRAKE VALVE 1) 1) STRUCTURE STRUCTURE 13-1 13-2 13-5 13-4 13-3 160D7ABS07 Body 12 Pedal plate 19 Hexagon bolt Spool 13 Pedal assembly 20 Hexagon nut Plug 13-1 Hexagon bolt 21 Name plate Holder 13-2 Lock plate 22 Screw drive Lower spring 13-3 Pedal rubber...
  • Page 253 2) 2) OPERATION OPERATION Hydraulic circuit Port Port name Port size Main pressure port PF3/8 Drain port PF3/8 Brake cylinder port PF3/8 Pressure switch port PF1/4 160D7ABS08 4-13...
  • Page 254 (1) (1) Purpose Purpose The purpose of the brake valve is to sensitively increase and decrease the braking pressure when the brake pedal is actuated. (2) (2) Ready position Ready position A connection is established between ports (BR) and ports (T) so that the wheel brakes ports (BR) are pressureless via the returns ports (T).
  • Page 255 (8) (8) Repair work Repair work When working on the braking system, always make sure that there is absolutely no When working on the braking system, always make sure that there is absolutely no pressure in the system. Even when the engine is switched off there will be some residual pressure in the system.
  • Page 256 5. CUT-OFF VALVE 5. CUT-OFF VALVE 1) 1) STRUCTURE STRUCTURE Hydraulic circuit 110D7EBS35 Manifold Check valve Solenoid valve Cut-off valve Coil Relief valve Check valve 2) 2) OPERATION OPERATION When the pump works, the oil under the pressure flows into P port. The oil in P port is stored in the accumulator on A3 port.
  • Page 257 6. BRAKE ACCUMULATOR 6. BRAKE ACCUMULATOR 1) 1) STRUCTURE STRUCTURE Item 81L1-0004 Diameter 110 mm Mounting height 164 mm Nominal volume 0.7ℓ Priming pressure 50 kgf/cm Operating medium Operating pressure Max 150 kgf/cm Thread M18×1.5 Priming gas Nitrogen A Fluid portion C Diaphragm B Gas portion D Valve disk...
  • Page 258 (4) (4) Maintenance of the accumulator Maintenance of the accumulator No special maintenance beyond the legal requirements is necessary. The accumulator should be checked annually. It should be replaced if the initial gas pressure has fallen by more than 30%(Please refer to Performance testing and checking of the Performance testing and checking of the accumulator accumulator).
  • Page 259 (7) (7) Repair work Repair work When working on the braking system, always make sure that there is absolutely no When working on the braking system, always make sure that there is absolutely no pressure in the system. Even when the engine in switched off there will be some residual pressure in the system.
  • Page 260 7. PRESSURE SWITCHES 7. PRESSURE SWITCHES STRUCTURE STRUCTURE 1) 1) - Normally closed - Normally open 7407ABS20 ·Technical data Technical data Adjusting range Adjusting pressure Voltage Item Type Medium kgf/cm kgf/cm 95 ± 5 Parking M12×1.5 50 ~ 150 Max 42 95 ±...
  • Page 261 2) 2) OPERATION OPERATION (1) (1) Purpose Purpose The pressure switches are used to visually or audibly warn the driver of the pressure within the system. Make contact / circuit closer Make contact / circuit closer (2) (2) The pressure switch can be fitted in the braking system or directly on one of its components. The system pressure acts on an absorption area within the switch, making an electrical contact as the pressure on that area is increased.
  • Page 262 (7) (7) Adjusting and testing pressure switch Adjusting and testing pressure switch The adjusting screw located between the two contact plugs can be set to the desired value within a certain range. For adjusting range, please refer to the table Technical data Technical data on the previous page.
  • Page 263 8. PARKING BRAKE 8. PARKING BRAKE 100D7BS109 Brake Brake disk Brake carrier Hexagon screw O-ring Hexagon screw 4-23...
  • Page 264 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS This procedure is designed so the mechanic can make a quick check of the system using a minimum amount of diagnostic equipment. If you need additional information, read structure and structure and function function, Group 1.
  • Page 265 ※Hydraulic oil must be at operating temperature for these checks. Hydraulic oil must be at operating temperature for these checks. Item Description Service action Parking brake capacity Parking brake capacity Start engine. check check Check completed. Fasten seat belt. Seat belt must be worn NOT OK NOT OK while doing this check to...
  • Page 266 Item Description Service action Service brake pump flow Service brake pump flow Stop engine. check check Check completed. Operate brake pedal approximately ※ Hydraulic oil must be at 20 times. NOT OK NOT OK operating temperature Start engine and run at low idle. Check for brake circuit for the check.
  • Page 267 Item Description Service action Brake accumulator Brake accumulator Star t and r un engine for 30 precharge check precharge check seconds. Check completed. ※The axles and hydraulic Stop engine and turn start switch NOT OK NOT OK oil must be at operating to ON and wait 5 seconds.
  • Page 268 Item Description Service action Ser vice brake pedal Ser vice brake pedal Slowly depress brake pedal. check check Check completed. Listen for a hissing noise that indicates oil is flowing to brake NOT OK NOT OK pistons. Inspect for debris under brake pedal.
  • Page 269 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) SERVICE BRAKE SERVICE BRAKE Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure (See section 1) Step 2.
  • Page 270 Problem Cause Remedy Brakes chatter Brakes chatter Air in brake system Do brake bleed procedure. Worn brake surface material Inspect brake surface material. Wrong oil in differential Drain. Refill. H i s s i n g n o i s e w h e n H i s s i n g n o i s e w h e n Leakage in brake valve, or brake Do brake system leakage test.
  • Page 271 2) 2) PARKING BRAKE MALFUNCTIONS ARKING BRAKE MALFUNCTIONS Problem Cause Remedy Brake will not hold Brake will not hold Pads not adjusted correctly Adjust parking brake. Malfunctioning parking brake Inspect and replace. solenoid Worn brake disk and / or brake Disassemble, inspect, repair.
  • Page 272 GROUP 3 TESTS AND ADJUSTMENTS GROUP 3 TESTS AND ADJUSTMENTS 1. PARKING BRAKE PERFORMANCE 1. PARKING BRAKE PERFORMANCE MEASUREMENT CONDITION MEASUREMENT CONDITION 1) 1) Tire inflation pressure:Specified pressure Road surface : Flat, dry, paved surface with 1/5 (11˚20') gradient. Machine : In operating condition gradient 11 20' Item...
  • Page 273 Turn the adjusting screw anticlockwise in order to set the following rated clearances. Model Adjusting screw Clearance (mm) Turns Min. 110D-7A 130D-7A M16 (SW 8) Clearance 160D-7A Max. Hold the adjusting screw in position with a hexagonal socket wrench and lock with lock nut.
  • Page 274 3. HYDRAULIC BRAKE BLEEDING PROCEDURE 3. HYDRAULIC BRAKE BLEEDING PROCEDURE E s c a p i n g f l u i d u n d e r p r e s s u r e c a n E s c a p i n g f l u i d u n d e r p r e s s u r e c a n penetrate the skin causing serious injury.
  • Page 275 GROUP 4 DISASSEMBLY AND ASSEMBLY GROUP 4 DISASSEMBLY AND ASSEMBLY 1. BRAKE PUMP 1. BRAKE PUMP STRUCTURE STRUCTURE 1) 1) 110D7EBS06 Body 10 Driven gear 19 Snap ring Body 11 Driven gear 20 Back up ring Body 12 Driven gear 21 Middle flange Mounting flange 13 Nut...
  • Page 276 2) 2) GENERAL INSTRUCTION GENERAL INSTRUCTION Always work in a clean environment. Wash all components in solvent and blow dry with compressed air before refitting. Take care not to damage rubber seals. Avoid damaging precision machined surfaces. Components should fit into their housings without excessive force. If force is necessary, this normally means that the component does not have the correct dimensional tolerances of is aligned incorrectly.
  • Page 277 (2) (2) 1st working section working section ① Remove the pressure plate (1) with prearranged parts, O-ring (2) and back up ring (3) from the working section and examnine it carefully. ② Remove square ring (6) posited on the groove of body. ③...
  • Page 278 (4) (4) Separation intermediate section Separation intermediate section ① R e m o v e t h e t h r o u g h s h a f t a n d intermediate section as well as guard pins. ②...
  • Page 279 Mounting flange Mounting flange ⑤ Locate shaft seal (1) inside shaft hole to the end. ⑥ Insert snap ring (2) and locate it into the groove prearranged. 110D7EBS20 Separation intermediate section Separation intermediate section ⑦ Insert shaft seal (1) and snap ring (2) with same way as for mounting flange (3).
  • Page 280 ⑦ Locate 2nd body on the semi assembled parts. ⑧ Insert all components inside of working body with same way as for 3rd section. 110D7EBS24 ⑨ Assemble standard intermediate cover (1) to the semi assembled part. 110D7EBS25 ⑩ Assemble 1st working section with same way as for 2nd and 3rd section.
  • Page 281 ⑪ Assemble preassembled mounting flange (1) to the body. ※ It is recommended to smear clean g r e a s e t o t h e s h a f t s e a l b e fo r e assembling to avoid any damage to the shaft seal by edge of shaft.
  • Page 282 2. BRAKE VALVE 2. BRAKE VALVE 1) 1) STRUCTURE STRUCTURE 13-1 13-2 13-5 13-4 13-3 160D7ABS07 Body 12 Pedal plate 19 Hexagon bolt Spool 13 Pedal assembly 20 Hexagon nut Plug 13-1 Hexagon bolt 21 Name plate Holder 13-2 Lock plate 22 Screw drive 13-3 Pedal rubber 23 Plain washer...
  • Page 283 2) 2) REASSEMBLY REASSEMBLY 9 23 24 (1) (1) Body assembly Body assembly Body Spool Plug Holder Spring Main spring 1 Spring retainer 1 Oil seal 110D7EBS50 DU bushing Rubber cover Plain washer Stop ring Spring retainer 2 (DIC axle) Main spring 2 (DIC axle) ①...
  • Page 284 ③ Tighten plug (3) - Tool : 19mm spanner - Tightening torque : 14.0~16.5 kgf·m Press-in the DU bushing (11) with a Press-in the DU bushing (11) with a exclusive jig. exclusive jig. Be careful of dust and scrap after Be careful of dust and scrap after washing the parts.
  • Page 285 (2) (2) Pedal plate assembly Pedal plate assembly 13-2 13-1 Pedal plate 13-1 Pedal 13-2 Pedal cover 13-3 13-3 Lock plate Lock pin (pedal) Torsion spring Stop ring Hexagon bolt 110D7EBS57 ① Pedal plate (12) assembly - Tool : 6 mm torque wrench - Tightening torque : 2.5~3.0 kgf·m 110D7EBS58 ②...
  • Page 286 ④ Rubber cover (13-2) 13-2 110D7EBS61 100D7BS20 ⑤ Hexagon bolt (19) - Tool : 13 mm spanner - Tightening torque : 2.0 kgf·m 110D7EBS62 Never remove the hexagon bolt. Never remove the hexagon bolt. (Pressure setting valve deviation occurs) 4-46...
  • Page 287 SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------- 5-1 Group 2 Operational checks and troubleshooting ------------------------------------------------------- 5-9 Group 3 Tests and adjustments ------------------------------------------------------------------------------------ 5-17 Group 4 Disassembly and assembly ---------------------------------------------------------------------------- 5-21...
  • Page 288 SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE Steering cylinder Tank flange Main pump "CF" Main pump "LS" 160D7ASS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and piping.
  • Page 289 2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT 22.5MPa Return line Fan drive TO AXLE motor EF CF Return line FROM AXLE Return line 160D7ASS02 Main pump 23 Suction strainer Auxiliary pump 24 Return filter Steering unit 34 Hydraulic tank 12 Steering cylinder...
  • Page 290 1) 1) NEUTRAL NEUTRAL 22.5MPa Return line Fan drive TO AXLE motor EF CF Return line FROM AXLE Return line 160D7ASS03 · The steering wheel is not being operated so control spool (G) does not move. · The oil from the main pump (1) enters port P of steering unit (4) and the inlet pressure oil moves the spool (D) to the left.
  • Page 291 2) 2) LEFT TURN LEFT TURN 22.5MPa Return line Fan drive TO AXLE motor EF CF Return line FROM AXLE Return line 160D7ASS04 · 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.
  • Page 292 3) 3) RIGHT TURN RIGHT TURN 22.5MPa Return line Fan drive TO AXLE motor EF CF Return line FROM AXLE Return line 160D7ASS05 · 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.
  • Page 293 3. STEERING UNIT 3. STEERING UNIT 1) 1) STRUCTURE STRUCTURE 26 34 32 35 33 25 16 17 51 52 13 10 11 12 8 7 23 SECTION E-E 44 45 46 47 48 43 41 42 SECTION E-E SECTION D-D ‚c ‚c DETAIL B...
  • Page 294 2) 2) OPERATION OPERATION The steering unit consists of a rotary valve and a rotary meter. Via a steering column the steering unit is connected to the steering wheel of the machine. When the steering wheel is turned, oil is directed from the steering system pump via the rotary valve (spool and sleeve) and rotary meter (gear wheel set) to the cylinder ports L or R, depending on the direction of turn.
  • Page 295 4. STEERING CYLINDER 4. STEERING CYLINDER 1) 1) STRUCTURE STRUCTURE 100D7SS06 Tube assembly Rod seal 11 Back up ring Rod assembly Back up ring 12 O-ring Piston seal Dust wiper 13 Pin bushing Gland Snap ring Du bushing 10 O-ring 2) 2) OPERATION OPERATION...
  • Page 296 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS This procedure is designed so the service man can make a quick check of the steering system using a minimum amount of diagnostic equipment. If you need additional information, refer to structure and function in group 1.
  • Page 297 ※Hydraulic oil must be at operating temperature for these checks. Hydraulic oil must be at operating temperature for these checks. Item Description Service action Steering unit check Steering unit check Run engine at low idle. Check completed. Turn steering wheel until frames are at maximum right (A) and then NOT OK NOT OK...
  • Page 298 2. TROUBLESHOOTING 2. TROUBLESHOOTING ※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure (See group 3 in section 1) Step 2.
  • Page 299 Problem Cause Remedy Slow or hard steering Slow or hard steering Too much friction in the mechanical parts of Lubricate bearings and joints of steering the machine column or repair if necessary. Check steering column installation. Cold oil Warm the hydraulic oil. Low priority valve pressure setting Do priority valve pressure test.
  • Page 300 Problem Cause Remedy Erratic steering Erratic steering Air in oil Check for foamy oil. Low oil level Add recommended oil. Sticking priority valve spool Remove and inspect spool. Loose cylinder piston Remove rod to inspect piston. Damaged steering unit Remove and inspect. Spongy or soft steering Spongy or soft steering Air in oil...
  • Page 301 Problem Cause Remedy "Motoring" effect. "Motoring" effect. Leaf springs are stuck or broken and have Replace leaf springs. The steering wheel can The steering wheel can therefore reduced spring force turn on its own. turn on its own. Inner and outer spools pinch, possibly due Clean steering unit or contact the nearest to dirt service shop.
  • Page 302 Problem Cause Remedy Backlash Backlash Cardan shaft fork worn or broken Replace cardan shaft. Leaf springs without spring force or broken Replace leaf springs. Worn splines on the steering column Replace steering column. "Shimmy" effect. The "Shimmy" effect. The Air in the steering cylinder Bleed cylinder.
  • Page 303 Problem Cause Remedy H e a v y k i c k - b a c k i n H e a v y k i c k - b a c k i n Wrong setting of cardan shaft and gear- Correct setting as shown in service steering wheel in both steering wheel in both...
  • Page 304 GROUP 3 TESTS AND ADJUSTMENTS GROUP 3 TESTS AND ADJUSTMENTS 1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY 1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY ※ Service equipment and tool. ·Portable filter caddy ·Two 3658 mm (12ft) × 1" I.D. 100R1 hoses with 3/4 M NPT ends ·Quick disconnect fittings ·Discharge wand...
  • Page 305 Start the filter caddy. Check to be sure oil is flowing through the filters. Operate filter caddy approximately 10 minutes so oil in hydraulic oil tank is circulated through filter a minimum of four times. ※ Hydraulic oil tank capacity 115ℓ(30.4U.S. gal).
  • Page 306 2. TEST TOOLS 2. TEST TOOLS CLAMP-ON ELECTRONIC TACHOMET- CLAMP-ON ELECTRONIC TACHOMET- 1) 1) ER INSTALLATION ER INSTALLATION · Service equipment and tools Tachometer A : Clamp on tachometer. Remove paint using emery cloth and connect to a straight section of injection line within 100 mm (4 in) of pump.
  • Page 307 3. STEERING UNIT LEAKAGE TEST 3. STEERING UNIT LEAKAGE TEST · SPECIFICATION SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Cap fitting Maximum leakage 7.5ℓ/min (2 gpm) · GAUGE AND TOOL GAUGE AND TOOL Temperature reader Measuring container (Approx. 20ℓ) Stop watch Install temperature reader.
  • Page 308 GROUP 4 DISASSEMBLY AND ASSEMBLY GROUP 4 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT 1. STEERING UNIT 1) 1) STRUCTURE STRUCTURE 14 13 100D7SS10 Cap screw 17 Needle bearing 35 Spring Retainer screw 18 O-ring 41 Retainer plug Cap end 19 Seal 42 Spring Gerotor 20 Dust seal...
  • Page 309 2) 2) TOOLS TOOLS Holding tool + Guide ring 7607SE08 Assembly tool for O-ring and kin-ring. 7607SE09 Assembly tool for lip seal. (780-3A) 5-69(3) Assembly tool for cardan shaft. (780-3A) 5-69(4) 5-22...
  • Page 310 Assembly tool for dust seal. (780-3A) 5-70(1) Torque wrench 0~7.1 kgf·m (0~54.4 lbf·ft) 13 mm socket spanner 6, 8 mm and 12 mm hexagon sockets 12 mm screwdriver 2 mm screwdriver 13 mm ring spanner 6, 8 and 12 mm hexagon socket spanners Plastic hammer (780-3A) 5-70(2) Tweezers...
  • Page 311 3) 3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS Hydraulic connections Hydraulic connections (1) (1) L : Left port R : Right port T : Tank T L P R P : Pump (780-3A) 5-71 (2) (2) Tightening torque Tightening torque 5-24...
  • Page 312 We cannot assure any troubles of orbitrol repaired by customers, so we commend sending We cannot assure any troubles of orbitrol repaired by customers, so we commend sending back to our Hyundai dealer when repairing. back to our Hyundai dealer when repairing.
  • Page 313 ⑦ Remove drive (8). ⑧ Remove spacer plate (7). ⑨ Replace O-ring (24) in housing (10). ※ Be careful that O-ring size (23) and (24) is different. 100D7SS14 ⑩ Put spacer plate (7) on housing (10). Align bolt holes in spacer plate (7) with tapped holes in housing (10).
  • Page 314 ⑭ Install spacer (s) (5) in gerotor (4). Anti-cavi check assy ⑮ Install end cap (3) on gerotor (4) aligning positions holes. Install cap screw (1) and retainer screw assy (2) in end cap (3). Tighten screws to 15 Nm (1.5 kgf·m) in advance. Retainer screw assy position Then tighten screws to tightening torque...
  • Page 315 ② Remove seal gland bushing (22) from housing (10). 100D7SS19 ③ Replace O-ring (18) with new one. ④ Remove oil seal (19) from seal gland Screw driver bushing (22) and replace oil seal (19) with new one. ※ When installing oil seal (19) in seal gland bushing (22), be careful not to twist and deform oil seal.
  • Page 316 · Tools required for repair Tools required for repair - Torque wrench (50 Nm capacity) - 5/12" socket - Screw driver - Plastic hammer or rubber hammer - Grease - Vice - Marker pen 5-29...
  • Page 317 2. STEERING CYLINDER 2. STEERING CYLINDER STRUCTURE STRUCTURE 1) 1) 100D7SS06 Tube assembly Rod seal 11 Back up ring Rod assembly Back up ring 12 O-ring Piston seal Dust wiper 13 Pin bushing Gland Snap ring DU bushing 10 O-ring 5-30...
  • Page 318 2) 2) DISASSEMBLY DISASSEMBLY ※ Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in & vice. Remove the cover by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube.
  • Page 319 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Using a special tool, install gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland ass- embly, and tighten it with torque 60±6 kgf·m (434±43 lbf·ft).
  • Page 320 3. STEERING AXLE 3. STEERING AXLE 1) 1) STRUCTURE STRUCTURE 1-39 1-41 1-43 1-43 1-42 1-15 1-16 1-14 1-33 1-46 1-32 1-34 1-31 1-27 1-27 1-42 1-26 1-38 1-44 1-29 1-43 1-41 1-30 1-45 1-40 1-36 1-13 1-35 1-37 1-12 1-11 1-28 1-10...
  • Page 321 2) 2) CHECK AND INSPECTION CHECK AND INSPECTION A1, A2 100D7SS22 unit : mm (in) Criteria Check item Remarks Standard size Repair limit OD of shaft 100(3.94) 99(3.90) Shaft ID of bushing 100(3.94) 99(3.90) OD of king pin 80(3.2) 79.5(3.1) Replace OD of steering cylinder pin 22(0.9)
  • Page 322 3) 3) DISASSEMBLY DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the balance Hub nut weight part of the truck. Loosen the hub nut and take off the steering wheel tire.
  • Page 323 4) 4) ASSEMBLY ASSEMBLY ※ In reassembling, have all parts washed, grease 1-15 1-16 1-14 1-46 applied to lubricating parts, and all expendable 1-27 items such as oil seal and spring washers replaced by new ones. 1-26 1-29 Perform the disassembly in reverse order. 1-30 Tighten the set screw (1-8) of king pin (1-6).
  • Page 324 SECTION 6 HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function ------------------------------------------------------------------------------------- 6-1 Group 2 Operational checks and troubleshooting ------------------------------------------------------- 6-31 Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 6-36...
  • Page 325 SECTION 6 WORK EQUIPMENT SECTION 6 WORK EQUIPMENT GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC SYSTEM OUTLINE 1. HYDRAULIC SYSTEM OUTLINE The hydraulic system is a pilot operated, open center system which is supplied with flow from the fixed displacement main hydraulic pump.
  • Page 326 2. HYDRAULIC CIRCUIT 22.5MPa 10.5MPa 21MPa From RCV From RCV 17MPa From RCV From RCV 12.5MPa ~ 15MPa PUSH PULL 320bar 16.5 3MPa ~ AXLE Oil cooler 4MPa 320bar 6MPa 16.5 Tilting Cabin Hyd. Circuit TO THE AXLE 16.5 16.5 FROM THE AXLE EF CF...
  • Page 327 3. WORK EQUIPMENT HYDRAULIC CIRCUIT 3. WORK EQUIPMENT HYDRAULIC CIRCUIT S1 S2 Steering 21MPa system From RCV From RCV From RCV From RCV 16.5 16.5 16.5 Return line 16.5 Cut off valve 21MPa AXLE 17.5MPa 14MPa TILT POSITIONER LIFT 160D7AHS02 Main pump 14 Tilt cylinder 30 Shockless valve...
  • Page 328 1) 1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION S1 S2 Steering 21MPa system From RCV From RCV From RCV From RCV Load check valve 16.5 16.5 16.5 Return line 16.5...
  • Page 329 2) 2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION S1 S2 Steering 21MPa system From RCV From RCV From RCV From RCV 16.5 16.5 16.5 Return line 16.5 Cut off valve 21MPa...
  • Page 330 3) 3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION S1 S2 Steering 21MPa system From RCV From RCV From RCV From RCV Load check valve 16.5 Load check valve 16.5...
  • Page 331 4) 4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION S1 S2 Steering 21MPa system From RCV From RCV From RCV From RCV Load check valve 16.5 Load check valve 16.5...
  • Page 332 5) 5) WHEN THE FORK POSITIONER LEVER IS IN THE SPREAD-OUT POSITION(OPTION) WHEN THE FORK POSITIONER LEVER IS IN THE SPREAD-OUT POSITION(OPTION) S1 S2 Steering 21MPa system From RCV From RCV From RCV From RCV 16.5 16.5 From RCV From RCV 16.5 Return line 16.5...
  • Page 333 6) 6) WHEN THE FORK POSITIONER LEVER IS IN THE CLOSE POSITION (OPTION) WHEN THE FORK POSITIONER LEVER IS IN THE CLOSE POSITION (OPTION) S1 S2 Steering 21MPa system From RCV From RCV From RCV From RCV 16.5 16.5 From RCV From RCV 16.5 Return line...
  • Page 334 4. MAIN PUMP 4. MAIN PUMP STRUCTURE STRUCTURE 25 26 100D7PMP00 Snap ring 10 Drive gear 19 Plug Shaft seal 11 Driven gear 20 Priority valve body Assembling bolt 12 Steel bushing 21 Compensation spool Assembling washer 13 Square ring 22 Cap Mounting flange 14 Front working section...
  • Page 335 2) 2) INSTRUCTION NSTRUCTION Hydraulic pumps used for the work equipment hydraulic units on construction machinery are pressure loaded type gear pumps. This gear pump could run under 300 kgf/cm (4,350 psi) maximum. The pressure loaded type gear pump is designed so that the clearance between the gear and the side plate can be automatically adjusted 100D7PMP21...
  • Page 336 3) 3) PRINCIPLE OF OPERATION PRINCIPLE OF OPERATION (1) (1) Mechanism for delivering oil Mechanism for delivering oil The below drawing shows the operational principle of an external gear pump on which two gears are rotation in mach. The oil entering through the suction port is Discharge Suction trapped in the space between two gear teeth,...
  • Page 337 If there is no resistance in the oil passage into which the discharged oil flows, the oil merely flows through the passage, producing no increase in pressure. If however, the oil passage is blocked with Discharge Suction something like a hydraulic cylinder, there will be no other place for the oil to flow, so the oil pressure will rise.
  • Page 338 (3) (3) Forces acting on the gear Forces acting on the gear The gear, whose outer surface is subjected to oil Drive gear pressure, receives force jointing towards its center. Due to the action of the delivery pressure, the oil pressure in higher on the Discharge Suction delivery side of the pump, and due to suction...
  • Page 339 4) 4) GENERAL REFERENCE GENERAL REFERENCE (1) (1) Installation Installation The direction of rotation of single-rotation pumps must be the same as that of the drive shaft. Check that the coupling flange correctly aligns the transmission shaft and the pump shaft. Flexible couplings should be used (never rigid fittings) which will not generate an axial or radial load on the pump shaft.
  • Page 340 5. REMOTE CONTROL VALVE 5. REMOTE CONTROL VALVE STRUCTURE STRUCTURE UT 1,2,3,4,5,6 100D7RCV00 Lever Metering spring 14 O-ring Seeger ring 15 Kit 3 Plug Seeger ring 16 Clamp Body 10 Docking rod 17 Rubber bellows Kit 1 11 Spring 18 Screw Plunger kit 12 Kit 2 19 Support kit...
  • Page 341 2) 2) OPERATION OPERATION HYDRAULIC CIRCUIT (1) (1) Hydraulic functional principle Hydraulic functional principle Pilot devices with end position locks operate as direct operated pressure reducing valves. They basically comprise of control lever (A), two pressure reducing valves, body (3) and locks. Each pressure reducing valve comprises of a plunger kit (5), a metering spring (7) and a spring (11).
  • Page 342 6. MAIN CONTROL VALVE 6. MAIN CONTROL VALVE STRUCTURE STRUCTURE 1) 1) 30-6 30-5 30-4 30-3 33-4 30-2 30-1 33-3 31-1 31-2 33-2 31-3 34-4 31-4 31-5 34-3 31-6 33-1 30-1 34-2 31-7 30-2 31-6 30-3 30-4 30-5 30-6 34-1 35-2 31-6 31-9...
  • Page 343 STRUCTURE STRUCTURE A6 B6 A5 B5 A4 B4 A2 B2 16.5 16.5 110D7EHS10 Port Port name Size Port Port name Size P1, P2 From main pump 1 5/16" - 12UNF A6, B6 To aux port 1 1/16" - 12UNF To hydraulic tank 1 5/16"...
  • Page 344 2) 2) LIFT SECTION OPERATION IFT SECTION OPERATION (1) (1) Neutral position of lift spool Neutral position of lift spool Cout Cout 100D7MCV31 Inlet from hydraulic pump Return passage to tank Outlet to tank Lift spool Pilot passage (Hydraulic pressure from joystick) Closed passage (Not used) (Hydraulic pressure from joystick) Passage to head end of lift cylinders (lift upward)
  • Page 345 (2) (2) Upward position for lift spool Upward position for lift spool Cout Cout 100D7MCV32 Inlet from hydraulic pump Return passage to tank Outlet to tank Lift spool Pilot passage (Hydraulic pressure from joystick) Plugged passage (Hydraulic pressure from joystick) Passage to head end of lift cylinders (lift upward) Working actuation Working actuation...
  • Page 346 (3) (3) Downward position for lift spool Downward position for lift spool Cout Cout 100D7MCV33 Inlet from hydraulic pump Return passage to tank Outlet to tank Lift spool Pilot passage (Hydraulic pressure from joystick) Plugged passage (Hydraulic pressure from joystick) Passage to head end of lift cylinders (lift upward) Working actuation Working actuation...
  • Page 347 3) 3) TILT & AUXILIARY SECTION OPERATION TILT & AUXILIARY SECTION OPERATION (1) (1) Neutral position of auxiliary spool Neutral position of auxiliary spool Cout Cout 100D7MCV34 Inlet from hydraulic pump Return passage to tank Outlet to tank Master spool Pilot passage (Hydraulic pressure from joystick) Passage to head end of cylinders...
  • Page 348 (2) (2) Forward position for auxiliary spool Forward position for auxiliary spool Cout Cout 100D7MCV35 Inlet from hydraulic pump Return passage to tank Outlet to tank Master spool Pilot passage (Hydraulic pressure from joystick) Passage to head end of cylinders (Hydraulic pressure from joystick) Passage to rod end of cylinders Working actuation...
  • Page 349 (3) (3) Backward position for auxiliary spool Backward position for auxiliary spool Cout Cout 100D7MCV36 Inlet from hydraulic pump Return passage to tank Outlet to tank Master spool Pilot passage (Hydraulic pressure from joystick) Passage to head end of cylinders (Hydraulic pressure from joystick) Passage to rod end of cylinders Working actuation...
  • Page 350 7. LIFT CYLINDER 7. LIFT CYLINDER 14 10 100D7CYL01 Tube assembly Stop ring 13 Back up ring Rod assembly Rod cover 14 O-ring Piston DU-bushing 15 Spacer U-packing 10 U-packing 16 O-ring Rod seal 11 Dust wiper Back up ring 12 O-ring 8.
  • Page 351 9. FREE CYLINDER 9. FREE CYLINDER 110D7EHS12 Tube assembly Rod cover 16 Plug Rod assembly 10 U-packing 17 O-ring Piston 11 Back up ring 18 Dust cap Check valve 12 Dust wiper 19 O-ring Retaining ring 13 Retaining ring 20 O-ring Seal slipper 14 O-ring 15 Back up ring...
  • Page 352 10. HYDRAULIC OIL TANK 10. HYDRAULIC OIL TANK 1) 1) STRUCTURE STRUCTURE · The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders. In the return circuit, the oil from various parts merges. ·...
  • Page 353 2) 2) AIR BREATHER AIR BREATHER The air breather is equipped with the c a p a c i t y t o p e r f o r m t w o f u n c t i o n s simultaneously-as an air filter and as a breathing valve.
  • Page 354 11. ACCUMULATOR 11. ACCUMULATOR The accumulator is installed at the cut off valve. When the mast is left the raised position, and the control levers are operated with the engine stopped the pressure of the compressed nitrogen gas inside the accumulator sends pilot pressure to the control valve to actuate it and allow the boom and bucket to come down under their own...
  • Page 355 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS 1) 1) CHECK ITEM CHECK ITEM Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1 m from ground.
  • Page 356 2. TROUBLESHOOTING 2. TROUBLESHOOTING SYSTEM SYSTEM 1) 1) Problem Problem Cause Cause Remedy 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.
  • Page 357 Problem Problem Cause Cause Remedy Remedy Actuator (cylinder or motor) · · Shortage of oil in oil tank. Check the oil level in the oil tank. · · works slowly or does not Decrease of relief valve pressure. Install pressure gauge on the circuit, operate.
  • Page 358 2) 2) HYDRAULIC GEAR PUMP HYDRAULIC GEAR PUMP Problem Problem Cause Cause Remedy 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.
  • Page 359 4) 4) CYLINDER CYLINDER Problem Problem Cause Cause Remedy 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.
  • Page 360 GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP 1. MAIN PUMP 1) 1) STRUCTURE STRUCTURE 25 26 100D7PMP00 Snap ring 10 Drive gear 19 Plug Shaft seal 11 Driven gear 20 Priority valve body Assembling bolt 12 Steel bushing 21 Compensation spool Assembling washer...
  • Page 361 2) 2) GENERAL INSTRUCTIONS GENERAL INSTRUCTIONS Check immediately that any spare parts you receive have not been damaged in shipment. Always work in a clean environment. Wash all components in solvent and blow dry with compressed air before refitting. Take care not to damage rubber seals. Avoid damaging precision machined surfaces.
  • Page 362 3) 3) DISASSEMBLY DISASSEMBLY MOUNTING FLANGE SECTION MOUNTING FLANGE SECTION Loosen and remove the assembling bolts (3) with washers (4) from the mounting flange. Remove the square-ring (13) from the mounting flange (5). ※ Replace the square-ring if damaged. 100D7PMP01 Remove the snap-ring (1) with proper tool (Only when it is needed to replace shaft seal.)
  • Page 363 Remove the assembling bolts (3) with washers (4) from the working section (14). Remove the square-ring (13) from the working section. 100D7PMP05 Remove the through shaft (15) from the drive gear (16). Remove the pressure plate (9) with related parts (7, 8) from the working section and examine it carefully.
  • Page 364 REAR WORKING SECTION REAR WORKING SECTION Loosen and remove the assembling bolts (3) with washers (4) from the priority valve body. L o o s e n a n d r e m o v e t h e L S p o r t connector (23) from the priority valve body (20).
  • Page 365 4) 4) ASSEMBLY ASSEMBLY IMPORTANT IMPORTANT ※ It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior with a proper cleaning solvent before continuing. ※ New seals should be installed upon reassembly.
  • Page 366 FRONT WORKING SECTION FRONT WORKING SECTION Locate the drive gear (10) and driven gear (11) into the rear working section (17) after fitting the parts of the pressure plate into the drive gear. ※ Locate the pressure plate (9+8+7) with care for the direction.
  • Page 367 MOUNTING FLANGE SECTION MOUNTING FLANGE SECTION Insert the shaft seal (2) carefully and fit it inside of the mounting flange (5) Fit the snap ring (1) in pre-arranged position with proper. 100D7PMP02 Insert the square ring (13) into the mounting flange (5). ※...
  • Page 368 2. MAIN CONTROL VALVE 2. MAIN CONTROL VALVE 1) 1) STRUCTURE STRUCTURE 30-6 30-5 30-4 30-3 33-4 30-2 30-1 33-3 31-1 31-2 33-2 34-4 31-3 31-4 34-3 31-5 31-6 33-1 30-1 34-2 31-7 30-2 31-6 30-3 30-4 30-5 30-6 34-1 35-2 31-6 31-9...
  • Page 369 2) 2) GENERAL PRECAUTIONS GENERAL PRECAUTIONS In the system, all of the pipes must be carefully cleaned before installation in order to remove dirt, rust, and deposits. The following cleaning procedures are recommended: Sanding, brushing, pickling, and flushing with a solvent to remove contaminating particles. The use of Teflon tape, hemp, or other "fillers"...
  • Page 370 6) 6) INSTRUCTION FOR DISASSEMBLY AND REASSEMBLY INSTRUCTION FOR DISASSEMBLY AND REASSEMBLY Before disassembly, visually inspect for leakage of oil and for part that have damage and clean the valve up. Preparation for assembly put the tag on each part to prevent wrong assembly and clean the parts completely.
  • Page 371 6) 6) DISASSEMBLY & ASSEMBLY DISASSEMBLY & ASSEMBLY Replacing complete working section Loosen tightening two bolts with 17 mm spanner. 100D7MCV01 Taking out working section one by one. 100D7MCV02 Remove O-rings on the surface of working section properly. Pay special attention not to give any scratch on the surface.
  • Page 372 Locate new or repaired working section in right position according to the order of functions. 100D7MCV05 Tighten four nuts (M17) in a crisscross pattern with proper assembling torque of 4.3 kgf·m (31 lbf·ft). 100D7MCV06 Replacing spool & control kit Loosen 4 screws holding aluminum kits to the body with 5 mm wrench.
  • Page 373 Take out the spool, as straight as possible. Even very little force on the spool while disassembling & assembling could make deformation on the spool. 100D7MCV09 Prepare all components before starting reassembling spool control kit. 100D7MCV10 Fit aluminum kit to the body with 5 mm wrench by 1.0 kgf·m (7.2 lbf·ft).
  • Page 374 Replace old relief valve with new one. Relief valve should be fitted with proper tool, 36 mm spanner, with 4.3 kgf·m (31 lbf·ft) torque. 100D7MCV13 6-50...
  • Page 375 3. REMOTE CONTROL VALVE 3. REMOTE CONTROL VALVE 1) 1) STRUCTURE STRUCTURE UT 1,2,3,4,5,6 100D7RCV00 Lever Metering spring 14 O-ring Seeger ring 15 Kit 3 Plug Seeger ring 16 Clamp Body 10 Docking rod 17 Rubber bellow Kit 1 11 Spring 18 Screw Plunger kit 12 Kit 2...
  • Page 376 2) 2) GENERAL PRECAUTIONS GENERAL PRECAUTIONS In the system, all of the pipes must be carefully cleaned before installation in order to remove dirt, rust, and deposits. The following cleaning procedures are recommended: Sanding, brushing, pickling, and flushing with a solvent to remove contaminating particles. The use of Teflon tape, hemp, or other "fillers"...
  • Page 377 6) 6) DISASSEMBLY & ASSEMBLY DISASSEMBLY & ASSEMBLY (1) (1) Replacing complete working section Replacing complete working section Loosen two tightening bolts with 13 mm spanner. 100D7RCV02 Taking out the damaged section and insert new one. Pay attention 2 O-rings on the internal passage to be in right position.
  • Page 378 Take off the fulcrum and mounting flange very carefully keeping all components in their own positions. 100D7RCV06 Take out the spool, return spring from the body. And replace any component if it is needed. 100D7RCV07 Reassemble the spool in opposite order mentioned above.
  • Page 379 Hold tightly mounting flange and lay fulcrum on the flange and screw in clamp bolts in a crisscross pattern. Clamp torque is 0.67 kgf·m (4.9 lbf·ft). 100D7RCV10 6-55...
  • Page 380 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component location ---------------------------------------------------------------------------------------- 7-1 Group 2 Electrical circuit ------------------------------------------------------------------------------------------------ 7-3 Group 3 Cluster -------------------------------------------------------------------------------------------------------------- 7-14 Group 4 Transmission message indication ---------------------------------------------------------------- 7-27 Group 5 Switches ---------------------------------------------------------------------------------------------------------- 7-31 Group 6 Electrical component specification ---------------------------------------------------------------- 7-37 Group 7 Connectors ------------------------------------------------------------------------------------------------------ 7-46 Group 8 Troubleshooting ----------------------------------------------------------------------------------------------- 7-64...
  • Page 381 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 1. LOCATION 1 1. LOCATION 1 Front Rear Switch panel 160D7AEL01 Cluster 12 Aircon & heater switch 23 Hazard switch Multi function switch 13 USB socket 24 Rear wiper/washer switch Gear selector lever 14 Cigar lighter...
  • Page 382 2. LOCATION 2 2. LOCATION 2 110DEEL02 Switch panel 14 Head lamp 27 License lamp Remote controller 15 Horn 28 Rear camera kit USB & socket assembly 16 Tilt switch 29 Heater relay Start switch 17 Int wiper relay 30 Travel alarm buzzer Cigar lighter 18 Alarm 31 Beacon lamp...
  • Page 383 GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT 101 AWG10 TRANSMISSION CONTROL UNIT(TCU) CDMP3-RADIO 103 AWG10 TCU(EST-37) ECU SERVICE TOOL CONNECTOR TO:RMCU(CN-125) FUSE BOX #1 FUSE BOX #2 FUSE BOX #3 TO:RMCU(CN-125) TO:S/W E/G MODE(CS-79) CN-246 USB(+5V) START KEY CN-59 BR ACC USB(D+) E/G MODE SWITCH...
  • Page 384 HEAD LAMP HEAD LAMP CN-95 103 AWG10 102 AWG10 F/LINK CN-60 101 AWG10 100 AWG10 F/LINK DO-1 203 AWG18 TO:PUMP RELAY 204 AWG18 CR-1 204 AWG18 DO-2 CN-19 G AWG18B G AWG18B 424 AWG18 DISCONNECT 204 AWG18 438 AWG18 SWITCH BATT.RY CHECK TO:START MOTOR...
  • Page 385 MEMORANDUM MEMORANDUM...
  • Page 386 1. POWER CIRCUIT 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. 1) 1) OPERATING FLOW OPERATING FLOW Battery(+) Master switch Battery relay[CR-1]...
  • Page 387 POWER CIRCUIT POWER CIRCUIT CS-2 START SWITCH CN-95 F/LINK CN-60 F/LINK DO-1 CR-1 DO-2 DISCONNECT SWITCH BATT RELAY TO START MOTOR MAIN EARTH 160D7AEL05...
  • Page 388 2. STARTING CIRCUIT 2. STARTING CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Battery(+) terminal Master Switch Battery relay[CR-1] I/conn[CN-1(1)] Start key(BR)[CS-2(2)] Start motor[CN-45(B+)] Start relay[CR-23(1)] ※ The engine can be started only when the gearshift is in neutral position. (1) (1) When start key switch is in ON position When start key switch is in ON position Start switch ON [CS-2(3)]...
  • Page 389 STARTING CIRCUIT STARTING CIRCUIT CN-2 CN-93(OEM)J-3 BATT.24V CR-51 BATT.24V KEY S/W INPUT(IG) INTAKE HEATER RELAY WAIT TO START LAMP BATT.24V BATT.24V RY-STARTLOCK CR-45 CS-2 ECM RELAY CR-5 START SWITCH NEUTRAL RELAY CR-23 CN-100 CN-95 START RELAY F/LINK CN-60 CN-45 F/LINK DO-1 START MOTOR MAIN...
  • Page 390 3. CHARGING CIRCUIT 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 391 CHARGING CIRCUIT CHARGING CIRCUIT CR-51 CN-56 CS-2 CAN LOW(-) RELAY CRUISE RESUME/INC STARTLOCK CR-42 RS232C RX INCHING SPEED GAUGE(CAN) CRUISE SET/DEC E/G TEMP GAUGE(CAN) BATT(+) RELAY START SWITCH CAN HIGH(+) PREHEAT CRUISE ENABLE DOWNLOAD RX232C TX ILLUMINATION CHARGING T/M TEMP GAUGE(CAN) FUEL GAUGE KEY ON POWER CLUSTER...
  • Page 392 4. PREHEATING CIRCUIT 4. PREHEATING CIRCUIT Combustion chamber glow plugs are used in order to give satisfactory starting of low ambient temperatures. 1) 1) OPERATING FLOW OPERATING FLOW Battery(+) terminal Master Switch Battery relay[CR-1] Fusible link[CN-95] I/conn[CN-1(2)] Fuse box #2[CN-37(1)] ※...
  • Page 393 PREHEATING CIRCUIT PREHEATING CIRCUIT FUSE BOX #1 FUSE BOX #3 FUSE BOX #2 CR-51 CN-93(OEM)J-3 BATT.24V BATT.24V STARTLOCK RELAY CN-2 KEY S/W INPUT(IG) CR-42 INTAKE HEATER RELAY WAIT TO START LAMP BATT.24V BATT.24V RELAY OUTPUT RETURN STARTER RELAY LOCKOUT J1939(+) PREHEAT RELAY J1939(-) CR-45...
  • Page 394 GROUP 3 CLUSTER GROUP 3 CLUSTER 1) 1) STRUCTURE STRUCTURE The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of abnormal truck operation or conditions for the appropriate operation and inspection. · Gauges : Indicate operating status of the truck.
  • Page 395 2) 2) GAUGE GAUGE Speed meter Speed meter ① The speedmeter displays the speed of truck in mph and km/h. 7807A3CD03 (2) (2) Fuel gauge Fuel gauge ① This gauge indicates the amount of fuel in the fuel tank. ② Fill the fuel when the indicator moves E point, refuel as soon as possible to avoid running out of fuel.
  • Page 396 3) 3) WARNING LAMPS WARNING LAMPS Transmission oil temperature warning lamp Brake fail warning lamp T/M error warning lamp Engine coolant temp warning lamp Parking brake warning lamp Seat belt warning lamp OPSS warning lamp Engine oil pressure warning lamp Battery charging warning lamp Water in fuel...
  • Page 397 ② Immediately pull the truck to a convenient stop. Stop the engine. Investigate the cause. ※ Consult a HYUNDAI dealer to investigate the cause. Consult a HYUNDAI dealer to investigate the cause. 160D7ECD19 ※ Do not operate until the cause has been corrected.
  • Page 398 (8) (8) Water in fuel warning lamp Water in fuel warning lamp ① This lamp lights up when the water separators full of water or malfunctioning. ※ When this lamp lights up, stop the truck and spill water out of When this lamp lights up, stop the truck and spill water out of the separator.
  • Page 399 (13) (13) OPSS warning lamp (option) OPSS warning lamp (option) ① This signal lamp lights ON when the operator leaves the seat. ② Powered travel movement of the truck shall be possible only if the operator is in the normal operating position. Transmission will automatically shift to neutral upon the exiting of the operator.
  • Page 400 4) 4) PILOT LAMPS PILOT LAMPS Head light pilot lamp Right turning pilot lamp Left turning pilot lamp Work lamp pilot lamp Fuel heater pilot lamp Preheater pilot lamp Inching pilot lamp 160D7ECD02-2 (1) (1) Direction pilot lamp Direction pilot lamp ①...
  • Page 401 (3) (3) Head light pilot lamp Head light pilot lamp ① This lamp comes ON when the main light switch is operated to 2nd step. 160D7CD07 (4) (4) Preheater pilot lamp Preheater pilot lamp ① This lamp lights ON when start switch is turned clockwise to the ON position.
  • Page 402 4) 4) CLUSTER BUTTON CLUSTER BUTTON Each button has the following function. Buzzer stop button Next button MENU button 160D7ECD121E (1) (1) Buzzer stop button Buzzer stop button ① This button is used to stop the buzzer sound. ② If another alarm condition occurs after this button has been pressed, the alarm buzzer will re-sound.
  • Page 403 (4) (4) Menu and next buttons Menu and next buttons ※ These buttons are used to select the model select mode. These buttons are used to select the model select mode. ※ The initial model is selected at the factory, so don't change The initial model is selected at the factory, so don't change the different model.
  • Page 404 Display Description ⑤ To Change another model, press (Equipment model screen) ⑥ To set the ton, press . Model select is completed. ※ If you want to return to the previous state, press If you want to return to the previous state, press 7-24...
  • Page 405 LCD has the functions to display start mode, standby mode, cruise function, engine error display, model select mode etc. Name and display Description Start mode - Displays initialization state with HYUNDAI logo and program version. Standby mode Displays on the idle state. Displays engine speed, odometer and hourmeter.
  • Page 406 Name and display Description Model select mode (Ton) On ton select mode, displays like this image. See page 7-23. Model select mode (Model) On model select mode, displays like this ① ② image. (If you choose the 50~70, displays like ① If you choose the 80, displays like ②...
  • Page 407 4.TRANSMISSION MESSAGE INDICATOR 4.TRANSMISSION MESSAGE INDICATOR 1) 1) TRANSMISSION ERROR DISPLAY TRANSMISSION ERROR DISPLAY (1) (1) Function Function The display can be used with the gear selector. It indicates speed and driving direction as well as the activated inching. When driving in the automatic mode, a bar indicator gives additionally also information about the selected driving range ;...
  • Page 408 2) 2) DO AEB WORK DO AEB WORK Start engine after parking the machine on flat floor and blocking wheels. Release parking brake. With stepping on the service brake, operate T/M STALL (3 stage). (To avoid defect of clutch pack, repeat 10 sec of operation and 10 sec of placing neutral) When the T/M oil temperature reaches 75~80˚C, lock the parking brake and then shift gear to neutral position to keep the machine at LOW RPM.
  • Page 409 3) 3) DISPLAY DURING AEB-MODE DISPLAY DURING AEB-MODE Symbol Meaning Remarks A E B - s t a r t e r i s p l u g g e d a t t h e diagnostic plug AEB-Starter-button is pressed K1..K3 Calibrating clutch K1...K3, KV or KR KV, KR...
  • Page 410 INITIALIZING THE INCHING SENSOR INITIALIZING THE INCHING SENSOR Start engine after parking the machine on flat floor and blocking wheels. Release parking brake and keep neutral gear shift. Adjust the inching sensor linkage so that the regular voltage is supplied to inching sensor when operating the pedal.
  • Page 411 5. SWITCHES 5. SWITCHES Cruise set-resume switch Cruise switch Cover Parking brake switch Auto/Manual select switch Clutch cut-off switch Main light switch Work lamp switch Hazard switch Cover(LH) Rear wiper/washer switch Aircon switch Seat heat switch Lock lever Inc/Dec switch Engine mode switch Fuel heater switch STOP...
  • Page 412 HAZARD SWITCH HAZARD SWITCH Use for parking, or loading truck. ※ If the switch is left ON for a long time, the battery may be discharged. 160D7CD42 CLUTCH CUT-OFF SWITCH CLUTCH CUT-OFF SWITCH If this switch is pressed, inching operation is applied to inching pedal.
  • Page 413 7) 7) REAR WIPER AND WASHER SWITCH REAR WIPER AND WASHER SWITCH This switch is used to operate the rear wiper and washer by two steps. ·First step : The rear wiper operates. ·Second step : The washer liquid is sprayed and the rear wiper is operated only while pressing.
  • Page 414 FUEL HEATER SWITCH FUEL HEATER SWITCH This switch is used to heat the fuel of pre-heater. 180D7ECD101 AIRCONDITIONER SWITCH AIRCONDITIONER SWITCH This switch is used to aircon compressor ON or OFF. 250D7ECD102 CRUISE SWITCH CRUISE SWITCH When this switch is turned ON, the cruise ready mode is selected and cruise active is ready for activation.
  • Page 415 ENGINE MODE SWITCH ENGINE MODE SWITCH This switch offers two selectable operating mode. POWER The operator can adjust the machine's performance with this STANDARD selection switch. Function ① STANDARD MODE : This mode provides maximum fuel efficiency for general loading. 160D7ECD60 ②...
  • Page 416 MASTER SWITCH MASTER SWITCH This switch is used to shut off the entire electrical system. When the machine is not operated for a long time, turn OFF the master switch for the safety purpose. I : The battery remains connected to the electrical system. O : The battery is disconnected to the electrical system.
  • Page 417 GROUP 6 ELECTRICAL COMPONENT SPECIFICATION GROUP 6 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check ※ Check specific gravity 12V × 200Ah 1.280 over : Over charged Battery (2EA) 1.280 ~ 1.250 : Normal 1.250 below : Recharging ※ Check disconnection Normal : 0Ω...
  • Page 418 Part name Symbol Specifications Check Pressure : ※ Check contact Air cleaner 635mmH pressure switch Normal : ∞Ω (N.O TYPE) CD-10 ※ Check resistance Reed switch : Fuel sender Full : About 50Ω Magnetic type Low level : About 700Ω CD-2 ※...
  • Page 419 Part name Symbol Specifications Check ※ Check disconnection Work lamp, 24V 65W Head lamp Normal : A fewΩ H3 bulb CL-3 CL-4 ※ Check disconnection 24V 15W Beacon lamp (Strobe type) Normal : A fewΩ CL-2 CL-7 ※ Check disconnection 24V 10W (tail) Combination lamp...
  • Page 420 Part name Symbol Specifications Check CS-10 CS-17 ※ Check contact CS-17 CS-18 CS-34 OFF : ∞Ω CS-41 CS-34 Switch 24V 8A (For terminal 1-5, 2-6) CS-42 CS-41 (Locking type) : ∞Ω CS-42 CS-54 (For terminal 5-7, 6-8) CS-79 CS-3 CS-3 CS-21 CS-19 ※...
  • Page 421 Part name Symbol Specifications Check Seat heater CN-170 ※ Check voltage Delco Remy 24SI Alternator Normal : 24~28V 24V 70A CN-74 DENSO ※ Operating or not Start motor 24V 3.7kW CN-45 ※ Check resistance Radio/USB Power ON : 4Ω+ 4Ω 28V 18W×2 player (For terminal 1-6, 4-8)
  • Page 422 Part name Symbol Specifications Check ※ Check resistance Speaker 4Ω 20W Normal : 50Ω CN-23 CN-23(LH) CN-24 CN-24(RH) ※ Check resistance Receiver Normal : Ω dryer CN-29 ※ Check contact Air conditioner 24V 79W compressor Normal : 13.4Ω CN-30 Cigar lighter 24V 5A CL-2 CL-2...
  • Page 423 Part name Symbol Specifications Check 24V 1.5A Wiper motor 2-speed Auto parking CN-102 ※ Check contact 24V 2.5A Motor Normal : 26.4Ω (For terminal 1-2) CN-103 24V 200mA Warning buzzer 90±5dB(ℓm) CN-26 Camera CN-249 CN-250 Pump relay CR-44 CR-44 Diode Diode spec : 1N5406 DO-01 DO-02...
  • Page 424 Part name Symbol Specifications Check ※ Check resistance Brake switch N.O type Normal : ∞Ω CD-4 CD-4 ※ Check resistance 24V 0.2A Tilt alarm Normal : A fewΩ 90dB±5dB CN-26 5V DC ※ Check voltage ON D 5V, hall sensor Accel pedal 0.5~3.9V (2-1) CO ON...
  • Page 425 Part name Symbol Specifications Check 24V 10A DC/DC ※ Check resistance Output voltage : converter Normal : A fewΩ(1-2, 1-3) 13±1VDC CN-138 7-45...
  • Page 426 GROUP 7 CONNECTORS GROUP 7 CONNECTORS 1. CONNECTOR DESTINATION 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Engine harness-Main harness) MG643241 MG613245 CN-2 I/conn(Main harness-Engine harness) MG643241 MG613245 CN-3 DEUTSCH Seat switch DT04-4P CN-4 DEUTSCH Work lamp switch...
  • Page 427 Connector part No. Connector No. of Type Destination number Female Male CN-50 Transmission control unit 963598-1 CN-51 T/M diagnostic 480704-0 926682-3 CN-52 Handsfree controller MG610331 MG640333 CN-55 OPSS unit MG610350 CN-56 Cluster 174047-2 CN-57 Cluster 175967-2 CN-58 Monitor 174047-2 CN-59 MCU (Machine control unit) 344111-1 CN-60...
  • Page 428 Connector part No. Connector No. of Type Destination number Female Male 174357-2 174359-2 CN-251 Camera spare 174877-2 174879-2 174357-2 174359-2 CN-252 Camera spare 174877-2 174879-2 Switch Switch CS-2 Start key MG610047 CS-3 DAEDONG Rear wiper washer switch 250-10PRG MG610335 CS-6 Center horn MG640322 CS-10...
  • Page 429 Connector part No. Connector No. of Type Destination number Female Male Relay Relay CR-3 HELLA Work lamp relay 8JA003526-001 CR-4 Wiper high speed relay VCFM-1002 CR-5 Netural relay VCFM-1002 CR-6 DEUTSCH Internal wiper relay HD10-9-96P CR-11 HELLA Flasher unit 8JA003526-001 21LM-01600 CR-23 Start relay...
  • Page 430 Connector part No. Connector No. of Type Destination number Female Male CD-75 Filter switch 282080-1 CD-76 Air temp sensor 963040-3 CD-96 PACKARD Coolant level sensor 12110293 CD-101 SUMITOMO TBAP sensor 6098-0144 Engine TBAP CD-102 FRAMATOME 54200415 (Temp. Barometric Absolute Pressure) Diode Diode DO-1...
  • Page 431 2. CONNECTION TABLE FOR CONNECTORS 2. CONNECTION TABLE FOR CONNECTORS 1) 1) 58-L TYPE CONNECTOR 58-L TYPE CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) S813-030100 S813-130100 S813-030200 S813-130200 7-51...
  • Page 432 2) 2) PA TYPE CONNECTOR PA TYPE CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 S811-109002 S811-011002 S811-111002 7-52...
  • Page 433 No. of Receptacle connector (Female) Plug connector (Male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 7-53...
  • Page 434 J TYPE CONNECTOR J TYPE CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) S816-002001 S816-102001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 7-54...
  • Page 435 SWP TYPE CONNECTOR SWP TYPE CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) S814-001000 S814-101000 S814-002000 S814-102000 S814-003000 S814-103000 S814-004000 S814-104000 7-55...
  • Page 436 No. of Receptacle connector (Female) Plug connector (Male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 7-56...
  • Page 437 5) 5) CN TYPE CONNECTOR CN TYPE CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) S810-001202 S810-101202 S810-002202 S810-102202 S810-003202 S810-103202 S810-004202 S810-104202 7-57...
  • Page 438 No. of Receptacle connector (Female) Plug connector (Male) S810-006202 S810-106202 S810-008202 S810-108202 7-58...
  • Page 439 6) 6) ITT SWF CONNECTOR ITT SWF CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) SWF593757 7) 7) HW090 SEALED CONNECTOR HW090 SEALED CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) 6189-0133 8) 8) MWP02F-B CONNECTOR MWP02F-B CONNECTOR No.
  • Page 440 9) 9) AMP ECONOSEAL CONNECTOR AMP ECONOSEAL CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 344111-1 344108-1 AMP TIMER CONNECTOR AMP TIMER CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 85202-1 AMP 040 MULTILOCK CONNECTOR AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 174045-2 7-60...
  • Page 441 KET 090 WP CONNECTORS KET 090 WP CONNECTORS No. of Receptacle connector (Female) Plug connector (Male) MG640795 ITT SWF CONNECTOR ITT SWF CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) SWF593757 MWP NMWP CONNECTOR MWP NMWP CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) NMWP01F-B...
  • Page 442 DEUTSCH DT CONNECTORS DT 06 - 3S - ★★★★ Modifications (See below) Number of contacts (P : Pin, S : Socket) 04 : Receptacle, 06 : Plug Deutsch connectors ※ Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
  • Page 443 No. of Receptacle connector(Female) Plug connector(Male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 7-63...
  • Page 444 GROUP 8 TROUBLESHOOTING GROUP 8 TROUBLESHOOTING Trouble symptom Trouble symptom Probable cause Probable cause Remedy 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.
  • Page 445 SECTION 8 MAST 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 -------------------------------------------------------------------------------- 8-9...
  • Page 446 SECTION 8 MAST SECTION 8 MAST GROUP 1 STRUCTURE GROUP 1 STRUCTURE 1. 2 STAGE MAST (V MAST) 1. 2 STAGE MAST (V MAST) Lift cylinder Lift cylinder Frame Carriage 110D7EMS01 Outer mast Lift chain Chain sheave bearing Roller bearing Anchor bolt 10 Anchor bolt Tilt cylinder pin...
  • Page 447 2. 3 STAGE MAST (TF MAST) 2. 3 STAGE MAST (TF MAST) Lift cylinder Lift cylinder Free lift cylinder 110D7EMS05 Outer mast Tilt cylinder pin Sheave Shim Mast mounting pin 10 Anchor bolt Roller bearing Inner mast Chain Side roller bearing Middle mast 12 Sheave bracket...
  • Page 448 3. CARRIAGE, BACKREST AND FORK (SHAFT TYPE) 3. CARRIAGE, BACKREST AND FORK (SHAFT TYPE) Shaft type fork Extension fork 110D7EMS02 Carriage & backrest Side roller Hanger bar Fork Fork retaining Extension fork Roller...
  • Page 449 Measure thickness of root of forks and check that it is more than specified value. EX : ℓ=1800 mm (71 in) mm (in) STD Fork assy Applicable model Standard Limit Thickness 61FT-70342 110D-7A 75(3.0) 68(2.7) 61FT-71440 130D-7A 90(3.5) 80(3.2) D507FK01 61FT-70143 160D-7A 95(3.7) 85(3.3)
  • Page 450 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) MAST MAST Problem Problem Cause ause Remedy 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.
  • Page 451 2) 2) FORKS FORKS Problem Problem Cause ause Remedy Remedy Abrasion Long-time operations causes the fork If the measured value is below the to wear and reduces the thickness of wear limit, replace fork. the fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion...
  • Page 452 GROUP 3 ADJUSTMENT GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER 1. MAST LOAD ROLLER 1) 1) INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480 mm (19 in). 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...
  • Page 453 2) 2) CARRIAGE LOAD ROLLER CARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100 mm 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.
  • Page 454 GROUP 4 REMOVAL AND INSTALLATION GROUP 4 REMOVAL AND INSTALLATION 1. FORKS 1. FORKS (SHAFT TYPE) (SHAFT TYPE) Lower the fork carriage until the forks are approximately 25 mm (1 in) from the floor. Release fork anchor pins and slide one fork Fork retainer at a time toward the center of the carriage Hanger bar...
  • Page 455 Pull the chains out of the sheaves and Inner mast drape them over the front of the carriage. Disconnect connector from the work lamp Outer mast assy. Work lamp assy Lift chain Block 110D7ERE55 Slowly raise inner mast upright until mast clears top of fork carriage.
  • Page 456 2) 2) SIDE ROLLER SIDE ROLLER Side roller Remove carriage as outlined in the carriage removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side plate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assem- Carriage &...
  • Page 457 4. MAST LOAD ROLLER 4. MAST LOAD ROLLER 1) 1) 2 STAGE MAST (V MAST) 2 STAGE MAST (V MAST) Remove the carriage assembly and move them to one side. Loosen and remove hexagon nuts and screws securing lift cylinders to inner mast. Loosen and remove hexagon bolts and nuts securing lift cylinders to outer mast.
  • Page 458 2) 2) 3 STAGE MAST(TF MAST) 3 STAGE MAST(TF MAST) Remove the carriage assembly and move it to one side. Lift chain Loosen and remove hexagon bolt secur- ing bottom cylinder from outer mast. Loosen and remove set screws and nuts securing lift cylinders to middle mast.
  • Page 459 5. CHAIN 5. CHAIN CHAIN SHEAVE CHAIN SHEAVE 1) 1) Place a sling around carriage and attach Chain to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage Sheave is blocked.
  • Page 460 3) 3) SHEAVE SUPPORT (TF MAST) SHEAVE SUPPORT (TF MAST) A, B Remove the carriage assembly and move to one side. Sheave Sheave support After removing bolt to securing sheave support assembly to free lift cylinder. Attach a sling to the sheave support Middle mast assembly.
  • Page 461 5) 5) CARRIAGE CHAIN CARRIAGE CHAIN Place a sling around carriage front plate Inner mast and attach to an overhead hoist. Lift and secure carriage high enough so that split and chain anchor pins on carriage can be Outer mast easily be removed.
  • Page 462 (2) (2) Rust and corrosion Rust and corrosion Chains used on lift trucks are highly stressed precision components. It is very important that the s-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 463 (8) (8) Chain wear scale 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 464 (3) (3) Adjustment 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 Adjustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor.

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