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Hyundai 25L 7A Manual
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Hyundai 25L 7A Manual

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SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Group 3 Periodic Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17
SECTION 2 REMOVAL AND INSTALLATION OF UNIT
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
SECTION 3 POWER TRAIN SYSTEM
Machine serial No. - 25L-7A : -#0060, 30L-7A : -#0025
Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-21
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-25
Machine serial No. - 25L-7A : #0061-, 30L-7A : #0026-, 33L-7A : #0001-
Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-76
Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-95
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-101
SECTION 4 BRAKE SYSTEM
Machine serial No. - 25L-7A : -#0060, 30L-7A : -#0025
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10
Machine serial No. - 25L-7A : #0061-, 30L-7A : #0026-, 33L-7A : #0001-
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-19
25LC-7A : -#0043, 30LC-7A : -#0016
25LC-7A : #0044-, 30LC-7A : #0017-
25G/30G/33G-7A : #0001-, 25GC/30GC-7A : #0001-
25LC-7A : -#0043, 30LC-7A : -#0016
25LC-7A : #0044-, 30LC-7A : #0017-
25G/30G/33G-7A : #0001-, 25GC/30GC-7A : #0001-
CONTENTS

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Summary of Contents for Hyundai 25L 7A

  • Page 1 CONTENTS SECTION 1 GENERAL Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17 SECTION 2 REMOVAL AND INSTALLATION OF UNIT...
  • Page 2 SECTION 5 STEERING SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15 SECTION 6 HYDRAULIC SYSTEM...
  • 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 Distribution and updating recorded on the bottom outside corner of the Any additions, amendments or other changes will pages. be sent to HYUNDAI distributors. Get the most up-to-date information before you Revisions start any work. Revised pages are shown at the list of revised...
  • Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 7 Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246...
  • Page 8 kgf·m to lbf·ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
  • Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
  • Page 11 SECTION 1 GENERAL Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17...
  • Page 12 GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. · Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
  • Page 13 Be particularly careful when removing the radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using the machine, there is a danger that boiled oil may spurt out. · The procedure for releasing the hydraulic pressure is as follows : lower the fork to the ground, and stop the engine(Motor), move the control levers to each position two or three times.
  • Page 14 · Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. D50ASF09 · When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
  • Page 15 Way to use dipstick Push the dipstick fully into the guide, and then pull out. Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request the HYUNDAI Forklift distributor to carry out...
  • Page 16 GROUP 2 SPECIFICATIONS 1. GENERAL LOCATIONS 25L7AOM57 Steering wheel Forks 15 LPG tank Mast Tilt cylinder 16 Clamp Lift chain 10 Front wheel 17 Overhead guard Lift cylinder 11 Bonnet 18 Rear combination lamp Cluster 12 Rear wheel 19 Turn signal lamp Backrest 13 Counterweight 20 Head lamp...
  • Page 17 2. SPECIFICATIONS 25L/30L/33L-7A, 25G/30G/33G-7A 25L7SP01 25L (G)-7A 30L (G)-7A 33L (G)-7A Model Unit 3000 (6000) 3300 (6500) 2500 (5000) Capacity kg (lb) ← ← 500 (24") Load center mm (in) 4237(9340) 4454 (9819) 3757 (8283) Weight(Unloaded) kg(lb) ← 3205 (10' 6") Lifting height 3305 (10' 10") mm (ft-in)
  • Page 18 25LC/30LC-7A 25LC7ASP01 25LC (GC)-7A 30LC (GC)-7A Model Unit 2500 (5000) 3000 (6000) Capacity kg (lb) ← 500 (24") Load center mm (in) 4214 (13' 10") 3753 (12' 4") Weight(Unloaded) kg(lb) ← 3300 (10' 10") Lifting height mm (ft-in) ← Free lift 115 (0' 5") mm (ft-in) 610/580...
  • Page 19 3. SPECIFICATION FOR MAJOR COMPONENTS 25L/30L/33L-7A, 25G/30G/33G-7A Engine Item Specification Unit Model HYUNDAI, L4KB [Theta] Type 4-cycle, vertical Cooling Method Water cooled Number of cylinders and arrangement 4 cylinders, In line Firing order 1-3-4-2 mm(in) Cylinder bore X stroke 88×97 (3.46×3.82)
  • Page 20 Steering unit Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev Rated flow 22.7 Back pressure Input torque 1.5±0.2 Power train devices Item Specification Model KAPEC 280DB Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type Power shift...
  • Page 21 25LC/30LC-7A, 25GC/30GC-7A Engine Item Specification Unit Model HYUNDAI, L4KB [Theta] Type 4-cycle, vertical Cooling Method Water cooled Number of cylinders and arrangement 4 cylinders, In line Firing order 1-3-4-2 mm(in) Cylinder bore X stroke 88×97 (3.46×3.82) Piston displacement cc(cu in) 2359 (143.95)
  • Page 22 Steering unit Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev Rated flow 22.7 Back pressure Input torque 1.5±0.2 Power train devices Item Specification Model KAPEC 280DB Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type Power shift...
  • Page 23 4. TIGHTENING TORQUE OF MAJOR COMPONENTS 25L/30L/33L-7A, 25G/30G/33G-7A Item Size kgf·m lbf·ft 90±18 Engine mounting bolt, nut M12×1.25 12.5±2.5 Engine M 8×1.25 2.5±0.5 18.1±3.6 Radiator mounting bolt, nut M10×1.25 6.9±1.4 50±10 Torque converter mounting bolt MCV mounting bolt, nut M10×1.5 4.0±0.5 29±3.6 Hydraulic...
  • Page 24 5. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT Coarse thread Bolt size kgf·m lbf·ft kgf·m lbf·ft × 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8 × 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8...
  • Page 25 PIPE AND HOSE(FLARE TYPE) Thread size Width across flat(mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" PIPE AND HOSE(ORFS TYPE) Thread size Width across flat(mm) kgf·m lbf·ft 9/16-18 28.9 11/16-16 36.2 13/16-16 68.7 1-3/16-12 1-7/16-12 1-11/16-12 FITTING Thread size Width across...
  • Page 26 6. RECOMMENDED LUBRICANTS 25L/30L/33L-7A, 25G/30G/33G-7A 。 C (。 F) Ambient temperature Service Kind of Capacity ℓ(U.S.gal) point fluid (-4) (14) (32) (50) (68) (86) (104) Engine oil Engine oil SAE 10W-30(API SL class or better) (1.5) Torque ATF DEXRON III converter (2.2) Engine oil...
  • Page 27 25LC/30LC-7A, 25GC/30GC-7A 。 C (。 F) Ambient temperature Service Kind of Capacity ℓ(U.S.gal) point fluid (-4) (14) (32) (50) (68) (86) (104) Engine oil Engine oil SAE 10W-30(API SL class or better) (1.5) Torque ATF DEXRON III converter (2.2) Engine oil transmission Axle Gear oil...
  • Page 28 GROUP 3 PERIODIC REPLACEMENT For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time of periodic maintenance;...
  • Page 29 SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2...
  • Page 30 SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE 9 10 11 12 13 14 15 16 17 25L7AOM23 Mast 10 Transmission 19 Radiator Lift cylinder 11 Torque converter 20 Muffler Steering unit 12 Engine 21 LPG tank Tilt cylinder 13 Air cleaner 22 Overhead guard Control valve...
  • Page 31 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL Forks Backrest ① Lower the fork carriage until the forks are approximately 25mm (1in) from the floor. ② Turn knob up and slide one fork at a time toward the center of the carriage where a Knob notch has been cut in the bottom plate for...
  • Page 32 ② While supporting lift chains, remove nuts and split pin from the anchor bolt. Lift chain Outer mast Split pin 20D7RE05 ③ Pull the chains out of the sheaves and drape them over the front of the carriage. Mast Carriage Lift chain Block 20D7RE06...
  • Page 33 Piping ① Remove the return hoses and clamps attached to the cylinder. ② Remove hose assembly, valve and tee from the lift cylinder. Band clamp ※ Put blind plugs in the piping immediately Hose clamp after removing hoses. Return hose This prevents the hydraulic oil from flowing out and also prevents dust and dirt from getting in.
  • Page 34 Inner mast ① Using an overhead hoist, raise the inner mast straight and carefully draw out of outer mast section. Be careful the mast not to swing or fall. Inner mast Outer mast 20D7RE10 Tilt cylinder pin Mast support cap ①...
  • Page 35 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. ※ Installation procedure for each of mast component is the reverse of the removal procedure. Mast support cap ① Check the mast support cap and spring pin for wear. ②...
  • Page 36 2. POWER TRAIN ASSEMBLY REMOVAL D503RE04 Mast Refer to the chapter 1. MAST (Page 2-2)
  • Page 37 Brake piping 25L-7A : -#0060, 30L-7A : -#0025 Disconnect the brake piping from the 25LC-7A : -#0043, 30LC-7A : -#0016 brake housing of drive axle. Brake valve Brake pipe Drive axle 20D7RE12 25L-7A : #0061-, 30L-7A : #0026- 33L-7A : #0001- 25LC-7A : #0044-, 30LC-7A : #0017- 25GC/30GC-7A : #0001- Brake valve...
  • Page 38 25L-7A : #0061-, 30L-7A : #0026- 33L-7A : #0001- 25LC-7A : #0044-, 30LC-7A : #0017- 25GC/30GC-7A : #0001- Parking brake cable Drive axle 15L7MRE13 Drive axle ① Attach a crane to the tilt cylinder notches Crane on the dashboard and raise the machine. ②...
  • Page 39 Inching linkage Clevis pin Remove the clevis pin from the transmission control valve. Inching pedal Transmission control valve 20D7RE15 Transmission cooling piping ① Disconnect cooling hose from the transmission. Radiator assy ※ Make sure that the coolant be drained from the hose. Transmission assy Hose Hose...
  • Page 40 ② Using a moving truck slowly, pull out transmission assembly to the front. Crane Frame Truck 15L7MRE19 INSTALLATION Bolt(1) Installation is the reverse order to removal, but be careful of the following points. Tightening torque Bolt(2) ·Bolt (1) : 5.5~8.3kgf·m (39.8~60lbf·ft) ·Bolt (2) : 2.7~4.1kgf·m (19.5~29.7lbf·ft) ·Bolt (3) : 5.5~8.3kgf·m (39.8~60lbf·ft) Bolt(5)
  • Page 41 3. ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL D503RE25 Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and flasher lamp on the stay of the overhead guard and then raise it together with the bonnet.
  • Page 42 Remove the torque converter housing cover, mounting bolts installed to flywheel housing. Engine For details, see page 2-10. Engine accessory Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. ① Wiring harness to alternator and starter. ②...
  • Page 43 INSTALLATION Installation is the reverse order of removal, but be careful of the following points. Tighten the engine mounting bolts and nuts. Tighten the engine mounting bracket bolts. ※ Do not remove the bolts unless necessary. Loctite is coated over the threads of bolt. So, once the bolts were removed, coat them with loctite (#243) when installing.
  • Page 44 4. STEERING AXLE REMOVAL 25L7ARE27 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) 25L(G)-7A 25LC(GC)-7A 1370kg (3020lb) 1390kg (3060lb) 30L(G)-7A 30LC(GC)-7A 1750kg (3860lb)
  • Page 45 Rear wheel - 25L/30L/33L-7A, 25G/30G/33G-7A ① 25L/30L/33L-7A, 25G/30G/33G-7A Remove mounting bolt and hub nut with Mounting bolt socket wrench and then carefully take out the tire assembly. ② Hub nut 25LC/30LC-7A, 25GC/30GC-7A Remove cap, split pin and then loosen castle nut. Hub cap Take out rear wheel assembly with taper roller bearing and oil seal.
  • Page 46 SECTION 3 POWER TRAIN SYSTEM Machine serial No. - 25L-7A : -#0060, 30L-7A : -#0025 25LC-7A : -#0043, 30LC-7A : -#0016 Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-21 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-25 Machine serial No.
  • Page 47 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION ·Machine serial No. - 25L-7A : -#0060, 30L-7A : -#0025 25LC-7A : -#0043, 30LC-7A : -#0016 1. POWER TRAIN DIAGRAM STRUCTURE 20L7PT26 Engine Drive shaft Brake Transmission Drive axle...
  • Page 48 SPECIFICATION Item Specification Model KAPEC280DB Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type Full auto, Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick down system 2.792 : 1(*), 2.444 : 1(**) Gear ratio 2.913 : 1(*), 2.538 : 1(**) Type...
  • Page 49 2. TORQUE CONVERTER STRUCTURE 20D7PT03 Bolt Bolt Plate Torque converter housing cover Flexible plate Temperature sensor Torque converter assembly Inner oil strainer Oil strainer spring Bolt O-ring O-ring Oil level gauge Oil strainer plug Torque converter housing Oil level gauge guide...
  • Page 50 OPERATION The torque converter is connected with a flywheel by a flexible plate, engine output is delivered from the flywheel to the flexible plate. The exterior of the torque converter is protected by the torque converter housing. The torque converter housing forms the oil path for the oil pump, it includes the oil strainer filtering sucked oil through this oil path and the oil level gauge measuring oil level of the transmission inside.
  • Page 51 3. TRANSMISSION STRUCTURE 20D7PT28 Control valve Output gear Torque converter Temperature sensor Turbine shaft Oil input path Impeller shaft Parking drum Stator Forward clutch Forward clutch gear Input shaft Oil pump Reverse clutch Reverse clutch gear...
  • Page 52 INSTALLATION VIEW 20D7PT05 1 Torque converter 5 Oil level pipe and dipstick 2 Temperature sensor 6 Air breather 3 Control valve 7 Transmission oil filter 4 Parking brake link lever 8 Transmission output (Universal joint link part) OPERATION The flywheel of engine transmits a power to torque converter through flexible plate. The torque converter consists of an impeller wheel connected to the input side, a turbine connected to the output side and a stator wheel.
  • Page 53 OPERATING MODES Forward Reverse INPUT INPUT OUTPUT OUTPUT 20D7PT29 20D7PT30...
  • Page 54 OIL PUMP AND SPACER Structure T/C output pressure check port T/C output pressure T/C input pressure control valve check port T/C input pressure control valve 20D7PT06 1 Oil seal Lock bolt 2 Oil pump case bush O-ring 3 Bolt Bolt 4 Plug Plug 5 Oil pump case...
  • Page 55 TRANSMISSION CASE, CONTROL VALVE, OIL PUMP AND PARKING BRAKE Structure 25L7APT07 Stoper pin Oil filter 13 O-ring Spacer Oil filter bolt 14 Nut Bolt 15 Parking brake control shaft Plug Case Pipe 16 Bolt Lock pin Washer 17 Oil seal Spring washer Control valve 18 Parking bracket...
  • Page 56 Operation The transmission case includes the function of a control valve, an oil filter and a parking brake. The oil filter is charge of filtering sucked oil by an oil pump before transmitting sucked oil to a control valve and a torque converter. Oil transmitted through an oil filter delivers oil pressure to the piston of the forward and reverse clutch through the solenoid valve.
  • Page 57 CONTROL VALVE Structure Main relief function charge Modulation function charge Main valve pressure detecting port Forward clutch pressure detecting port Inching valve pressure detecting port Reverse clutch pressure detecting port To cooler From cooler Inching function charge Change of direction function charge 20D7PT08 1 Stoper 10 O-ring...
  • Page 58 Operation The control valve mainly consists of the main relief valve, inching valve, accumulator valve and directional valve. The discharged oil from the gear pump enters main relief valve of the control valve and its pressure is adjusted 10.8~14.9 (154~212psi). kgf/cm The oil adjusted pressure by the main relief valve is decided on the direction of forward or reverse by the solenoid valve.
  • Page 59 FORWARD CLUTCH Operation Clutch pack plugging Clutch pack lubrication line pressure delivery line (From control valve) (From control valve) 20D7PT31 Drum gear Friction plate and plate Forward shaft Clutch piston Clutch gear When forward mode is selected through the solenoid valve of control valve, the flux flowed by the oil pump flows into forward clutch pack in 9~14.2 (128~202psi) of pressure through the oil kgf/cm...
  • Page 60 Structure 20D7PT11 21 Forward drum gear 1 Forward clutch gear 11 Thrust needle bearing 22 Snap ring 2 Forward shaft 12 Thrust washer 23 Thrust washer 3 Piston 13 Spring 24 O-ring 4 Piston ring 14 Snap ring 5 Friction plate 15 Seal ring 25 Parking drum 26 Snap ring...
  • Page 61 REVERSE CLUTCH Operation Clutch pack plugging Clutch pack lubrication line pressure delivery line (From control valve) (From control valve) 20D7PT32 Reverse drum gear Friction plate and plate Reverse shaft Clutch piston Clutch gear When reverse mode is selected through the solenoid valve of control valve, the flux flowed by the oil pump flows into the oil path of reverse shaft in 9~14.2 (128~202psi) of pressure through kgf/cm...
  • Page 62 Structure 8 19 20D7PT13 19 Taper roller bearing 1 Reverse clutch gear 10 O-ring 20 Taper roller bearing 2 Reverse shaft 11 Snap ring 21 Reverse drum gear 3 Piston 12 Needle bearing 22 Snap ring 4 Piston ring 13 Thrust needle bearing 5 Friction plate 14 Thrust washer 23 Thrust washer...
  • Page 63 OUTPUT GEAR Operation The output gear is engaging the forward clutch gear and reverse clutch gear together. If a driver selects forward, the forward clutch gets plugging, the forward clutch gear revolves and the power of forward clutch gear is delivered to output gear. If a driver selects reverse, the reverse clutch gets plugging, the reverse clutch gear revolves and the power of reverse clutch gear is delivered to output gear.
  • Page 64 4. DRIVE AXLE INSTALLATION VIEW Carrier assembly Traveling brake Oil level gage Drive axle housing STRUCTURE Pinion shaft Differential device Ring gear Axle shaft Traveling brake The drive axle is connected with the transmission output gear and universal joint. The power transferred by the universal joint is connected to the pinion shaft of drive axle, the pinion shaft delivers the power to the differential device through the ring gear.
  • Page 65 CARRIER ASSEMBLY Operation The pinion shaft is supported by the taper roller bearing in the carrier case and the bolt at the end of a pinion shaft and transfers the power which is delivered from the universal joint to the ring gear assembled from bolts at a differential device.
  • Page 66 DIFFERENTIAL DEVICE Operation Since the ring gear is linked with the right of the differential case and the bolt, the power transferred to the ring gear makes the differential device revolve. And also, the left and right of the differential case are connected with the left and right of the axle shaft and the spline respectively, it delivers the power to the final drive.
  • Page 67 GROUP 2 TROUBLESHOOTING Trouble symptom Probable cause Remedy 1. Excessive oil temperature rise ·Improper oil level. ·Check oil level. Add or drain oil as 1) Torque converter necessary. ·Impeller interfering with surroundings. ·After draining oil from oil tank and tra- nsmission, check and replace interfe- ring parts.
  • Page 68 Trouble symptom Probable cause Remedy 3. Low output power 1) Torque converter ·Insufficient hydraulic pressure : - Low oil level. - Check oil level and add oil. - Air sucked in. - Check joints and pipes. If necessary, retighten joint or repla- ce packing.
  • Page 69 Trouble symptom Probable cause Remedy 4. Unusual oil pressure 1) Oil pressure is high ·Control valve malfunctioning. (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair. ·Cold weather. (high oil viscosity) ·When atmospheric temp is below fr- eezing point (when normal oil pressure is recover-...
  • Page 70 Trouble symptom Probable cause Remedy ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or 6. Power is not transmitted (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. 7. Oil leakage ·Oil leaks from oil seal. ·Disassemble and check for wear of (Transmission and torque seal lips and mating sliding surfaces...
  • Page 71 GROUP 3 DISASSEMBLY AND ASSEMBLY 1.TRANSMISSION DISASSEMBLY ① Transmission assembly set. 20D7TM001 ② Disconnect torque converter. 20D7TM002 ③ Extract PTO shaft. 20D7TM003 ④ Remove control valve bolt. 20D7TM004 3-25...
  • Page 72 ⑤ Extract control valve. 20D7TM005 20D7TM006 ⑥ Extract oil filter. 20D7TM007 ⑦ Remove snap ring. 20D7TM008 ⑧ Remove parking lever. 20D7TM009 3-26...
  • Page 73 ⑨ Remove snap ring. 20D7TM010 ⑩ Remove bolt. 20D7TM011 ⑪ Remove out wheel bolt. 20D7TM012 ⑫ Remove bolt on the back side of filter. 20D7TM013 ⑬ Remove bolt. 20D7TM014 3-27...
  • Page 74 ⑭ Connect disassembly bolt. 20D7TM015 ⑮ Disassemble torque converter housing. 20D7TM016 Disassemble spacer. 20D7TM017 After disassemble. 20D7TM018 Disassemble output gear assembly set. 20D7TM019 3-28...
  • Page 75 Disassemble connection. 20D7TM020 Extract band brake. 20D7TM021 Disassemble forward clutch gear. 20D7TM022 Disassemble reverse clutch gear. 20D7TM023 After disassemble. 20D7TM024 3-29...
  • Page 76 ASSEMBLY Assembly of transmission case outside part Plug assembly ※ Before assemble taper plug, spread loctite #577. ① Assemble the upper part taper plug of hydraulic pipe. 20D7TM025 ② Assemble installation part taper plug of control valve. 20D7TM026 ③ Assemble space installation part. 20D7TM027 ④...
  • Page 77 ⑤ Confirm torque. ·Tightening torque : 3.5~4.5 kgf·m (25~33 lbf·ft) 20D7TM029 Oil seal pressurizer of cam shaft ① Spread sealant on oil seal. ※ Spread loctite #592 on the out wheel of oil seal. Spread grease on inside wheel of oil seal. 20D7TM030 ②...
  • Page 78 Assembly of transmission case inside Assembly of bearing and parking control shaft ① Pressurize R part of bearing out wheel. ※ R part : Installation part of reverse clutch gear. 20D7TM034 ② Pressurize O part of bearing out wheel. ※ O part : Installation part of output gear assembly.
  • Page 79 ⑤ Assemble nut. 20D7TM038 ⑥ Spread grease on bearing out wheel. ※ When installing taper roller bearing, make sure whether or not it is close. ※ Spread grease in taper roller bearing. 20D7TM039 Assembly of forward / reverse clutch pack ①...
  • Page 80 ④ Confirm seal ring of forward clutch. 20D7TM043 ⑤ Spread oil on seal ring of forward clutch. 20D7TM044 ⑥ Assemble forward clutch at transmission. ※ After finishing assembly, make sure whether or not revolution of forward/reverse clutch pack is good. 20D7TM045 Assembly of parking brake system ①...
  • Page 81 ③ Spread grease on cam shaft. 20D7TM048 ④ Fix large connection in cam shaft. 20D7TM049 ⑤ Fit large connection in PBB. 20D7TM050 ⑥ Assemble an eccentric shaft in PBB. 20D7TM051 Assembly of output gear assembly ① Assembly output gear. 20D7TM052 3-35...
  • Page 82 ② Confirm gear revolution condition. 20D7TM053 Assembly of spacer sub assembly Assembly of oil pump ① Assemble O-ring of charging pump. ※ Spread grease at O-ring surface. 20D7TM054 ② Spread sealant on charging pump. ※ Spread loctite #5127 at stator shaft lower in oil pump. 20D7TM055 ③...
  • Page 83 ⑤ Spread sealant on hexagon bolt. ※ Spread loctite #242 at bolt. 20D7TM058 ⑥ Confirm assembly and torque. ·Tightening torque : 3.5~4.0 kgf·m (25~29 lbf·ft) 20D7TM059 Assembly of inlet and outlet of pressure adjustment ① Fix steel ball in spacer. 20D7TM060 ②...
  • Page 84 ④ Confirm torque. ·Tightening torque : 3.5~4.5 kgf·m (25~33 lbf·ft) 20D7TM063 ⑤ Spread sealant on hex bolt. 20D7TM064 ⑥ Confirm torque. ·Tightening torque : 3.5~4.5 kgf·m (25~33 lbf·ft) 20D7TM065 Assembly of bearing cup ※ After measuring the transmission case, spacer and each clutch pack and estimating a proper amount of shim.
  • Page 85 ③ Pressurize O part of bearing out wheel. 20D7TM068 Assembly of torque converter housing sub assembly Assembly of temperature sensor and O-ring ① Spread loctite #577 on temperature sensor. 20D7TM069 ② Confirm assembly and torque. ·Tightening torque : 3.0~4.0 kgf·m (22~29 lbf·ft) 20D7TM070 ③...
  • Page 86 ② Fix strainer in torque converter housing. 20D7TM073 ③ Temporarily assemble plug. 20D7TM074 ④ Confirm torque. ·Tightening torque : 8~10 kgf·m (58~72 lbf·ft) 20D7TM075 Assembly of sub assembly Assembly of transmission case and spacer sub assembly ① Spread oil. 20D7TM076 ②...
  • Page 87 ③ Spread loctite #5127 on transmission case. 20D7TM078 ④ Pressurize lock pin. 20D7TM079 ⑤ Assemble space. 20D7TM080 ⑥ Confirm gear revolution condition. 20D7TM081 Torque converter assembly ① Spread loctite #5127 on space. 20D7TM082 3-41...
  • Page 88 ② Work roller. ※ Pay attention to tear O-ring of torque converter and oil pump. 20D7TM083 ③ Fit torque converter housing in space. 20D7TM084 ④ Spread loctite #277 on bolt. 20D7TM085 ⑤ Temporarily assemble bolt. 20D7TM086 ⑥ Confirm torque. ·Tightening torque : 5.5~6.5 kgf·m (40~47 lbf·ft) 20D7TM087 3-42...
  • Page 89 Transmission outside assembly Fastening of transmission case bolt ① Revolve 90。 . 20D7TM088 ② Spread sealant on socket bolt. 20D7TM089 ③ Temporarily assemble at transmission case. 20D7TM090 ④ Confirm torque. 20D7TM091 ⑤ Spread sealant on hexagon bolt. ※ Spread loctite #277 on bolt. 20D7TM092 3-43...
  • Page 90 ⑥ Confirm torque. ·Tightening torque : 5.5~6.5 kgf·m (40~47 lbf·ft) 20D7TM093 Oil filter assembly ① Temporarily assemble filter. 20D7TM094 ② Confirm fastening. ·Tightening torque : 0.8~1.2 kgf·m (5.8~8.7 lbf·ft) 20D7TM095 Parking brake part assembly ① Assemble snap ring. 20D7TM096 ② Spread loctite #277 on support pin.
  • Page 91 ③ Temporarily assemble support pin. 20D7TM098 ④ Confirm torque. ·Tightening torque : 2.0~3.0 kgf·m (14~22 lbf·ft) 20D7TM099 ⑤ Fix parking lever. 20D7TM100 ⑥ Assemble snap ring. 20D7TM101 ⑦ Fix spring and spread loctite #277 on bolt. 20D7TM102 3-45...
  • Page 92 ⑧ Temporarily assemble parking bracket. 20D7TM103 ⑨ Confirm torque. ·Tightening torque : 0.6~0.8 kgf·m (4.3~5.8 lbf·ft) 20D7TM104 The way to adjusting parking brake ① Tighten the adjustment shaft and loosen the shaft a 3/4 revolution. ·Tightening torque : 0.65kgf·m (4.7lbf·ft) ②...
  • Page 93 ② Spread loctite #577 on nipple plug. 20D7TM106 ③ Temporarily assemble oil pressure pipe and seal washer at the same time. 20D7TM107 ④ Spread sealant on nipple plug. 20D7TM108 ⑤ Temporarily assemble oil pressure pipe and seal washer at the same time. 20D7TM109 ⑥...
  • Page 94 Oil seal output gear assembly ① Spread loctite #592 on the out wheel of oil seal. 20D7TM111 ② Pressurize oil seal. 20D7TM112 ③ Spread grease on inside wheel of oil seal. 20D7TM113 Control valve assembly ① As assembling, use guide pin at two spot. Fix guide pin.
  • Page 95 ③ Assemble hex bolt and confirm torque. ·Tightening torque : 3~4 kgf·m (22~29 lbf·ft) 20D7TM116 Air breather and oil level gauge guide pipe assembly ① Assemble air breather. Air breather ※ Spread loctite #577 on air breather. 20D7TM117 ② Spread sealant on oil level gauge guide. ※...
  • Page 96 2. DRIVE AXLE DISASSEMBLY ① Drive axle. 20D7AXLE001 ② Remove the bolt of axle shaft. 20D7AXLE002 ③ Extract the left axle shaft. 20D7AXLE003 ④ Extract the right axle shaft. 20D7AXLE004 3-50...
  • Page 97 ⑤ Remove the bolt of plate / nut. 20D7AXLE005 ⑥ Extract the nut. 20D7AXLE006 ⑦ Extract the plate. 20D7AXLE007 ⑧ Extract the hub bearing. 20D7AXLE008 ⑨ Extract the hub. 20D7AXLE009 3-51...
  • Page 98 ⑩ Remove the bolt of flange shaft. 20D7AXLE010 ⑪ Extract the flange shaft. 20D7AXLE011 ⑫ Disassemble the piston brake. 20D7AXLE012 ⑬ Disassemble the carrier assembly. 20D7AXLE013 ⑭ Fix the carrier assembly. 20D7AXLE014 3-52...
  • Page 99 ⑮ Remove the bolt of carrier cap. 20D7AXLE015 Extract the carrier cap. 20D7AXLE016 Remove the left adjusting cap of bearing cup. 20D7AXLE017 Remove the right adjusting cap of bearing cup. 20D7AXLE018 Disassemble the differential assembly. 20D7AXLE019 3-53...
  • Page 100 After disassemble the carrier. 20D7AXLE020 ASSEMBLY Assembly of carrier assembly Differential device assembly ① Assemble spider and the differential pinion. 20D7AXLE021 ② Assemble the washer and the differential gear. 20D7AXLE022 ③ Assemble the spider and the differential. 20D7AXLE023 3-54...
  • Page 101 ④ Assemble the washer and the differential gear. 20D7AXLE024 ⑤ Assemble the differential case. 20D7AXLE025 ⑥ Fix the bolt. 20D7AXLE026 ⑦ Confirm the differential gear backlash. ※ Adjust backlash of differential gear within 0.015mm. 20D7AXLE027 ⑧ Assemble the ring gear. 20D7AXLE028 3-55...
  • Page 102 ⑨ Assemble the bearing of differential. 20D7AXLE029 Assembly of carrier sub assembly Adjusting shim and pinion shaft assembly ① Fix the carrier case. 20D7AXLE030 ② Measure a gap(A) for deciding an amount of shim with feeler gauge. ※ Determine shim X. ·X = A Mounting distance (MD) of pinion gear ±...
  • Page 103 ⑤ Pressurize the bearing cone into the pinion shaft. 20D7AXLE034 ⑥ Fix the pinion shaft. 20D7AXLE035 ⑦ Set the ball. 20D7AXLE036 ⑧ Fix the fixing jig. 20D7AXLE037 ⑨ Fix the ball. 20D7AXLE038 3-57...
  • Page 104 ⑩ Revolve the carrier case in 180 。 20D7AXLE039 ⑪ Fix the spacer. 20D7AXLE040 ⑫ Shim measuring gauge 1 insert. 20D7AXLE041 ⑬ Shim measuring gauge 2 insert. 20D7AXLE042 ⑭ Put the shim measuring block. 20D7AXLE043 3-58...
  • Page 105 ⑮ Measure a gap (B). ※ Determine shim X. ·X = B - End play (0.03~0.06) Ex 1) B = 0.5, X = 0.5 - (0.03~0.06) = 0.47~0.44mm 20D7AXLE044 Remove the pinion shaft. 20D7AXLE045 Assemble the bearing cup. 20D7AXLE046 Assemble and fit the pinion. 20D7AXLE047 Assemble the shim.
  • Page 106 Fix the bearing cone. 20D7AXLE049 Assembly of carrier sub assembly ① Pressurize the oil seal. 20D7AXLE050 ② Fix the U-joint flange. ※ Assemble U-joint flange in preload 0.01~0.19 kgf · 20D7AXLE051 ③ Fix the O-ring. 20D7AXLE052 ④ Temporarily assemble the nut. ※...
  • Page 107 ⑤ Fasten the torque. ·Tightening torque : 16.2~19.1 kgf·m (117~138 lbf·ft) 20D7AXLE054 ⑥ Confirm the preload. 20D7AXLE055 ⑦ Perform the calking. Calking 20D7PT34 ⑧ Assemble the differential sub in case. 20D7AXLE057 ⑨ Fix the steel ball. Paint marking(Both sides) 20D7PT35 3-61...
  • Page 108 ⑩ Temporarily assemble the carrier cap. 20D7AXLE059 ⑪ Fasten the torque. ※ Spread loctite #277 on bolt. ·Tightening torque : 26.8~32 kgf·m (194~231 lbf·ft) 20D7AXLE060 Adjust backlash ① Assemble the RING BRG ADJUST. 20D7AXLE062 ② Adjust the RING BRG ADJUST. 20D7AXLE063 ③...
  • Page 109 ④ Fasten RING BRG ADJUST. 20D7AXLE065 ⑤ Measure backlash again. ※ Bachlash of pinion shaft and ring gear is 0.15~0.2mm (0.006~0.008 in) ※ If backlash is wrong, carry out adjusting work. Adjust the left / right of RING BRG ADJUST by one and one clip.
  • Page 110 Assembly of carrier assembly ① Pressurize lock pin into drive axle. 20D7AXLE069 ② Spread sealant on the installation surface of carrier. 20D7AXLE070 ③ Fix assembly guide bar. 20D7AXLE071 ④ Fit carrier at drive axle housing. ※ Spread loctite #5127 on drive axle housing. 20D7AXLE072 ⑤...
  • Page 111 ⑥ Temporarily assemble bolt and confirm torque. ·Tightening torque : 6~7 kgf·m (43~51 lbf·ft) 20D7AXLE074 TRAVELING BRAKE SYSTEM ASSEMBLY Piston assembly ① Fix large quad ring into brake. 20D7AXLE075 ② Fix small quad ring into brake. ※ When assembling quad ring, pay attent to chopping. 20D7AXLE076 ③...
  • Page 112 ⑤ Set assembly jig. 20D7AXLE079 ⑥ Assemble close to drive axle housing. 20D7AXLE080 ⑦ Pressurize lock pin. 20D7AXLE081 ⑧ Measure projection degree of piston. ※ Manage projection degree of piston in 0.6~0.9mm. 20D7AXLE082 Friction plate and plate assembly ① Pressurize oil seal into flange. 20D7AXLE083 3-66...
  • Page 113 ② Assemble snap ring at socket. 20D7AXLE084 ③ Fix socket gear into flange shaft. 20D7AXLE085 ④ Fix plate into socket gear. 20D7AXLE086 ⑤ Fix friction plate into socket gear. 20D7AXLE087 ⑥ Fix friction plate and confirm the direction. 20D7AXLE088 3-67...
  • Page 114 ⑦ Assemble snap ring at socket. 20D7AXLE089 ⑧ Measure stepped pulley between flange and plate and record. ※ Manage stepped pulley of flange 0.6~0.9mm. 20D7AXLE090 Flange shaft assembly ① Select flange shaft. 20D7AXLE091 ② Spread loctite # 5127. 20D7AXLE092 ③ Spread on the whole surface of flange shaft.
  • Page 115 ④ Fit flange into drive axle housing. 20D7AXLE094 ⑤ Spread loctite #242 on bolt. 20D7AXLE095 ⑥ Fasten bolt. ·Tightening torque : 9~11.5 kgf·m (65~83 lbf·ft) 20D7AXLE096 Hub assembly Hub sub assembly ① Pressurize bolt. 20D7AXLE097 ② Put a bearing cup on the upper and lower of hub. 20D7AXLE098 3-69...
  • Page 116 ③ Pressurize bearing cup. 20D7AXLE099 ④ Spread grease on the bearing of flange. 20D7AXLE100 ⑤ Fix bearing into hub. 20D7AXLE101 ⑥ Spread grease in the oil seal. 20D7AXLE102 ⑦ Spread sealant on the outside of oil. 20D7AXLE103 3-70...
  • Page 117 ⑧ Pressurize oil seal. 20D7AXLE104 ⑨ Spread grease on the bearing of axle. 20D7AXLE105 ⑩ Fix bearing into hub. 20D7AXLE106 ⑪ Spread grease on hub. 20D7AXLE107 Hub assembly ① Spread grease on the flange shaft. 20D7AXLE108 3-71...
  • Page 118 ② Fix hub. 20D7AXLE109 ③ Fix plate. 20D7AXLE110 ④ Fix nut. 20D7AXLE111 ⑤ Fasten torque and loosen. ·Tightening torque : 21~25 kgf·m (152~181 lbf·ft) 20D7AXLE112 ⑥ Adjust preload. ·0.6~0.8 kgf·m 20D7AXLE113 3-72...
  • Page 119 ⑦ Fit the position of plate, nut and hole. 20D7AXLE114 ⑧ Spread loctite #277. 20D7AXLE115 ⑨ Confirm torque. ·Tightening torque : 0.8~1.2 kgf·m (5.8~11 lbf·ft) 20D7AXLE116 Axle shaft assembly ① Spread loctite #5127 on axle shaft. 20D7AXLE117 ② Fix into hub. 20D7AXLE118 3-73...
  • Page 120 ③ Close to hub. 20D7AXLE119 ④ Spread loctite #277 on bolt. ·Tightening torque : 6~7 kgf·m (43~51 lbf·ft) 20D7AXLE120 ⑤ Fasten torque. 20D7AXLE121 The rest part assembly ① Assemble the air breather into LH. 20D7AXLE122 ② Assemble the air breather into RH. ※...
  • Page 121 ③ Assemble hanger bolt. 20D7AXLE124 ④ Fix dipstick. 20D7AXLE125 ⑤ Assemble the magnetic plug. ※ Spread loctite #577 on plug. Loctite #577 20D7PT36 3-75...
  • Page 122 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION ·Machine serial No. - 25L-7A : #0061-, 30L-7A : #0026-, 33L-7A : #0001- 25LC-7A : #0044-, 30LC-7A : #0017- 25G/30G/33G-7A : #0001-, 25GC/30GC-7A : #0001- 1. POWER TRAIN DIAGRAM STRUCTURE 15L7MPT26 Engine Drive shaft...
  • Page 123 SPECIFICATION Item Specification Model KAPEC 280 DB Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type Power shift Gear shift(FR/RR) Transmission Control Electrical single lever type, kick-down system 1.308 : 1(*) 1.143 : 1(**) Overhaul ratio 1.308 : 1(*) 1.143 : 1(**)
  • Page 124 2. TORQUE CONVERTER STRUCTURE 11 21 15L7APT03 Hexagon bolt Plug Air breather Plain washer O-ring Magnetic plug Flexible plate Torque converter housing Temperature sensor Torque converter assembly Hexagon bolt Inner oil strainer Shaft Torque converter cover Oil strainer spring Snap ring O-ring O-ring Gear...
  • Page 125 OPERATION The torque converter is connected with a flywheel by a flexible plate, engine output is delivered from the flywheel to the flexible plate. The exterior of the torque converter is protected by the torque converter housing. The torque converter housing forms the oil path for the oil pump, it includes the oil strainer filtering sucked oil through this oil path and the oil level gauge measuring oil level of the transmission inside.
  • Page 126 3. TRANSMISSION STRUCTURE 15L7APT28 Control valve Output gear Torque converter Temperature sensor Turbine wheel Oil strainer Impeller wheel Idle gear Stator wheel Forward clutch pack Forward clutch gear Input shaft Oil pump Reverse clutch pack Reverse clutch gear 3-80...
  • Page 127 INSTALLATION VIEW 15L7APT05 1 Torque converter 5 Air breather 2 Temperature sensor 6 Transmission oil filter 3 Control valve 7 Transmission output (Universal joint link part) 4 Oil level pipe and dipstick OPERATION The torque converter is an automatic fluid drive. It transmits engine torque by means of hydraulic force.
  • Page 128 OPERATING MODES Forward → Torque converter → Clutch shaft → Input Forward clutch gear → Output gear → Output 15L7APT29 Reverse Input → Torque converter → Clutch shaft → Reverse clutch gear → Output gear → Output 15L7APT30 3-82...
  • Page 129 TRANSMISSION CASE AND CONTROL VALVE Structure 15L7APT07 Transmission case 12 Socket bolt Cylinder gear Plug 13 Oil gauge Idle gear Oil seal 14 Clamp Output gear Ball 15 Socket bolt Socket bolt Spring 16 Flange bolt Lock pin O-ring 17 Control valve O-ring Plug 18 Solenoid valve...
  • Page 130 Operation The transmission case includes the function of a control valve, an oil filter and a parking brake. The oil filter is charge of filtering sucked oil by an oil pump before transmitting sucked oil to a control valve and a torque converter. Oil transmitted through an oil filter delivers oil pressure to the piston of the forward and reverse clutch through the solenoid valve.
  • Page 131 CONTROL VALVE Operation 15L7APT08 Modulation Inching valve pressure check port Solenoid valve Forward clutch pressure check port Inching spool Reverse clutch pressure check port Main relief valve Main pressure check port The control valve consists of the main relief valve, solenoid valve, modulation valve and inching valve.
  • Page 132 Structure Main relief valve Modulation Forward clutch pressure check port Inching valve pressure check port Main pressure check port Reverse clutch pressure check port Inching spool Solenoid valve 15L7APT22 1 Plug 11 Spring 21 Stopper 2 O-ring 12 Solenoid valve 22 Spring 3 Spring 13 Seal...
  • Page 133 CLUTCH Operation Reverse Forward 15L7APT31 Forward clutch plugging pressure delivery line ( Reverse clutch plugging pressure delivery line ( Clutch pack lubrication line ( When (forward/reverse) mode is selected through the solenoid valve of control valve, the flux flowed by the oil pump flows into forward (reverse) clutch pack in 9~14.2 kgf/cm (128~202 psi) of pressure through the oil path of transmission inside.
  • Page 134 Structure 15L7APT11 21 Wire ring 1 Shaft 11 Seal ring 2 Seal ring 12 Piston 22 Plate 23 Clutch drum 3 Needle bearing 13 Quad ring 24 Spacer 4 Ring 14 Quad ring 25 Snap ring 5 Seal ring 15 Plate 26 Ball bearing 6 Bushing 16 Friction plate...
  • Page 135 OUTPUT GEAR Operation The output gear is engaging the forward clutch gear and reverse clutch gear together. If a driver selects forward, the forward clutch gets plugging, the forward clutch gear revolves and the power of forward clutch gear is delivered to output gear. If a driver selects reverse, the reverse clutch gets plugging, the reverse clutch gear revolves and the power of reverse clutch gear is delivered to output gear.
  • Page 136 4. DRIVE AXLE INSTALLATION VIEW 15L7APT15 Carrier assembly Traveling brake Oil level gage Drive axle housing STRUCTURE 15L7APT16 Piston shaft Axle shaft Ring gear Traveling brake Differential device Hub reduction The drive axle is connected with the transmission output gear and universal joint. The power transferred by the universal joint is connected to the pinion shaft of drive axle, the pinion shaft delivers the power to the differential device through the ring gear.
  • Page 137 CARRIER ASSEMBLY Operation Carrier sub assy includes differential device and parking brake. The pinion shaft is supported by the taper roller bearing in the carrier case and the bolt at the end of pinion shaft and transfers the power which is delivered from the drive shaft assy to the ring gear assembled from bolts at a differential device.
  • Page 138 Structure 15L7APT18 9 Eccentric shaft 1 Parallel pin 5 Actuator 2 Parking plate 6 Push pin 10 Lever 3 Friction plate-parking 7 Parking spline 4 Cone spring 8 Carrier case cover 3-92...
  • Page 139 DIFFERENTIAL DEVICE · · Machine serial No. - 25L-7A : #0061-0579, 30L-7A : #0026-0290, 33L-7A : #0001-0035 25LC-7A : #0001-0215, 30LC-7A : #0001-0091 Operation Since the ring gear is linked with the right of the differential case and the bolt, the power transferred to the ring gear makes the differential device revolve.
  • Page 140 · · Machine serial No. - 25L-7A : #0580-, 30L-7A : #0291-, 33L-7A : #0036- 25LC-7A : #0216-, 30LC-7A : #0092- 25G/30G/33G-7A : #0001-, 25GC/30GC-7A : #0001- Operation Since the ring gear is linked with the right of the differential case and the bolt, the power transferred to the ring gear makes the differential device revolve.
  • Page 141 GROUP 2 TROUBLESHOOTING 1. TRANSMISSION Trouble symptom Probable cause Remedy 1. Output does not go up 1) Torque converter - Torque converter oil ·The oil is in short supply. ·Replenish oil. ·The oil that is not regulated is used. ·Change the oil to regular oil. ·The air has mixed into oil.
  • Page 142 Trouble symptom Probable cause Remedy 2. Power is not transmitted. ·The flexible plate is broken. ·Change the flexible plate. 1) Torque converter ·The oil is in short supply. ·Replenish oil. ·The shaft and spline are worn. ·Change the shaft and the spline. ·The gear is broken.
  • Page 143 Trouble symptom Probable cause Remedy 4. Clutch or converter oil pressure is too high 1) Torque converter ·Viscosity of oil is too high (at cold · Warm up the torque converter if the time). temperature of torque converter oil is below outside air temperature.
  • Page 144 2. DRIVE AXLE Trouble symptom Probable cause Remedy 1. Noise and vibration ·Lubricating oil shortage. ·Check oil level and refill lubricating oil. 1) Drive axle ·Using different lubricating oil. ·Change lubricating oil. ·Maladjustment or detect of wheel ·Change wheel bearing. bearing.
  • Page 145 Trouble symptom Probable cause Remedy 2. Oil leakage 1) External leakage ·Excess of oil. ·Check oil level. Set of oil amount. ·Using different oil. ·Change oil. ·Blocking air breather. ·Washing or change air breather. ·Damaged of hub oil seal. ·Disassemble, check and change. ·Leakage at pinion shaft.
  • Page 146 Trouble symptom Probable cause Remedy 4. Brake does not apply 1) Service brake. ·Empty fluid reservoir. ·Fill reservoir to correct level with specified - Low or no pressure to fluid. brake. ·Damaged hydraulic system. ·Check hydraulic system. ·Leakage of brake actuation fluid. ·Refer to "Brake leaks actuation fluid"...
  • Page 147 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF TRANSMISSION DISASSEMBLING OF TRANSMISSION ASSY Drain the transmission oil. Remove the drain plug at T/C housing. Lay the wood plate (or plastic plate) on the workshop's table (bottom). And put the T/M assy on the wood plate (or plastic plate) : For an (dis)assembly at the time of damage prevent.
  • Page 148 Remove the socket gear. Next remove the snap-ring at socket gear. 15L7ATM005 Removal the oil pump sub assy. ① Remove the hexagon bolt (M8×1.25P×38L), and then remove the copper washer. 15L7ATM006 ② Remove the plug. (PT 1/8) 15L7ATM007 ③ Remove the pump sub assy + gasket using the plug hole for pulling out from the T/C housing.
  • Page 149 Removal the control valve sub assy. ① Remove the hexagon bolt (M8×1.25P×60L). 15L7ATM010 ② Remove the part slowly with hit the end side softly. ※ Using a plastic hammer . Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.
  • Page 150 (10) Remove the cooler (in/out) plug.(PT 3/8) 15L7ATM015 (11) Remove the air breather. 15L7ATM016 (12) Remove the hexagon bolt, and then remove the T/C cover. 15L7ATM017 (13) Remove the oil level gauge. 15L7ATM018 (14) Remove the socket bolt, and then remove the clamp.
  • Page 151 (15) Remove the socket bolt, and then remove the pipe. Next remove the O-ring at the pipe. 15L7ATM020 (16) Remove the temperature sensor. 15L7ATM021 (17) Lay the T/M assy without damage to the T/C housing.(engine mounting surface) 15L7ATM022 (18) Remove the plug, and then remove the spring, oil strainer.
  • Page 152 (19) Remove the plug.(PT 1/8) 15L7ATM024 (20) Remove the socket bolt (T/M case + T/C housing fastening bolt) 4 socket bolt exclusions. 15L7ATM025 15L7ATM026 (21) To turn over T/M assy without damage to the T/M case.(main pump mounting surface) Next remove the 4 socket bolt. 15L7ATM027 3-106...
  • Page 153 Remove the part slowly with hit the end side softly. (22) ※ Using a plastic hammer. 15L7ATM028 (23) Remove the T/C housing. 15L7ATM029 (24) Gear assemblies arrangements. 15L7ATM030 (25) Remove the O-ring. 15L7ATM031 (26) Remove the output gear assy. 15L7ATM032 3-107...
  • Page 154 (27) Remove the idle gear assy. 15L7ATM033 (28) Remove the clutch gear assy. ※ Store each gear assembly in separate box. 15L7ATM034 (29) Remove the oil seal. 15L7ATM035 3-108...
  • Page 155 DISASSEMBLING OF GEAR ASSEMBLIES Disassembling clutch gear assy. 15L7ATM036 ① Remove the seal ring. 15L7ATM037 ② Pull out the bearing(#6207) and spacer from the shaft. 15L7ATM038 ③ Pull out the forward clutch sub assy. 15L7ATM039 ④ Pull out the bearing(#6911) from the shaft. 15L7ATM040 3-109...
  • Page 156 ⑤ Pull out the reverse clutch sub assy. 15L7ATM041 ⑥ Forward clutch sub assy. 15L7ATM042 ⑦ Remove the forward clutch gear sub, and then remove the spacer. 15L7ATM043 ⑧ Remove the snap ring, and then remove the bearing. 15L7ATM044 3-110...
  • Page 157 ⑨ Remove the snap ring, and then remove the back plate, friction disk, and steel plate. 15L7ATM045 ⑩ Remove the wire ring, and then remove the back plate and spring. When you remove the wire-ring, it might be shot out by impact of spring. Certainly fixing the spring, will have to remove.
  • Page 158 ⑭ Remove the snap ring, and then remove the bearing. 15L7ATM049 ⑮ Remove the snap ring, and then remove the back plate, friction disk, and steel plate. 15L7ATM050 Remove the wire ring, and then remove the back plate and spring. When you remove the wire-ring, it might be shot out by impact of spring.
  • Page 159 Disassembling of Idle gear assy. 15L7ATM052 ① Pull out the bearing, and then remove the idle gear upper(lower). 15L7ATM053 Disassembling of output gear assy. 15L7ATM054 3-113...
  • Page 160 ① Remove the seal ring, oil seal and sealing cap. 15L7ATM055 ② Pull out the bearing. 15L7ATM056 3-114...
  • Page 161 2. ASSEMBLY OF TRANSMISSION ASSEMBLING OF GEAR ASSEMBLIES ※ Assemble the part with reverse the aforementioned disassemble procedure. · Assembling of clutch gear assembly. Forward clutch drum sub assembly. ① In drum internal groove tefron seal assembly. ※ Spread grease on seal ring. 15L7ATM057 ②...
  • Page 162 ⑤ First insert steel plate, and then insert friction disk alternately. Next insert the back plate, and then assemble the snap ring. 15L7ATM061 ⑥ Assemble the bearing, and then assemble the snap ring alternately. 15L7ATM062 ⑦ Arrange serration of the friction disk, and then assemble the spacer, clutch gear sub.
  • Page 163 Reverse clutch drum sub assembly. ① Do work as the same way like forward clutch drum ① ~ ⑤. sub assembly procedure 1) ② Assemble the bearing, and then assemble the snap ring alternately. 15L7ATM065 ③ Arrange serration of the friction disk, and then assemble the clutch gear sub.
  • Page 164 ③ Assemble the forward clutch drum sub assy at the shaft sub assy. 15L7ATM070 ④ Assemble the spacer and bearing. - Used method of heating bearing. 15L7ATM071 ⑤ Assemble the seal ring. ※ Spread grease on seal ring 15L7ATM072 ⑥ Clutch gear assy.
  • Page 165 Assembling of output gear assembly. ① Assemble the bearing. - Used method of heating bearing ※ All bearings should never be heated above 120。 C 15L7ATM074 ② Assemble the oil seal, seal ring and sealing cap. ※ Spread loctite #609 on the out wheel of oil seal, spread grease on inside wheel of oil seal.
  • Page 166 Assembling of idle gear assembly. ① Press the idle gear upper and idle gear lower at the idle gear shaft, and then assemble the bearing. - Used method of heating bearing ※ All bearings should never be heated above 120。 C 15L7ATM077 ②...
  • Page 167 ASSEMBLING OF TRANSMISSION ASSY Press the oil seal. ※ Spread loctite #592 on the out wheel of oil seal, spread grease on inside wheel of oil seal. 15L7ATM079 Assemble the clutch gear assy. ※ When you insert the shaft after install the seal ring in the shaft, please insert the shaft with turning it into the shaft side and hole side of shaft for prevent the damage of shaft.
  • Page 168 Press the lock-pins. ※ After the assembling, please check whether you can turn the input(output) gear lightly by your hand. 15L7ATM084 Spread loctite #5127 on T/C housing space. 15L7ATM085 Assemble the T/C housing. 15L7ATM086 Assemble the part slowly with hit the end side softly. ※...
  • Page 169 (11) Turn over T/M assy without damage to the T/C housing.(engine mounting surface) Next assemble the socket bolts. ·Socket bolt (M10×1.5p×40mm) ×16EA ·Tightening torque : 5.5~6.5 kgf·m(40~47 lbf·ft) ※ Spread loctite #277 on socket bolt. 15L7ATM089 (12) Assemble the socket bolts. ·Socket bolt (M10×1.5p×25mm) ×2EA ·Tightening torque : 5.5~6.5 kgf·m(40~47 lbf·ft) ※...
  • Page 170 (15) Assemble the O-ring at the plug. Insert the oil strainer, spring ,and then assemble O- ring+plug assy. ·Plug tightening torque : 8~10 kgf·m(58~72 lbf·ft) ※ Spread grease on O-ring. 15L7ATM093 (16) Assemble the temperature sensor. ·Tightening torque : 3.0~4.0 kgf·m(22~29 lbf·ft) ※...
  • Page 171 (20) Assemble the T/C cover and hexagon bolts. ·Hexagon bolt (M8×1.25p×16mm) ×2EA ·Tightening torque : 2.0~3.0 kgf·m(14.5~21.7 lbf·ft) ※ Spread loctite #277 on socket bolt. 15L7ATM098 (21) Assemble the air breather. ·Tightening torque : 1.0~1.5 kgf·m(7.0~11 lbf·ft) ※ Spread loctite #577 on air breather. 15L7ATM099 (22) Assemble the O-ring at the plug, and then insert...
  • Page 172 (25) Assemble the hex bolt. ·Hexagon bolt (M8×1.25p×60mm) ×10EA ·Tightening torque : 3.0~3.3 kgf·m(22~24 lbf·ft) 15L7ATM103 (26) Assemble the o-ring at the charging pump assy. ※ Spread grease on O-ring. 15L7ATM104 (27) Install the gasket at the T/C housing, and then install the charging pump assy.
  • Page 173 (30) Install the flexible plate at the torque converter, and then install the hexagon bolt and washer. ·Hexagon bolt (3/8-24UNF-2B) ×6EA ·Tightening torque : 3.0~3.5 kgf·m(21.6~25.3 lbf·ft) ※ Spread loctite #277 on hexagon bolt 15L7ATM108 (31) Insert the T/C sub assy at the T/M sub assy. 15L7ATM109 (32) Transmission assy.
  • Page 174 3. DISASSEMBLY OF DRIVE AXLE DISASSEMBLY Disassembling of drive axle assy. 15L7ADA001 Remove bolts of hub sub assembly. To avoid serious personal injury and possible damage to components, be very careful when using lifting devices during removal and disassembly procedures. Inspect to make sure that neither lifting strap is damaged.
  • Page 175 Remove pins. 15L7ADA005 → return spring. Disassemble in order of special bolt 15L7ADA006 Detach brake piston. 15L7ADA007 After remove retaining ring, pull out left axle shaft. (Do work as the same way like right axle shaft) Use a brass, leather or rubber mallet for assembly and disassembly procedures.
  • Page 176 (10) Remove all snap rings. 15L7ADA010 (11) → Remove all each parts in order of thrust washer planet gear → needle bearing → thrust washer. 15L7ADA011 (12) Loose lock nut by using jig. 15L7ADA012 (13) Extract planet carrier. 15L7ADA013 (14) Extract carrier housing with bearing.
  • Page 177 (15) Remove bolts fixing flange hub and wheel shaft. 15L7ADA015 (16) Remove bolts fixing carrier assy. 15L7ADA016 (17) Extract the bracket. 15L7ADA017 (18) Extract carrier assembly. 15L7ADA018 (19) Fix carrier assembly to a jig. 15L7ADA019 3-131...
  • Page 178 (20) Remove carrier cap bolt. 15L7ADA020 (21) Extract the carrier cap (apply marking a match). 15L7ADA021 (22) Remove adjusting ring of both sides bearing cup. 15L7ADA022 (23) Extract differential assembly. 15L7ADA023 (24) After turn over carrier assy and fix it, remove nut. 15L7ADA024 3-132...
  • Page 179 (25) Remove U-joint flange. 15L7ADA025 (26) Remove carrier case cover bolts. 15L7ADA026 (27) Extract carrier case cover assembly. 15L7ADA027 (28) Extract push pins and actuator. 15L7ADA028 (29) Remove O-ring and spline parking. 15L7ADA029 3-133...
  • Page 180 (30) Remove parking friction plates and separate plates. 15L7ADA030 (31) Finish disassembling of carrier assembly. 15L7ADA031 3-134...
  • Page 181 ASSEMBLY Type 1 Carrier sub assembly Differential device assembly ① Prepare parts for assembly of differential. ·Machine serial No. 25L-7A : #0061-0579, 30L-7A : #0026-0290, 33L-7A : #0001-0035 25LC-7A : #0001-0215, 30LC-7A : #0001-0091 15L7ADA032 Type 2 · · Machine serial No. Thrust washer 25L-7A : #0580-, 30L-7A : #0291-, 33L-7A : #0036-...
  • Page 182 Adjusting shim and pinion shaft assembly ① Fix carrier case to the jig. ※ Read the following information before installing new gearset in the carrier. Always inspect the gearset for correct marks to make sure the gears are a matched set. 15L7ADA036 The locations of the gearset marks are shown in right figure.
  • Page 183 ② Decide thickness of shim by gauge and measuring apparatus (Standard gap between bearing and carrier case step : A) (Mounting distance(MD) of pinion shaft : B) ※ Thickness of shim · X = A - B + Carrier case bearing step depth ex1) A= 0.35, B= -0.1, Bearing step depth= +0.1 ·...
  • Page 184 ⑦ Set a ball. 15L7ADA043 ⑧ Equip jig for fixing. 15L7ADA044 ⑨ Fasten the ball. 15L7ADA045 ⑩ Revolve carrier case 180。 . 15L7ADA046 ⑪ Put into spacer. 15L7ADA047 3-138...
  • Page 185 ⑫ Decide thickness of shim by gauge and measuring apparatus (thickness : B) ※ Thickness of shim · X = B - End play (0.03~0.06) ex 1) B = 0.45, · X = 0.45 - (0.03~0.06) = 0.42~0.39mm 15L7ADA048 ⑬ Remove pinion shaft.
  • Page 186 Assemble bearing cone. Assemble after paste grease on bearing cone roller. 15L7ADA053 Assemble of parking sub assembly ① Assemble pin into carrier case. 15L7ADA054 ② → cone spring Assemble in order of separate plate → friction plate. But assemble separate plate lastly. ·Separate plates : 4EA ·Friction plates : 3EA 15L7ADA055...
  • Page 187 ⑤ Assemble push pin into actuator. 15L7ADA058 ⑥ Assemble O-ring on groove of pinion shaft. Assemble after paste grease on O-ring grease. 15L7ADA059 ⑦ Assemble pin into the carrier case. 15L7ADA060 Assemble of carrier case cover assemble ① Assemble oil seal into carrier case cover. Paste #592 on outside of oil seal and grease on inside of oil seal.
  • Page 188 ③ Assemble cover by first putting small O-ring on eccentric shaft, and then put big O-ring on collor. 15L7ADA063 ④ Assemble set screw. Assemble paste loctite #277. Confirm torque : 200~250 kgf·cm 15L7ADA064 ⑤ After complete assembling of axle when pull parking lever.
  • Page 189 ⑦ Assemble cap. Assemble after paste loctite #609. 15L7ADA067 ⑧ Assemble carrier cover assy. Assemble after paste loctite #277. Confirm torque : 304~405 kgf·cm Paste loctite #5127 on assembling side of carrier case cover and carrier case. 15L7ADA068 ※ Applying liquid gasket material. ※...
  • Page 190 ⑨ Assemble flange U-joint. 15L7ADA070 ⑩ Fasten nut. Assemble paste loctite #242. Confirm torque : 2600~2950 kgf·cm ※ Preload : 10~19 kgf·cm 15L7ADA071 ⑪ Calking. (2 EA) 15L7ADA072 ⑫ Assemble differential sub in carrier case. 15L7ADA073 ⑬ Fit carrier cap with steel ball. Bolt : paste loctite #277 Confirm torque : 1170~1130 kgf·cm...
  • Page 191 Adjusting the gearset backlash ① Assemble bearing adjust ring. 15L7ADA076 ② Adjust bearing adjust ring. 15L7ADA077 ③ Measure backlash. 15L7ADA078 ④ Fasten bearing adjust ring. 15L7ADA079 ⑤ Measure again backlash. ※ Backlash of pinion and ring gear : 0.15~0.20mm ※ If backlash is wrong, carry out adjusting work.
  • Page 192 ※ Backlash is increased by moving the ring gear away from the pinion shaft. Backlash is decreased by moving the ring gear toward the pinion shaft. Refer to figure DA076 and DA077. ⑥ Loosen one bearing adjusting ring one notch, then tighten the opposite ring the same amount.
  • Page 193 ② Rotate ring gear forward and backward so that the 6 marked teeth go past the drive pinion six time to get a good contact pattern. ③ Compare the contact patterns to figure DA086, DA087 and DA088. ※ In new gearsets, a good contact pattern is toward the toe of the tooth, and centered between the top and bottom of the tooth.
  • Page 194 ④ If the contact patterns require adjustment along the ⓐ-ⓑ. width of tooth (top/bottom), follow steps If the contact patterns require adjustment along the length of tooth (toe/heel), follow steps ⓒ-ⓓ. ⓐ High pattern : A high contact pattern indicates that the pinion was installed too shallow into the carrier.
  • Page 195 ⑤ Fix spring pin with ring bearing adjust. And assemble them. 15L7ADA094 15L7ADA095 3-149...
  • Page 196 Assemble of carrier assembly ① Pressurize lock pin into axle housing. 15L7ADA096 ② Paste sealant on axle housing. (Loctite #5127) 15L7ADA097 ③ Assemble carrier assembly on axle housing. 15L7ADA098 ④ Fasten bolt. Assemble bolt after spread loctite #277. Confirm torque : 610~650 kgf·cm 15L7ADA099 3-150...
  • Page 197 Traveling brake system assembly Axle shaft assembly ① Insert snap ring on the axle shaft. 15L7ADA100 ② After put the ball bearing, fix it with snap ring. 15L7ADA101 ③ After put axle shaft into axle housing fix with snap ring. 15L7ADA102 Piston assembly ①...
  • Page 198 ※ When assembling the shim, you calculate the value of the shim ad then assemble it. · "L" : Piston assembling part axle housing stage depth (standard : 56.9mm) · "C":Carrier housing stage height (standard : 9mm) · "F" : The total thickness of friction plate and separate plate (standard : 20.5mm) ·...
  • Page 199 ⑥ → friction plate Assemble in order of separate plate → cone spring. But Assemble separate plate lastly. (Separate plate : 4EA , friction plate : 3EA) 15L7ADA109 Hub assembly Hub sub assembly ① Pressurize hub bolt. 15L7ADA110 ② Pressurize oil seal with loctite #592. Spread grease inside of oil seal.
  • Page 200 ⑤ Assemble flange hub and wheel shaft. ※ Paste loctite #5127 Confirm torque : 600~700kgf·cm Bolt : Spread loctite #277 15L7ADA114 ⑥ Fix spacer. 15L7ADA115 ⑦ Assemble oil seal at carrier housing. Oil seal with loctite #592. 15L7ADA116 ⑧ Assemble bearing cup at carrier housing. 15L7ADA117 ⑨...
  • Page 201 ⑩ Put carrier housing on assembled flange hub and wheel shaft. Before assembling, spread grease inside of flange hub. ·Grease : Shell retinax 0434 - 60~80% spread 15L7ADA119 ⑪ Adjust preload for fix shim. ·Preload : 40~50kgf·cm 15L7ADA120 ⑫ Put into shim. ※...
  • Page 202 ⑮ Fasten lock nut. Confirm torque : 2800~3200kgf·cm, calke after assembling. ·Preload : 40~50kgf·cm 15L7ADA124 Assemble in order of washer → needle bearing → planet gear → washer . Before assembling washer, paste oil, spread grease on needle bearing. 15L7ADA125 Fix snap ring.
  • Page 203 The rest part assembly ① Assemble O-ring and fitting bleeder for LH and RH. Confirm torque : 380~420kgf·cm 15L7ADA129 ② Assemble bleeder and cap. Screw : Assemble after spread loctite #577. Confirm torque : 150~200kgf·cm 15L7ADA130 ③ Assemble air breather. 15L7ADA131 ④...
  • Page 204 ⑥ Put in dipstick. ※ Fill axle oil as much as standard. Standard between the upper limit and the lowest limit. Figure DA134. 15L7ADA134 15L7ADA135 ⑦ Assemble bracket. Bolt : Paste loctite #277. Confirm torque : 610~650kgf·cm 15L7ADA136 ⑧ Finish drive axle assembly. 15L7ADA137 3-158...
  • Page 205 Functional test of hydraulic apply brake ※ The following procedure describes how to test the hydraulic apply brake system only. To perform this test, use a device that allows you to observe possible leaks through oil seals and that also allows you to verify that the piston return system works correctly .
  • Page 206 SECTION 4 BRAKE SYSTEM Machine serial No. - 25L-7A : -#0060, 30L-7A : -#0025 25LC-7A : -#0043, 30LC-7A : -#0016 Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8 Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10 Machine serial No.
  • Page 207 SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION · · Machine serial No. - 25L-7A : -#0060, 30L-7A : -#0025 25LC-7A : -#0043, 30LC-7A : -#0016 1. OUTLINE There are two brake systems, the foot brake system and the hand brake system. The foot brake adopts the brake system of oil type at drive axle.
  • Page 208 3. BRAKE PEDAL AND PIPING STRUCTURE T/M control valve Transmission Drive axle 20D7BS01 Brake pedal Reservoir tank assembly Parking lever assembly Brake master cylinder...
  • Page 209 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the drive axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force. By treading the pedal further, the brake is applied. Idle stroke: 1~3mm Floor plate Control valve...
  • Page 210 5. WET DISK BRAKE STRUCTURE 20D7PT20 Drive axle housing Piston brake Socket gear Square ring Plate Snap ring Square ring Friction plate Flange shaft OPERATION Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 211 6. BRAKE VALVE STRUCTURE 20 19 18 17 20D7BS03 Front housing 11 Seal 20 O-ring Rear housing 12 Seal 21 Check ball Push rod 13 Seal 22 O-ring Bellows 14 Seal 23 Check spring Master piston 15 Relief piston 24 Cage Lock washer 16 Shim 25 Air bent...
  • Page 212 DISASSEMBLY Remove push rod (3), bellows (4), air vent (25) and bolt (28). 20D7BS04 Remove front housing (1), rear housing (2), servo spring (10), servo piston (9) and master piston (5). 20D7BS05 Remove relief plug (18) with O-ring (19), relief spring (17), shim (16) and relief piston (15).
  • Page 213 INSPECTION AND ASSEMBLY Clean all parts thoroughly and lubricate the parts either with mineral or with hydraulic oil, according to their use destination. All single parts are to be checked for damage and replaced, if required. Assembly is in opposite order to disassembly. Seal kit : XKAU-00176 Use only brake fluid (Azola ZS10) into the compensation reservoirs.
  • Page 214 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS BRAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. PARKING BRAKE Operating force of parking lever is 35 - 40 ·...
  • Page 215 2. TROUBLESHOOTING Problem cause Remedy Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil. ·Hydraulic system leaks air. ·Bleed air. ·Disk worn. ·Replace. ·Brake valve malfunctioning. ·Repair or replace. ·Hydraulic system clogged. ·Clean. Brake acting unevenly. ·Tires unequally inflated. ·Adjust tire pressure.
  • Page 216 GROUP 3 TESTS AND ADJUSTMENTS 1. AIR BLEEDING OF BRAKE SYSTEM Air bleeding should be performed by two persons : One rides on truck for depressing and releasing brake pedal : the other person is on the ground and removes cap from air Air vent plug vent plug on wheel cylinder.
  • Page 217 Micro switch for parking brake (if equipped) ① Lever stroke 12.1 After assembling parking brake and parking cable, put the parking brake lever ② released. Loosen the nut for parking brake plate to Micro switch ③ play up and down. Move up the plate so that the stopper can Rachet be contacted with the pin and then...
  • Page 218 SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION · · Machine serial No. - 25L-7A : #0061-, 30L-7A : #0026-, 33L-7A : #0001- 25LC-7A : #0044-, 30LC-7A : #0017- 25G/30G/33G-7A : #0001-, 25GC/30GC-7A : #0001- 1. OUTLINE There are two brake systems, the foot brake system and the hand brake system. The foot brake adopts the brake system of oil type at drive axle.
  • Page 219 3. BRAKE PEDAL AND PIPING STRUCTURE T/M control valve Drive axle 15L7ABS01 Brake pedal Reservoir tank assembly Parking lever assembly Brake master cylinder 4-13...
  • Page 220 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the drive axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force.
  • Page 221 5. WET DISK BRAKE STRUCTURE 15L7APT20 Drive axle housing Piston brake Socket gear Square ring Plate Snap ring Square ring Friction plate Flange shaft OPERATION Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 222 6. BRAKE MASTER CYLINDER STRUCTURE 8 17 16 D205SBS04 Body Boot 15 Head Piston Spacer 16 Head pin Secondary cup 10 Spring seat 17 Nut Primary cup 11 Union 18 Seat Spring 12 Union bolt 19 Cap Plate 13 Washer 20 Cap Snap ring 14 Rod...
  • Page 223 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS BRAKE PIPING Check pipes, hoses and joints for damage, oil leakage or interference. Operate brake pedal and check operating force when pedal in depressed. Check also change in operating force, and change in position of pedal when pedal is kept depressed. PARKING BRAKE Operating force of parking lever is 35~40 ·...
  • Page 224 2. TROUBLESHOOTING Problem cause Remedy Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil. ·Hydraulic system leaks air. ·Bleed air. ·Disk worn. ·Replace. ·Brake valve malfunctioning. ·Repair or replace. ·Hydraulic system clogged. ·Clean. Brake acting unevenly. ·Tires unequally inflated. ·Adjust tire pressure.
  • Page 225 GROUP 3 TESTS AND ADJUSTMENTS 1. AIR BLEEDING OF BRAKE SYSTEM Air bleeding should be performed by two persons : One rides on truck for depressing and releasing brake pedal : the other person is Air vent plug on the ground and removes cap from air vent plug on wheel cylinder.
  • Page 226 Micro switch for parking brake (if equipped) ① Lever stroke 12.1 After assembling parking brake and parking cable, put the parking brake lever ② released. Loosen the nut for parking brake plate to Micro switch ③ play up and down. Move up the plate so that the stopper can Rachet be contacted with the pin and then...
  • Page 227 SECTION 5 STEERING SYSTEM Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15...
  • Page 228 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE Steering wheel Steering cylinder Steering unit Hydraulic tank Priority valve 25LC7ASS01 The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and pipings. The steering force given to the steering wheel enters the steering unit through the steering column.
  • Page 229 2. HYDRAULIC CIRCUIT 9.0MPa 20L7SS02 Gear pump with priority valve Suction strainer Steering unit Return filter Steering cylinder 10 Hydraulic tank...
  • Page 230 NEUTRAL 9.0MPa 20L7SS03 The steering wheel is not being operated so control spool(G) does not move. The oil from hydraulic gear pump(1) moves the priority valve spool(D) to the left. Oil flow into LS port to the hydraulic tank(10). So, the pump flow is routed to the main control valve.
  • Page 231 LEFT TURN 9.0MPa 20L7SS04 When the steering wheel is turned to the left, the spool(G) within the steering unit(4) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through the spool(D) of priority valve in gear pump(1) and flows to the gerotor(H).
  • Page 232 RIGHT TURN 9.0MPa 20L7SS05 When the steering wheel is turned to the right, the spool(G) within the steering unit(3) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool(G) within the steering unit (3) through the spool (D) of priority valve in gear pump (1) and flows to the gerotor(H).
  • Page 233 3. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing 14 Bearing race 24 Plate spring Ball 15 Bore screw 25 P-port check valve.
  • Page 234 OPERATION The steering unit is composed of the control valve(rotary valve) and the metering device. The control valve controls the flow of oil from the pump in the interior of the unit depending on the condition of the steering wheel. The metering device is a kind of hydraulic motor composed of a stator and a rotor. It meters the required oil volume, feeds the metered oil to the power cylinder and detects cylinder’s motion value, that is, cylinder’s motion rate.
  • Page 235 4. STEERING AXLE STRUCTURE 25L/30L/33L-7A, 25G/30G/33G-7A 20D7SS07 Steering axle 17 Hub 33 Thrust washer Knuckle-RH 18 Hub bolt 34 Pin Knuckle-LH 19 Hub nut 35 Spring washer Special bolt 20 Hub cap 36 Hardened washer King pin 21 Steering link 37 Upper cover Taper roller bearing 22 Steering cylinder...
  • Page 236 25LC/30LC-7A ·Machine serial No. - 25LC-7A : -#0099, 30LC-7A : -#0040 20L7SS06 Steering axle 14 King pin washer 27 Hex bolt Knuckle-RH 15 Needle bearing 28 Hex nut Knuckle-LH 16 Thrust bearing 29 Lock plate Oil seal 17 Shim (0.13t) 30 Hex bolt Taper roller bearing 18 Shim (0.25t)
  • Page 237 ·Machine serial No. - 25LC-7A : #0100-, 30LC-7A : #0041- 25LC7ASS06 Steering axle center 15 Special bolt 29 Trunnion sub block-Front Hub cap 16 Spring washer 30 Shim Upper cover sub 17 Link Sub Assy 31 Shim Lower cover sub 18 Steer link pin 32 Shim Hex bolt...
  • Page 238 TIGHTENING TORQUE AND SPECIFICATION 25L/30L/33L-7A, 25G/30G/33G-7A Stroke 86mm Stroke 86mm Apply loctite #277 49.5~66.5 kgf m(358~481 lbf ft) 20D7SS08 Type Unit Center pin support single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of wheels(Inside/Outside) degree...
  • Page 239 25LC/30LC-7A, 25GC/30GC-7A Stroke Stroke 86 1mm 86 1mm Apply loctite #277 49.5~66.5 kgf m(358~481 lbf ft) 25L7ASS08 Type Unit Center pin support single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of wheels(Inside/Outside) degree 78.9/56.6 Tread...
  • Page 240 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS Check item Checking procedure Steering wheel · Set rear wheels facing straight forward, then turn steering wheel to left and right. 30-60mm Measure range of steering wheel movement before rear wheel starts to move. (1.2-2.4 in) Range should be 30~60mm at rim of steering wheel.
  • Page 241 Problem Cause Remedy Steering wheel turns unstea- ·Lockout loosening. ·Retighten. dily. ·Metal spring deteriorated. ·Replace. Steering system makes abn- ·Gear backlash out of adjustment. ·Adjust. ormal sound or vibration. ·Lockout loosening. ·Retighten. ·Air in oil circuit. ·Bleed air. Abnormal sound heard when Valve ·Faulty.
  • Page 242 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing 14 Bearing race 24 Plate spring Ball 15 Bore screw 25 P-port check valve.
  • Page 243 TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-16...
  • Page 244 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1kgf·m (0~54.4lbf·ft) 13mm socket spanner 6, 8mm and 12mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 5-70(2) TIGHTENING TORQUE L : Left port R : Right port T : Tank P : Pump...
  • Page 245 DISASSEMBLY Disassemble steering column from steering unit and place the steering unit in the holding tool. Screw out the screws in the end cover(6- off plus one special screw). 5-72(1) Remove the end cover, sideways. 5-72(2) Lift the gearwheel set(With spacer if fitted) off the unit.
  • Page 246 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool.
  • Page 247 Take ring, bearing races and thrust bearing from sleeve and spool. The outer (Thin) bearing race can sometimes "stick" in the housing, therefore check that it has come out. 5-74(1) (10) Press out the cross pin. Use the special screw from the end cover. 5-74(2) ※...
  • Page 248 (12) Press the neutral position springs out of their slots in the spool. 5-75(1) (13) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (14) Screw out the plug using an 8mm hexagon socket spanner. Remove seal washers. D353SE10 (15) Unscrew the setting screw using an 8mm...
  • Page 249 (16) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (17) The pressure relief valve is now disassem- bled. D353SE13 5-22...
  • Page 250 ASSEMBLY Assemble spool and sleeve. ※ When assembling spool and sleeve only one of two possible ways of positioning the spring slots is correct. There are three slots in the spool and three holes in the sleeve in the end of the spool / sleeve opposite to the end with spring 5-76(1) slots.
  • Page 251 Press the springs together and push the neutral position springs into place in the sleeve. 5-77(2) Line up the springs and center them. 5-77(3) Guide the ring down over the sleeve. ※ The ring should be able to rotate free of the springs.
  • Page 252 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) ※ Assembly pattern for standard bearings 1 Outer bearing race 2 Thrust bearing 3 Inner bearing race 4 Spool 5 Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
  • Page 253 (11) Grease O-ring with hydraulic oil and place them on the tool. 5-79(1) 5-79(2) (12) Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.
  • Page 254 (14) Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore. 5-80(1) Installation instructions for lip seal (15) Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 255 (17) Press and turn the lip seal into place in the housing. 5-81(1) (18) With a light turning movement, guide the spool and sleeve into the bore. ※ Fit the spool set holding the cross pin horizontal. 5-81(2) (19) The spool set will push out the assembly tool guide.
  • Page 256 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20° C. 5-82(2) (23) Place the distributor plate so that the...
  • Page 257 (25) Place the cardan shaft as shown - so that it is held in position by the mounting fork. 5-83(1) (26) Grease the two O-rings with mineral oil approx. viscosity 500 cSt at 20° C and place them in the two grooves in the gear rim.
  • Page 258 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ·Tightening torque : 3.0 ±...
  • Page 259 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. ※ Do not use a hammer! 5-85(2) 5-32...
  • Page 260 2. STEERING CYLINDER STRUCTURE 25L/30L/33L-7A, 25G/30G/33G-7A D255SS11 Tube assembly Rod seal O-ring Back up ring 10 O-ring Gland Dust wiper 11 Piston seal DU bushing Snap ring 12 Pin bush 5-33...
  • Page 261 25LC/30LC-7A, 25GC/30GC-7A L255SS11 Tube assembly Bushing Rod assembly U-packing Piston seal Dust wiper Wear ring O-ring Gland DISASSEMBLY ※ Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in a vice. Remove the gland by hook a wrench in the notch of cylinder head and turn counter-clockwise.
  • Page 262 CHECK AND INSPECTION · · Machine serial No. - 25/30/33L-7A : #0001-, 25/30/33G-7A : #0001- mm(in) 25LC-7A : -#0099, 30LC-7A : -#0040 Criteria Check item Remedy Standard size Repair limit Clearance between 0.064~0.137 0.180 Replace piston & cylinder tube (0.0025~0.0054) (0.0070) piston seal Clearance between...
  • Page 263 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Set a special tool the cylinder, gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland assembly and tighten it with torque 45±4.5kgf·m (325±32.5lbf·ft).
  • Page 264 3. STEERING AXLE STRUCTURE 25L/30L/33L-7A, 25G/30G/33G-7A 20D7SS07 Steering axle 17 Hub 33 Thrust washer Knuckle-RH 18 Hub bolt 34 Pin Knuckle-LH 19 Hub nut 35 Spring washer Special bolt 20 Hub cap 36 Hardened washer King pin 21 Steering link 37 Upper cover Taper roller bearing 22 Steering cylinder...
  • Page 265 25LC/30LC-7A ·Machine serial No. - 25LC-7A : -#0099, 30LC-7A : -#0040 20L7SS06 Steering axle 14 King pin washer 27 Hex bolt 15 Needle bearing 28 Hex nut Knuckle-RH Knuckle-LH 16 Thrust bearing 29 Lock plate Oil seal 17 Shim (0.13t) 30 Hex bolt Taper roller bearing 18 Shim (0.25t)
  • Page 266 ·Machine serial No. - 25LC-7A : #0100-, 30LC-7A : #0041- 25LC7ASS06 Steering axle center 15 Special bolt 29 Trunnion sub block-Front Hub cap 16 Spring washer 30 Shim Upper cover sub 17 Link Sub Assy 31 Shim Lower cover sub 18 Steer link pin 32 Shim Hex bolt...
  • Page 267 CHECK AND INSPECTION 25L/30L/33L-7A, 25G/30G/33G-7A A1,A2 20D7SS10 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 55(2.2) 54.5(2.1) Shaft ID of bushing 55(2.2) 55.5(2.2) 35(1.4) 34.5(1.4) Replace OD of king pin OD of steering cylinder pin 20(0.8) 19.5(0.8) OD of pin...
  • Page 268 25LC/30LC-7A, 25GC/30GC-7A A1,A2 20L7SS10 · · Machine serial No. - 25LC-7A : -#0099, 30LC-7A : -#0040 unit : mm(in) Criteria Remarks Check item Standard size Repair limit OD of shaft 50(2.0) 49.5(1.9) Shaft ID of bushing 50(2.0) 50.5(2.0) 35(1.4) 34.5(1.4) Replace OD of king pin OD of steering cylinder pin...
  • Page 269 DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the counter weight part of the truck. 25L/30L/33L-7A, 25G/30G/33G-7A ① Loosen the hub nut and take off the steering wheel tire.
  • Page 270 ⑧ Loosen special bolt (4) and spring washer (35). ⑨ Remove hexagon bolt (39) and upper cover (37). ⑩ Push out the king pin (5) without damaging the knuckle arm (3). ⑪ If defect is observed in bearing (6), pull it out by using extractor.
  • Page 271 ⑦ Loosen special bolt(27) and spring washer(28). ⑧ Pry out the retaining ring(15) and remove oil seal(13). ⑨ Push out the king pin(36) without damaging the knuckle(2). ⑩ Pull out the needle bearing(17). If defect is observed in needle bearing(17), pull it out by using extractor.
  • Page 272 ASSEMBLY ※ In reassembling, have all parts washed, grease applied to lubricating parts, and all expendable items such as oil seal and spring washers replaced by new ones. Perform the disassembly in reverse order. 25L/30L/33L-7A, 25G/30G/33G-7A ① Tighten the special bolt (4) and washer (35) of king pin (5).
  • Page 273 25LC/30LC-7A, 25GC/30GC-7A · · Machine serial No. - 25LC-7A : -#0099, 30LC-7A : -#0040 ① Tighten the special bolt(27) of king pin. ※ There is a notch in the middle of the king pin(36), make sure that this notch is on the special bolt side.
  • Page 274 · · Machine serial No. - 25LC-7A : #0100-, 30LC-7A : #0041-, 25GC/30GC-7A : #0001- ① Tighten the special bolt(15) of king pin. ※ There is a notch in the middle of the king pin(9), make sure that this notch is on the special bolt side.
  • Page 275 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and Function ----------------------------------------------------------------------------------- 6-1 Group 2 Operational Checks and Troubleshooting ----------------------------------------------------- 6-19 Group 3 Disassembly and Assembly --------------------------------------------------------------------------- 6-23...
  • Page 276 SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT (Non OPSS and non boosted brake) 4B 4A 3B 3A 16.5MPa LIFT TILT AUX1 AUX2 22.0MPa 9.0MPa 20L7HS01 Gear pump with priority valve Tilt cylinder Main control valve Suction strainer Steering unit Return filter...
  • Page 277 HYDRAULIC CIRCUIT (OPSS and boosted brake) 3B 3A 4B 4A LIFT 16.5MPa AUX2 TILT AUX1 22.0MPa TO BRAKE 20L7HS02 Hydraulic gear pump Lift cylinder Dual flow divider Tilt cylinder Main control valve Suction strainer Brake valve 10 Return filter Steering unit 11 Down safety valve Steering cylinder 12 Hydraulic tank...
  • Page 278 HYDRAULIC CIRCUIT (fingertip control) V-MAST TILT AUX 1 AUX 2 EMERGENCY LIFTING MAIN RELIEF LOWERING TF-MAST TS-MAST VF-MAST QF-MAST 33HF-10110 Hydraulic gear pump Tilt cylinder 11 Priority valve Main control valve Suction strainer 12 Fork positioner cylinder Steering unit Return filter 13 Free lift cylinder Steering cylinder Down safety valve...
  • Page 279 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION 4B 4A 3B 3A 16.5MPa LIFT TILT AUX1 AUX2 22.0MPa Steering system 9.0MPa Return line 20L7HS03 When the lift control lever is pulled back, the spool on the first block moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of lift cylinder(5) by pushing the load check valve of the spool.
  • Page 280 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 4B 4A 3B 3A LIFT 16.5MPa TILT AUX1 AUX2 22.0MPa Steering system 9.0MPa Return line 20L7HS04 When the lift control lever is pushed forward, the spool on the first block moves to lower position. The work port(1A) and the small and the large chamber of lift cylinder are connected to the return passage, so the fork will be lowered due to its own weight.
  • Page 281 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION 4B 4A 3B 3A 16.5MPa TILT LIFT AUX1 AUX2 22.0MPa Steering system 9.0MPa Return line 20L7HS05 When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position.
  • Page 282 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION 4B 4A 3B 3A 16.5MPa TILT LIFT AUX1 AUX2 22.0MPa Steering system 9.0MPa Return line 20L7HS06 When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position.
  • Page 283 2. HYDRAULIC GEAR PUMP STRUCTURE (Booster brake) 5 12 9 10 11 13 14 20D7HS14 Housing Drive gear 12 Side plate Body Idle gear 13 Oil seal Rear cover Side plate 14 Snap ring Bushing 10 O-ring 15 Bolt O-ring 11 Back up ring 16 Washer...
  • Page 284 STRUCTURE (Non booster brake) 29,30 2 7 9 10 11 1 13 14 SECTION B - B" 20L7HS07 Housing 11 Back up ring 21 Spring Body 12 Side plate 22 Plug Priority valve body 13 Oil seal 23 O-ring Bushing 14 Snap ring 24 Adjust screw O-ring...
  • Page 285 3. MAIN CONTROL VALVE STRUCTURE (4- Spool) 16 15 SECTION H - H SECTION T - T SECTION E - E VIEW F - F VIEW I - I VIEW G - G Port name Size Inlet port 1-1/16-12UNF-2B Outlet port 1-1/16-12UNF-2B 20D7HS07 Lift block assy...
  • Page 286 INLET SECTION OPERATION Structure and description (Relief valve piston) 9 10 Relief valve piston 20D7HS08 Hydrostat plug 14 Relief plug O-ring 16 Relief spring 10 Hydrostat spring 17 Pilot poppet 11 Hydrostat sleeve 28 O-ring 12 Relief piston 29 System relief seat 13 Nut 30 Secondary relief seat 6-10...
  • Page 287 Operation Secondary relief valve To neutral passage To aux block 16.5MPa To neutral passage System relief valve 22.0MPa To load check valve 20L7HS15 Oil flows from P(pump) port to reservoir(T) by pushing hydrostat spool(1). Before the center bypass line closed, hydrostat spool is keep opening, so pump port(P) and tank port(T) are always connected in operation to minimize heat generation.
  • Page 288 LIFT SECTION OPERATION Lift position Load check valve 20D7HS09 When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flow into lift cylinder port(1A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 289 Lower position Load check valve 20D7HS10 When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (1A) → T. In lift lower position the fork drops due to its own weight.
  • Page 290 TILT SECTION OPERATION Tilt forward position Tilt lock spool Load check valve 20D7HS11 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flow into tilt cylinder port(2B). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage.
  • Page 291 Tilt backward position Tilt lock spool Load check valve 20D7HS12 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flows into tilt cylinder port(2A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
  • Page 292 MAIN RELIEF VALVE Pressure setting Relief plug Seat A good pressure gauge must be installed Lock nut O-ring in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit.
  • Page 293 MAIN CONTROL VALVE (FINGERTIP, OPT) STRUCTURE AUX 2 AUX 1 TILTING MAIN Main section Aux 2 section Aux 1 section Tilt section (lifting and lowering) 3-1-1 25L7AFT01 ※ Tightening torque - Item (3-1-1, 4-1, 5-1, 10) : 0.97 kgf·m (7.0 lbf.ft) - Item (9) : 2.3 kgf·m (17.0 lbf.ft) Main block...
  • Page 294 MAIN SECTION 25L7AFT02 ※ Flow rate : 100 lpm ※ Maximum pressure : 250 bar Lifting and lowering valve ① Main section ※ When it can’t control lifting & lowering, need to check EMP valve. Because of contamination EMP 31V material EMP valve often can’t operate properly lifting valve that means valve poppet and seat opened.
  • Page 295 3-way controller 9 bar spring ※ During unloading, supplied oil by the pump return to tank keeping 9 bar of system pressure. 25L7AFT06 25L7AFT07 6-16-3...
  • Page 296 Pressure reducing valve and S damping screw ① Pressure reducing valve ※ Pressure reducing valve controls valve actuation by suppling internal control oil. ※ Use a flat screw driver. ※ Tightening torque 0.71 kgf·m (5.2 lbf·ft) 25L7AFT08 ② S damping screw ※...
  • Page 297 Pressure relief valve 25L7AFT10 ※ Use with a 12 mm spanner. ※ Tightening torque (1) 1.43 kgf·m (10.3 lbf·ft) 25L7AFT11 ※ Use with a 3 mm wrench. ※ Tightening torque (2) 1.43 kgf·m (10.3 lbf·ft) = Pressure increases = Pressure decreases 25L7AFT13 ※...
  • Page 298 Emergency lowering valve and shuttle valve ① Emergency lowering valve 25L7AFT14 ※ When need to force lowering, rotate counter clockwise increasingly with emergency lowering valve. ② Shuttle valve 25L7AFT15 ※ Transfer bigger load pressure through shuttle valve. ※ Use a flat a screw driver. 6-16-6...
  • Page 299 TILT SECTION 25L7AFT16 ※ Flow rate : 40 lpm ※ Load holding pressure : 210 bar ※ Pressure limit : 162 bar Proportional directional valve 25L7AFT17 ① ② Valve section block Counter balance valve block 6-16-7...
  • Page 300 Disassembly valve section ① Disassemble spool ※ All block type, 40 lpm ② Disassemble coil 25L7AFT18 ※ AMP 4 pin coil ③ Disassembling process a. Release spring cap. 25L7AFT19 b. Release spring cap completely. 25L7AFT20 c. Release lever block. 25L7AFT21 d.
  • Page 301 2 way controller and shuttle valve ① 2 way controller ※ 2 way controller make it keep 6 bar regardless of load change between in and out of spool. 6 bar spring 25L7AFT24 ② Shuttle valve ※ Transfer bigger load pressure through shuttle valve. ※...
  • Page 302 Second relief valve ※ Controlling individual section pressure, rotating clockwise to increase setting pressure with wrench. ※ 80 bar increase and decrease per 1 turn. Relief valve 25L7AFT26 25L7AFT27 ※ ※ Use with a 12 mm spanner. Use with a 3 mm wrench. ※...
  • Page 303 Counter balance valve ※ Counter balance valve needs during tilting out operation. 61~250 bar Tightening torque = Pressure increases = Pressure decreases 25L7AFT28 6-16-11...
  • Page 304 AUXILIARY SECTION 25L7AFT29 ※ Flow rate AUX 1 : 25 lpm, AUX 2 : 40 lpm ※ Pressure limit AUX 1 : 162 bar, AUX 2 : 140 bar Proportional directional valve 25L7AFT30 ① ② Valve section block Ancillary block 6-16-12...
  • Page 305 2 way controller and shuttle valve ① 2 way controller ※ 2 way controller make it keep 6 bar regardless of load change between in and out of spool. 6 bar spring 25L7AFT24 ② Shuttle valve ※ Transfer bigger load pressure through shuttle valve. ※...
  • Page 306 Second relief valve ※ Controlling individual section pressure, rotating clockwise to increase setting pressure with wrench. ※ 80 bar increase and decrease per 1 turn. Relief valve 25L7AFT26 25L7AFT27 ※ ※ Use with a 12 mm spanner. Use with a 3 mm wrench. ※...
  • Page 307 ADD SECTION PART Disassembly ※ Tightening torque - Item 1 (2 EA) : 2.3 kgf·m (17.0 lbf·ft) - Item 2 (1 EA) : 0.97 kgf·m (7.0 lbf·ft) 25L7AFT31 25L7AFT32 25L7AFT33 ※ From 3 spool to 4 spool. ※ When it needs to disassemble section valve, it’s possible to release tension rod sets. 6-16-15...
  • Page 308 Assembly ※ From 3 spool to 4 spool. ※ When it needs to assemble section valve, it’s possible to combine with tension rod sets. 4 spool tension rod set 25L7AFT34 25L7AFT35 25L7AFT36 25L7AFT37 6-16-16...
  • Page 309 EMERGENCY LOWERING In case of the mast cannot be lowered due Main block to a problem in the controller, active the emergency lowering valve on the valve block with hexagonal wrench. Pressure setting Rotate counter clockwise the emergency lowering valve using hexagonal wrench and lower the mast and the load carriage slowly.
  • Page 310 4. LIFT CYLINDER D255HS18 Tube assembly Wear ring 11 O-ring Retaining ring 12 Guide Piston Gland 13 DU bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 5. TILT CYLINDER 23 18 19 20,21,22 11,10 15,14 13,12...
  • Page 311 6. FREE LIFT CYLINDER 11,12 13,14 20L7HS20 Tube assembly Check valve 11 Dust wiper Retaining ring 12 Retaining ring Piston Set screw 13 O-ring Piston seal Gland 14 Back up ring Wear ring 10 U-packing 6-18 6-18...
  • Page 312 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 20L7HS16 - Hydraulic oil : Normal operating temp...
  • Page 313 2. TROUBLESHOOTING SYSTEM Problem Cause Remedy Large fork lowering speed. ·Seal inside control valve defective. ·Replace spool or valve body. ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. Large spontaneous tilt of ·Tilting backward : Check valve defec- ·Clean or replace.
  • Page 314 HYDRAULIC GEAR PUMP Problem Cause Remedy Pump does not develop full ·System relief valve set too low or ·Check system relief valve for proper pressure. leaking. setting. ·Oil viscosity too low. ·Change to proper viscosity oil. ·Pump is worn out. ·Repair or replace pump.
  • Page 315 LIFT CYLINDER Problem Cause Remedy Oil leaks out from gland ·Foreign matters on packing. ·Replace packing. through rod. ·Unallowable score on rod. ·Smooth rod surface with an oil stone. ·Unusual distortion of dust seal. ·Replace dust seal. ·Chrome plating is striped. ·Replace rod.
  • Page 316 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP ※ Tools required ·Metric socket set ·Internal snap ring pliers ·Shaft seal sleeve ·Torque wrench It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
  • Page 317 Lift and remove end cover. PUMP 03 Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts. PUMP 04 (10) Remove rear bearing block from drive and idler shafts. PUMP 05 (11) Remove idler shaft from bearing block.
  • Page 318 (12) Remove drive shaft from mounting flange. There is no need to protect the shaft seal as it will be replaced as a new item. PUMP 07 (13) Remove the front bearing block. PUMP 08 (14) Turn mounting flange over, with shaft seal up, and remove the retaining ring with proper snap ring pliers.
  • Page 319 (17) Remove seals from both bearing blocks and discard. PUMP 11 INSPECT PARTS FOR WEAR Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be replaced as new items. Check drive shaft spline for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway.
  • Page 320 Inspect bearing blocks for excessive wear or scoring on the surfaces which are in contact with the gears. Also inspect the bearings for excessive wear or scoring. Inspect the area inside the gear housing. It is normal for the surface inside the gear housing to show a clean "wipe"...
  • Page 321 ASSEMBLY ※ New seals should be installed upon reassembly of pump. Install new shaft seal in mounting flange with part number side facing outboard. Press the seal into the seal bore until the seal reaches the bottom of the bore. Uniform pressure must be used to prevent misalignment or damage to the seal.
  • Page 322 Insert the drive end of the drive shaft through the bearing block with the seal side down, and the open side of the E-seal pointing to the intake side of the pump. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal.
  • Page 323 (13) Gently slide the gear housing over the rear bearing block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place with hands, do not force or use any tool. Check to make sure the intake port in the housing in on the same side as the open end of the E-seal and that the marked lines on the mounting flange and gear...
  • Page 324 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. ·Tighten torque : 3.0~4.0kgf·m (22~29lbf·ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
  • Page 325 2. MAIN CONTROL VALVE Remove bolt (1) to separate the valve section. 20D7MCV01 Divide the valve body. Aux2 Aux1 Tilt Lift T-cover 20D7MCV02 Remove dust cap (3) and bolt (2) from the valve body. 20D7MCV03 Remove attachment spool (4) from the valve body.
  • Page 326 Remove O-ring seals (5) from the valve body. 20D7MCV05 Remove tilt spool (6) from the valve body. 20D7MCV06 Remove lift spool (7) from the valve body. Remove lock poppet (8) from the valve body. Remove normal close solenoid valve (9, Opt) from the valve body.
  • Page 327 Remove relief plugs (15), springs (14) and poppets (13). 20D7MCV09 Remove normal open solenoid valve (16, Opt) from the valve body. 20D7MCV10 6-34 6-34...
  • Page 328 3. LIFT CYLINDER STRUCTURE Down safety valve D255HS24 Tube assy Wear ring 11 O-ring Rod assy Retaining ring 12 Guide Piston Gland 13 Du bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring 6-35 6-35...
  • Page 329 DISASSEMBLY Hold the cylinder tube in a vice, loosen the Guide Guide cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn.
  • Page 330 4. TILT CYLINDER STRUCTURE 20L7HS27 Tube assembly Bushing 17 Washer 10 U-packing 18 Eye Piston 11 Back up ring 19 Bushing Glyd ring 12 Dust wiper 20 Hexagon bolt Wear ring 13 Stop ring 21 Spring washer O-ring 14 O-ring 22 Lock nut Nylon nut 15 Back up ring...
  • Page 331 DISASSEMBLY Hold the parallel parts of the cylinder tube bottom in a vice and mark the rod head end to show how much it is screwed in, then remove the rod head. Next, hook a wrench into the notch at the cylinder head and remove the cylinder head from cylinder tube.
  • Page 332 SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location -------------------------------------------------------------------------------------- 7-1 Group 2 Electrical Circuit ---------------------------------------------------------------------------------------------- 7-2 Group 3 Component Specification ------------------------------------------------------------------------------- 7-14 Group 4 Connector Destination ------------------------------------------------------------------------------------ 7-15 Group 5 Troubleshooting ----------------------------------------------------------------------------------------------- 7-17...
  • Page 333 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 9 10 11 12 HYUNDAI 25G7AEL02 Flasher lamp Forward-reverse lever 13 OPSS unit Work lamp Operating panel 14 Flasher unit Combination switch Start switch 15 Battery Horn assembly 10 Horn button 16 Beacon lamp...
  • Page 334 GROUP 2 ELECTRICAL CIRCUIT ·ELECTRICAL CIRCUIT ( 25L-7A : -#0503, 30L-7A : -#0241, 33L-7A : -#0017, 25LC-7A : -#0202, 30LC-7A : -#0091) CABIN PART DASHBOARD PART FRAME/ENGINE PART CN-27 F/COMBI H/LAMP S.R- CN-17 S.L- CLUSTER ILL+ FOR CABIN(ASSY) 9 10 11 12 S.R+ CR-11 310-WB...
  • Page 335 ·ELECTRICAL CIRCUIT ( 25L-7A : #0504-2057, 30L-7A : #0242-1075, 33L-7A : #0018-0176, 25LC-7A : #0203-705, 30LC-7A : #0092-0227) CABIN PART DASHBOARD PART CN-27 FRAME/ENGINE PART F/COMBI H/LAMP S.R- CN-17 S.L- CLUSTER ILL+ GRAMMER SEAT FOR CABIN(ASSY) 9 10 11 12 CS-73 S.R+ CN-71...
  • Page 336 ·ELECTRICAL CIRCUIT ( 25L-7A : #2058-2793, 30L-7A : #1086-1548, 33L-7A : #0177-0296, 25LC-7A : #0706-1036, 30LC-7A : #0228-0347) CABIN PART CN-17 DASHBOARD PART CN-27 FRAME/ENGINE PART F/COMBI H/LAMP S.R- FOR CABIN(ASSY) S.L- CR-11 CLUSTER 310-WB 210-Gr ILL+ GRAMMER SEAT G1-B 9 10 11 12 CS-73 S.R+...
  • Page 337 ·ELECTRICAL CIRCUIT ( 25L-7A : #2794-3177, 30L-7A : #1549-1711, 33L-7A : #0297-0326, 25LC-7A : #1037-, 30LC-7A : #0348-) DASHBOARD PART F/COMBI F/COMBI H/LAMP H/LAMP CLUSTER C T G FRAME/ENGINE PART 1 2 3 9 10 11 12 CN-17 GRAMMER SEAT FOR CABIN(ASSY) CS-73 CN-71...
  • Page 338 ·ELECTRICAL CIRCUIT ( 25L-7A : #3178-, 30L-7A : #1712-, 33L-7A : #0327-) DASHBOARD PART H/LAMP F/COMBI H/LAMP F/COMBI CLUSTER FRAME/ENGINE PART (STANDARD) 9 10 11 12 CN-17 GRAMMER SEAT FOR CABIN(ASSY) CS-73 CN-71 CR-11 310-WB G5-B 210-Gr 260-R G1-B 460-LgR CS-73 FLASHER UNIT CS-2...
  • Page 339 ·ELECTRICAL CIRCUIT ( 25L-7A : #3178-, 30L-7A : #1712-, 33L-7A : #0327-) FRAME/ENGINE PART(FINGERTIP OPTION) FINGERTIP PART(HARNESS-MCV) FINGERTIP PART(HARNESS-ARMREST) COMMON USE FOR 3TON 9SERIES GRAMMER SEAT CS-73 CN-71 G3-B 260-R 460-LgR CS-73 SWITCH-EMERGENCY STOP(FOR MCV) 120 AWG18 G3-B 234 AWG18 CN-160 334 AWG18 120 AWG18...
  • Page 340 ·ELECTRICAL CIRCUIT (25L-7A : #5220~, 30L-7A : #2786~, 33L-7A : #518~) ·ELECTRICAL CIRCUIT (25L-7A : #5220~, 30L-7A : #2786~, 33L-7A : #518~) 7-2-6...
  • Page 341 ·ELECTRICAL CIRCUIT (25L-7A : #5220~, 30L-7A : #2786~, 33L-7A : #518~) ·ELECTRICAL CIRCUIT (25L-7A : #5220~, 30L-7A : #2786~, 33L-7A : #518~) 7-2-7...
  • Page 342 ·ELECTRICAL CIRCUIT (25L-7A : #5479~, 30L-7A : #2914~, 33L-7A : #543~) ELECTRICAL CIRCUIT (25L-7A : #5479~, 30L-7A : #2914~, 33L-7A : #543~) 7-2-8...
  • Page 343 ·ELECTRICAL CIRCUIT (25L-7A : #5479~, 30L-7A : #2914~, 33L-7A : #543~) ELECTRICAL CIRCUIT (25L-7A : #5479~, 30L-7A : #2914~, 33L-7A : #543~) 7-2-9...
  • Page 344 ·ELECTRICAL CIRCUIT (25L-7A : #5672~, 30L-7A : #3078~, 33L-7A : #563~) ELECTRICAL CIRCUIT (25L-7A : #5672~, 30L-7A : #3078~, 33L-7A : #563~) 7-2-10...
  • Page 345 ·ELECTRICAL CIRCUIT (25L-7A : #5672~, 30L-7A : #3078~, 33L-7A : #563~) ELECTRICAL CIRCUIT (25L-7A : #5672~, 30L-7A : #3078~, 33L-7A : #563~) 7-2-11...
  • Page 346 ·ELECTRICAL CIRCUIT (25L-7A : #5733~, 30L-7A : #3107~, 33L-7A : #565~) ELECTRICAL CIRCUIT (25L-7A : #5733~, 30L-7A : #3107~, 33L-7A : #565~) 7-2-12...
  • Page 347 ·ELECTRICAL CIRCUIT (25L-7A : #5733~, 30L-7A : #3107~, 33L-7A : #565~) ELECTRICAL CIRCUIT (25L-7A : #5733~, 30L-7A : #3107~, 33L-7A : #565~) 7-2-13...
  • Page 348 ·ELECTRICAL CIRCUIT (25L-7A : #6657~, 30L-7A : #3559~, 33L-7A : #670~) ELECTRICAL CIRCUIT (25L-7A : #6657~, 30L-7A : #3559~, 33L-7A : #670~) 7-2-14...
  • Page 349 ·ELECTRICAL CIRCUIT ( ELECTRICAL CIRCUIT (25L-7A : #6657~, 30L-7A : #3559~, 33L-7A : #670~) 25L-7A : #6657~, 30L-7A : #3559~, 33L-7A : #670~) 7-2-15...
  • Page 350 ·ELECTRICAL CIRCUIT (25L-7A : #6967~, 30L-7A : #3745~, 33L-7A : #706~) ELECTRICAL CIRCUIT (25L-7A : #6967~, 30L-7A : #3745~, 33L-7A : #706~) 7-2-16...
  • Page 351 ·ELECTRICAL CIRCUIT ELECTRICAL CIRCUIT (25L-7A : #6967~, 30L-7A : #3745~, 33L-7A : #706~) (25L-7A : #6967~, 30L-7A : #3745~, 33L-7A : #706~) 7-2-17...
  • Page 352 ·ELECTRICAL CIRCUIT (25L-7A : #7146~, 30L-7A : #3825~, 33L-7A : #724~) ELECTRICAL CIRCUIT (25L-7A : #7146~, 30L-7A : #3825~, 33L-7A : #724~) 7-2-18...
  • Page 353 ·ELECTRICAL CIRCUIT (25L-7A : #5733~, 30L-7A : #3107~, 33L-7A : #565~) ELECTRICAL CIRCUIT (25L-7A : #5733~, 30L-7A : #3107~, 33L-7A : #565~) 7-2-19...
  • Page 354 ·ELECTRICAL CIRCUIT ( 7/11, KIA GEORGIA, 25L-7A : -#2057, 30L-7A : -#1085, 33L-7A : -#0176) CABIN PART DASHBOARD PART CN-27 FRAME/ENGINE PART F/COMBI H/LAMP S.R- CN-17 S.L- CLUSTER SEAT SWITCH ILL+ FOR CABIN(ASSY) 9 10 11 12 S.R+ CR-11 310-WB 210-Gr S.L+ G1-B...
  • Page 355 ·ELECTRICAL CIRCUIT ( 8/11, KIA GEORGIA, 25L-7A : #2058-, 30L-7A : #1086-, 33L-7A : #0177-) CABIN PART DASHBOARD PART CN-27 FRAME/ENGINE PART F/COMBI H/LAMP S.R- CN-17 S.L- CLUSTER SEAT SWITCH ILL+ FOR CABIN(ASSY) 9 10 11 12 S.R+ CR-11 310-WB 210-Gr S.L+ G1-B...
  • Page 356 ·ELECTRICAL CIRCUIT ( 9/11, 25G/30G/33G(C)-7A : #0001-) CABIN PART FRAME/ENGINE PART DASHBOARD PART CN-27 ILL- CN-17 F/COMBI H/LAMP GRAMMAR SEAT SPK FRT RH- 200-R SPK FRT LH- 290-W CN-72 TEL MUTE 340-L CLUSTER CN-71 ANT 12V G5-B BACK UP+ FOR CABIN(Á¶¸³½Ä) 250-R ILL+ G3-B...
  • Page 357 ·ELECTRICAL CIRCUIT ( 10/11, CERTI, 25L/30L/33L(C)-7A : #0001-, 25G/30G/33G(C)-7A : #0001-) HDGCP90 15L7AEL07-1...
  • Page 358 ·ELECTRICAL CIRCUIT ( 11/11, NON-CERTI, 25L/30L/33L(C)-7A : #0001-, 25G/30G/33G(C)-7A : #0001-) HDGCP90 15L7AEL07-2 7-4-1...
  • Page 359 - WOODWARD LPG FUEL KIT KIA 21HC-26000 7-4-2...
  • Page 360 - WOODWARD LPG FUEL KIT 1/2 21HC-16060 7-4-3...
  • Page 361 - WOODWARD LPG FUEL KIT 2/2 21HC-16060 7-4-4...
  • Page 362 ·WOODWARD LPG FUEL KIT (NON CERTI.) 7-4-5...
  • Page 363 ·WOODEARD LPG FUEL KIT (CERTI.) 7-4-6...
  • Page 364 MEMORANDUM...
  • Page 365 1. POWER CIRCUIT 25L/30L/33L-7A, 25LC/30LC-7A The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal. OPERATING FLOW Battery(+) Start motor[CN-45(B+)] I/conn[CN-1(12,13,14)] Start switch[CS-2(3)] Fuse box[CN-36] (No.1)
  • Page 366 POWER CIRCUIT 25L/30L/33L-7A, 25LC/30LC-7A CL-16 CS-2 CN-36 CN-17 HORN/STOP LAMP TURN LAMP OPS-UNIT 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR (CABIN) TRAVEL - ACC 4 BR - ACC SPEED CONTROL 2 R2 R/COMBI RH - ST SEAT HEAT START KEY CLUSTER...
  • Page 367 25G/30G/33G-7A, 25GC/30GC-7A The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal. OPERATING FLOW Battery(+) Start motor[CN-45(B+)] I/conn[CN-1(12,13,14)] Start switch[CS-2(3)] Fuse box[CN-36] (No.1) Cab[CN-17(1),18(1)] OPSS buzzer[CN-113(2)]...
  • Page 368 25G/30G/33G-7A, 25GC/30GC-7A CL-16 CS-2 CN-36 CN-17 HORN/STOP LAMP TURN LAMP OPS-UNIT 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR (CABIN) - ACC TRAVEL 4 BR - ACC SPEED CONTROL 2 R2 R/COMBI RH - ST BI-FUEL SELECT/HEAT START KEY CLUSTER WORK/BEACON LAMP...
  • Page 369 2. STARTING CIRCUIT 25L/30L/33L-7A, 25LC/30LC-7A OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] I/conn[CN-1(12,13,14)] Start switch[CS-2(3)] ※The engine can be started only when the gearshift is in neutral position. When start key switch is in ON position Start switch ON [CS-2(4)] Fuse box[No. 5] I/conn[CN-1(19)] Fuel system interface[CN-6(1)] When start key switch is START position...
  • Page 370 25L/30L/33L-7A, 25LC/30LC-7A CS-2 CN-36 HORN/STOP LAMP TURN LAMP OPS-UNIT CR-5 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR TRAVEL - ACC 4 BR - ACC SPEED CONTROL 2 R2 - ST RELAY START KEY CLUSTER NEUTRAL WORK/BEACON LAMP FOR CABIN OPSS SYSTEM...
  • Page 371 25G/30G/33G-7A, 25GC/30GC-7A OPERATING FLOW Battery(+) terminal Start motor[CN-45(B+)] I/conn[CN-1(12,13,14)] Start switch[CS-2(3)] ※The engine can be started only when the gearshift is in neutral position. When start key switch is in ON position Start switch ON [CS-2(4)] Fuse box[No. 5] I/conn[CN-1(19)] Fuel system interface[CN-6(1)] When start key switch is START position Start switch START[CS-2(2)]...
  • Page 372 25G/30G/33G-7A, 25GC/30GC-7A CS-2 CN-36 HORN/STOP LAMP TURN LAMP CR-5 OPS-UNIT 4 BR START RELAY - ACC 1 R1 ILL/HEAD LAMP 4 BR - ACC TRAVEL 4 BR - ACC SPEED CONTROL 2 R2 - ST SEAT HEAT START KEY CLUSTER RELAY NEUTRAL WORK/BEACON LAMP FOR CABIN...
  • Page 373 GROUP 3 COMPONENT SPECIFICATION Specification Remark Part name CCA : 550 Battery 20HR : 60AH CMF 60(223×168×220) 12V, 55W Working lamp License lamp 12V, 3.4W×2 Combination lamp 12V, 21W(T/S) 12V, 10W(Back) 12V, 5W (Tail) 12V, 21W(Stop) 12V, 55W Head lamp 85±10 C/M, (23W+23W)×2+3W×2 Flasher lamp Flasher &...
  • Page 374 GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn(Dashboard harness-frame harness) 1743059-2 1743062-2 CN-2 I/conn (Dashboard harness-travel ext harness) MG610331 MG640329 CN-3 Bi - Fuel extension MG610335 CN-4 I/conn (Dashboard harness-head guard harness) MG610346 MG640348 CN-5...
  • Page 375 Connector part No. Connector No. of Type Destination number Female Male Lamp CL-3 Head lamp S822-014000 S822-114000 CL-7 Beacon lamp S822-014000 S822-114000 CL-15 DAEDONG Combination lamp-LH 110-6PR CL-16 DAEDONG Combination lamp-RH 110-6PR CL-23 Rear working lamp S822-014000 S822-114000 Relay CR-5 Neutral relay S810-004201 CR-11...
  • Page 376 GROUP 5 TROUBLESHOOTING Trouble symptom Probable cause Remedy ·Faulty wiring. ·Check for loose terminal and discon- Lamps dimming even at maxi- mum engine speed. nected wire. ·Improper belt tension. ·Adjust belt tension. Lamps flicker during engine operation. ·Charge lamp defective. ·Replace.
  • Page 377 SECTION 8 MAST Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8 Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11...
  • Page 378 SECTION 8 MAST GROUP 1 STRUCTURE 1. 2 STAGE MAST(V MAST) TILT CYLINDER LIFT CYLINDER CARRIAGE 20D7MS01 Outer mast Anchor bolt 10 Trunnion cap Inner mast Chain wheel bearing 11 Bushing Roller Retaining ring 12 Roller Shim(0.5, 1.0t) Tilt cylinder pin 13 Shim(0.5, 1.0t) Chain...
  • Page 379 2. 2 STAGE MAST(VF MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE 20D7MS02 Outer mast Shim(0.5, 1.0t) 11 Bushing Inner mast Roller 12 Sheave Chain Shim(0.5, 1.0t) 13 Sheave bracket Anchor bolt Tilt cylinder pin 14 U-bolt Back up liner 10 Support cap...
  • Page 380 3. 3 STAGE MAST(TF MAST) TILT CYLINDER LIFT CYLINDER FREE LIFT CYLINDER CARRIAGE 20D7MS21 Outer mast Roller 11 Sheave Middle mast Shim(0.5, 1.0t) 12 Tilt cylinder pin Inner mast Back up liner 13 Support cap Chain Shim(0.5, 1.0t) 14 Bushing Anchor bolt 10 Sheave bracket 15 Clamp...
  • Page 381 4. CARRIAGE, BACKREST AND FORK D255MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...
  • Page 382 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS FORKS Measure thickness of root of forks and check that it is more than specified value. ℓ=1050mm(41.3in) EX : mm(in) STD Fork assy Applicable model Standard Limit Thickness 25L(C)-7A, 64HN-21030 45(1.8) 40(1.6) 25G(C)-7A D507FK01...
  • Page 383 2. TROUBLESHOOTING MAST Problem Cause Remedy Forks fail to lower. ·Deformed mast or carriage. ·Disassemble, repair or replace. Fork fails to elevate ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system. ·Deformed mast assembly. ·Disassemble mast and replace damaged parts or replace complete mast assembly.
  • Page 384 FORKS Problem Cause Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear wear and reduces the thickness of the limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion Forks are bent out of shape by a...
  • Page 385 GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER(V, VF MAST) INNER/OUTER MAST ROLLER CLEAR-ANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the roller side face and mast at the closest position on the opposite side to the...
  • Page 386 2. MAST LOAD ROLLER(TF MAST) INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480mm. Shift the inner mast to one side to bring the roller into contact with the outer mast and the middle mast, and adjust the clearance between the roller side face and mast at the closest position on the L15C3MS06...
  • Page 387 CARRIAGE LOAD ROLLER Outer mast Adjust Bring into Measure the clearance when the center of screw contact the carriage upper roller is 100mm from the top of the inner mast. Measure the clearance at upper, middle Side and lower rollers after loosen the adjust roller Carriage screws from the side rollers.
  • Page 388 GROUP 4 REMOVAL AND INSTALLATION 1. FORKS Lower the fork carriage until the forks are approximately 25mm(1inch) from the floor. Knob Turn knob up and slide forks, one by one, Spring toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 389 SIDE ROLLER Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly. ※...
  • Page 390 MAST LOAD ROLLER AND BACK UP LINER 2 stage mast(V mast) Chain ① Remove the carriage assembly and Stud move them to one side. bolt ② Loosen and remove hexagon bolts and Inner mast washers securing lift cylinders to inner mast.
  • Page 391 2 stage mast(VF mast) ① Remove free lift chain connected between carriage and free lift cylinder. Chain ② Remove the carriage assembly and move them to one side. Stud ③ Loosen and remove hexagon bolts and bolt Inner washers securing lift cylinders to inner mast mast.
  • Page 392 3 stage mast(TF mast) ① Remove the carriage assembly and move to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. ③ Loosen and remove bolts and special washers securing lift cylinders to middle mast. ④...
  • Page 393 ELEVATING MAST Inner mast (V, VF mast) ① After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. ② Lift inner mast upright straight up and out of outer mast section. ③...
  • Page 394 CHAIN Chain Outer mast Chain sheave(V, VF mast) ① Place a sling around carriage and attach Sheave to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 395 Chain wheel bearing support(TF mast) ① Remove the carriage assembly and move to one side. ② After removing bolt to securing chain wheel bearing support assembly to free lift cylinder. After a sling to the chain wheel bearing support assembly, using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 396 ② ② Rust and corrosion Chains used on lift trucks are highly stressed precision components. It is very important that the “as-manufactured” ultimate strength and fatigue strength be maintained throughout the chain service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or roller chain because corrosion causes side plate cracking.
  • Page 397 ⑧ ⑧ Chain wear scale The chain can be checked for wear or stretching with the use of a chain wear scale. Stretching of a chain is due to the elongation of the pitch holes and wearing of the pin O.D. The greatest amount of stretching occurs at the areas of the chain that flex over the sheaves most frequently.
  • Page 398 ③ ③ Adjustment Chain adjustments are important for the following reasons : ·Equal loading of chain. ·Proper sequencing of mast. ·Prevent over-stretching of chains. ·Prevent chains from jumping off sheaves if they are too loose. ④ Adjustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor. ·Adjust the chain length by loosening or tightening nut on the chain anchor.

This manual is also suitable for:

30l 7a33l 7a25lc 7a30lc 7a25l g-7a30l g-7a ... Show all