Hyundai 250D-7E Operating Manual

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SECTION 1 GENERAL

Group 1 Safety hints --------------------------------------------------------------------------------------------------------

Group 2 Specifications ----------------------------------------------------------------------------------------------------

Group 3 Operational checkout record sheet -----------------------------------------------------------------

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

Group 1 Structure ------------------------------------------------------------------------------------------------------------

Group 2 Removal and Installation of Unit ----------------------------------------------------------------------

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation ------------------------------------------------------------------------------------

Group 2 Operation and maintenance ----------------------------------------------------------------------------

Group 3 Disassembly and assembly -----------------------------------------------------------------------------

Group 4 Adjustment ---------------------------------------------------------------------------------------------------------

SECTION 4 BRAKE SYSTEM

Group 1 Structure and function --------------------------------------------------------------------------------------

Group 2 Operational checks and troubleshooting --------------------------------------------------------

Group 3 Tests and adjustments --------------------------------------------------------------------------------------

Group 4 Disassembly and assembly -----------------------------------------------------------------------------

SECTION 5 STEERING SYSTEM

Group 1 Structure and function --------------------------------------------------------------------------------------

Group 2 Operational checks and troubleshooting --------------------------------------------------------

Group 3 Tests and adjustments --------------------------------------------------------------------------------------

Group 4 Disassembly and assembly -----------------------------------------------------------------------------

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function --------------------------------------------------------------------------------------

Group 2 Operational checks and troubleshooting --------------------------------------------------------

Group 3 Disassembly and assembly -----------------------------------------------------------------------------

CONTENTS

1-1

1-5

1-13

2-1

2-2

3-1

3-46

3-57

3-185

4-1

4-32

4-40

4-43

5-1

5-9

5-17

5-21

6-1

6-28

6-33

Summary of Contents for Hyundai 250D-7E

Page 1 CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints -------------------------------------------------------------------------------------------------------- Group 2 Specifications ---------------------------------------------------------------------------------------------------- Group 3 Operational checkout record sheet ----------------------------------------------------------------- 1-13 SECTION 2 REMOVAL AND INSTALLATION OF UNIT SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure ------------------------------------------------------------------------------------------------------------ Group 2 Removal and Installation of Unit ---------------------------------------------------------------------- SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM...
Page 2 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component location ----------------------------------------------------------------------------------------- Group 2 Electrical circuit ------------------------------------------------------------------------------------------------- Group 3 Cluster --------------------------------------------------------------------------------------------------------------- 7-14 Group 4 Transmission message indicator --------------------------------------------------------------------- 7-23 Group 5 Switches ------------------------------------------------------------------------------------------------------------ 7-27 Group 6 Electrical component specification ------------------------------------------------------------------ 7-32 Group 7 Connectors -------------------------------------------------------------------------------------------------------- 7-42...
Page 3 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
Page 4 Revised edition mark( Any additions, amendments or other changes 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 = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
Page 8 m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 11 SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Operational checkout record sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13...
Page 12 GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
Page 13 Be particularly careful when removing the radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using the machine, there is a danger that boiled water and oil may spurt out. The procedure for releasing the hydraulic pressure is as follows : lower the fork to the ground, and stop the engine(Motor), move the control levers to each position two or three times.
Page 14 Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. D50ASF09 When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
Page 15 160D7ESP01 Push the dipstick fully into the guide, and then pull out. Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request the HYUNDAI Forklift distributor to carry out...
Page 16 GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENTS 250D7EOM54 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 12 Operator's seat...
Page 17 2. SPECIFICATIONS C' C Model Unit 250D-7E Capacity 25000 Load center 1200 Weight(Unloaded) 37020 Lifting height 4030 Free lift Fork Lifting speed (Unload/Load) mm/sec 280/250 Lowering speed (Unload/Load) 300/400 mm/sec L W T L,W,T 2450 250 110 Tilt angle (forward/backward)
Page 18 3. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Item Specification Unit Model CUMMINS QSC Type 4 cycle turbocharged and inter cooled 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 X stroke mm(in) 114 135mm (4.49"...
Page 19 TEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev Rated flow POWER TRAIN DEVICES Item Specification Model W340, 1.773/271 (ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 1.773 : 1 Type Full auto, power shift Gear shift(FR/RR) Transmission...
Page 20 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Items Size kgf m lbf ft Engine mounting bolt, nut M24 3.0 100 15 723 109 Engine M12 1.75 12.8 3.0 93 22 Radiator mounting bolt, nut Hydraulic pump mounting bolt M12 1.75 12.8 3.0 93 22 Hydraulic MCV mounting bolt, nut...
Page 21 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT - Coarse thread Bolt size kgf m lbf ft kgf m lbf ft M 6 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1...
Page 22 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat mm kgf m lbf ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 130.2 1" 151.9 1-1/4" 253.2 IPE AND HOSE(ORFS TYPE) Width across flat mm kgf m lbf ft Thread size(PF) 28.9 9/16-18 36.2...
Page 23 6. RECOMMENDED LUBRICANTS Ambient temperature Service Kind of Capacity (U.S.gal) point fluid (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil Engine oil (5.3) SAE 10W-30 SAE 15W-40 SAE 10W-30 Torque Engine oil converter (7.1) transmission SAE 15W-40 27.5+2 3.2 Gear oil...
Page 24 GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET Owner Date Hours Serial No. Technician U U se 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(Engine OFF) Hour meter and gauge check Battery check Monitor indicator circuit check...
Page 25 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 Brake system leakage check Service brake pedal check Service and park brake system drag check Clutch cut off check .
Page 26 7. Steering system checks Steering valve check Steering system leakage check Priority valve(built in MCV) Low check pressure High check pressure . Accessory checks Operating lights check Work light check Brake light check Cab light check Horn circuit check Windshield washer and wiper check Heater/Air conditioner blower check Heater functional check Air conditioner functional check...
Page 27 SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
Page 28 GROUP 1 STRUCTURE 250D7EOM21 Mast Transmission 17 Counterweight Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder 12 Steering cylinder 20 Cabin Main control valve 13 Hydraulic pump 21 Steering wheel Fork 14 Steering axle 22 Muffler Front wheel 15 Rear wheel...
Page 29 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Fork Carriage Piping Mast FORKS Cylinder retainer pin Lower the fork carriage until the forks are Fork retainer pin approximately 25mm(1in) from the floor.
Page 30 Pull the chains out of the sheaves and drape them over the front of the carriage. Inner mast Outer mast Work lamp assy Lift chain Block 250D7ERE55 Slowly raise inner mast upright until mast clears top of fork carriage. Move Inner mast carriage to work area and lower the mast.
Page 31 PIPING Remove the hoses and clamps attached to the cylinder. Inner mast Put blind plugs in the piping immediately after removing hoses. This prevents the hydraulic oil from flowing out and also prevents dust and dirt from getting in. Outer mast Lift cylinder Outer mast 250D7ERE57...
Page 32 LIFT CYLINDER Loosen and remove hexagon bolts and washers securing lift cylinders to inner Inner mast mast. Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no slack or binding. Make sure the lift cylinder be tightened Lift cylinder firmly for safety.
Page 33 INNER MAST Using an overhead hoist raise the inner mast straight and carefully draw out of Inner mast outer mast section. Be careful the mast not to swing or fall. Outer mast 250D7ERE59 TILT CYLINDER PIN Outer mast MAST SUPPORT PIN Attach a crane to the stay at the top of the Tilt cylinder outer mast, and raise it.
Page 34 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. Installation procedure for each of mast component is the reverse of the removal procedure. MAST SUPPORT PIN Check the mast support pins for wear, then install pins into the mast support bracket and drive axle.
Page 35 2. POWER TRAIN ASSEMBLY 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 Mast Refer to section on mast(Page 2-2)
Page 36 Brake piping Disconnect the brake hydraulic hoses Brake hose Return from the brake housing of drive axle unit. hose When disconnecting the brake hydraulic hoses, take care that oil should not be spilt on the floor. If someone slips due to oil spillage, it can cause to do him severe injuries.
Page 37 Transmission and axle cooling piping Disconnect cooling hose and connector from the transmission. Radiator assembly Make sure that the transmission cooling oil has been drained from the line. Transmission assembly Cooling hose 250D7ERE10 Disconnect axle cooling hose and Radiator connector from the axle. assembly Make sure that the axle cooling oil has AXLE OIL...
Page 38 Mounting bolts holding to flywheel housing Bolt Remove the transmission assembly from engine by loosen-ing 12 pieces of the Engine mounting bolts.(Bolt②) Transmission 180D7ERE15 Using a moving truck slowly pull out transmission assembly to the front. Transmission Truck 250D7ERE13 2-11...
Page 39 2 2 ) INSTALLATION Bolt Installation is the reverse order to removal, but be careful of the following points. Bolt 1 Tightening torque of mounting bolts Engine flywheel housing. 5.5~8.3kgf m (39.8~60.0lbf ft) Tightening torque of mounting bolts Transmission the flywheel for flexible plate. 3.9~5.1kgf m (28.2~36.9lbf ft) 180D7ERE12 Tightening torque of mounting bolts...
Page 40 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL Mounting bolts T/C housing holding to engine cover flywheel Engine hood Engine accessory Shroud Mounting bolts Overhead Radiator guard hose Air cleaner hose 100D7RE25 Engine hood...
Page 41 Engine cover(center) Aircleaner Pull upside the precleaner by loosening License Mounting bolt plate the bolts and seal in the air intake hole Engine of air cleaner. cover(RH) cover Remove engine cover and radiator Engine cover(LH) cover upward. 250D7ERE18 Torque converter housing cover and mounting bolts.
Page 42 Engine mounting bracket Attach a crane to the engine hook and raise, then remove mounting bolts. Raise Bolt the engine slightly, slide towards the radiator, then lift up. When sliding the engine, be careful of the collision of engine and radiator. Bolt Rubber mount 180D7ERE93...
Page 43 4. REAR AXLE REMOVAL Counter Mounting Rear wheel Hose weight bolt Mounting bolt(1) Mounting pin Mounting bolt(3) Mounting bolt(2) 250D7ERE30 Counterweight Hold the counterweight with hoist bars, and raise it with a crane. Remove the mounting bolts, raise slightly and move it slowly to rear side. Weight of counterweight (standard) Description Weight...
Page 44 Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. 100D7RE31 Hose Steering axle Disconnect the hose from the steering axle and then drain out oil from the hoses. When disconnecting the hoses, take care that oil should not be spilt on the floor.
Page 45 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation ---------------------------------------------------------------------------------- Group 2 Operation and maintenance --------------------------------------------------------------------------- 3-46 Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 3-57 Group 4 Adjustment ------------------------------------------------------------------------------------------------------- 3-185...
Page 46 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION . POWER TRAIN COMPONENT OVERVIEW Drive axle Transmission Steering axle Propeller shaft Torque converter Engine 250D7EPT01 The power train consists of the following components : Torque converter Transmission Propeller shaft Drive axle Engine power is transmitted to the transmission through the torque converter.
Page 47 ydraulic 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 By pass valve 11+2 bar 5.5 bar Pump 16+2 bar Oil sump Main oil circuit Lubrication D507PT31 Positions...
Page 48 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 49 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 50 3. TRANSMISSION LAYOUT Gearbox diagram AN/PTO K3/AB 180D7ETM03 Clutch shaft (lay shaft, K4) Clutch shaft (KZ) Clutch shaft (KV) Clutch shaft / Output (K3/AB) Input shaft / Power take-off (AN/PTO) Clutch shaft (K1) Clutch shaft (KR) Electro-hydraulic control...
Page 51 INSTALLATION VIEW 180D7EPT26 Electro - hydraulic control Lifting lugs Converter bell Converter bell Lifting lugs 13 Converter with diaphragm - direct mounting Gearbox housing front and rear section 14 Converter with diaphragm Oil level tube with oil dipstick (rear side) 15 Exchange filter with filter head Transmission suspension holes M20 16 Transmission suspension holes M20...
Page 52 OPERATION OF TRANSMISSION Gearbox diagram 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. The 3-speed reversing transmission is equipped with 5 multi-disk clutches.
Page 53 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. Transmission diagram 1st speed-reverse Converter AN/PTO Opinion direction K3/AB of rotation Legend = Clutch forward = Clutch reverse...
Page 54 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. Transmission diagram 1st speed-reverse Converter AN/PTO Opinion direction K3/AB of rotation Legend = Clutch forward = Clutch reverse...
Page 55 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 3-10...
Page 56 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 = 105 /min, at n = 2000 min...
Page 57 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)). For the protection from unintended start off, a neutral interlock is installed : Position "...
Page 58 Gear selector(DW-3) LEVER FOR MECHANICAL CODING GEAR SELECTOR NEUTRAL INTERLOCK OUTPUT FORWARD REVERSE NEUTRAL SPEED IN POSITION(NEUTRAL), F-R NOT SWITCHABLE CIRCUIT DIAGRAM SELECTOR TYPE PLATE GEAR POSITIONS AD3(B3) AD1(B1) ED1(+/VP) F = FORWARD AD6(N) N = NEUTRAL R = REVERSE AD4(FORWARD) D = MECANICAL NEUTRAL INTERLOCK 1 = 1st SPEED...
Page 59 TRANSMISSION ERROR DISPLAY 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 60 isplay 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 61 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 TCU shifts transmission to Check the cables from TCU to neutral shift lever TCU detected a wrong signal combination...
Page 62 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Retarder function is affected Check the cable from TCU to the S.C. to battery voltage at load sensor input TCU uses default load sensor OP mode : Normal...
Page 63 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction, TCU uses default Check the cable from TCU to the S.C. to ground at retarder temperature sensor input temperature sensor OP mode : Normal...
Page 64 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 Check the cable from TCU to the control TCU measures a engine speed over a sensor threshold and the next moment the...
Page 65 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 Check the cable from TCU to the control TCU measures a internal speed over a sensor threshold and at the next moment the...
Page 66 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 the cable from TCU to the S.C. to battery voltage at clutch K1 OP mode : Limp home gearbox The measured resistance value of the valve If failure at another clutch is...
Page 67 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 S.C. to battery voltage at clutch K3 Check the cable from TCU to the OP mode : Limp home The measured resistance value of the gearbox If failure at another clutch is...
Page 68 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 engine derating device OP mode : Normal engine derating device TCU detected a wrong voltage at the Check the connectors from engine output pin, that looks like a O.C.
Page 69 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 S.C. to ground at clutch KR Check the cable from TCU to the OP mode : Limp home The measured resistance value of the valve gearbox If failure at another clutch is...
Page 70 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 OP mode : Normal backup alarm device TCU detected a wrong voltage at the Check the connectors from...
Page 71 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction S.C. to ground at park brake solenoid Check the cable from TCU to the OP mode : Normal TCU detected a wrong voltage at the park brake solenoid output pin, that looks like a S.C.
Page 72 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction S.C. to battery voltage at converter lock Check the cable from TCU to the up clutch solenoid OP mode : Normal converter clutch solenoid TCU detected a wrong voltage at the...
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 S.C. to ground at difflock or axle Check the cable from TCU to the connection solenoid OP mode : Normal difflock solenoid TCU detected a wrong voltage at the Check the connectors from difflock...
Page 74 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 OP mode : Limp home Check main pressure in the TCU calculates a differential speed at If failure at another clutch is system...
Page 75 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 Check pressure at clutch KV OP mode : Limp home TCU calculates a differential speed at Check main pressure in the If failure at another clutch is closed clutch KV.
Page 76 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 Check pressure at converter TCU calculates a differential speed at lockup clutch closed converter lockup clutch. If this Check main pressure in the calculated value is out of range, TCU...
Page 77 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction Cool down machine Overtemp converter output OP mode : Normal Check oil level TCU measured a oil temperature at the Check temperature sensor converter output that is the allowed threshold...
Page 78 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection See fault codes No.21 to 2C Check cables and connectors to S.C. to battery voltage at power supply for sensors sensors, which are supplied from TCU measures more than 6V at the pin Check the power supply at the pin...
Page 79 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection Not used S.C. battery voltage at speedometer output S.C. to ground or O.C at speedometer Not used output S.C. to battery voltage at display output No reaction Check the cable from TCU to the TCU sends data to the display and...
Page 80 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection No reaction Replace TCU General EEPROM fault OP mode : Normal Often shown together with fault TCU can't read non volatile memory code F2 TCU is defective onfiguration lost...
Page 81 Measuring of resistance at actuator/sensor and cable Actuator 76043PT19 Open circuit Short cut to ground = R; R = 0, R = R or R = R, R (For S.C. to ground, G is connected to vehicle ground) Short cut to battery = R;...
Page 82 ELECTRONIC CONTROL FOR POWER TRANSMISSION 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. Protection from operating error as far as necessary, is possible via electronic protect- tion(programming).
Page 83 Automatic calibration of the shifting elements (AEB) The AEB serves to compensate tolerances (plate clearance and pressure level), which are in fluencing the filling procedure of the clutches. For each clutch, the correct filling parameters for * Period of the rapid - filling time * Level of the filling equalizing pressure are defined in a test cycle.
Page 84 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. In his way, the driver can move the vehicle very exactly to a determined position. At the same time and important part of the engine power for the output of the hydraulic system is at disposal by the high engine speed.
Page 85 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS The measurement have to be carried out with hot transmission(about 80~95 C) 51 48 (See Detail-A) (See Detail-B) Detail-A Detail-B 180D7ETM04 ·Pressure regulator under voltage Engaged clutch Driving direction Speed ● ● ● ● Forward ●...
Page 86 OIL PRESSURE AND TEMPERATURE Port Description Size In front of converter - Opening pressure 11+2 bar M10x1 Clutch Forward 16 + 2 bar M10x1 Clutch reverse 16 + 2 bar M10x1 Clutch 16 + 2 bar M10x1 Clutch 16 + 2 bar M10x1 Clutch 16 + 2 bar...
Page 87 5. DRIVE AXLE STRUCTURE 1 250D7EDR02 400 Differential & carrier 413 Hexagon socket screw 428 Sealing ring 401 Drive pinion 414 Hexagon screw 432 Tapered roller bearing 402 Ring gear 415 Tapered roller bearing 433 Thrust washer 403 Differential housing 417 Differential carrier housing 436 Tapered roller bearing 404 Differential housing...
Page 88 STRUCTURE 2 250D7EDR03 250 Inner disk 261 Brake housing 274 Screw plug 251 Outer disk 262 O-ring 275 Sealing ring 252 Piston 264 O-ring 278 Bleeding socket 253 Bushing 265 O-ring 279 Sealing ring 254 Hex socket screw 266 Hex socket screw 280 Bleeder valve 255 Disk carrier 267 Hex socket screw...
Page 89 STRUCTURE 3 250D7EDR04 300 Planetary housing 314 Sun gear 331 Planetary pin 304 O-ring 318 Sleeve 333 Locking pin 305 Screw plug 319 Hexagon socket screw 335 Ring gear 306 Sealing ring 320 Thrust ring 336 Ring gear carrier 307 Screw plug 322 Planetary gear 337 Retainer 308 Sealing ring...
Page 90 6. TIRE AND WHEEL 250D7EAX68 Wheel rim Side ring Harden washer Tire Extension valve Lock ring Hub 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 91 GROUP 2 OPERATION AND MAINTENANCE 1. OPERATION 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. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filters as well as the pipes must get filled with oil.
Page 92 - 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 mode will be then carried out if the vehicle should be related. If the vehicle will be stopped and is standing with running engine and engaged transmission, the engine cannot be stalled.
Page 93 Now, the temperature must drop quickly(in about 2-3minutes) 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 94 2. MAINTENANCE TRANSMISSION Oil level check 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 - Transmission in neutral position "...
Page 95 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. Oil change and oil filling capacity The oil change has to be carried out as follows.
Page 96 180D7EPT19 Legend: 1 = Oil filter tube with oil dipstick 2 = Oil drain plug M38 3 = Fine filter Oil dipstick COLD MIEASURED AT LOW IDLING NEUTRAL Zone "HOT" 180D7EPT20 3-51...
Page 97 DRIVE AXLE Important remarks 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 the brake system parts : if the screws are tightable, the loctite contact breaks loose and remounting is necessary.
Page 98 Lubrication points Legend 1 : Oil fill plug 2 : Oil level control plug 3 : Oil drain plug 250D7EXL03 3-53...
Page 99 3. TROUBLESHOOTING BRAKE LEAKS ACTUATION FLUID Condition ossible cause Correction Internal leak : Fluid 1. Worn or damaged piston seal. 1. Replace piston seals. bypasses seals into axle 2. Melted or extruded piston seals. 2. Correct cause of overheating and replace and fills axle with fluid seals.
Page 100 BRAKE OVERHEATS Condition Possible cause 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. Inadequate coolant flow Low pump output, blocked filter or Check pump output at different operating coolant lines.
Page 101 BRAKE DOES NOT RELEASE Condition Possible cause Correction Vehicle does not move Damaged hydraulic system. Repair hydraulic system. Brakes dragging 1. More than 1.4bar(20psi) pressure 1. Repair hydraulic system so pressure is less applied when brakes released. than 1.4bar(20psi) when brakes released and while machine is operating in any mode.
Page 102 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY ELECTRO-HYDRAULIC CONTROL UNIT AND FINE FILTER Fix transmission on assembly truck. (S)Assembly truck 5870 350 000 (S)Holding fixtures (1) 5870 350 063 (S)Clamping Angle (2) 5870 350 124 180DTM011 Remove oil drain plug and oil filler tube Drain oil before starting disassembly Loosen screw plug (1) and remove seal ring (2).
Page 103 Dismounting of filter Separate fine filter (1) from filter head by belt wrench. (S)Belt wrench 5870 105 005 180DTM014 Loosen torx screws (1), separate filter head (2) from transmission housing and remove O-rings (3). (S)Socket wrench TX 40 5873 042 004 180DTM015 D D ismounting of electric control unit Dismantle control unit (1).
Page 104 Remove differential pressure switch for fine filter from the duct plate. 1 = Switch with O-ring 2 = Piston 3 = Compression spring 180DTM018 Loosen torx screws and separate duct plate (1) and seals (2 and 3) from housing front part. 180DTM019 Pull converter safety valve out of housing hole.
Page 105 Loosen torx screws (1). (S)Socket wrench TX-27 5873 042 002 180DTM022 Separate duct plate (1) and sealing plate plate (2) from valve block (3). 180DTM023 Remove retaining clamp (1). 180DTM024 Loosen torx screws (1) and remove lid (2). Remove opposite cover (3) in the same way.
Page 106 Remove wiring harness (1). Loosen cyl screws (3), remove fixing plates and dismount pressure controllers (2). 180DTM026 Loosen cyl screws on opposite side, remove fixing plates and dismount pressure controllers (1). 180DTM027 Loosen two torx screws (1) and temporarily fix housing by means of adjusting screws (S).
Page 107 Remove single components : 1 = Pressure reducing valve 2 = Vibration damper 3 = Follow-on slide 180DTM030 Remove single components of the opposite side analogously : 1 = Main pressure valve 2 = Vibration damper 3 = Follow-on slide 180DTM031 3-62...
Page 108 INDUCTIVE SENSOR, HALL SENSOR, BREATHER AND TEMPERATURE SENSOR Dismantle positioned parts. 1 = Breather 2 = Inductive sensor-n central gear chain 3 = Inductive sensor-n turbine 180DTM032 Dismantle inductive sensor - n engine (1) and temperature sensor (3) Loosen cyl screw and remove speed sensor (2).
Page 109 ENGINE CONNECTION AND OIL PRESSURE PUMP Engine connection Loosen two hex screws (2), fit eye bolts (1) and pull off converter by means of lifting device. Separate flexplate (3) from converter. (S)Eye bolts assortment 5870 204 002 (S)Lifting chain 5870 281 047 180DTM034 Loosen threaded connection converter bell-housing/transmission housing and...
Page 110 Oil pressure pump Pull off stator hollow shaft/oil pressure pump by means of puller and lifting device. (S)Puller 5870 000 107 180DTM037 Remove O-ring (1). Loosen cylindrical screws (2). 180DTM038 Check oil gear pump : In case of wear marks in the pump housing, cover or on the inner and outer rotor, the complete oil pressure pump is to be replaced.
Page 111 DISASSEMBLY PTO Loosen hex screws (1) and remove lid (2). 180DTM041 Take O-ring (1) out of lid, unsnap and remove retaining ring (2). Pull pump shaft (3) out of housing hole. Unsnap rectangular ring (4). 180DTM042 Snap out retaining ring (1) and press ball bearing (2) off the pump shaft.
Page 112 REMOVAL OF INPUT SHAFT AND CLUTCHES Loosen hex Screws (1), remove disc and O-ring. 180DTM044 Pull-off output flange (1) and remove shaft seal (2). Force out both cylindrical pins (3). Loosen threaded connection (4) housing front and rear part. 180DTM045 Separate housing rear part by means of lifting device.
Page 113 Dismantle bearing outer rings from housing front part. Legend: see figure TM050. If, contrary to the ZF recommendation, the tapered roller bearings of clutches and input are not replaced, it is imperative to ensure the previous pairing (bearing outer ring/bearing inner ring). Bearing outer ring and bearing inner ring 180DTM048 must be marked.
Page 114 Dismantle bearing outer rings from housing rear part. Legend : see figure TM050. If, contrary to the recommendation, the tapered roller bearings of clutches and input are not replaced, it is imperative to ensure the previous pairing (bearing outer ring/bearing inner ring). Bearing outer ring and bearing inner ring 180DTM052 must be marked.
Page 115 CLUTCHES KV/KR/K1/K2/K3/K4 INPUT SHAFT 1 = Clutch K3 / Output 2 = Clutch K2 3 = Clutch K1 4 = Clutch K4 (Intermediate shaft) 5 = Clutch KR 6 = Clutch KV 7 = Input shaft 180DTM050 Clutch KV Unsnap piston ring (1). 180DTM053 Pull tapered roller bearing (internal ring) off the shaft.
Page 116 Pull clutch (1) off the shaft. (S)Two-armed puller 5870 970 004 180DTM056 Remove snap ring (1). 180DTM057 Remove end plate (1) and disc package (2) from disc carrier (3). 180DTM058 Preload compression spring and remove L-ring (1). (S)Assembly aid 5870 345 088 180DTM059 3-71...
Page 117 Remove guide ring (1), compression spring (2) and disc (3). 180DTM060 Lift piston (1) off the disc package by compressed air out of hole, and remove 180DTM061 Remove both O-rings (1 and 2). 180DTM062 Pull spur gear off the shaft. (S)Cut-off device 5870 300 024 (S)Puller...
Page 118 Unsnap retaining ring (2) out of idler gear (1) and remove ball bearing (3). (S)Set of internal pliers 5870 900 013 180DTM064 Pull needle cage (1) off the shaft (2). 180DTM065 Pull tapered roller bearing (internal ring) off the shaft. (S)Forcing device 5870 026 100 (S)Grab sleeve...
Page 119 Clutch KR Unsnap piston ring (1). 180DTM068 Pull tapered roller bearing (internal ring) off the shaft. (S)Forcing device 5870 026 100 (S)Grab sleeve 5873 001 059 180DTM069 Unsnap retaining ring (1). (S)Set of external pliers 5870 900 015 180DTM070 Pull clutch (1) together with spur gear off the shaft.
Page 120 Pull clutch (1) off the spur gear (2). No further disassembly of spur gear (2) is possible. 180DTM072 Remove snap ring (1). 180DTM057 Remove end plate (1) and disc package (2) from disc carrier. 180DTM058 Preload compression spring and remove L-ring (1).
Page 121 Remove guide ring (1), compression spring (2) and disc (3). 180DTM060 Lift piston (1) off the disc carrier by compressed air out of hole, and remove 180DTM061 Remove both O-rings (1 and 2). 180DTM062 Pull off needle cage (1) off the shaft (2). 180DTM073 3-76...
Page 122 Unsnap retaining ring (2) from idler gear (1) and dismount ball bearing (3). (S)Set of internal pliers 5870 900 013 180DTM074 Pull tapered roller bearing (internal ring) off the shaft. (S)Forcing device 5870 026 100 (S)Grab sleeve 5873 001 057 (S)Rapid grip 5873 011 011 180DTM066...
Page 123 Clutch K1 Unsnap piston ring (1). 180DTM075 Pull tapered roller bearing (internal ring) off the shaft. (S)Forcing device 5870 026 100 (S)Grab sleeve 5873 001 059 180DTM076 Unsnap retaining ring (1). (S)Set of external pliers 5870 900 015 180DTM077 Remove cpl axial bearing (1) and idler gear (2).
Page 124 Remove needle cage (1) and cpl axial bearing (2). 180DTM079 Pull clutch (1) off the shaft. (S)Two-armed puller 5870 970 004 180DTM080 Remove snap ring (1). 180DTM057 Remove end plate (1) and disc package (2) from disc carrier. 180DTM081 3-79...
Page 125 Preload cup springs and remove L-ring (1). (S)Assembly aid 5870 345 088 180DTM059 Remove guide ring (1) and cup spring package (2). 180DTM082 Lift piston (1) off the disc carrier by compressed air out of hole, and remove 180DTM061 180DTM062 3-80...
Page 126 Unsnap piston ring (1). 180DTM083 Pull tapered roller bearing (internal ring) off the shaft. (S)Basic tool 5873 002 001 (S)Grab sleeve 5873 002 038 180DTM084 3-81...
Page 127 Clutch K2 Unsnap piston ring (1). 180DTM085 Pull tapered roller bearing (internal ring) off the shaft. (S)Forcing device 5870 026 100 (S)Grab sleeve 5873 001 059 180DTM086 Unsnap retaining ring (1). (S)Set of external pliers 5870 900 015 180DTM087 Remove cpl axial bearing (1) and idler gear (2).
Page 128 Remove needle cage (1) and cpl axial bearing (2). 180DTM089 Pull clutch (1) off the shaft. (S)Two-armed puller 5870 970 004 180DTM090 Remove snap ring (1). 180DTM057 Remove end plate (1) and disc package (2) from disc carrier. 180DTM091 3-83...
Page 129 Preload cup springs and remove L-ring (1). (S)Assembly aid 5870 345 088 180DTM059 Remove guide ring (1) and cup spring package (2). 180DTM082 Lift piston (1) off the disc carrier by compressed air out of hole, and remove 180DTM061 Remove both O-rings (1 and 2). 180DTM062 3-84...
Page 130 Unsnap piston ring (1). 180DTM092 Pull tapered roller bearing (internal ring) off the shaft. (S)Forcing device 5870 026 100 (S)Grab sleeve 5873 001 059 180DTM093 3-85...
Page 131 Clutch K3 Unsnap piston ring (1). 180DTM094 Pull tapered roller bearing (internal ring) off the shaft. (S)Forcing device 5870 026 100 (S)Grab sleeve 5873 001 059 180DTM095 Remove cpl axial bearing (1) and idler gear (2). 180DTM096 Remove needle cage (1) and cpl axial bearing (2).
Page 132 Pull clutch (1) off the shaft. (S)Two-armed puller 5870 970 004 180DTM090 Remove snap ring (1). 180DTM057 Remove end plate (1) and disc package (2) from disc carrier. 180DTM081 Preload cup springs and remove L-ring (1). (S)Assembly aid 5870 345 088 180DTM059 3-87...
Page 133 Remove guide ring (1) and cup spring package (2). 180DTM082 Lift piston (1) off the disc carrier by compressed air out of hole, and remove 180DTM061 Remove both O-rings (1 and 2). 180DTM062 Unsnap piston rings (1). 180DTM098 3-88...
Page 134 Pull tapered roller bearing (internal ring) off the shaft. (S) Basic tool 5873 002 001 (S) Grab sleeve 5873 002 038 180DTM099 3-89...
Page 135 Clutch K4 (Intermediate shaft) Unsnap piston ring (1). 180DTM100 Pull tapered roller bearing (internal ring) off the shaft. (S)Forcing device 5870 026 100 (S)Grab sleeve 5873 001 057 (S)Rapid grip 5873 011 011 180DTM101 The gear (3) cannot be removed (shrink fit).
Page 136 Pull tapered roller bearing (internal ring) off the shaft. (S)Forcing device 5870 026 100 (S)Grab sleeve 5873 001 059 180DTM104 3-91...
Page 137 Input shaft Unsnap piston rings (1). Turbine wheel shaft (2) and drive gear (3) are fixed by means of a snap ring. When separated, the components will be destroyed. 180DTM105 Pull tapered roller bearing (internal ring) off the drive gear. (S)Basic tool 5873 001 000 (S)Rapid grip...
Page 138 EASSEMBLY OF CLUTCHES Clutch KV Shaft - clutch shaft KV- (1). 180DTM108 Heat up bearing inner ring (app. 120 C). (S)Hot air blower 230 V 5870 221 500 (S)Hot air blower 115 V 5870 221 501 180DTM109 Mount bearing inner ring (1) until contact. Mount piston ring (2).
Page 139 Mount stud bolt (1). Tightening torque (M10/8.8 16) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - M =1.7 Nm 180DTM112 Insert ball bearing 55 90 18 (2) into...
Page 140 Insert both O-rings (1 and 2) into piston grooves and oil them. 1 = 75 3 2 = 142 3 Check function of the drain valve (see arrow) - there must be no jamming of the ball. 180DTM116 Insert piston (1) into disc carrier. Observe installation position, see figure.
Page 141 Preload compression spring by means of assembly aid (S1) and pressure piece (S2), until L-ring has engaged into the annular groove. (S) Assembly aid 5870 345 088 (S) Assembly fixture 5870 345 124 (Inner installer and pressure piece) It is always necessary to mount a new L- ring.
Page 142 Press on end plate with F (approx. 100 N = 10 kg) and set dial indicator to "zero". 180DTM124 Then press end plate against the snap ring (upwards) and read disk clearance. Disk clearance : 2.65 ~ 2.95 mm In case of deviations, the disk clearance must be corrected with an appropriate snap ring (optional thicknesses = 2.1~4.2 mm).
Page 143 Fix clutch (1) by means of retaining ring 55 2 (2). 180DTM128 Heat up bearing inner ring (approx. 120 C) 180DTM129 Mount bearing inner ring (1) until contact is obtained. ear protective gloves. Adjust bearing inner ring after cooling- down. Check closing and opening of the clutch by means of compressed air at the hole (see arrow).
Page 144 lutch KR Shaft - clutch shaft KR- (1). 180DTM108 Heat up bearing inner ring (app. 120 C). (S)Hot air blower 230 V 5870 221 500 (S)Hot air blower 115 V 5870 221 501 180DTM109 Mount bearing inner ring (1) until contact. Mount piston ring (2).
Page 145 Mount stud bolt (1). Tightening torque (M10/8.8 16) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - M = 17 Nm 180DTM112 Insert ball bearing 55x90x18 (2) into idler...
Page 146 Insert both O-rings (1 and 2) into piston grooves and oil them. 1 = 75 3 2 = 142 3 Check function of the drain valve (see arrow) - there must be no jamming of the ball. 180DTM116 Insert piston (1) into disc carrier. Observe installation position, see figure.
Page 147 Preload compression spring by means of assembly aid (S1) and pressure piece (S2), until L-ring has engaged into the annular groove. (S)Assembly aid 5870 345 088 (S)Assembly fixture 5870 345 124 (Inner installer and pressure piece) It is always necessary to mount a new L- ring.
Page 148 Press on end plate with F (approx. 100 N = 10 kg) and set dial indicator to "zero". 180DTM124 Then press end plate against the snap ring (upwards) and read disk clearance. Disk clearance : 2.65 ~ 2.95 mm In case of deviations, the disk clearance must be corrected with an appropriate snap ring (optional thicknesses = 2.1~4.2 mm).
Page 149 Fix clutch (1) by means of retaining ring 2 (2). 180DTM134 Heat up bearing inner ring (approx. 120 C). 180DTM135 Mount bearing inner ring (1) until contact is obtained. Wear protective gloves. Adjust bearing inner ring after cooling- down. Check closing and opening of the clutch by means of compressed air at the hole (see arrow).
Page 150 Clutch K1 Shaft - clutch shaft K1- (1). 180DTM137 Heat up bearing inner ring (app. 120 C). (S)Hot air blower 230 V 5870 221 500 (S)Hot air blower 115 V 5870 221 501 180DTM109 Mount bearing inner ring (1) until contact. Mount piston ring (2).
Page 151 Insert piston (1) into disc carrier. Observe installation position, see figure. 180DTM117 Use a hand-operated press to place piston into the disc carrier by means of the assembly aid. (S) Assembly aid 5870 345 088 180DTM118 Mount inner installer (S) onto the disk carrier.
Page 152 Disk carrier with piston retraction : Legend : 1 = Cup spring package 2 = L-ring 3 = Disk carrier 4 = Piston with O-rings 180DTM139 Install outer and inner clutch discs alternately into disc carrier (4) as described in figure. Legend : 1 = Friction disc - coated on one side (1pc)
Page 153 Then press end plate against snap ring (upwards) and read disc clearance. Disc clearance : 2.35 ~ 2.65 mm Any deviation demands a correction of the disc clearance by a suitable snap ring (optional s = 2.1~4.2 mm). 180DTM125 Heat up internal diameter of clutch (app. 120 C).
Page 154 Mount needle cage 55 63 64 (1) on shaft and oil it. 180DTM143 Install idler gear. Install inner discs on inner disc carrier (idler gear) by shortly rotating them cw/ccw. 180DTM144 Mount and oil axial washer 55 78 1 (1), axial cage (2) and running disc 55 78 5 (3).
Page 155 Heat up bearing inner ring (app. 120 C). (S)Hot air blower 230 V 5870 221 500 (S)Hot air blower 115 V 5870 221 501 180DTM135 Mount bearing inner ring (1) until contact. Mount stud bolt (1). Tightening torque (M10/8.8 16) ............
Page 156 Clutch K2 Heat up bearing inner ring (app. 120 C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501 180DTM135 Mount bearing inner ring (1) until contact. Mount piston ring (2). Wear protective gloves.
Page 157 Use a hand-operated press to place piston into the disc carrier by means of the assembly aid. (S)Assembly aid 5870 345 088 180DTM118 Mount inner installer (S) onto the disk carrier. Install cup spring package (1) and L-ring (2). Installation position cup spring package and L-ring see figure TM139.
Page 158 Install outer and inner clutch discs alternately into disc carrier (4) as described in figure TM150. Legend : 1 = Friction disc- coated on one side (1 pc) 2 = Outer discs (7 pcs) 3 = Inner discs (7 pcs) When mounting the friction disc (1) 180DTM150 ensure that its uncoated (bare) side...
Page 159 Heat up internal diameter of clutch (app. 120 C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501 180DTM126 Mount clutch until contact is obtained. ear protective gloves. 180DTM151 Mount and oil running disc 55 78 5 (1), axial cage (2) and axial washer 55 78 1 (3).
Page 160 Install idler gear. Install inner discs on inner disc carrier (idler gear) by shortly rotating them cw/ccw. 180DTM154 Mount axial washer 55 78 1 (1), axial cage (2) and running disc 55 78 5 (3) and oil them. Install running disc (arrow) with chamfer (see arrow) showing towards the axial cage.
Page 161 Mount bearing inner ring (1) until contact. Mount stud bolt (1). Tightening torque (M10/8.8 16) ............M = 17 Nm ear protective gloves. Readjust bearing inner ring after cooling down. 180DTM157 Check closing and opening of the clutch by means of compressed air at the hole (see arrow).
Page 162 Clutch K3 Close machining aperture of the oil supply hole by means of plug (1). (S)Lever riveting pliers 5870 320 016 180DTM159 Heat up bearing inner ring (app. 120 C). (S)Hot air blower 230 V 5870 221 500 (S)Hot air blower 115 V 5870 221 501 180DTM135 Mount bearing inner ring (1) until contact.
Page 163 Insert piston (1) into disc carrier. Observe installation position, see figure. 180DTM117 Use a hand-operated press to place piston into the disc carrier by means of the assembly aid. (S) Assembly aid 5870 345 088 180DTM118 Mount inner installer (S) onto the disk carrier.
Page 164 Disk carrier with piston retraction : Legend : 1 = Cup spring package 2 = L-ring 3 = Disk carrier 4 = Piston with O-rings 180DTM139 Install outer and inner clutch discs alternately into disc carrier (4) as described in figure TM150. Legend : 1 = Friction disc-coated on one side (1 pc)
Page 165 Then press end plate against snap ring (upwards) and read disc clearance. Disc clearance : 1.75 ~ 2.05 mm Any deviation demands a correction of the disc clearance by a suitable snap ring (optional s = 2.1 ~ 4.2 mm). 180DTM125 Heat up internal diameter of clutch (app.
Page 166 Mount needle cage 55 63 50 (1) on shaft and oil it. 180DTM164 Install idler gear. Install inner discs on inner disc carrier (idler gear) by shortly rotating them cw/ccw. 180DTM165 Mount and oil axial washer 55 78 1 (1), axial cage (2) and running disc 55 78 5 (3).
Page 167 Heat up bearing inner ring (app. 120 C). (S)Hot air blower 230 V 5870 221 500 (S)Hot air blower 115 V 5870 221 501 180DTM135 Mount bearing inner ring (1) until contact. ear protective gloves. Readjust bearing inner ring after cooling down.
Page 168 Clutch K4 Heat up bearing inner ring (app. 120 C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501 180DTM135 Mount bearing inner ring (1) until contact. Mount piston ring (2). Wear protective gloves.
Page 169 Input shaft Install snap ring SB-38 (1) into annular groove of turbine shaft (2). 180DTM173 Press turbine shaft (1) into the input shaft (2) under a handoperated press until snap ring engages into the groove. Axial fixture of turbine shaft. 180DTM174 Heat up both bearing inner rings (app.
Page 170 Heat up bearing inner ring (app. 120 (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501 180DTM135 Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring 40 2.5 (2). ear protective gloves.
Page 171 INSTALLATION OF INPUT SHAFT AND CLUTCHES Preassembly of front and rear transmission housing Stop for converter outlet pressure valve. Fit threaded pin M10 16 (1) with pin. Tightening torque ....M = 10 Nm Fit threaded pin M10 12 (2). 180DTM177 Tightening torque ....
Page 172 ousing rear part : Legend see figure TM179. Insert bearing outer rings into bearing holes with assembly grease. If, contrary to the recommendation, the tapered roller bearings of clutches and the input are not replaced, it is imperative to ensure the previous pairing (bearing inner ring/bearing outer ring) - see 180DTM180 chapter 5) figure TM048 and TM052.
Page 173 Place closing covers (1) until contact and fasten fixing plate (2) with cyl screws on the transmission housing rear part. 1 = Closing cover 2 = Fixing plate with cyl screw Tightening torque (item. 2) M10/8.8 20 ..........M = 46 Nm Wet contact face of closing covers (1) with Loctite (type no.
Page 174 nsert clutches into transmission housing front part Install piston rings in clutches KV and KR, as well as rectangular ring 60 3 into input shaft, align and grease them. Insert clutch KR (2), clutch KV (3) and input shaft (1) jointly into bearing outer rings.
Page 175 Mount piston ring into clutch K2, align and grease it. Bring clutch K2 (1) into proper position. 180DTM190 Mount piston ring into clutch K3, align and grease it. Place screen sheet (1) and bring clutch K3 (2) into proper position. 180DTM191 Place screen sheet (1) and fix it with cyl screws (2) with sleeves and with cyl...
Page 176 Install piston rings on clutches KV, KR, K1, K2, K4, and rectangular ring 65 3 on clutch K3 and rectangular ring 60 3 on input shaft, align and grease them. 1 = Clutch K2 2 = Clutch K1 3 = Clutch K3 4 = Clutch K4 - Intermediate shaft - 5 = Input shaft 6 = Clutch KR...
Page 177 Install output flange Mount shaft seal 90 120 13 (1) by means of driver tool, with the sealing lip showing to the oil sump. (S)Driver tool 5870 048 237 Use the specified driver tool (S), to obtain the exact installation position. Fill space between sealing lip and dust lip with grease.
Page 178 Insert O-ring 48 4 into the space between output flange and shaft. Fix output flange with washer (1) and hex screws (2). Oil hexagon screws before the assembly. Tightening torque M10/8.8 30 .............. M = 46 Nm It is always necessary to use new 180DTM199 hexagon screws.
Page 179 REASSEMBLY ENGINE CONNECTION AND OIL PRESSURE PUMP Oil pressure pump : In case of wear marks in the pump housing or on the control disk, the pump assy must be replaced. Install outer rotor. Chamfer (see arrow) show downwards. 180DTM201 Install inner rotor.
Page 180 Install two adjusting screws and mount stator shaft (1). Pay attention to hole pattern. (S)Adjusting screws (M10) 5870 204 007 180DTM205 Oil sliding bearing (see arrow) before the assembly. Mount pre-assembled pump (1). Pay attention to hole pattern. 180DTM206 Provide cylinder screws with O-rings 9.5 1.6.
Page 181 Converter connection : Install two adjusting screws and place converter bell-housing (1), and bring into contact position evenly with 3 cylinder screws (3 180 offset). Make sure that O-ring will not be damaged (sheared off). Fix converter bell-housing with cylinder screws (2).
Page 182 Insert the converter by using the lifting device until contact is obtained. Remove the eyebolts and fix the flexplates with hexagon screws (see figure TM211). 180DTM212 3-137...
Page 183 REASSEMBLY PTO Press ball bearing (1) on pump shaft (2) until contact is obtained. Mount, align and grease rectangular ring (4) 60 3. 180DTM213 Mount pump shaft (1) into turbine wheel of converter until contact is obtained and fix with retaining ring (2) 85 3. Grease O-ring (3) 180 3 and insert it into hole.
Page 184 REASSEMBLY INDUCTIVE SENSOR, HALL SENSOR, BREATHER AND TEMPERATURE SENSOR Mount positioned parts. 1 = Breather Tightening torque .... M = 12 Nm 2 = Inductive sensor with O-ring 15.5 2.6 (n central gear chain) Tightening torque .... M = 30 Nm 180DTM216 3 = Inductive sensor with O-ring 15.5 2.6 (n turbine)
Page 185 REASSEMBLY Electro-hydraulic control with proportional valves : Different versions regarding the wiring harness position are possible. The following sketches show the sectional views of the electro-hydraulic control. 180DTM218 180DTM219 180DTM220 3-140...
Page 186 Fitting of electric control All single parts are to be checked for damage and replaced, if required. Ensure free travel of the moving parts in the valve block prior to installation. Pistons can be exchanged individually. Prior to the installation, oil single parts. With the concave side showing upwards, insert orifice (1 and 2) until contact is 180DTM221...
Page 187 Bring housing (1) into contact position by means of the Torx screws. This will preload the pistons, and you can remove the cylindrical pins (assembly aid). 180DTM225 Fix housing by means of Torx screws (1). Tightening torque (M5/10.9 30) ............
Page 188 Preload the pistons with Torx screws and remove the cyl pins (assembly aid) again. Then fasten the housing cover by means of cap screws (1). Tightening torque (M5/10.9 30) ............M = 5.5 Nm (S) Adjusting screws 5870 204 036 (S) Reducer 5870 656 056 (S) Socket spanner TX-27 5873 042 002...
Page 189 Assemble the wiring harness (1) and connect the pressure regulators (5 ). See figure TM218, page 3-142 for installation position of pressure regulators. Pay attention to the installation position of the wiring harness, also see markings (Chapter 1) figure TM019). 180DTM232 Put on the flat gasket (1).
Page 190 Flush-mount screens (1) into the holes of the sealing plate, see arrows. Pay attention to the installation position - screens to show upwards (towards the duct plate). 180DTM236 Put on sealing plate (1) and duct plate (2). Screens (3) to show upwards. It is not permitted to re-assemble the seal plate after opening the threaded joint shift unit/duct plate.
Page 191 Insert converter outlet pressure valve (1) into housing hole. 180DTM240 Fit 4 adjusting screws. Mount sealing (1 and 2) and duct plate (3). (S) Adjusting screws 5870 204 063 180DTM241 Fix duct plate with torx screws (1). Tightening torque (M6/10.9 25) ............
Page 192 Fit two adjusting screws. (S) Adjusting screws 5870 204 063 Mount sealing plate (1) and electro- hydraulic control unit (2). It is not permitted to re-assemble the seal plate after opening the threaded joint shift unit/gearbox housing. In case of repair it is always necessary to mount a new seal plate.
Page 193 REASSEMBLY FINE FILTER (PRE- SSURE FILTER), OIL FILLER TUBE AND OIL DRAIN PLUG Installation of fine filter (pressure filter) Fix filter head (1) with O-rings 34.2x3 (2) by means of torx screws (3) on housing rear part. Tightening torque (M8/10.9 35) ............
Page 194 Install oil drain plug (1) with O-ring (2) 35 Tightening torque (M38 1.5) ..............M = 80 Nm Fix identification plate (3) to the housing front part. Use Loctite (type no. 5069). 180DTM249 Fit screw plug M16 1.5 (1) with O-ring 13 2.
Page 195 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 196 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 Glueing with big width of slit Epple Grey Surface gasket...
Page 197 UTILIZATION OF LOCTITE AND OPERATING SUPPLIES 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 In planetary housing Support Screw Ring gear retainer...
Page 198 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 M12 1.5...
Page 199 Tightening torque of the adjusting nut respective slotted nut at flanges respective gear Thread Torque d1(mm) (Nm) 100D7XL13 3-154...
Page 200 SERVICE TOOLS When ordering service tools please provide order number(Installation drawing no), respective fabrication number identification plate.(The illustrations are not binding for the design) Spanner for wheel safety nut 100D7XL14 100D7XL15 Spanner for splined nut(hub assembly) 100D7XL16 3-155...
Page 201 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 3-156...
Page 202 Centering tool for discs. 100D7XL20 Installation tool for face seal. 100D7XL21 3-157...
Page 203 ASSEMBLY DRIVE ASSEMBLY Adjustment of gear meshing of gleason gears 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 204 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 Using of Loctite and other operating supplies Striking nut at drive flange - In thread : Assembly paste with MoS (exception through drive pinion see point Z).
Page 205 Drive assembly D 71 250DEXL27 3-160...
Page 206 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. The necessary thickness of the adjustment disk for first time assembly can be obtained by measurement(see calculation example).
Page 207 Assembly of drive pinion bearing Insert the two outer rings of the taper roller bearings into the differential carrier. Calculate the thickness C of the spacer ring. Place the two inner rings of the taper roller bearings in their outer rings. Measure A.
Page 208 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 209 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. During this operation be careful of the alignment marks on the differential straps with respect to the differential carrier.(Do...
Page 210 ASSEMBLY OF HUB ASSEMBLY Assembly of the spacer ring 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.(The steering knuckle respective axle spindle must be free of corrosion) Oil the seal ring tread onto the spacer ring.
Page 211 ASSEMBLY OF THE DRIVE ASSEMBLY ONTO THE AXLE HOUSING 100D7XL39 100D7XL40 Coat the contact surface of the axle housing with Epple 33 and mount the complete drive assembly. The axle housing being placed in a horizontal position, secure the screws with Loctite 262.
Page 212 Mount wheel hub Push the pre-assembled wheel hub(5) parallel onto the axle spindle respective steering knuckle. Be carefully not to damage the radial seal rings(4). 250DE7XL41 Adjustment of wheel bearings Tightening torque of the wheel safety nut. Series Adjustment of wheel bearings The temperature of the axle parts should be between 0 and +20 C at the bearing adjustment.
Page 213 Assembly of the face seal 1 Seal ring 2 Rubber toric ring 3 Housing retaining lip 4 Housing ramp 5 Seal ring housing 100D7XL46 Seal rings, torics, and housings must be clean and free of any oil film, dust, or other foreign matter.
Page 214 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 Toric sliding on retainer ramp. 100D7XL51 Toric caught on housing retainer lip. 100D7XL52 Toric sliding on seal ramp.
Page 215 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 216 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 217 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 218 ASSEMBLY OF PLANETARY GEAR DRIVE Prepare the ring gear and the ring gear carrier Heat the taper roller bearing inner ring with cage(1) to about 100 C and install it onto the ring gear carrier(2). Place the ring gear(3) onto the ring gear carrier. Bolt the retainer(5) with the screws(4), secure the screws with Loctite 270.
Page 219 The binding lubrication points have to be taken from the according installation drawing of the axle. Single drive assembly The position is dependent from the respective axle version. I=Oil fill plug II=Oil level control plug III=Oil drain plug 250DE7XL04 Hub assembly with planetary gear drive 250DE7XL08 Hub assembly with wet disc brake 250DE7XL10...
Page 220 Assembly of planetary gear Prepare planetary gear : Install the needle bearing(10) into the planetary gear(12). 180D7EXL63 Insert the preassembled planetary gears (12) with needle bearings (10) and thrust disks (14 , 15) into the planetary housing (22) (planetary housing in horizontal position).
Page 221 Disassembly of planetary gear Knock the locking pin(20, 21) completely to the inner side of the planetary pin. 100D7XL66 Press the planetary pin in direction of arrow out of the planetary housing. Because of the difference of diameter of 0.1mm do not press the planetary pin against the direction of arrow out of the planetary housing, to prevent damaging the bore.
Page 222 Adjustment of the axial clearance The axial clearance between sun gear and thrust disc (27) in the planetary housing must be 0.3-0.7 Measure distances : Dimension A = Dimension B = Calculate required thickness, take the axial clearance (0.3 to 0.7 mm) into consideration. Mount the correctly dimensioned thrust disc (if necessary, make final correction on a lathe) into the planetary housing.
Page 223 Assembly of service brake 100D7XL83 Brake carrier Seal ring 17 Seal ring Brake housing 10 Seal ring 18 Screw plug Piston 11 Connection piece 19 O-ring Inner disk 12 Breather 20 Face seal Outer disk 13 Sealing ring 21 Screw O-ring 14 Sealing ring 22 Tube...
Page 224 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. Assembly of O-ring and supporting ring Install the supporting rings to the averting side of pressure. Pressure 100D7XL73/84 Large supporting ring...
Page 225 Assembly of the piston 100D7XL86 Lubricate cylinder bore, apply the thread holes at wet disk brakes with Loctite 243. Place the piston onto the brake carrier(do not cant it). Press the piston equal by hand into the brake carrier. 3-180...
Page 226 Prepare housing and check the air gap 100D7XL87 Lay discs into the housing. Check the air gap Air gap = measure A-measure B(measured without pressure) Rated size about 0.5mm smaller than the air gap pressurized(see table). Install O-ring(brake housing / brake carrier) free of torsion and loops. Air gap and wear dimension Brake type Air gap sL new(Pressurized) (mm)
Page 227 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. Check the air gap(pressurized) Measure through the check hole the distance from brake carrier to the piston end face, while non actuated brake, actuate the brake and repeat the measure operation-the difference of the...
Page 228 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. 3-183...
Page 229 Brake disk 100D7XL78 Network - like formation of cracks admissible Radially shaped crack not admissible C Uneven brake surface characteristics below 1.0mm admissible D Continuous cracks not admissible (10) Spring - loaded sliding caliper brakes Safety notes : Warning Before commencing work on the parking brake, ensure that no unintended machine movement can happen when the braking effect is removed.
Page 230 GROUP 4 ADJUSTMENT 1. CHECKING THE RING GEAR BACKFACE RUNOUT Runout specification : 0.20mm(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 231 2. ADJUSTING THE GEARSET BACKLASH Backlash specification : 0.13~0.18mm (0.005-0.007inch) 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 232 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 (CONVEX) D507AX57 D507AX58 Rotate ring gear forward and backward so that the 12 marked teeth go past the drive pinion six times to get a good contact pattern.
Page 233 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 234 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. Perfect marking The following figures are showing improper gear meshing marks of the ring gear.
Page 235 5. 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. 100D7XL25 100D7XL26 Using of Loctite and other operating supplies Striking nut at drive flange - In thread : Assembly paste with MoS (Exception through drive pinion see point Z)
Page 236 SECTION 4 BRAKE SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32 Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-40 Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-43...
Page 237 ECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION 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 The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit and park brake circuits.
Page 238 FULL POWER HYDRAULIC BRAKE SYSTEM Response time ADVANTAGES - The full power hydraulic Full power brake actuation VS brake system has several advantages over Air/Hydraulic brake actuation traditional brake actuation systems. These systems are capable of supplying fluid to a 1000 range of very small and large volume service brakes with actuation that is faster...
Page 239 2. HYDRAULIC CIRCUIT FRONT AXLE 5bar 145bar STEERING UNIT 210bar 100bar 160bar~ 185bar LIFT TILT 100bar 10bar DOWN b1 a2 30bar~ 40bar 60bar HYD. COOLER 23bar 20bar 260bar 260bar 74cc/rev 74cc/rev 20cc/rev 32cc/rev 140bar L3 S3 250D7EBS01 Main pump 11 RCV 23 Strainer Auxiliary pump 17 Pressure switch...
Page 240 SERVICE BRAKE RELEASED FRONT AXLE 5bar 145bar STEERING STEERING UNIT UNIT 210bar 100bar 160bar~ 185bar LIFT TILT 100bar 10bar DOWN b1 a2 30bar~ 40bar 60bar HYD. COOLER 23bar 20bar 260bar 260bar 74cc/rev 20cc/rev 74cc/rev 32cc/rev 140bar L3 S3 250D7EBS02 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 241 SERVICE BRAKE OPERATED FRONT AXLE 5bar 145bar STEERING STEERING UNIT UNIT 210bar 100bar 160bar~ 185bar LIFT TILT 100bar 10bar DOWN b1 a2 30bar~ 40bar 60bar HYD. COOLER 23bar 20bar 260bar 260bar 74cc/rev 74cc/rev 20cc/rev 32cc/rev 140bar L3 S3 250D7EBS03 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 242 PARKING BRAKE RELEASED FRONT AXLE 5bar 145bar STEERING STEERING UNIT UNIT 210bar Parking brake switch 100bar 160bar~ 185bar LIFT TILT 100bar Parking brake 10bar solenoid valve DOWN b1 a2 30bar~ 40bar 60bar HYD. COOLER 23bar 20bar 260bar 260bar 74cc/rev 20cc/rev 74cc/rev 32cc/rev 140bar...
Page 243 PARKING BRAKE OPERATED FRONT AXLE 5bar 145bar STEERING UNIT 210bar Parking brake switch 100bar 160bar~ 185bar LIFT TILT 100bar Parking brake 10bar solenoid valve DOWN b1 a2 30bar~ 40bar 60bar HYD. COOLER 23bar 20bar 260bar 260bar 74cc/rev 74cc/rev 20cc/rev 32cc/rev 140bar L3 S3 250D7EBS05...
Page 244 3. AUXILIARY PUMP (BRAKE) STRUCTURE 180D7EBS06 Shaft gear Seal Driven gear Back up seal Front cover 10 Retainer seal Gear housing 11 Snap ring Rear cover 12 O-ring Bush block 13 Bolt Bush 14 Spring washer This gear pump have a maximum delivery pressure of 170 kgf/cm The pressure loaded type gear pump is designed so that the clearance between the gear and the bushing can be automatically adjusted according to the delivery pressure.
Page 245 PRINCIPLE OF OPERATION Mechanism for delivering oil The drawing at right shows the operational principle of an external gear pump in which two gears are rotating in mesh. The oil entering through the suction port is Suction Discharge trapped in the space between two gear teeth, and is delivered to the discharge port as the gear rotates.
Page 246 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 247 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 248 4. PARKING BRAKE SYSTEM STRUCTURE 100D7BS111 Housing Adjust screw Lining pad Pressure ring Bank of cup springs Lining pad Thrust bolt Piston Gliding bolt OPERATION The two identical brake pads and slide freely on the guide bolt, which is fastened in the housing. The guide bolts are guided in an additional brake anchor plate which in turn is screwed onto the vehicle, i.e.
Page 249 MOUNTING AND BASIC SETTING REGULATIONS Basic brake setting is required after mounting new brake lining plates or brake disks, as well as during all repair stages and in the event of insufficient braking performance. 100D7BS112 Thrust bolt Screw cap Even surface Bank of cup springs Lock nut Socket wrench...
Page 250 Turn the adjusting screw anticlockwise in order to set the following rated clearances. Model Adjusting screw Clearance(mm) Turns Min. 250D-7E M16(SW 8) Clearance Max. Hold the adjusting screw in position with a hexagonal socket wrench and lock with lock nut. Mount the screw cap and tighten as far as possible manually.
Page 251 EMERGENCY RELEASE OF THE PARKING BRAKE After the failure of the pressure release the parking brake by using following manual procedure. 100D7BS117 Thrust bolt Screw cap Even surface Bank of cup springs Lock nut Socket wrench Adjusting screw Piston The vehicle has to be secured against rolling away. Release the screw cap and unscrew Release the lock nut(size 24 or 30) and turn the adjusting screw with socket wrench size 8 or 10 manually counter-clockwise until the brake disc is free.
Page 252 MAINTENANCE AND REPAIR WORK Maintenance and exchange of brake pads The brake pads themselves are maintenance free. All that is required here is a check for damaged parts, as well as inspection to ensure that the brake disk remains easy running. The thickness of the brake lining must be subjected to a visual inspection at regular intervals, which depend on vehicle usage, but every six months at the latest.
Page 253 100D7BS114 Guide bolt Castellated nut Lining pad 6a Safety splint Lining pad 6b Safety clip Permanent magnet Depending on the free space available, release one of the two guide bolts, removing the safety splint, unscrewing the castellated nut and pulling the guide bolt out of the brake anchor plate. Now, the brake lining pads can be removed tangentially to the brake disk.
Page 254 Changing the seal DETAIL A DETAIL B 100D7BS115 Piston Circlip Bank of cup spring Adjusting screw Seal Detail of the seal Lock nut Guide bolt Detail of the seal Housing Thrust bolt Faulty seals must be exchanged in accordance with the instructions below. Stand the vehicle on an even surface and secure against rolling away.
Page 255 General Any discovered defects or damage to parts not listed here must naturally be repaired or replaced using original parts. For any other information not contained in these instructions or for more detailed instructions, please contact Hyundai dealer. 4-19...
Page 256 5. BRAKE VALVE STRUCTURE 13-1 13-2 13-5 13-4 13-3 110D7EBS07 Body 11 Du bushing 17 Torsion spring Spool 12 Pedal plate 18 Snap ring Plug 13 Pedal assembly 19 Hexagon bolt Holder(piston) 13-1 Pedal 20 Hexagon nut Lower spring 13-2 Rubber 23 Plain washer Main spring 13-3 Lock plate...
Page 257 OPERATION Hydraulic circuit Port Port name Port size PF3/8 Main pressure port Drain port PF3/8 Brake cylinder port PF3/8 Pressure switch port PF1/4 110D7EBS08 4-21...
Page 258 Purpose The purpose of the brake valve is to sensitively increase and decrease the braking pressure when the brake pedal is actuated. 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). Partial braking When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot force applied.
Page 259 Repair work 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. When doing repair work, make sure your environment is very clean. Immediately close all open ports on the components and on pipes using plugs.
Page 260 6. CUT- OFF VALVE STRUCTURE Hydraulic circuit 180D7EBS35 Manifold Check valve Solenoid valve Cut-off valve Coil Relief valve Check valve Logic valve 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. As the pressure on P line rises to 185bar, the cut off valve(1) starts cut-offing and the oil in the P port is unloaded.
Page 261 7. BRAKE ACCUMULATOR STRUCTURE Item 81L1-0004 31E3-3187 Diameter 110mm 90mm Mounting height 164mm 140mm Nominal volume 0.35 Priming pressure 50kgf/cm 15kgf/cm Operating medium Operating pressure Max 150kgf/cm Max 170kgf/cm Thread M18 1.5 PF1/2 Priming gas Nitrogen Nitrogen A Fluid portion C Diaphragm B Gas portion D Valve disk...
Page 262 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 accumulator).
Page 263 Repair work 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. When doing repair work, make sure your environment is very clean. Immediately close all open ports on the components and on pipes using plugs.
Page 264 8. PRESSURE SWITCHES STRUCTURE - Normally closed - Normally open 7407ABS20 Technical data Adjusting range Adjusting pressure Voltage Item Type Medium kgf/cm kgf/cm 50 ~ 150 Max 42 Parking M12 1.5 Charging M12 1.5 50 ~ 150 Max 42 1~10 Max 42 Brake stop M12 1.5...
Page 265 OPERATION Purpose The pressure switches are used to visually or audibly warn the driver of the pressure within the system. Make contact / circuit closer 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 266 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 on the previous page. After making the adjustment, the adjusting screw should be secured using wax or a similar material.
Page 267 9. PARKING BRAKE 100D7BS109 Brake Brake disk Brake carrier Hexagon screw O-ring Hexagon screw 4-31...
Page 268 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 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 function, Group 1.
Page 269 Hydraulic oil must be at operating temperature for these checks. Item Description Service action Parking brake capacity Start engine. check Check completed. Fasten seat belt. Seat belt must be worn NOT OK while doing this check to Release parking brake and put Inspect parking brake.
Page 270 Item Description Service action Service brake pump flow Stop engine. check Check completed. Operate brake pedal approximately 20 Hydraulic oil must be at times. NOT OK operating temperature Start engine and run at low idle. Check for brake circuit for the check. leakage.
Page 271 Item Description Service action Brake accumulator Start and run engine for 30 precharge check seconds. Check completed. The axles and hydraulic Stop engine and turn start switch NOT OK oil must be at operating to ON and wait 5 seconds. Make sure brake pedal is temperature for this not binding and keeping...
Page 272 Item Description Service action Service brake pedal Slowly depress brake pedal. check Check completed. Listen for a hissing noise that indicates oil is flowing to brake NOT OK pistons. Inspect for debris under brake pedal. Inspect LISTEN/FEEL : A hissing noise clutch cut-off linkage.
Page 273 2. TROUBLESHOOTING 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 274 Problem Cause Remedy Brakes chatter Air in brake system Do brake bleed procedure. Worn brake surface material Inspect brake surface material. Wrong oil in differential Drain. Refill. Hissing noise when Leakage in brake valve, or brake Do brake system leakage test. brake pedal is held with piston engine stopped...
Page 275 PARKING BRAKE MALFUNCTIONS Problem Cause Remedy 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. pads Brake piston hangs up in bore Remove and inspect.
Page 276 GROUP 3 TESTS AND ADJUSTMENTS 1 1 . PARKING BRAKE PERFORMANCE MEASUREMENT CONDITION 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 Standard value Parking brake Keep machine on 20 performance (11 20') gradient...
Page 277 Turn the adjusting screw anticlockwise in order to set the following rated clearances. Model Adjusting screw Clearance(mm) Turns Min. 250D-7E M16(SW 8) Clearance Max. Hold the adjusting screw in position with a hexagonal socket wrench and lock with lock nut. Mount the screw cap and tighten as far as possible manually.
Page 278 3. HYDRAULIC BRAKE BLEEDING PROCEDURE Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high Breather vent pressure fluids.
Page 279 GROUP 4 DISASSEMBLY AND ASSEMBLY 1. AUXILIARY PUMP (BRAKE) STRUCTURE 180D7EBP00 Housing Front cover Bush block Retainer seal Backup seal 10 Snap ring Channel seal 11 Rear cover Shaft gear 12 Washer Driven gear 13 Bolt O-ring 4-43...
Page 280 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 281 After removing the snap ring (10), take out the shaft gear (5) and the drive gear (6) from the housing (1). For the gear face of the shaft gear (5) and the driven gear (6), inspect for excessive wear, scoring or crack. 180D7EBP51 Remove bush block (2), back up seal (3), channel seal (4) and O-ring (7) from the...
Page 282 2. BRAKE VALVE STRUCTURE 13-1 13-2 13-5 13-4 13-3 110D7EBS07 Body 11 Du bushing 17 Torsion spring Spool 12 Pedal plate 18 Snap ring Plug 13 Pedal assembly 19 Hexagon bolt Holder(piston) 13-1 Pedal 20 Hexagon nut Lower spring 13-2 Rubber 23 Plain washer Main spring 13-3 Lock plate...
Page 283 REASSEMBLY 9 23 24 Body assembly 1 Body 2 Spool 3 Plug 4 Holder 5 Spring 6 Main spring 7 Spring retainer 9 Oil seal 110D7EBS50 DU bushing Rubber cover Plain washer Stop ring Install oil seal(9), plain washer(23), stop ring(24), DU bushing(11).
Page 284 Tighten plug(3) - Tool : 19mm spanner - Tightening torque : 14.0~16.5kgf m ress-in the DU bushing(11) with a exclusive jig. Be careful of dust and scrap after washing the parts. 110D7EBS53 Spring retainer(7), main spring(6) and holder(4). 110D7EBS54 Holder(4) Body(1) 110D7EBS55 Rubber cover(15)
Page 285 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 Pedal plate(12) assembly - Tool : 6mm torque wrench - Tightening torque : 2.5~3.0kgf 110D7EBS58 Pre-assemble pedal assembly(13-1, 13- 3) and torsion spring(17) on the pedal 13-1,13-3...
Page 286 Rubber cover(13-2) 13-2 110D7EBS61 100D7BS20 Hexagon bolt(19) - Tool : 13mm spanner - Tightening torque : 2.0kgf 110D7EBS62 Never remove the hexagon bolt. (Pressure setting valve deviation occurs) 4-50...
Page 287 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 GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering cylinder Steering wheel Steering unit Main control valve Terminal Main pump Shuttle valve 180D7ESS01 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 225bar 160bar 165bar 165bar 165bar 165bar T/FWD T/BWD Tilt cylinder Brake system HOIST LOWER Lift cylinder 23bar 280bar 20bar 260bar 260bar MLS1 220bar 74cc/rev 20cc/rev 74cc/rev L3 S3 180D7ESS02 Main pump 24 Return filter Auxiliary pump 34 Hydraulic tank Steering unit 35 Shuttle valve 12 Steering cylinder...
Page 290 NEUTRAL 225bar 160bar 165bar 165bar 165bar 165bar T/FWD T/BWD Tilt cylinder Brake system HOIST LOWER Lift cylinder 23bar 280bar 20bar 260bar 260bar MLS1 220bar 74cc/rev 74cc/rev 20cc/rev L3 S3 180D7ESS03 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 almost all of pump flow goes to the main control valve.
Page 291 LEFT TURN 225bar 160bar 165bar 165bar 165bar 165bar T/FWD T/BWD Tilt cylinder Brake system HOIST LOWER Lift cylinder 23bar 280bar 20bar 260bar 260bar MLS1 220bar 74cc/rev 20cc/rev 74cc/rev L3 S3 180D7ESS04 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 RIGHT TURN 225bar 160bar 165bar 165bar 165bar 165bar T/FWD T/BWD Tilt cylinder Brake system HOIST LOWER Lift cylinder 23bar 280bar 20bar 260bar 260bar MLS1 220bar 20cc/rev 74cc/rev 74cc/rev L3 S3 180D7ESS05 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 STRUCTURE 74095SE05 Dust seal ring 10 Cardan shaft 19 Screw Housing, spool, sleeve 11 O-ring 31 Set of O-rings Ball 12 Intermediate plate 33 Rolled pin Thread bushing 13 O-ring 34 Screw Roto glyd ring 14 Distributor plate 35 Shock valve Bearing assembly 15 Gearwheel set...
Page 294 OPERATION SECTION A - A 7407SE06 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 STRUCTURE 5 14 9 ,8 ,7 250D7ESS06 Tube assembly Rod bush 11 Retaining ring Rod assembly Retaining ring 12 O-ring Piston seal U-packing 13 Back up ring Wear ring Back up-ring 14 O-ring Rod cover 10 Dust wiper OPERATION This machine use to cross connected cylinder for steering operation.
Page 296 G G ROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 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. Item Description Service action Steering unit check Run engine at low idle. Check completed. Turn steering wheel until frames are at maximum right(A) and then NOT OK left(B) positions. Go to next check. LOOK : Frames must move smoothly in both directions.
Page 298 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 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 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 Air in oil Check for foamy oil.
Page 301 Problem Cause Remedy "Motoring" effect. Leaf springs are stuck or broken and have Replace leaf springs. The steering wheel can therefore reduced spring force 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 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 Air in the steering cylinder Bleed cylinder.
Page 303 Problem Cause Remedy Heavy kick-back Wrong setting of cardan shaft and gear- Correct setting as shown in service manual. steering wheel in both wheel set directions. Turning the steering Hydraulic hoses for the steering cylinders Connect lines to correct ports. wheel activates have been switched around...
Page 304 GROUP 3 TESTS AND ADJUSTMENTS 1 1 . HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY Service equipment and tool. Portable filter caddy Two 3658mm(12ft) 1" I.D. 100R1 hoses with 3/4 M NPT ends Quick disconnect fittings Discharge wand Various size fittings and hoses Brake system uses oil from hydraulic oil tank.
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 268 (71U.S. gal). Leave filter caddy operating for the next steps.
Page 306 2. TEST TOOLS CLAMP-ON ELECTRONIC TACHOMET- 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 100mm(4in) of pump. Finger tighten only-do not over tighten.
Page 307 3. STEERING UNIT LEAKAGE TEST SPECIFICATION Oil temperature 45 5 C(113 9 F) Engine speed High idle Cap fitting Maximum leakage 7.5 /min(2gpm) AUGE AND TOOL Temperature reader Measuring container(Approx. 20 ) Stop watch Install temperature reader. (See temperature reader installation procedure in this group).
Page 308 GROUP 4 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 74095SE05 Dust seal ring 10 Cardan shaft 19 Screw Housing, spool, sleeve 11 O-ring 31 Set of O-rings Ball 12 Intermediate plate 33 Rolled pin Thread bushing 13 O-ring 34 Screw Roto glyd ring 14 Distributor plate 35 Shock valve...
Page 309 TOOLS Holding tool. 7405S STVLV38(1) Assembly tool for O-ring and kin-ring. 7405S STVLV38(2) Assembly tool for dust seal. 7405S STVLV38(3) Torque wrench 0-7.1kgf m (0-51.6lb ft). 13mm socket spanner 12mm screwdriver 6mm screwdriver 2mm screwdriver Plastic hammer Ratchet spanner 7405S STVLV38(4) 5-22...
Page 310 DISASSEMBLY Disassemble steering column from steering unit and place the steering unit in the holding tool. Screw out the screws in the end cover (7-off-one rolled pin). 7405S STVLV39(1) Remove the end cover, sideways. 7405S STVLV39(2) Lift the gearwheel set with spacer bushing (and spacer if fitted) off the unit.
Page 311 Remove cardan shaft. 7405S STVLV40(1) Remove distributor plate. 7405S STVLV40(2) Remove O-ring. 7405S STVLV40(3) Lift off intermediate plate. 7405S STVLV40(4) 5-24...
Page 312 Remove O-ring. 7405S STVLV41(1) (10) Screw out the threaded bushing. 7405S STVLV41(2) (11) Remove cross pin. 7405S STVLV41(3) (12) Shake out the ball ( 8.5 mm). 7405S STVLV41(4) 5-25...
Page 313 (13) Pull sleeve and spool out of the housing. 7405S STVLV42(1) (14) Take ring, bearing races and needle bearing from sleeve and spool. The outer (thin) bearing race can sometimes "stick" in the housing, therefore check that it has come out. 7405S STVLV42(2) (15) Carefully pull the spool out of the sleeve.
Page 314 (17) Remove dust seal and O-ring. 7405S STVLV43(1) (18) The steering unit is now completely disassembled. 7405S STVLV43(2) Cleaning Clamp all parts carefully in Shellsol K or the like. Inspection an replacement Replace all seals and washer. Check all parts carefully and make any replacements necessary.
Page 315 DISASSEMBLY Assemble spool and sleeve. The sleeve and spool are correctly assembled when The slots-in sleeve and spool-for the neutral position springs are opposite each other and One of the 3 T-shaped grooves (A) in the spool is opposite one of the sets 7405S STVLV44(1) (B) of small holes in the sleeve.
Page 316 Guide the spool into the sleeve. 7405S STVLV45(1) Press the springs together and push the neutral position springs into place in the sleeve. 7405S STVLV45(2) Line up the springs and center them. 7405S STVLV45(3) Guide the ring down over the sleeve. The ring should be able to rotate-free of the springs.
Page 317 Fit the cross pin into the spool/sleeve. 7405S STVLV46(1) (10) Fit bearing races and needle bearing as shown on below drawing. 7405S STVLV46(2) Outer bearing race Needle bearing Inner bearing race Spool Sleeve Inside chamfer on inner bearing race must face inner spool. 7405S STVLV46(3) (11) Grease O-ring and kin-ring with hydraulic...
Page 318 7405S STVLV47(1) (12) Put the steering unit in the holding tool keeping the bore vertical. Guide the outer part of the assembly tool into the bore. Guide the inner part of the tool right to the bottom. 7405S STVLV47(2) (13) Press and turn the O-ring into position in the housing.
Page 319 (15) The spool set will push out the assembly tool guide. The O-ring is now in position. 7405S STVLV48(1) (16) Put the steering unit back into the holding tool keeping the bore vertical. place the cross pin in the spool/sleeve so that it is parallel to the port flange.
Page 320 (19) The spool set will push out the assembly tool guide. The O-ring is now in position. 7405S STVLV49(1) (20) Put the steering unit back into the holding tool keeping the bore vertical. place the cross pin in the spool/sleeve so that it is parallel to the port flange.
Page 321 (23) Guide the cardan shaft down into the bore so that the slot is parallel with the connection flange. 7405S STVLV50(1) (24) Place the gear wheel (rotor) so that the cross pin from item 33 is positioned in relation to two tooth bases - as the screw driver indicates.
Page 322 (27) Place the end cover in position. 7405S STVLV51(3) (28) Place the washers over the holes and the rolled pin in the hole shown. 7405S STVLV51(4) (29) Fit the other six screws. Cross - tighten all the screws and the rolled pin with a torque of 3 kgf m (22 lb ft).
Page 323 (31) Fit the dust seal ring in the housing using special tool and a plastic hammer. 7405S STVLV52(3) (32) Press the plastic plugs into the connection ports. Do not use a hammer. 7405S STVLV52(4) 5-36...
Page 324 2. STEERING CYLINDER STRUCTURE 5 14 9 ,8 ,7 250D7ESS06 Tube assembly Rod bush 11 Retaining ring Rod assembly Retaining ring 12 O-ring Piston seal U-packing 13 Back up ring Wear ring Back up-ring 14 O-ring Rod cover 10 Dust wiper 5-37...
Page 325 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. Check wear condition of the sealing parts(O-ring, oil seal, dust seal, U-packing, bush).
Page 326 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Using a special tool, install gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland ass- embly, and tighten it with torque 60 6kgf m (434 43lbf ft).
Page 327 3. STEERING AXLE STRUCTURE Do not remove the stopper bolt unless necessary. 1-1-9 1-1-10 1-50 1-44 1-1-9 1-45 1-1-6 1-46 1-1-10 1-49 1-47 1-1-7 1-17 1-17 1-16 1-16 1-36 1-40 1-41 1-31 1-31 1-32 1-37 1-32 1-38 1-30 1-33 1-11 1-34 1-10 1-39...
Page 328 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 weight part of the truck. Hub nut Loosen the hub nut and take off the steering wheel tire.
Page 329 ASSEMBLY In reassembling, have all parts washed, grease 1-31 1-17 applied to lubricating parts, and all expendable 1-36 1-16 1-41 items such as oil seal and spring washers 1-32 1-38 replaced by new ones. 1-37 Perform the disassembly in reverse order. 1-30 1-33 1-34...
Page 330 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-28 Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-33...
Page 331 SECTION 6 WORK EQUIPMENT GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC SYSTEM OUTLINE The hydraulic system is a pilot operated, ciosed center system which is supplied with flow from the fixed displacement main hydraulic pump. The pilot control system is a low pressure, system which is supplied with flow from the auxiliary pump.
Page 332 2. HYDRAULIC CIRCUIT TILT CYLINDER FRONT AXLE STEERING CYLINDER LIFT CYLINDER LATCH CYLINDER 280bar 200bar 5bar 145bar 180bar CABIN TILT CYLINDER 210bar 165bar 120bar 100bar 165bar 160bar~ Tilting Cabin Hyd. Circuit 185bar LIFT TILT 165bar 100bar 10bar 165bar DOWN Main pump 15 Accumulator T/BWD T/FWD...
Page 333 PILOT CIRCUIT(7 function for 5-lever) 3-LEVER S/W OFF 3-LEVER S/W ON 5-LEVER S/W ON 5-LEVER S/W OFF (SELECTOR #1 INACTIVATION) (SELECTOR #1 ACTIVATION) (SELECTOR #2 INACTIVATION) (SELECTOR #2 ACTIVATION) 3-LEVER AUX 1 functioning AUX 1, 2 functioning 4-LEVER AUX 2 functioning Non-functioning 5-LEVER AUX 3 functioning...
Page 334 3. WORK EQUIPMENT HYDRAULIC CIRCUIT 200bar 180bar 165bar Steering System 165bar TILT LIFT 165bar 165bar DOWN T/BWD T/FWD Cut off valve Return line HOIST LOWER Cut off valve 280bar MLS1 210bar 26bar 22bar 260bar 260bar 74cc/rev 74cc/rev 20cc/rev 250D7EHS02 Main pump Return filter 23 Check valve Shuttle valve...
Page 335 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 200bar 180bar 165bar Steering System 165bar TILT LIFT 165bar 165bar DOWN T/BWD T/FWD Cut off valve Return line HOIST LOWER Cut off valve 280bar MLS1 210bar 26bar 22bar 260bar 260bar 74cc/rev 20cc/rev 74cc/rev...
Page 336 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 200bar 180bar 165bar Steering System 165bar LIFT TILT 165bar 165bar DOWN T/BWD T/FWD Cut off valve Return line HOIST LOWER Cut off valve 280bar MLS1 210bar 26bar 22bar 260bar 260bar 74cc/rev 74cc/rev 20cc/rev...
Page 337 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 200bar 180bar 165bar Steering System 165bar TILT LIFT 165bar 165bar DOWN T/BWD T/FWD Cut off valve Return line HOIST LOWER Cut off valve 280bar MLS1 210bar 26bar 22bar 260bar 260bar 74cc/rev 20cc/rev 74cc/rev...
Page 338 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 200bar 180bar 165bar Steering System 165bar TILT LIFT 165bar 165bar DOWN T/BWD T/FWD Cut off valve Return line HOIST LOWER Cut off valve 280bar MLS1 210bar 26bar 22bar 260bar 260bar 74cc/rev 20cc/rev 74cc/rev...
Page 339 4. MAIN PUMP STRUCTURE (1/2) This variable displacement piston pump consists of steering pump and working pump. L2 L1 L4 L3 HYDRAULIC CIRCUIT 180D7EMP04 Size Port Port name Pressure port SAE 1" Pressure port SAE 1" Suction port SAE 2" Suction port SAE 2"...
Page 340 · FRONT PUMP 180D7EMP01 1-1 High speed rotary 15 Taper roller bearing 28 Locking screw 1-2 Control plate 16 Taper roller bearing 30 Locking screw Adjusting piece 17 Bearing liner 33 Cylinder pin Pump housing 20 Shaft seal ring 36 O-ring Port plate 22 O-ring 51 Control valve...
Page 341 · REAR PUMP 180D7EMP02 55-1 High speed rotary 62 Shim 71 Locking screw 55-2 Control plate 63 Taper roller bearing 72 Locking screw 56 Adjusting piece 64 Taper roller bearing 73 Cylinder pin 57 Pump housing 65 Bearing liner 89 Control valve 58 Port plate 66 Shaft seal ring 90 Flange cover...
Page 342 FUNCTION LS pressure 75796WE33 Drive shaft Counter spring 11 Control plate Swash plate Pressure & flow compensator valve 12 Pressure compensator spool Shoe plate Piston shoe 13 Flow compensator spool Counter piston Cylinder Piston 10 Control piston The steering pump and loader pump are variable displacement piston pump. The steering pump and loader pump are flow controlled by LS signal.
Page 343 Control piston (10) diameter is larger than counter piston (4) diameter, the oil pressure that is acting against control piston (10) overcomes the force of counter spring (6). The oil pressure than causes the pump to destoke. Pressure and flow compensator valve (7) also controls the maximum output of pump pressure. When steering and loader pressure rises above pressure compensator setting, pressure compensator spool (12) overrides flow compensator spool (13).
Page 344 Upstroking LS pressure LS pressure oil System pressure oil Return oil 75796WE35 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage 22 Passage 10 Control piston...
Page 345 Destroking LS pressure LS pressure oil System pressure oil Return oil 75796WE34 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage 22 Passage 10 Control piston...
Page 346 Low pressure standby LS pressure LS pressure oil System pressure oil Return oil 23 13 75796WE36 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage...
Page 347 Cross-drilled hole (24) limits the maximum travel of control piston (10) to the left. The pump supplies a sufficient amount of flow that compensates for system leakage. The pump also supplies a sufficient of flow that compensates for leakage to the pump case. The leakage to the pump case is a result of the cross-drilled hole.
Page 348 High pressure stall LS pressure LS pressure oil System pressure oil Return oil 23 13 75796WE36 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage...
Page 349 Adjustment of flow control Flow compensator setting must be carried out following procedures and conditions. Conditions Engine is running (at high or low idle). RCV is operated slowly (example : Boom up). Pressure gauges are installed. Discharge pump flow should be less than max pump flow. Procedures Loosening the hexagon nut (2).
Page 350 5. REMOTE CONTROL VALVE STRUCTURE UT 1,2,3,4,5,6 100D7RCV00 Metering spring 14 O-ring Lever 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 Spring guide 13 Tie rod with nut...
Page 351 OPERATION HYDRAULIC CIRCUIT 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 352 6. MAIN CONTROL VALVE STRUCTURE 134.23 134.23 180D7EMCV01 100 Housing 160 Spool 220 Spool 286 Reducing piece 101 Housing 164 Compression spring 224 Locking screw 475 Locking screw 111 Plate 167 Locking screw 225 Locking screw 500 Blank flange 125 Cylinder 170 Cone 230 Connection piece 502 Blank flange...
Page 353 STRUCTURE 180D7EMCV02 Size Port Port Port name Port name Size From main pump SAE 6000 psi 1 1/14" a1, b1 From RCV lift port 9/16" - 18UNF To hydraulic tank SAE 6000 psi 1 1/14" a2, b2 From RCV tilt port 9/16"...
Page 354 LIFT & TILT SECTION 180D7EMCV12 AUXILIARY SECTION 180D7EMCV13 6-23...
Page 355 7. LIFT CYLINDER 6 8 5 3 4 7 14 9 13 12 11,10 250D7ECY01 Tube assembly Dust wiper 11 Back up ring O-ring 12 Wear ring Rod cover O-ring 13 Dust ring DU-bushing Piston 14 Stop ring U-packing 10 U-packing 8.
Page 356 9. HYDRAULIC OIL TANK 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. A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the hydraulic tank.
Page 357 AIR BREATHER The air breather is equipped with the capacity to perform two functions simultaneously-as an air filter and as a Element breathing valve. Retaining ring Preventing negative pressure inside the Bolt Strainer tank Bolt The tank is a pressurized sealed type, so Cover negative pressure is formed inside the O-ring...
Page 358 10. 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 weight.
Page 359 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1m from ground. Wait for 10 minutes and measure hydraulic drift(amount forks move down and amount mast tilts forward). Check condition 250D7EHS14 - Hydraulic oil : Normal operating temp...
Page 360 . TROUBLESHOOTING SYSTEM Problem ause Remedy Large fork lowering speed. Seal inside control valve defective. Replace spool or valve body. Oil leaks from joint or hose. Replace. Seal inside cylinder defective. Replace packing. Large spontaneous tilt of Tilting backward : Check valve defec- Clean or replace.
Page 361 Problem Cause Remedy Actuator(cylinder or motor) Shortage of oil in oil tank. Check the oil level in the oil tank. works slowly or does not Decrease of relief valve pressure. Install pressure gauge on the circuit, operate. and check the pressure with it by handling the lever.
Page 362 HYDRAULIC GEAR PUMP Problem ause Remedy Pump does not develop full System relief valve set too low or Check system relief valve for proper pressure. leaking. setting. Oil viscosity too low. Change to proper viscosity oil. Pump is worn out. Repair or replace pump.
Page 363 CYLINDER Problem ause Remedy Oil leaks out from gland Foreign matters on packing. Replace packing. through rod. Unallowable score on rod. Smooth rod surface with an oil stone. Unusual distortion of dust seal. Replace dust seal. Chrome plating is striped. Replace rod.
Page 364 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP STRUCTURE (front) 180D7EMP01 Rotary group 10 Splined hub 23 O-ring 1-1 Control plate 12 Adjustment shim 24 O-ring Adjusting piece 15 Tapered R/bearing 25 Retaining ring Pump housing 16 Tapered R/bearing 27 Socket head screw Port plate 17 Bearing liner 31 Double break-off pin...
Page 365 STRUCTURE (rear) 180D7EMP02 Rotary group 12 Adjustment shim 24 O-ring 1-1 Control plate 15 Tapered R/bearing 25 Retaining ring Adjusting piece 16 Tapered R/bearing 27 Socket head screw Pump housing 17 Bearing liner 31 Double break-off pin Port plate 20 Shaft seal ring 33 Cylinder pin Swash plate 22 O-ring...
Page 366 GENERAL REPAIR GUIDE LINES Observe the following guidelines when carrying out repairs on hydraulic pumps. Close off all openings of the hydraulic unit. Replace all of the seals. Use only original spare parts. Check all sealing and sliding surfaces for wear.
Page 367 SEALING / CLEANING THE CONTROL VALVE Disassemble the control valve. Measure dimension A and note down. Check sealing surface (1). 75796WE62 DISASSEMBLE THE PUMP Remove the control valve. 75796WE63 Mark the location of the connection plate on the housing. 75796WE64 6-36...
Page 368 Remove the connection plate fixing bolts and the connection plate. Distributor plate and adjustment piston can drop down. 75796WE65 Remove distributor plate. Take note of the orientation. Remove bearing with withdrawal tool. Do not damage the sealing surface. 75796WE66 Remove the rotary group in a horizontal position.
Page 369 Remove swash plate and bearing shells. 75796WE68 Remove the circlip and the shaft seal. 75796WE69 Remove the drive shaft through rear side. 75796WE70 Pre-tension the spring (1) using a suitable device. Remove circlip (2). Remove spring (1) and pressure pins (3). 75796WE72 6-38...
Page 370 (10) Use bearing puller to remove outer bearing race of front bearing out of housing press seat. 75796WE74 (11) Remove the control plate. 75796WE75 (12) Use bearing puller to remove outer bearing race of rear bearing - press seat. 75796WE76 (13) Disassemble the guide of control piston (Mounting position: pilot valve side).
Page 371 (14) Disassemble the guide of the opposite piston. 75796WE78 INSPECT HINTS Renew all bearings. 75796WE79 Check : Wear on splines, rust Drive shaft seal wear grooves Bearing seat Splines for cylinder drive Bearing seat 75796WE80 Check : Sliding surface free of grooves. 75796WE81 6-40...
Page 372 Check : Bearing surfaces. 75796WE82 Check : That the retaining plate is free of grooves and that there is no wear in the slipper pad area. 75796WE83 Check : Check to see that there are no scratches or metal deposits on the sliding surface (1) and that there is no axial play (2) (Pistons must only be replaced as a set).
Page 373 Free of grooves, no signs of wear. 75796WE86 Check : Cylinder sliding surface free of grooves, no wear, no embedded foreign particles. That there are no scratches on the control plate. (Only replace them as a set). 75796WE87 (10) Check : Mounting surface - control plate undamaged.
Page 374 (12) Check : Check running conditions of the opposite piston. 75796WE90 ADJUSTMENT OF TAPER ROLLER 0~0.05mm BEARING SET Cast iron housing must have initial tension of the bearings : 0~0,05 mm, grind position A if necessary. Position A 75796WE91 PUMP ASSEMBLY Fit the seal into the housing.
Page 375 Fit pressure pins using an assembly aid. 75796WE94 Pre-tension the spring using a suitable device. 75796WE95 Assemble piston with retaining plate. Oil piston and slipper pad. 75796WE97 6-44...
Page 376 Fit rotary group. Hold the piston by using an O-ring. Fit O-ring (1). 75796WE98 Fit bearing (1) in connection plate. Fit cyilindrical pin (2). Fit O-rings (3) 4 pieces. Fit adjustment spool (4) and guide piston (4a). Fit distributor plate (5) (direction of rotation dependent) Assembly.
Page 377 Fit distributor plate. Assembly aid : Grease 75796WE100 For clockwise rotation pumps the distributor plate is off-set by 4 to the right from the centre position. (Clockwise and anti-clockwise rotation distributor plates are not identical). 75796WE101 (10) Fit connection plate and control valve. 75796WE63 6-46...
Page 378 6. MAIN CONTROL VALVE STRUCTURE 134.23 134.23 180D7EMCV01 100 Housing 160 Spool 220 Spool 286 Reducing piece 101 Housing 164 Compression spring 224 Locking screw 475 Locking screw 111 Plate 167 Locking screw 225 Locking screw 500 Blank flange 125 Cylinder 170 Cone 230 Connection piece 502 Blank flange...
Page 379 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 380 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. Inspect the parts if there is any scratch or dent, and check the movement. In assembly process, follow the tightening torque specification.
Page 381 DISASSEMBLY & ASSEMBLY Replacing complete working section Loosen tightening two bolts with 17mm 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. 100D7MCV03 Prepare two sizes of O-rings.
Page 382 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 4.3kgf m(31lbf ft). 100D7MCV06 Replacing spool & control kit Loosen 4 screws holding aluminum kits to the body with 5mm wrench.
Page 383 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 5mm wrench by 1.0kgf m(7.2lbf ft).
Page 384 Replace old relief valve with new one. Relief valve should be fitted with proper tool, 36mm spanner, with 4.3kgf m(31lbf ft) torque. 100D7MCV13 6-53...
Page 385 3. REMOTE CONTROL VALVE 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 19 Support kit Spring guide 13 Tie rod with nut...
Page 386 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 387 DISASSEMBLY & ASSEMBLY Replacing complete working section Loosen two tightening bolts with 13mm 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. 100D7RCV03 Tight M13 nut with proper torque 3.06kgf m(22.1lbf ft).
Page 388 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 389 Hold tightly mounting flange and lay fulcrum on the flange and screw in clamp bolts in a crisscross pattern. Clamp torque is 0.67kgf m(4.9lbf ft). 100D7RCV10 6-58...
Page 390 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 indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23...
Page 391 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Front Rear Switch panel 250D7EEL01 Cluster 11 Starting switch 21 Hazard switch Multi function switch 12 Aircon & heater switch 22 Rear wiper/washer switch Gear selector lever 13 Handsfree(opt) 23 Aircon switch Inching pedal 14 Cigar lighter...
Page 392 2. LOCATION 2 250D7EEL02 Switch panel 15 Horn 29 Start key Remote controller 16 Tilt switch 30 Heater relay USB & socket assembly 17 Int wiper relay 31 Travel alarm buzzer Start switch 18 Alarm 32 Beacon lamp Cigar lighter 19 Handsfree control relay 33 Work lamp assembly Monitor assembly...
Page 393 GROUP 2 ELECTRICAL CIRCUIT ELECTRICAL CIRCUIT (1/4, -#0150) · 101 AWG10 TRANSMISSION CONTROL UNIT(TCU) CDMP3-RADIO 103 AWG10 TCU(EST-37) ECU SERVICE TOOL CONNECTOR TO:RMCU(CN-125) FUSE BOX(BATT POWER) FUSE BOX(IG #2) FUSE BOX(IG #1) TO:RMCU(CN-125) TO:S/W E/G MODE(CS-79) CN-246 START KEY USB(+5V) CN-59 BR ACC USB(D+)
Page 394 ELECTRICAL CIRCUIT (2/4, #0151-) · 101 AWG10 TRANSMISSION CONTROL UNIT(TCU) CDMP3-RADIO 103 AWG10 TCU(EST-37) ECU SERVICE TOOL CONNECTOR FUSE BOX(IG #2) FUSE BOX(IG #1) FUSE BOX(BATT POWER) TO:RMCU(CN-125) TO:RMCU(CN-125) TO:S/W E/G MODE(CS-79) CN-246 START KEY USB(+5V) CN-59 H BRACC USB(D+) E/G MODE SWITCH USB(D-) TO:HARNESS AIRCON...
Page 395 ELECTRICAL CIRCUIT (3/4, -#0150) · 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 BATT.RY...
Page 396 ELECTRICAL CIRCUIT (4/4, #0151-) · HEAD LAMP HEAD LAMP CN-95 SWITCH BRAKE 103 AWG10 PARKING FAIL 102 AWG10 TILT SWITCH F/LINK CN-60 101 AWG10 S/W CAB TILT 100 AWG10 F/LINK DO-1 203 AWG18 TO:PUMP RELAY 204 AWG18 CR-1 204 AWG18 DO-2 CN-19 G AWG18B...
Page 397 GROUP 3 CLUSTER 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 398 uel gauge ① This gauge indicates the amount of fuel in the fuel tank. Fill the fuel when the indicator moves E point, refuel as soon as ② possible to avoid running out of fuel. ※ If the gauge indicates below E point even though the truck is on the normal condition, check the electric device as that can be caused by the poor connection of electricity or sensor.
Page 399 irection pilot lamp ① This lamp flashes when the signal indicator lever is moved. 77073CD10 Work lamp pilot lamp (front / rear) ① This lamp lights ON when cabin work lamp switch is pressed. 77073CD11 Head light pilot lamp ① This lamp comes ON when the main light switch is operated to 2nd step.
Page 400 ② Immediately pull the truck to a convenient stop. Stop the engine. Investigate the cause. ※ onsult a HYUNDAI dealer to investigate the cause. 160D7ECD19 ※ Do not operate until the cause has been corrected. 7-17...
Page 401 (12) ir cleaner warning lamp ① This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged. ② Check the filter and clean or replace it when the lamp is ON. 77073CD20 (13) Battery charging warning lamp ①...
Page 402 (17) ngine coolant temperature warning lamp ① This lamp is turned ON when the temperature of cooling water is over the normal temperature(104° C, 219° F). ② Check the cooling system when the lamp is ON. 77073CD17 (18) ransmission oil temperature warning lamp ①...
Page 403 CLUSTER BUTTON Each button has the following function. Buzzer stop button Next button MENU button 160D7ECD121E uzzer stop button ① This swich is used to stop the buzzer sound. Stop the buzzer when the switch is pressed. ② 160D7ECD22 Menu and next button ①...
Page 404 LCD has the functions to display start mode, standby mode, cruise function, model select and engine error. Display Name Description Display initialization state with HYUNDAI logo and Start mode program version. Displays on the idle state. Standby mode Displays rpm, odometer and hourmeter Odometer is on, is activated.
Page 405 Display Name Description Model select On model select mode, displays like this image. ※ Refer to the page 7-20. Engine error In case of below 4 engine errors displays like this display image. ※ Refer to the page 7-20. In case of over 4 engine errors displays like this image.
Page 406 GROUP 4 TRANSMISSION MESSAGE INDICATOR TRANSMISSION ERROR DISPLAY 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 407 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°...
Page 408 ISPLAY DURING AEB-MODE Symbol Meaning Remarks AEB-starter is plugged at the diagnostic plug AEB-Starter-button is pressed K1..K3 Calibrating clutch K1...K3, KV or KV, KR KR resp. _and Kx Wait for start, initialization of clutch Kx, x : 1, 2, 3, V, R ≡and Kx Fast fill time determination of clutch Kx =and Kx...
Page 409 4 4 ) 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 410 GROUP 5 SWITCHES Cruise set-resume switch Cruise switch Cover Parking with lock switch Auto/Manual select switch Clutch cut off switch Main light switch Cover(LH) Work lamp switch Hazard switch Rear wiper/washer switch Aircon switch Seat heat switch Lock lever Inc/Decrement switch Alt.
Page 411 HAZARD SWITCH Use for parking, or loading truck. ※ If the switch is left ON for a long time, the battery may be discharged. 160D7CD42 INCHING SWITCH If this switch is pressed, inching operation is applied to inching pedal. Also, inching lamp on the cluster is illuminated. 160D7CD43 PARKING BRAKE SWITCH If this switch is pressed, the parking brake is applied and the gauge...
Page 412 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. If release the switch, return to the first step position.
Page 413 HORN BUTTON If you press the button on the top of the multifunction switch and the Horn button center of the steering wheel, the horn will sound. 160D7ECD28 CAB LAMP SWITCH This switch turns ON the cab room lamp. 73033CD24 ULTI FUNCTION SWITCH Front wiper and washer switch Ⅰ...
Page 414 RUISE SET/RESUME SWITCH Auto cruise function is used to travel at constant engine speed with RESUME a desired engine rpm. CRUISE This function is activated only when the CRUISE SWITCH is turned ON. If you want to travel the truck at constant speed, you raise the engine rpm and then press the CRUISE SET switch.
Page 415 GROUP 6 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check ※ When checking the battery charging indicator, × 112Ah Battery Green : Normal condition (2EA) Black : Discharge condition Transparency : change ※ Check disconnection Normal : 0Ω CN-60 : 24V 45A Fusible link (Connect ring terminal and CN-95 : 24V 45A...
Page 416 Part name Symbol Specifications Check Solenoid valve ※ Check resistance (cabin up About 24Ω solenoid, cabin 24V max 1.5A down solenoid, parking CN-133, CN-135 CN-133 CN-135 solenoid Pressure : ※ Check contact Air cleaner 635mmH pressure switch Normal : ∞Ω (N.O type) CD-10 CD-10...
Page 417 Part name Symbol Specifications Check ※ Check resistance Normal : 10Ω 24V 300A (For terminal 2-4) Exciting current : Start relay : ∞Ω 2.3A (For terminal 1-3) CR-23 CR-23 ※ Check resistance PRE-HEATER Normal : 10Ω 24V 200A (For terminal coil) Preheat relay Exciting current : 2.3A...
Page 418 Part name Symbol Specifications Check ※ Check disconnection 24V 15W Normal : A fewΩ Beacon lamp (Strobe type) Abnormal : ∞Ω CL-7 ※ Check disconnection 24V 1W(tail) Combination Normal : A fewΩ 24V 21W(turn) lamp Abnormal : ∞Ω CL-15A CL-15B CL-16A CL-16B ※...
Page 419 Part name Symbol Specifications Check ※ Check contact Ⅰ : 0Ω(2-4, 1-3) ∞Ω(8-4, 7-3) Switch 24V 8A Ⅱ : 0Ω(8-4, 7-3) (Cabin tilt) ∞Ω(2-4, 1-3) 0 :∞Ω(7-3, 1-3, 8-4, 2-4) CS-77 CS-77 ※ Check contact 0 :∞Ω(1-2) Switch 24V 20A (Cabin tilt) Ⅰ...
Page 420 Part name Symbol Specifications Check ※ Check contact Seat switch 24V 8A OFF : ∞Ω CS-73 CS-73 ※ Check voltage Delco Remy 24SI Alternator 24V 70A Normal : 24~28V 3 FI 4 NC CN-74 CS-74 ※ Check contact 0 :∞Ω(2-4, 1-7, 1-5) Ⅰ...
Page 421 Part name Symbol Specifications Check ※ Check resistance Radio/USB DC28V Power ON : 4Ω+ 4Ω player 40Ohm×2 (For terminal 1-6, 4-8) CN-27 CN-27 20~28V CN-25 ※ Check operation 100~115dB (A) Horn Supply power(24V) to each (at 25V 2m) terminal and connect ground. CN-25 Max.
Page 422 Part name Symbol Specifications Check 24V 1A Wiper motor 2-speed Auto parking CN-21 CN-21 ※ Check contact CN-103 Washer pump 24V 2.5A Normal : 26.4Ω (For terminal 1-2) CN-22 CN-103 CN-83 CN-26 18~32V Warning buzzer 115±3dB(A) at 1m CN-26 24V 2.5W Signaling : NTSC Camera Angle of view :...
Page 423 Part name Symbol Specifications Check ※ Check resistance Brake temp N.O type Normal : ∞Ω switch CS-10 CS-10 (5V DC) EARTH ※ Check voltage (SIG) (ON IDLE) 5V, hall sensor Accel pedal 0.5~3.9V (2-1) (OFF IDLE) (COMMON) CN-124 CN-124 3(24VDC) ※...
Page 424 Part name Symbol Specifications Check ※ Check resistance 24V 0.2A Tilt alarm Normal : A fewΩ 90dB±5dB CN-26 ※ Check resistance Normal : A fewΩ(86-85) Relay 30-87 : 20A 85 87 0Ω(30-87a) 30-87a : 15A ∞Ω(30-87) CR-3 CR-46 CR-55 24V 1A Rear wiper 1-Speed Auto parking...
Page 425 GROUP 7 CONNECTORS 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Engine harness-Main harness) MG643241 CN-2 I/conn(Main harness-Engine harness) MG613245 CN-3 DEUTSCH Seat switch DT04-4P CN-5 DEUTSCH Beacon DT06-2S DT04-2P CN-6 I/conn(Frame harness-Engine harness) 368047-1 368050-1 CN-7...
Page 426 Connector part No. Connector No. of Type Destination number Female Male CN-51 T/M diagnostic 926682-3 CN-52 Handsfree controller MG610331 CN-55 Opss unit MG610350 CN-56 Cluster 174047-2 CN-57 Cluster 175967-2 CN-59 Fan drive control unit 344111 CN-60 Fusible link MG620558 CN-65 DEUTSCH Back-up buzzer DT06-2S...
Page 427 Connector part No. Connector No. of Type Destination number Female Male Switch CS-2 Start key MG610335 CS-3 DAEDONG Rear wiper washer switch 250-10PRG CS-6 Center horn MG640322 CS-10 DAEDONG Fuel warmer switch 250-10PRG CS-11 Combination switch MG610339 CS-12 Combination switch MG610335 CS-14 PACKARD...
Page 428 Connector part No. Connector No. of Type Destination number Female Male Relay CR-3 HELLA Front w/lamp relay 8TA003526-001 CR-4 Wiper HI relay VCFM-1002 CR-5 Netural relay VCFM-1002 CR-6 Internal wiper relay MG610047 CR-11 HELLA Flasher unit 8JA003526-001 CR-12 Fan motor relay VCFM-1002 CR-23 Starter relay...
Page 429 2. CONNECTION TABLE FOR CONNECTORS 58-L TYPE CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) S813-030100 S813-130100 S813-030200 S813-130200 7-46...
Page 430 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 7-47...
Page 431 No. of Receptacle connector(Female) Plug connector(Male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 7-48...
Page 432 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 7-49...
Page 433 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 7-50...
Page 434 No. of Receptacle connector(Female) Plug connector(Male) S814-106000 S814-006000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 7-51...
Page 435 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 7-52...
Page 436 No. of Receptacle connector(Female) Plug connector(Male) S810-006202 S810-106202 S810-008202 S810-108202 7-53...
Page 437 ITT SWF CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) SWF593757 HW090 SEALED CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 6189-0133 MWP02F-B CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) PH805-02028 7-54...
Page 438 AMP ECONOSEAL CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 344111-1 344108-1 344111-1 344108-1 AMP TIMER CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 85202-1 AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) 174045-2 7-55...
Page 439 KET 090 WP CONNECTORS No. of Receptacle connector(Female) Plug connector(Male) MG640795 ITT SWF CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) SWF593757 MWP NMWP CONNECTOR No. of Receptacle connector(Female) Plug connector(Male) NMWP01F-B 7-56...
Page 440 DEUTSCH DT CONNECTORS ★★★★ DT 06 - 3S - Modifications(See below) Number of contacts(P : Pin, S : Socket) 06 : Receptacle, 04 : Plug Deutsch connectors ※ Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
Page 441 No. of Receptacle connector(Female) Plug connector(Male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 7-58...
Page 442 GROUP 8 TROUBLESHOOTING Trouble symptom robable cause Remedy Lamps dimming even at maxi- ·Faulty wiring. ·Check for loose terminal and discon- mum engine speed. nected wire. Lamps flicker during engine ·Improper belt tension. ·Adjust belt tension. operation. Charge lamp does not light ·Charge lamp defective.
Page 443 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-3 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-6 Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8...
Page 444 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) LIFT CYLINDER 250D7EMS01 Outer mast Lift chain Chain sheave bearing Roller bearing Anchor bolt 10 Anchor bolt Tilt cylinder pin Side roller bearing 11 Roller bearing Mast mounting pin Inner mast...
Page 445 2. CARRIAGE AND FORK FORK 250D7EMS02 Carriage Roller Load roller bearing Roller Load roller bearing Side roller Fork Roller...
Page 446 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. EX : =2450mm(96in) mm(in) 61HV-71201 110(4.3) 90(3.5) Thickness 180D7EFK01 Set forks in middle and measure out of parallel and difference in height at the top of forks.
Page 447 2. TROUBLESHOOTING MAST Problem ause Remedy Forks fail to lower. Deformed mast or carriage. Disassemble, repair or replace. Fork fails to elevate. Faulty hydraulic equipment. See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. Deformed mast assembly. Disassemble mast and replace damaged parts or replace complete mast assembly.
Page 448 FORKS Problem ause Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear wear and reduces the thickness of the limit, replace fork. fork. Inspection for thickness is needed. Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...
Page 449 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm(19in). Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the roller side face and mast at the closest position on the opposite side to the following value by adjust bolt.
Page 450 CARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, middle and lower rollers after loosen the adjust screws from the side rollers. Shift the carriage to one side to bring the roller into contact with the inner mast, and measure the clearance between the roller side face...
Page 451 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are Bolt-w/washer approximately 25mm(1in) from the floor. Loosen and remove the bolt and washer from the bracket. Remove only one fork at a time. Bolt On larger forks it may be necessary to Bracket use a block of wood.
Page 452 Pull the chains out of the sheaves and drape them over the front of the carriage. Inner mast Disconnect connector from the work lamp assy. Outer mast Work lamp assy Lift chain Block 250D7ERE55 Slowly raise inner mast upright until mast clears top of fork carriage.
Page 453 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- Side roller bly.
Page 454 4. MAST LOAD ROLLER 2 STAGE MAST(V MAST) Remove the carriage assembly and move them to one side. Loosen and remove hexagon nuts and Chain screws securing lift cylinders to inner mast. Loosen and remove hexagon bolts and nuts securing lift cylinders to outer mast. Attach chains or sling to the inner mast section at top crossmember.
Page 455 5. CHAIN CHAIN SHEAVE 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 Inner mast is blocked. Position wooden blocks under the carriage and lower it.
Page 456 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. Remove chain anchor Work lamp assy pins from carriage and drape chains out over carriage.
Page 457 Rust and corrosion Chains used on lift trucks are highly stressed precision components. It is very important that the “as-manufactured” ultimate strength and fatigue strength be maintained throughout the chain service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or roller chain because corrosion causes side plate cracking.
Page 458 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 459 Adjustment Chain adjustments are important for the following reasons : Equal loading of chain. Proper sequencing of mast. Prevent over-stretching of chains. Prevent chains from jumping off sheaves if they are too loose. djustment procedure With mast in its fully collapsed and vertical position, lower the fork to the floor. Adjust the chain length by loosening or tightening nut on the chain anchor.

Hyundai 250D-7E Operating Manual

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