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Hyundai 25DE-7U Manual

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FOREWORD ....................................................................................................................................... 2
SECTION 1
GENERAL ................................................................................................................. 11
GROUP1
SAFETY HINTS ...................................................................................................... 12
GROUP2
SPECIFICATIONS ................................................................................................... 16
GROUP3
PERIODIC REPLACEMENT .................................................................................... 24
SECTION2
REMOVAL AND INSTALLATION OF UNIT .................................................................. 25
GROUP1
STRUCTURE ......................................................................................................... 26
GROUP2
REMOVAL AND INSTALLATION OF UNIT .............................................................. 27
SECTION3
POWER TRAIN SYSTEM ............................................................................................ 42
GROUP1
STRUCTURE AND OPERATION ............................................................................. 43
GROUP2
DISASSEMBLY AND ASSEMBLY AND TROUBLESHOOTING ................................... 46
SECTION4
BRAKE SYSTEM ........................................................................................................ 68
GROUP1
STRUCTURE AND FUNCTION ............................................................................... 69
GROUP2
OPERATIONAL CHECKS AND TROUBLESHOOTING ............................................... 79
GROUP3
TESTS AND ADJUSTMENTS .................................................................................. 81
SECTION5
STEERING SYSTEM ................................................................................................... 83
GROUP1
STRUCTURE AND FUNCTION ............................................................................... 84
GROUP2
OPERATIONAL CHECKS AND TROUBLESHOOTING ............................................... 93
GROUP3
DISASSEMBLY AND ASSEMBLY ............................................................................. 96
SECTION6
HYDRAULIC SYSTEM .............................................................................................. 121
GROUP1
STRUCTURE AND FUNCTION ............................................................................. 122
GROUP2
OPERATIONAL CHECKS AND TROUBLESHOOTING ............................................. 134
GROUP3
DISASSEMBLY AND ASSEMBLY ........................................................................... 138
SECTION7
ELECTRICAL SYSTEM .............................................................................................. 152
GROUP1
COMPONENT LOCATION ................................................................................... 153
GROUP2
ELECTRICAL CIRCUIT .......................................................................................... 154
GROUP3
COMPONENT SPECIFICATION ............................................................................ 161
GROUP4
CONNECTOR DESTINATION ............................................................................... 162
GROUP5
TROUBLESHOOTING .......................................................................................... 165
SECTION8
MAST ..................................................................................................................... 166
GROUP1
STRUCTURE ....................................................................................................... 167
GROUP2
OPERATIONALCHECKS AND TROUBLESHOOTING .............................................. 171
GROUP3
ADJUSTMENT .................................................................................................... 174
GROUP4
REMOVAL AND INSTALLATION ........................................................................... 177
CONTENTS
1 / 189

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Summary of Contents for Hyundai 25DE-7U

  • Page 1 CONTENTS FOREWORD ............................2 SECTION 1 GENERAL ......................... 11 GROUP1 SAFETY HINTS ...................... 12 GROUP2 SPECIFICATIONS ....................16 GROUP3 PERIODIC REPLACEMENT ..................24 SECTION2 REMOVAL AND INSTALLATION OF UNIT ..............25 GROUP1 STRUCTURE ......................26 GROUP2 REMOVAL AND INSTALLATION OF UNIT .............. 27 SECTION3 POWER TRAIN SYSTEM ....................
  • Page 2 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. 2 / 189...
  • Page 3 2 HOW TO READ THE SERVICE MANUAL Distribution and updating Any additions, amendments or other changes will be sent to HYUNDAI distributors. Get the most up-to-date information before you start any work. 1) Filing method See the page number on the bottom of the page.
  • Page 4 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 1) Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 5 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.354 0.315 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.945 0.984 1.024 1.063 0.787 0.827 0.866 0.906 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 6 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 2.378 2.113 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 6.340 6.604 6.869 7.133 5.283 5.548 5.812 6.6076 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246...
  • Page 7 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 94.0 101.3 108.5 115.7 123.0 130.2 137.4 159.1 166.4 188.1 195.3 144.7 151.9 173.6 180.8 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
  • Page 8 kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2 28.4 128.0 14.2 42.7 56.9 71.1 85.3 99.6 113.8 142.2 156.5 170.7 184.9 199.1 213.4 241.8 256.0 227.6 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 455.1 497.8 540.5 426.7...
  • Page 9 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 10 ℃ ℃/℉ ℉ ℃ ℃/℉ ℉ ℃ ℃/℉ ℉ ℃ ℃/℉ ℉ -40.4 -40.0 -11.7 51.8 114.8 27.2 117.8 -37.2 -31.0 -11.1 53.6 116.6 27.8 179.6 -22.0 -10.6 118.4 28.3 181.4 -34.4 55.4 -31.7 -13.0 -10.0 57.2 120.2 28.9 183.2 -4.0 29.4 -28.9...
  • Page 11 SECTION 1 GENERAL Group 1 Safety hints----------------------------------------------------------------12-15 Group 2 Specifications-------------------------------------------------------------16-23 Group 3 Periodic replacement -------------------------------------------------------24 11 / 189...
  • Page 12 GROUP1 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. As preparation in case of fire, always know the location and directions for use of fire extinguishers and other fire...
  • 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...
  • Page 14 • Immediately remove any oil or grease floor operator's compartment, or on the handrail. It is very dangerous if someone slips while on the machine. • When working with others, choose a group leader and work according to his instructions. perform maintenance beyond the agreed work.
  • Page 15 • Always use HYUNDAI Forklift genuine parts for replacement. • Always use the grades of grease and oil recommended by HYUNDAI Forklift. Choose the viscosity oil specified for the ambient temperature. • Always use pure oil or grease, and be sure to use clean containers.
  • Page 16 GROUP2 SPECIFICATIONS 1 GENERAL LOCATIONS Steering wheel Forks Overhead guard Mast Tilt cylinder Rear combination lamp Lift chain Front wheel Turn signal lamp Lift cylinder Bonnet Head lamp Cluster Rear wheel Sub bonnet Backrest Counterweight Carriage Seat 16 / 189...
  • Page 17 2 SPECIFICATIONS Model Unit 25DE-7U 30DE-7U 35DE-7U 3000 3500 2500 Capacity Load center 4223 4595 3815 Weight (Unloaded) Lifting height 3005 3005 3005 Free lift Lifting speed (Unload/Load) 550/660 450/550 450/550 Fork mm/sec 580/460 480/350 480/350 Lowering speed (Unload/Load) mm/sec 1050×125×45...
  • Page 18 3 SPECIFICATION FOR MAJOR COMPONENTS 1) Engine Item Unit Specification Model MITSUBISHI / S4S Type 4-cycle, vertical Cooling Method Water cooled Number of cylinders and arrangement 4 cylinders, In line Firing order 1-3-4-2 Cylinder bore X stroke 94X120 Piston displacement 3331 Compression ratio 22:1...
  • Page 19 4) Steering unit Item Unit Specification Type Load sensing/Non load reaction/Dynamic signal Capacity mL/r Back pressure Input torque 1.4±0.2 5) Power train devices Item Specification Model YJH265 Torque converter Type Stall ratio 3.05 Power shift Type Gear shift (FR/RR) Electrical single lever type Transmission Adjustment 17.4972...
  • Page 20 4 TIGHTENING TORQUE OF MAJOR COMPONENTS Item Size kgf·m lbf·ft Engine mounting bolt, nut M12×1.25 12.5±2.5 90±18 Engine Radiator mounting bolt, nut M 8×1.25 2.5±0.5 18.1±3.6 Torque converter mounting M10×1.25 6.9±1.4 50±10 MCV mounting bolt, nut M10×1.5 4.0±0.5 29±3.6 Hydraulic Steering unit mounting bolt M10×1.5 4.0±0.5...
  • Page 21 ② Fine thread Bolt size kgf·m lbf·ft kgf·m lbf·ft M 8 × 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0 M10 × 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6 M12 ×...
  • Page 22 2) PIPE AND HOSE (FLARE TYPE) Width across flat(mm) kgf·m lbf·ft Thread size 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 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...
  • Page 23 6 RECOMMENDED LUBRICANTS Service Kind of fluid Capacity Ambient temperature℃ (℉) point (-4) (14) (32) (50) (68) (86) (104) Engine oil Engine oil CD15W-40 Torque transmission converter PTF-1 transmission Drive Axle Gear oil 6.5L 85/90 GL-5 Hydraulic Hydraulic oil STD:40L tank OPT:50L L-HM32...
  • Page 24 GROUP3 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; therefore, even if no apparent wear is found, always replace with new parts within the prescribed period of replacement (Or earlier if trouble is found).
  • Page 25 SECTION2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure --------------------------------------------------------------------- 26 Group 2 Removal and Installation of Unit ----------------------------------- 27-41 25 / 189...
  • Page 26 GROUP1 STRUCTURE 1 Mast Torque converter 15 Counterweight 2 Lift cylinder Engine 16 Steering wheel 3 Tilt cylinder 10 Fan 17 Overhead guard 4 Fork 11 Rear wheel 18 Seat 5 Front wheel 12 Steering cylinder 19 Air cleaner 6 Drive axle 13 Steering axle （Rear）...
  • Page 27 GROUP2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1 MAST 1) REMOVAL Fork Carriage Piping Mast A. Forks a) Lower the fork carriage until the forks are approximately 25mm (1in) from the floor. b) Turn knob up and slide one fork at a time toward the center of the carriage where a notch has been cut in the bottom plate for...
  • Page 28 b) While supporting lift chains, remove nuts and split pin from the anchor bolt. c) Pull the chains out of the sheaves and drape them over the front of the carriage d) Slowly raise inner mast upright until mast clears top of fork carriage.
  • Page 29 D. Piping a) Remove the return hoses and clamps attached to the cylinder. b) Remove hose assembly, valve and tee from the lift cylinder. Put blind plugs in the piping ※ immediately after removing hoses. This prevents the hydraulic oil from flowing out and also prevents dust and dirt from getting in.
  • Page 30 F. Inner mast a) 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. G. Tilt cylinder pin Hold the mast with a crane, remove the bolt of the pin, then remove the pin.
  • Page 31 2) 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. A. Mast support cap a) Check the mast support cap and spring pin for wear. b) Jack up the machine so that the front is raised and then using an overhead hoist assemble outer mast to drive axle unit.
  • Page 32 2 POWER TRAIN ASSEMBLY 1) REMOVAL 32 / 189...
  • Page 33 ① Mast Refer to the chapter MAST. ② Brake piping Disconnect the brake piping from the brake housing of drive axle. ③ Parking brake cable Disconnect parking brake cable from hand brake. 33 / 189...
  • Page 34 ④ Drive axle a) Attach a crane to the tilt cylinder notches dashboard raise machine. b) Loosen hexagonal bolts (1) connection drive axle to the transmission. c) Put the block under the drive axle and support under the drive axle with a truck. d) Remove drive axle mount bolts (2) from the frame and then slowly pull out the truck with...
  • Page 35 ⑦ Transmission a) Remove the cover on top face of the Transmission housing then remove the 8mounting bolts installed on the engine flywheel. To rotate the flywheel, remove 1 mounting bolt, then insert a turning tool in the mounting hole. One man must turn the engine fan by hand while the other turns the...
  • Page 36 2) INSTALLATION A. Installation is the reverse order to removal, but be careful of the following points. B. Tightening torque Bolt (1): 5.9~8.9kgf•m Bolt (2): 2.7~4.1kgf•m Bolt (3): 7.8~11.6kgf•m Bolt (4): 18.9~25.2±3 kgf•m 36 / 189...
  • Page 37 3 ENGINE Lever the torque converter, transmission and front axle inside the frame, then remove the engine assembly. 1) REMOVAL Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and flasher lamp stay overhead guard and then raise it together with the bonnet.
  • Page 38 Remove the torque converter housing cover, mounting bolts installed to flywheel housing. For details, see section 2. Engine accessory Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. a) Wiring harness to alternator and starter. b) Wiring harness for oil pressure and engine water temperature gauges.
  • Page 39 2) INSTALLATION Installation is the reverse order of removal, but be careful of the following points. ① Tighten the engine mounting bolts and nuts. ② Tighten the engine mounting bracket bolts. ※ Do not remove the bolts unless necessary. Loctite is coated over the threads of bolt.
  • Page 40 Counterweight→Rear wheel→Hose→Mounting bolt ① 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) 25DE-7U 1390kg (3060lb) 30DE-7U 1740kg (3840lb) 35DE-7U...
  • Page 41 ② Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take tire assembly. ③ Hose After draining out oil in the hoses, disconnect the hoses from the steering axle. ④ Mounting bolt Put a block under the steering axle, support on a truck, a raise frame with...
  • Page 42 SECTION3 POWER TRAIN SYSTEM Group 1 Structure and Operation ----------------------------------------------- 43-45 Group 2 Disassembly and assembly and troubleshooting---------------- 46-67 42 / 189...
  • Page 43 GROUP1 STRUCTURE AND OPERATION 1 POWER TRAIN DIAGRAM STRUCTURE 1 Engine 3 Drive axle 2 Transmission 4 Brake 43 / 189...
  • Page 44 2 TORQUE CONVERTER 1) STRUCTURE 1 Bolt 9 Bolt 2 Plate 10 Torque converter housing cover 3 Flexible plate 11 Temperature sensor 4 Torque converter assembly 12 Inner oil strainer 5 Bolt 13 Oil strainer spring 6 O-ring 14 O-ring 7 Oil level gauge 15 Oil strainer plug 8 Oil level gauge guide...
  • Page 45 2) OPERATION A. The torque converter is connected with a flywheel by a flexible plate, engine output is delivered from the flywheel to the flexible plate. B. The exterior of the torque converter is protected by the torque converter housing. C.
  • Page 46 GROUP2 DISASSEMBLY ASSEMBLY TROUBLESHOOTING 1 Parameters Table 1 Main technical parameters of gearbox Items JHTY30 Matching engine rated power KW 35.3 Matching engine rated speed r/min 2250 Transmission Forward gear 17.4972 ratio Back gear 17.4972 Main oil pressure MPa 1.1―1.5 Torque converter inlet pressure MPa 0.3―0.7 Electrical device (voltage/power)
  • Page 47 1) Maintenance and adjustment ① Oil level check Fill in the oil and drive in neutral for 5 minutes. After turning off the engine, check the oil level of the oil dipstick. The oil should be within the specified range of the dipstick.
  • Page 48 f) Refill oil (perform the above 1). g) After the new machine is used for 100 hours, the fine filter should be replaced and the coarse filter should be cleaned; the fine filter should be replaced and the coarse filter should be cleaned every 500 hours after use; the coarse filter should be replaced every 2000 hours of use.
  • Page 49 Figure 1 The schematic diagram of JHTY30B hydraulic transmission gearbox 1 Elastic coupling plate 8 friction plate 15 differential assembly 2 Turbine 9 separator 16 planet gear 3 Guide wheel 10 reverse gear 17 helical bevel gear 4 Pump wheel 11 input shaft assembly 18 idler shaft 5 Turbine shaft...
  • Page 50 Figure 2 Schematic diagram of oil circuit of JHTY30B hydraulic transmission gearbox 1 Oil filter 4 Micro valve 7 Safety valve 2 Oil pump 5 Buffer valve 8 Oil filter 3 Main pressure regulating 6 Electromagnetic shift valve 9 Car cooler valve ②...
  • Page 51 51 / 189...
  • Page 52 b) hydraulic torque converter The structure diagram of YJH265 hydraulic torque converter is shown in Figure 4. It is mainly composed of turbine shaft 8, pump wheel 10, guide wheel 4, turbine 3, elastic coupling plate 2 and other components. Figure 4 YJH265 torque converter structure diagram 1 Oil drain plug 5 Thrust bearing...
  • Page 53 than the input torque, and an automatic torque conversion is generated. When the ratio of the turbine speed to the pump wheel speed is greater than a certain value, the guide wheel disengages and rotates freely, and the torque conversion ends. This state is Coupling state. YJH265 is a press-welding hydraulic torque converter, which cannot be disassembled.
  • Page 54 d) Micro valve assembly The structure diagram of YQX30-5000 micro valve assembly is shown in Figure 6. The micro valve assembly is mainly composed of micro slide valve 13, micro valve body 12, spring 8, micro valve stem 7, and other parts. The micro valve assembly is installed on the outside of the gearbox.
  • Page 55 e) Clutch The YQX38-1000 clutch assembly structure diagram is shown in Figure 7. It is used for JHTY30B hydraulic transmission gearbox. The clutch assembly consists of input shaft 9, forward gear 4, piston 2, clutch housing 22, friction plate 19, spacer 18, Return spring 5, reverse gear 6, sealing ring 8 and other parts and components.
  • Page 56 f) Differential assembly The structure diagram of the YQX30-2000 differential assembly is shown in Figure 9. It is used in the JHTY30B hydraulic transmission gearbox and is supported on the gearbox housing by ball bearings 8 at both ends. The differential assembly is equipped with two side gears 9 and four planetary gears 10.
  • Page 57 g) Cover and control valve assembly The structure diagram of YQXD30-4000 covers and control valve assembly is shown in Figure 10 and 11. It is composed of solenoid valve 1 and housing cover 2 and control valve assembly 3. The control valve assembly is installed on the inner side of the housing cover.
  • Page 58 The general structure diagram of YQXD30-4100 control valve is shown in Figure 11. It is composed of main pressure valve 1, reverse buffer valve 2, forward buffer valve 3 and so on. The main pressure valve controls the clutch oil pressure in the range of 1.1MPa-1.4 MPa, part of the oil enters the control valve through the micro valve to realize gear shifting;...
  • Page 59 3) Disassembly and assembly ① Gearbox disassembly and assembly Before disassembling gearbox, drain the residual oil in the box and replace the gasket at the oil drain plug. After draining the residual oil, screw the drain plug back to the gearbox. Parts description Characteristic requirements Tooling, tools...
  • Page 60 Remove the torque converter assembly 5. Parts description Characteristic requirements Tooling, tools 5-Torque converter assembly Rotate and push in while installing Remove the fixing bolt 6 and remove the oil supply pump assembly 8. If the paper pad is damaged during installation, clean the remaining paper pad on the joint surface and...
  • Page 61 Remove the fixing bolts, and remove torque converter housing assembly When disassembling, pay attention to the large and two small three O-rings on the joint surface; if the paper pad is damaged during installation, clean the remaining paper pad on the joint surface. Replace with a new paper pad.
  • Page 62 Remove the fixing bolts and remove the micro valve assembly 22; pay attention to the two O-rings on the joint surface when disassembling; if the paper pad is damaged during installation, clean the remaining paper pad on the joint surface and replace it with a new one.
  • Page 63 Use a crowbar to gently remove the clutch assembly and idler shaft. Parts description Characteristic requirements Tooling, tools 30-Idler 31-Clutch assembly Remove the bearing caps 33 (42) at both ends, and remove the pinion 38 and the driven spiral bevel gear 45. When installing, note that the adjustment pads 34 and 39 at both ends should be installed back to the original place...
  • Page 64 Remove the fixing bolts and remove the output shaft assembly 51. When installing, pay attention to the adjustment pads 52 and 49 should be installed back to the original place according to the amount of disassembly. Parts description Characteristic requirements Tooling, tools 47-bolt Tightening torque 22-30N.m...
  • Page 65 Remove the ring gear 3, open the differential, take out the internal planetary gear 9 and the side gear 7; pay attention to check the wear of gaskets 6 and 8 during installation, replace gaskets if necessary. All bolts here need to be used the torque wrench is tightened, and the tightening torque is 70-80N.m.
  • Page 66 Remove the bearing and clutch gear 3 at both ends, remove the retaining ring 7 and remove the friction plates 8, 9, and then remove the retaining ring 11 to take out the return spring 13 and the piston assembly 14; check the wear of each friction plate before installation, if necessary, replace the friction plate, and replace the...
  • Page 67 ② Matters needing attention a) The sequence of disassembly and assembly of the gearbox is basically the opposite. b) When disassembling and assembling the gearbox, handle it with care to prevent parts from bumping and damage. After disassembly, the parts must be placed in an orderly manner.
  • Page 68 SECTION4 BRAKE SYSTEM Group 1 Structure and function ------------------------------------------------- 69-78 Group 2 Operational checks and troubleshooting -------------------------- 79-80 Group 3 Tests and adjustments ------------------------------------------------- 81-82 68 / 189...
  • Page 69 GROUP1 STRUCTURE AND FUNCTION 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. Oil pressure is generated in maximum 140kgf/cm2 through brake oil input path of the left and right drive axle housing, this pressure allows the piston brake to advance and compresses a friction plate and a plate.
  • Page 70 3 BRAKE PEDAL AND PIPING 1) STRUCTURE Drive axle Brake pedal Reservoir tank assembly Parking lever assembly Brake master cylinder 70 / 189...
  • Page 71 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.
  • Page 72 5 DRY DISK BRAKE Two Types Front wheel Brake，Internal expanding and Hydraulic Pedal lever ratio 7.52 Master cylinder 19.05mm bore Wheel Brake 2-3.5t Type Two Servo mechanism with Parking Brake Slave cylinder bore 28.58 Size of friction plate 348×76×8mm （length×width× depth）...
  • Page 73 by oil return port. The pressure will be adjusted to a certain proportion with the pressure in brake slave cylinder, putting the cup in slave cylinder in the right position to prevent oil from spilling, and removing air-resistor which might arise in emergent brake.
  • Page 74 1 Brake slave cylinder assembly 2 Spring 3 Cup 4 Piston 5 Slave cylinder cover 6 Piston carrier rod 7 Brake shoe return spring 8 Friction plate 9 Spring 10 Manual push-rod 11 Spring stay device 12 Brake shoe 13 Compression spring seat 14 Compression spring pull rod 15 Compression spring 16 Spring...
  • Page 75 5.4 Automatic gap adjustment (The following is 2t brake theory, 2-3.5t are same as 2t) Automatic gap adjustment can keep distance of friction plate and brake drum in 0.4-0.45mm （3-3.5t, 0.25-0.4mm） automatically. But it only works in backward brake. In backward, brake shoe will disconnect when push brake pedal, so then, master brake shoe and slave brake shoe touch brake drum and turn together until the top of master brake shoe start touching supporting pin.
  • Page 76 6 BRAKE VALVE 1) STRUCTURE 1 Front housing 11 Seal 20 O-ring 2 Rear housing 12 Seal 21 Check ball 3 Push rod 13 Seal 22 O-ring 4 Bellows 14 Seal 23 Check spring 5 Master piston 15 Relief piston 24 Cage 6 Lock washer 16 Shim...
  • Page 77 2) DISASSEMBLY ① Remove push rod (3), bellows (4), air vent (25) and bolt (28). ② Remove front housing (1), rear housing (2), servo spring (10), servo piston (9) and master piston (5). ③ Remove relief plug (18) with O-ring (19), relief spring (17), shim (16) and relief piston (15).
  • Page 78 3) INSPECTION AND ASSEMBLY ① Clean all parts thoroughly and lubricate the parts either with mineral or with hydraulic oil, according to their use destination. ② All single parts are to be checked for damage and replaced, if required. ③ Assembly is in opposite order to disassembly. ④...
  • Page 79 GROUP2 OPERATIONAL CHECKS TROUBLESHOOTING OPERATIONAL CHECKS 1) BRAKE PIPING ① Check pipes, hoses and joints for damage, oil leakage or interference. ② 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.
  • Page 80 2 TROUBLESHOOTING Problem cause Remedy Insufficient •Hydraulic system leaks oil. •Repair and add oil. braking force •Hydraulic system leaks air. •Bleed air. •Disk worn. •Replace. •Brake valve malfunctioning. •Repair or replace. •Hydraulic system clogged. •Clean. Brake acting •Tires unequally inflated. •Adjust tire pressure.
  • Page 81 GROUP3 TESTS AND ADJUSTMENTS 1 AIR BLEEDING OF BRAKESYSTEM 1) 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 vent plug on wheel cylinder.
  • Page 82 3 MICRO SWITCH FOR PARKING BRAKE (IF EQUIPPDE) 1) After assembling parking brake parking cable, parking brake lever released. Loosen the nut for parking brake plate to play up and down. Move up the plate so that the stopper can be contacted with the pin and then reassemble nut.
  • Page 83 SECTION5 STEERING SYSTEM Group 1 Structure and Function ------------------------------------------------ 84-91 Group 2 Operational Checks and Troubleshooting ------------------------92-95 Group 3 Disassembly and Assembly -----------------------------------------96-120 83 / 189...
  • Page 84 GROUP1 STRUCTURE AND FUNCTION 1 OUTLINE The steering system for this machine is composed of steering wheel assembly, steering unit, steering cylinder, steering axle and piping. The steering force given to the steering wheel enters the steering unit through the steering column. The required oil flow is sensed by the function of the control section of the unit, and pressurized oil delivered from the hydraulic pump is fed to the steering cylinder.
  • Page 85 2 HYDRAULIC CIRCUIT 1 Gear pump 4 Steering cylinder 2 Hydraulic tank 5 Return filter 3 Steering unit 6 Suction strainer 85 / 189...
  • Page 86 1) NEUTRAL LIFT CYLINDER The steering wheel is not being operated so control spool (G) does not move. The oil from hydraulic gear pump (1) enters priority valve and the inlet pressure oil moves the spool (D) to the left. Oil flow into LS port to the hydraulic tank (5).
  • Page 87 2) LEFT TURN LIFT CYLINDER When the steering wheel is turned to the left, the spool (G) within the steering unit (2) 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 (2) through the spool (D) of priority valve and flows to the gerotor (H).
  • Page 88 3) RIGHT TURN LIFT CYLINDER When the steering wheel is turned to the right, the spool (G) within the steering unit (2) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool (G) where it is directed out of the right work port (R).
  • Page 89 3 STEERING UNIT 1) STRUCTURE 1 Dust seal 11 O-ring 21 Housing 2 Retaining ring 12 Rolled screw 22 Spool 3 Cap seal 13 Gear set 23 Sleeve 4 Thrust bearing 14 Bearing race 24 Plate spring 5 Ball 15 Bore screw 25 P-port check valve.
  • Page 90 2) OPERATION ① 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.
  • Page 91 4 STEERING AXLE 1) STRUCTURE Steering axle Thrust washer Knuckle-RH Hub bolt Knuckle-LH Hub nut Spring washer Special bolt Hub cap Hardened washer King pin Steering link Upper cover Taper roller bearing Steering cylinder Lower cover Oil seal SPH plain bearing Hex bolt Retaining ring Steer link pin...
  • Page 92 2) TIGHTENING TORQUE AND SPECIFICATION Type Unit Center pin support single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree steering angle wheels degree 79 / 56 (Inside/Outside) Tread 92 / 189...
  • Page 93 • Fit bar and a piece of chalk at outside edge of counterweight to mark line of turning radius. • If minimum turning radius is not within±100mm (±4in) of specified value, adjust turning angle stopper bolt. Min turning radius (Outside) 25DE-7U 2076mm(82in) 30DE-7U 2136mm(84in) 35DE-7U...
  • Page 94 Steering •Bearing faulty. •Clean or replace. wheel fails to •Reaction plunger faulty. •Replace. return •Ball-and-screw assy faulty •Clean or replace. smoothly. •Gears poorly meshing. •Check and correct meshing. Problem Cause Remedy Steering wheel turns •Lockout loosening. •Retighten. unsteadily. •Metal spring deteriorated. •Replace.
  • Page 95 Steering cylinder head •O-ring damage. •Replace thread (A little bit leak is no problem) Welding leakage •Cylinder tube damage. •Tube replace. •Tube inside damage. •Grind surface with oil •Piston seal damage and store. distortion •Replace Piston rod bushing inner •Bushing wear. •Replace diameter excessive gap 95 / 189...
  • Page 96 GROUP3 DISASSEMBLY AND ASSEMBLY 1 STEERING UNIT 1) STRUCTURE 1 Bolt-socket 12 Needle Roller Thrust Bearing 23 Rotor 2 Washer-Spring 13 Washer 24 O-Ring 29×2 3 Cap-Front 14 Spool 25 Ring 4 O-Ring 15 Washer 26 Limited Post 5 X-Type Seal Ring 16 Pin 27 Cap-Rear 6 Screw-Bore 17 Spring-Plate...
  • Page 97 2) TOOLS ① Holding tool ② Assembly tool for O-ring and kin-ring. ③ Assembly tool for lip seal. ④ Assembly tool for cardan shaft. 97 / 189...
  • Page 98 ⑤ Assembly tool for dust seal. ⑥ Torque wrench 0~7.1kgf•m (0~54.4lbf•ft) 13mm socket spanner6, 8mm and 12 mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 3) TIGHTENING TORQUE L : Left port R : Right port T : Tank...
  • Page 99 4) DISASSEMBLY ① 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). ② Remove the end cover, sideways. ③ Lift the gearwheel set (With spacer if fitted) off the unit.
  • Page 100 ⑤ Remove distributor plate ⑥ Screw out the threaded bush over the check valve. ⑦ Remove O-ring. ⑧ Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and thrust bearing will be pushed out...
  • Page 101 ⑨ 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. ⑩ Press out the cross pin. Use the special screw from the end cover.
  • Page 102 ⑫ Press the neutral position springs out of their slots in the spool. ⑬ Remove dust seal and O-ring. ⑭ Disassembling the pressure relief valve Screw out the plug using an 8mm hexagon socket spanner. Remove seal washers. ⑮ Unscrew the setting screw using an 8mm hexagon socket spanner.
  • Page 103 16 Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. 17 The pressure relief valve is now disassembled. 103 / 189...
  • Page 104 5) ASSEMBLY A. Assemble spool and sleeve. ※ When assembling spool and Sleeve only one of two possible ways of positioning the spring slots is correct. There are three slots in the spool And three holes in the sleeve in the end of the spool / sleeve opposite to the end with spring slots.
  • Page 105 E. Press the springs together and push the neutral position springs into place in the sleeve. F. Line up the springs and center them. G. Guide the ring down over the sleeve. ※ The ring should be able to rotate free of the springs. H.
  • Page 106 I. Fit bearing races and needle bearing as shown on below drawing. ※ Assembly pattern for standard bearings a) Outer bearing race b) Thrust bearing Inner bearing race d) Spool e) Sleeve J. Installation instruction for O-ring Turn the steering until the bore is horizontal.
  • Page 107 K. Grease O-ring with hydraulic oil and place them on the tool. L. 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. M.
  • Page 108 N. 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. O. Installation instructions for lip seal Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 109 Q. Press and turn the lip seal into place in the housing. R. With a light turning movement, guide the spool and sleeve into the bore. ※ Fit the spool set holding the cross pin horizontal. S. The spool set will push out the Assembly tool guide.
  • Page 110 U. Screw the threaded bush lightly Into the check valve bore. The top of the bush must lie just below the surface of the housing. V. Grease the O-ring with mineral oil approx. viscosity 500 cst at 20℃. W. Place the distributor plate so that the channel holes match the holes in the housing.
  • Page 111 Y. Place the cardan shaft as shown so that it is held in position by the mounting fork. Z. 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. Fit the gearwheel and rim on the cardan shaft.
  • Page 112 CC. Place the end cover in position. DD. Fit the special screw with washer and place it in the hole shown. EE. Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. •Tightening torque: 3.0 ±...
  • Page 113 GG.Fit the dust seal ring in the housing HH.Press the plastic plugs into the connection ports. ※ Do not use a hammer! 113 / 189...
  • Page 114 2 STEERING CYLINDER 1) STRUCTURE 1 Tube assembly 6 Bushing 2 Rod assembly 7 U-packing 3 Piston seal 8 Dust wiper 4 Wear ring 9 O-ring 5 Gland 2) DISASSEMBLY ※ Before disassembling steering cylinder, release oil in the cylinder first. ①...
  • Page 115 3) CHECK AND INSPECTION mm(in) Check item Criteria Remedy Standard size Repair limit Replace piston seal Clearance between 0.064~0.137 0.180 (0.0070) piston & cylinder (0.0025~0.0054) tube Replace bushing Clearance between 0.024~0.112 0.120 (0.0049) cylinder rod & (0.0009~0.0044) bushing Seals, O-ring Damage Replace Cylinder rod...
  • Page 116 C. Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. D. Set a special tool the cylinder, gland assembly into the cylinder tube. E. Using a hook spanner, install the gland assembly, and tighten it with torque 45±4.5kgf•m (325±32.5lbf•ft).
  • Page 117 3 STEERING AXLE 1) STRUCTURE 1 Steering axle 17 Hub 33 Thrust washer 2 Knuckle-RH 18 Hub bolt 34 Pin 3 Knuckle-LH 19 Hub nut 35 Spring washer 4 Special bolt 20 Hub cap 36 Hardened washer 5 King pin 21 Steering link 37 Upper cover 6 Taper roller bearing...
  • Page 118 2) CHECK AND INSPECTION unit: mm(in) Check item Criteria Remarks Standard Repair limit size OD of shaft 55(2.2) 54.5(2.1) Shaft ID of bushing 55(2.2) 55.5(2.2) OD of king pin 35(1.4) 34.5(1.4) Replace OD of steering cylinder pin 20(0.8) 19.5(0.8) OD of pin 20(0.8) 19.5(0.8) Knuckle...
  • Page 119 B. Remove Hub cap. C. Pull out split pin and remove slotted nut. D. Using the puller, take off the hub together with the roller bearing. ※Be very careful because just before the hub comes off, tapered roller bearing will fall out. E.
  • Page 120 4) 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. A. Tighten the special bolt (4) and washer (35) of king pin (5). B.
  • Page 121 SECTION6 HYDRAULIC SYSTEM Group 1 Structure and Function ---------------------------------------------122-133 Group 2 Operational Checks and Troubleshooting ---------------------134-137 Group 3 Disassembly and Assembly ---------------------------------------138-151 121 / 189...
  • Page 122 GROUP1 STRUCTURE AND FUNCTION 1 HYDRAULIC CIRCUIT Hydraulic tank Side shift cylinder Suction strainer Fork positioner cylinder Hydraulic gear pump Steering unit Main control valve 10 Steering cylinder Lift cylinder 11 Return filter Tilt cylinder 12 Down safety valve 122 / 189...
  • Page 123 2 HYDRAULIC GEAR PUMP 1) STRUCTURE GEAR PUMP ASSY CONNECTOR ELBOW-90 BOLT-W/WASHER HEX O-RING 123 / 189...
  • Page 124 MAIN CONTROL VALVE 1) STRUCTURE (4- Spool) 1 T cover 6 Lift block assy 2 Aux2 block assy 7 Main Relief valve 3 Aux Relief valve 8 PF port fitting 4 Aux1 block assy 9 inlet block assy 5 Tilt block assy 10 Aux Relief valve 124 / 189...
  • Page 125 2) INLET SECTION OPERATION ① Structure and description 1 plug 5 Relief valve 2 Body 6 Steering relief valve 3 PF port fitting 7 LS port fitting 4 priority valve 125 / 189...
  • Page 126 ② Operation The P port is the pump oil inlet, the PF port is connected to the steering unit inlet, the EF port is connected to the working valve, the LS port is connected to the steering unit control port, and the T port is the safety valve return port. When the oil is in the P port, the hydraulic oil is preferentially supplied to the PF port through the priority valve.
  • Page 127 3) LIFT SECTION OPERATION ① Lift position 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 flow into lift cylinder port(1A). The pump pressure reaches proportionally the load of cylinder.
  • Page 128 ② Lower position 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 129 4) TILT SECTION OPERATION ① Tilt forward position 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 flow into tilt cylinder port(2B). The pump pressure reaches proportionally the load of cylinders.
  • Page 130 ② Tilt backward position 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 flows into tilt cylinder port(2A). The pump pressure reaches proportionally the load of cylinder. The return oil from cylinder port(2B) flows into the tank via the low-pressure passage.
  • Page 131 5) MAIN RELIEF VALVE ① Pressure setting A good pressure gauge must be installed in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit. Procedure Loosen lock nut.
  • Page 132 3 LIFT CYLINDER 1 Tube assembly 6 Wear ring 11 O-ring 2 Rod 7 Retaining ring 12 Guide 3 Piston 8 Gland 13 DU bushing 4 Piston seal 9 Dust wiper 14 Spacer 5 Back up ring 10 Rod seal 15 O-ring 4 TILT CYLINDER 1 Tube assembly...
  • Page 133 5 FREE LIFT CYLINDER 1 Tube assembly 6 Check valve 11 Dust wiper 2 Rod 7 Retaining ring 12 Retaining ring 3 Piston 8 Set screw 13 O-ring 4 Piston seal 9 Gland 14 Back up ring 5 Wear ring 10 U-packing 133 / 189...
  • Page 134 GROUP2 OPERATIONAL CHECKS TROUBLESHOOTING 1 OPERATIONAL CHECKS 1) CHECK ITEM ① Check visually for deformation, cracks or damage of rod. ② 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).
  • Page 135 2 TROUBLESHOOTING 1) SYSTEM Problem Cause Remedy Large fork •Seal inside control valve defective. •Replace spool or valve body. lowering •Oil leaks from joint or hose. •Replace. speed. •Seal inside cylinder defective. •Replace packing. Large •Tilting backward: Check valve Clean or replace. spontaneou defective.
  • Page 136 2) HYDRAULIC GEAR PUMP Problem Cause Remedy Pump does not •System relief valve set too low •Check system relief valve for develop full or leaking. proper setting. pressure. •Oil viscosity too low. •Change to proper viscosity oil. •Pump is worn out. •Repair or replace pump.
  • Page 137 4) LIFT CYLINDER Problem Cause Remedy Oil leaks out •Foreign matters on packing. •Replace packing. from gland •Unallowable score on rod. •Smooth rod surface with an oil through rod. stone. •Unusual distortion of dust •Replace dust seal. seal. •Chrome plating is striped. •Replace rod.
  • Page 138 GROUP3 DISASSEMBLY AND ASSEMBLY 1 HYDRAULIC GEAR PUMP ※ Tools required •Metric socket set •Internal snap ring pliers •Shaft seal sleeve •Torque wrench 138 / 189...
  • Page 139 1) 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 continuing. 2) Remove port plugs and drain oil from pump. 3) Use a permanent marker pen to mark a line across the mounting flange, gear housing and end cover.
  • Page 140 8) Lift and remove end cover. 9) Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts. 10) Remove rear bearing block from drive and idler shafts. 11) Remove idler shaft from bearing block. 140 / 189...
  • Page 141 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. 13) Remove the front bearing block. 14) Turn mounting flange over, with shaft seal up, and remove the retaining ring with proper snap ring pliers.
  • Page 142 17) Remove seals from both bearing blocks and discard. 2 INSPECT PARTS FOR WEAR 1) 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. 2) Check drive shaft spline for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway.
  • Page 143 5) 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. 6) Inspect the area inside the gear housing. It is normal for the surface inside the gear housing to show a clean "wipe"...
  • Page 144 3 ASSEMBLY ※New seals should be installed upon reassembly of pump. 1) 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 145 7) 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. 8) Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal.
  • Page 146 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 housing are in alignment.
  • Page 147 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 148 4 LIFT CYLINDER 1) STRUCTURE 1 Tube assy 6 Wear ring 11 O-ring 2 Rod assy 7 Retaining ring 12 Guide 3 Piston 8 Gland 13 Du bushing 4 Piston seal 9 Dust wiper 14 Spacer 5 Back up ring 10 Rod seal 15 O-ring 148 / 189...
  • Page 149 2) DISASSEMBLY ① Hold the cylinder tube in a vice, loosen the cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn. Lever up the edge of the guide, then turn the guide in again, and the guide can be removed.
  • Page 150 5 TILT CYLINDER 1) STRUCTURE 1 Tube assembly 9 Bushing 17 Washer 2 Rod 10 U-packing 18 Eye 3 Piston 11 Back up ring 19 Bushing 4 Guide ring 12 Dust wiper 20 Hexagon bolt 5 Wear ring 13 Stop ring 21 Spring washer 6 O-ring 14 O-ring...
  • Page 151 2) 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 152 SECTION7 ELECTRICAL SYSTEM Group 1 Component Location ------------------------------------------------------153 Group 2 Electrical Circuit ------------------------------------------------------154-160 Group 3 Component Specification ------------------------------------------------161 Group 4 Connector Destination ---------------------------------------------- 162-164 Group 5 Troubleshooting ------------------------------------------------------------165 152 / 189...
  • Page 153 GROUP1 COMPONENT LOCATION 1 Flasher lamp 7 Forward-reverse lever 13 OPSS unit 2 Work lamp 8 Operating panel 14 Flasher unit 3 Combination switch 9 Start switch 15 Battery 4 Horn assembly 10 Light switch 16 Beacon lamp 5 Combination lamp 11 Switch board 6 Back buzzer 12 Fuse box...
  • Page 154 GROUP2 ELECTRICAL CIRCUIT 154 / 189...
  • Page 155 MEMORANDUM POWER CIRCUIT The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal. 1) OPERATING FLOW Battery(+) Start motor[CN-45(B+)] Fusible link [CN-95A] Alternator [CN-74(B+)] I/Conn [CN-7(2)] Start switch [CS-2(3)]...
  • Page 156 POWER CIRCUIT 156 / 189...
  • Page 157 STARTING CIRCUIT 1) OPERATING FLOW Fusible link [CN-95A] Battery(+) terminal Start motor[CN-45(B+)] Alternator [CN-74(B+)] I/Conn [CN-7(2)] ※The engine can be started only when the gearshift is in neutral position. ① When start key switch is in ON position Start switch ON [CS-2(4)] Fuse box[No.
  • Page 158 STARTING CIRCUIT 158 / 189...
  • Page 159 CHARGING CIRCUIT When the starter is activated and the engine is started, the operator releases the start switch to the ON position. Charging current generated by operating alternator flows into the battery. The current also flows from alternator to each electrical component through the fusible link (CN-95A) and the fuse box.
  • Page 160 CHARGING CIRCUIT 160 / 189...
  • Page 161 GROUP3 COMPONENT SPECIFICATION Part name Specification Remark Battery CCA: 750A 20HR: 93AH 6-QW-93(300×170×225) Working lamp 9-36V, 12W（3W×4） Combination lamp 12V, 21W(T/S) 12V, 10W(Back) 12V, 5W (Tail) 12V, 5W(Stop) Head lamp 9-36V, 12W（3W×4） Flasher lamp 12V, 21W(T/S), 12V, 4W(Tail) Flasher & Relay 12V, 40A (Relay) 5W + 21W X 2+5W + 21W X 2 12V, 80A (Relay-Power)
  • Page 162 GROUP4 CONNECTOR DESTINATION Connector Type No. of Destination Connector part No. number Female Male CN-1 I/conn (Dashboard harness-frame harness) 368047-1 368050-1 CN-2 I/conn (Dashboard harness-travel harness) MG610331 MG640333 CN-3 I/conn (Dashboard harness-frame harness) MG642292-5 MG652290-5 CN-4 I/conn (Dashboard harness-head guard harness) MG610346 MG640348 CN-5...
  • Page 163 Connector Type No. of Destination Connector part No. number Female Male Lamp CL-3 Head lamp-LH ST730018-3 ST750036-3 CL-4 Head lamp-RH ST730018-3 ST750036-3 CL-7 Beacon lamp ST730018-3 ST750036-3 CL-15 Combination lamp-LH ST730018-3 ST750036-3 CL-16 Flasher lamp-RH ST730018-3 ST750036-3 CL-16 Combination lamp-RH ST730018-3 ST750036-3 CL-17...
  • Page 164 CD-18 E/G Oil Pressure Sensor switch ST730057-2 CD-29 T/M temp switch 171809-2 DO-1 Diode 174352-2 21EA-50550 RS-1 Resistor MG610043 21HA-40110 164 / 189...
  • Page 165 GROUP5 TROUBLESHOOTING Trouble symptom Probable cause Remedy Lamps dimming even •Faulty wiring. •Check for loose maxi- mum engine speed. terminal and disconnected wire. Lamps flicker during engine •Improper belt tension. •Adjust belt tension. operation. Charge lamp does not light •Charge lamp defective. •Replace.
  • Page 166 SECTION8 MAST Group 1 Structure ----------------------------------------------------167-170 Group 2 Operational Checks and Troubleshooting ----------171-173 Group 3 Adjustment -------------------------------------------------174-176 Group 4 Removal and Installation -------------------------------177-189 166 / 189...
  • Page 167 GROUP1 STRUCTURE 1 2 STAGE MAST (V MAST) 1 Outer mast 6 Anchor bolt 10 Trunnion cap 2 Inner mast 7 Chain wheel bearing 11 Bushing 3 Roller 8 Retaining ring 12 Roller 4 Shim (0.5, 1.0t) 9 Tilt cylinder pin 13 Shim (0.5, 1.0t) 5 Chain 167 / 189...
  • Page 168 2 2 STAGE MAST (VF MAST) 1 Outer mast 6 Shim (0.5, 1.0t) 11 Bushing 2 Inner mast 7 Roller 12 Sheave 3 Chain 8 Shim (0.5, 1.0t) 13 Sheave bracket 4 Anchor bolt 9 Tilt cylinder pin 14 Clamp 5 Back up liner 10 Support cap 168 / 189...
  • Page 169 3 3 STAGE MAST (TF MAST) 1 Outer mast 6 Roller 11 Sheave 2 Middle mast 7 Shim (0.5, 1.0t) 12 Tilt cylinder pin 3 Inner mast 8 Back up liner 13 Support cap 4 Chain 9 Shim (0.5, 1.0t) 14 Bushing 5 Anchor bolt 10 Sheave bracket...
  • Page 170 4 CARRIAGE, BACKREST AND FORK 1 Backrest 3 Load roller 5 Fork assembly 2 Carriage 4 Side roller 6 Extension fork 170 / 189...
  • Page 171 1) FORKS ① Measure thickness of root of forks and check that it is more than specified value. EX: ℓ=1050mm(41.3in) mm(in) STD Fork assy Applicable mode Standard Limit 64HN-21030 25DE-7U 45(1.8) 40(1.6) 64HN-31020 30DE-7U 45(1.8) 40(1.6) 64HN-31020 35DE-7U 45(1.8) 40(1.6) ②...
  • Page 172 TROUBLESHOOTING 1) MAST Problem Cause Remedy Forks fail to lower. •Deformed mast or carriage. •Disassemble, repair or replace. Fork fails to •Faulty hydraulic equipment. •See troubleshooting hydraulic elevate pump and cylinders in section 6, hydraulic system. •Deformed mast assembly. •Disassemble mast and replace damaged parts or replace complete mast assembly.
  • Page 173 2) FORKS Problem Cause Remedy Abrasion Long-time operations cause the fork to If the measured value wear and reduces the thickness of the fork. is below the wear Inspection for thickness is needed. limit, replace fork. •Wear limit: Must be 90% of fork thickness Distortion Forks are bent out of shape by a number of If the measured value...
  • Page 174 GROUP3 ADJUSTMENT 1 MAST LOAD ROLLER (V, VF MAST) 1) INNER/OUTERMASTROLLER CLEAR-ANCE ADJUSTMENT ① Measure the clearance with the mast overlap at near 480mm. ② Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the roller side face and mast at the closest position on the opposite side to the following value by inserting the inner/outer mast roller shim.
  • Page 175 2 MAST LOAD ROLLER (TF MAST) 1) INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT ① Measure the clearance with the mast overlap at near 480mm. ② 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...
  • Page 176 3) CARRIAGE LOAD ROLLER ① Measure the clearance when the center of the carriage upper roller is 100mm from the top of the inner mast. ② Measure the clearance at upper, middle and lower rollers after loosen the adjust screws from the side rollers. Shift the carriage to one side to bring the roller into contact with the inner mast, and measure the clearance between the...
  • Page 177 GROUP4 REMOVAL AND INSTALLATION 1 FORKS 1) Lower the fork carriage until the forks are approximately 25mm(1inch) from the floor. 2) Turn knob up and slide forks, one by one, toward the center of the carriage where a notch has been cut in the bottom plate for easy fork removal.
  • Page 178 2) SIDE ROLLER ① Remove carriage as outlined in the carriage assembly and removal paragraph. ② Loosen and remove nuts, adjust screws and side rollers from carriage side pate. ③ Thoroughly clean, inspect and replace all worn or damaged parts. ④...
  • Page 179 4) MAST LOAD ROLLERANDBACK UP LINER ① 2 stage mast (V mast) a) Remove the carriage assembly and move them to one side. b) Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast. c) Loosen and remove hexagon bolts and nuts securing lift cylinders to inner mast.
  • Page 180 ② 2 stage mast (VF mast) a) Remove free lift chain connected between carriage and free lift cylinder. b) Remove the carriage assembly and move them to one side. c) Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast.
  • Page 181 ③ 3 stage mast (TF mast) a) Remove the carriage assembly and move to one side. b) Loosen and remove hexagon bolt securing bottom cylinder from outer mast. c) Loosen and remove bolts and special washers securing lift cylinders to middle mast. d) Attach chains or sling to the inner and middle mast section at top crossmember.
  • Page 182 5) ELEVATING MAST ① Inner mast (V, VF mast) a) 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. b) Lift inner mast upright straight up and out of outer mast section. c) Replace and reverse above procedure to install.
  • Page 183 6) CHAIN ① Chain sheave (V, VF mast) a) Place a sling around carriage and attach to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked. Position wooden blocks under the carriage and lower it.
  • Page 184 ② Rear chain sheave (TF mast) a) Raise and securely block carriage and inner mast section. b) Remove the split pin securing the chain anchor pins and discard. While supporting the chains, remove the chain anchor pins from outer mast section.
  • Page 185 ③ Chain wheel bearing support (TF mast) a) Remove the carriage assembly and move to one side. b) 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 186 Refer to this section for Load chain lubrication and adjustment. ⑥ Load chain inspection and maintenance After every 200 hours of truck operation, lift chains should be inspected and lubricated inspect for the following chain conditions: a) Wear As the chain flexes on and off the chain wheel bearings, the joints very gradually wear.
  • Page 187 f) Protruding or turned pins Heavily loaded chains operating with lube generate tremendous friction between pins and plates. In extreme cases, the frictional torque in the joint can actually turn pins in the press-fit outside plates. If chain is allowed to operate in this condition, the pins slowly work out of the chain causing chain failure.
  • Page 188 stretching etc.), the chains should be replaced in pairs as a complete assembly. Order chains by part number to insure the correct chain length, pitch and material specifications. ⑦ Load chain lubrication and adjustment a) Lubrication The most important consideration in field maintenance of lift chains is lubrication.
  • Page 189 •Prevent over-stretching of chains. •Prevent chains from jumping off sheaves if they are too loose. d) 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.

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