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Hyundai 100D-9V Manual

Hyundai 100D-9V Manual

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Table of Contents

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SECTION 1 GENERAL
Group 1 Safety hints ------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications --------------------------------------------------------------------------------------------------- 1-5
Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-18
Group 1 Structure ----------------------------------------------------------------------------------------------------------- 2-1
Group 2 Removal and installation of unit ---------------------------------------------------------------------- 2-2
Group 3 Maintenance for hose -------------------------------------------------------------------------------------- 2-21
Group 1 Structure and operation ----------------------------------------------------------------------------------- 3-1
Group 2 Operation and maintenance --------------------------------------------------------------------------- 3-31
Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 3-59
Group 1 Structure and function ------------------------------------------------------------------------------------- 4-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------- 4-26
Group 3 Tests and adjustments ------------------------------------------------------------------------------------- 4-28
Group 4 Disassembly and assembly ---------------------------------------------------------------------------- 4-31
Group 1 Structure and function ------------------------------------------------------------------------------------- 5-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------- 5-12
Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 5-14
Group 1 Structure and function ------------------------------------------------------------------------------------- 6-1
Group 2 Operational checks and troubleshooting ------------------------------------------------------- 6-30
Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 6-35
Group 1 Component location ---------------------------------------------------------------------------------------- 7-1
Group 2 Electrical circuit ------------------------------------------------------------------------------------------------ 7-3
Group 3 Cluster -------------------------------------------------------------------------------------------------------------- 7-27
Group 4 Component specification -------------------------------------------------------------------------------- 7-71
Group 5 Connector destination ------------------------------------------------------------------------------------- 7-72
Group 6 Troubleshooting ------------------------------------------------------------------------------------------------ 7-77
CONTENTS
CONTENTS

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Summary of Contents for Hyundai 100D-9V

  • Page 1: Table Of Contents

    CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints ------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications --------------------------------------------------------------------------------------------------- 1-5 Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-18 SECTION 2 REMOVAL AND INSTALLATION OF UNIT SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure ----------------------------------------------------------------------------------------------------------- 2-1 Group 2 Removal and installation of unit ---------------------------------------------------------------------- 2-2 Group 3 Maintenance for hose -------------------------------------------------------------------------------------- 2-21 SECTION 3 POWER TRAIN SYSTEM...
  • Page 2 SECTION 8 MAST SECTION 8 MAST Group 1 Structure ------------------------------------------------------------------------------------------------------------- 8-1 Group 2 Operational checks and troubleshooting --------------------------------------------------------- 8-4 Group 3 Adjustment --------------------------------------------------------------------------------------------------------- 8-7 Group 4 Removal and installation ----------------------------------------------------------------------------------- 8-9...
  • Page 3 SECTION 8 MAST This section explains the structure of mast, carriage, backrest and forks. The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
  • Page 4 Revised edition mark (①②③…) Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.

  • Page 5: Conversion Table

    3. CONVERSION TABLE 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 Example Method of using the Conversion Table to convert from millimeters to inches...
  • Page 6 Millimeters to inches Millimeters to inches 1 mm = 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...
  • Page 7 Liter to U.S. Gallon 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...
  • Page 8 kgf·m to to lbf lbf·ft ft 1 kgf·m = 7.233 lbf·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...
  • Page 9 kgf/cm 1.02 14.504 1280 1300 1340 1420 1600 1710 1740 1770 1840 1890 1920 1960 2030 2100 2130 2180 2280 2320 2350 2390 2420 2470 2500 2540 2570 2610 2680 2710 2760 2830 2850 3000 3050 3150 3190 3400 6000...
  • Page 10 kgf/cm kgf/cm to to lbf/in lbf/in 1 kgf / cm = 14.2233 lbf / 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...
  • Page 11 TEMPERATURE 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 12: Section 1 General

    SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints -- -- -- -- -- -- -- -- -- -- - - - - - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - - 1-1 Group 2 Specifications -- -- -- -- -- -- -- -- -- - - - - - - -- - - -- - - -- - -- - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - 1-5 Group 3 Periodic replacement -- -- - - - - - - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - -- - - -- - - -- - - -- - -- - - -- - - 1-18...

  • Page 13: Group 1 Safety Hints

    GROUP 1 SAFETY HINTS GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. · Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
  • Page 14 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 15 · 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 16 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 17: Group 2 Specifications

    GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENTS 1. MAJOR COMPONENTS 100D9V3CD10 Mast Rear view mirror 15 Beacon lamp (option) Lift chain Rear wheel 16 Camera (option) Lift cylinder 10 Body wing cover 17 Silencer Carriage and backrest 11 Rear combination lamp 18 Rear work lamp Tilt cylinder 12 Preclenaer...

  • Page 18: Specifications

    2. SPECIFICATIONS 2. SPECIFICATIONS 100D9V8SP01 Model Unit 100D-9V Capacity kg (lb) 10000 (22000) Load center mm (in) 600 (24") Weight(Unloaded) kg (lb) 13125 (28936) Lifting height mm (ft · in) 3025 (9' 11") Free lift mm (in) 150 (5.9) Lifting speed (Unload/Load) 500/440 (98.4/86.6)
  • Page 19 3. SPECIFICATION FOR MAJOR COMPONENTS 3. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Unit Specification Model Cummins F3.8 Type Vertical, 4 cycle DI, EU Stage V diesel engine Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, In-line Firing order 1-3-4-2 Combustion chamber type...
  • Page 20 (lbf) 3 spool : 28 (61.7), 4 spool : 36 (79.4), 5 spool : 43 (94.8) 4) 4) STEERING UNIT STEERING UNIT Specification Item Unit 100D-9V Type Load sensing Model VSP 200 LSH Capacity 200 (12.2) cc/rev (in /rev)
  • Page 21 6) 6) POWER TRAIN DEVICE POWER TRAIN DEVICE Specification Item 100D-9V Type 3 Element, 1 stage, 2 phases Torque converter Stall ratio 2.395 : 1 Model ZF 3WG94 Type Full auto, power shift Gear shift (F/R) Transmission Adjustment Electrical single lever type 1 : 4.714...
  • Page 22 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS 4. TIGHTENING TORQUE FOR MAJOR COMPONENTS Item Size kgf·m lbf·ft Engine mounting bolt M12×1.25 12.3±3.0 89±21.7 Engine Engine bracket mounting nut M10×1.5 6.9±1.4 50±10.1 Radiator mounting bolt, nut M10×1.5 6.9±1.4 50±10.1 Hydraulic pump mounting bolt M16×2.0 19±2 138±14.5...

  • Page 23: Torque Chart

    5. TORQUE CHART 5. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread 8.8T 10.9T 12.9T Bolt size kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8...
  • Page 24 2) PIPE AND HOSE (FLARE TYPE) 2) PIPE AND HOSE (FLARE TYPE) Tightening torque Thread Hex. across fl at Hose size (PF) (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 130.2 1" 151.9 1-1/4" 1-1/14 253.2 3) PIPE AND HOSE (ORFS TYPE) 3) PIPE AND HOSE (ORFS TYPE) Tightening torque Thread...
  • Page 25 5) BAND CLAMP 5) BAND CLAMP Tightening torque Hose size Band width Tag No. (mm) (mm) kgf·m lbf·ft S20-15 8 ~ 14 2.17 S20-17 11 ~ 17 S20-22 13 ~ 20 S20-25 15 ~ 24 0.35 2.53 S20-28 19 ~ 28 S20-32 22 ~ 32 S20-40...
  • Page 26 6. WRENCH AND SPANEER CHART 6. WRENCH AND SPANEER CHART Wrench & Spanner Thread PIPE AND HOSE ORFS FLARE inch UNF/UN PF/G (UNF/UN) (PF) 0.050 0.059 1/16 0.063 5/64 0.078 3/32 0.094 0.098 7/64 0.109 0.118 0.125 9/64 0.141 5/32 0.156 0.177 3/16...
  • Page 27 Wrench & Spanner Thread PIPE AND HOSE ORFS FLARE inch UNF/UN PF/G (UNF/UN) (PF) 11/16 0.69 17.5 0.75 9/16-18 G1/4 9/16-18 PF1/4 25/32 0.78 19.8 13/16 0.81 20.6 G3/8 11/16-16 PF3/8 0.88 22.2 29/32 0.91 15/16 0.94 23.8 3/4-16 13/16-16 31/32 0.97 26.4...
  • Page 28 Wrench & Spanner Thread PIPE AND HOSE ORFS FLARE inch UNF/UN PF/G (UNF/UN) (PF) 1 11/16 1.69 1 3/4 1.75 1 13/16 1.81 1 7/8 1.88 47.6 1-11/16-12 1 15/16 1.94 49.2 1-5/8-12 G1-1/4 PF1-1/4 2.00 50.8 2 1/8 2.13 1-7-8-12 G1-1/2 PF1-1/2...

  • Page 29: Recommended Lubricants

    7. RECOMMENDED LUBRICANTS 7. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature˚C (˚F) Capacityℓ Service point Kind of fluid (U.S. gal) (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) ★ SAE 5W-40 SAE 10W SAE 10W-30...

  • Page 30: Group 3 Periodic Replacement

    GROUP 3 PERIODIC REPLACEMENT 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 31: Section 2 Removal And Installation Of Unit

    SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT Group 1 Structure ------------------------------------------------------------------------------------------------------------- 2-1 Group 2 Removal and installation of unit ----------------------------------------------------------------------- 2-2 Group 3 Maintenance for hose --------------------------------------------------------------------------------------- 2-21...

  • Page 32: Group 1 Structure

    GROUP 1 STRUCTURE GROUP 1 STRUCTURE 9 10 11 12 100D9V7PM01 Mast Propeller shaft 17 Radiator Lift cylinder 10 Hydraulic pump 18 Air cleaner Tilt cylinder 11 Transmission 19 Precleaner Steering unit 12 Torque converter 20 Counterweight Main control valve 13 Engine 21 Cabin Fork...

  • Page 33: Group 2 Removal And Installation Of Unit

    GROUP 2 REMOVAL AND INSTALLATION OF UNIT GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST 1. MAST 1) 1) REMOVAL REMOVAL (1) (1) SHAFT TYPE FORKS SHAFT TYPE FORKS Fork retainer ①...
  • Page 34 (2) (2) CARRIAGE CARRIAGE Crane ① With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor.
  • Page 35 ④ Slowly raise inner mast upright until mast clears top of fork carriage. Move carriage Inner mast to work area and lower the mast. Make sure that carriage remains on Make sure that carriage remains on floor and does not bind while mast is floor and does not bind while mast is being raised.

  • Page 36: Lift Cylinder

    LIFT CYLINDER LIFT CYLINDER Hexagon nut ① Loosen and remove hexagon nuts and Set bolt set bolts securing lift cylinders to inner mast. ② Bind the lift cylinder with overhead hoist Inner mast rope and pull up so that the rope has no slack or binding.
  • Page 37 (8) (8) TILT CYLINDER PIN TILT CYLINDER PIN Loosen the bolt and remove the lock plate and tilt cylinder pin. (9) (9) MAST MOUNTING PIN MAST MOUNTING PIN ① Attach a crane to the stay at the top of the outer mast, and raise it. Tilt cylinder ②...

  • Page 38: Installation

    2) 2) INSTALLATION INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. ※ Installation procedure for each of mast component is the reverse of the removal procedure. (1) (1) MAST MOUNTING PIN MAST MOUNTING PIN ①...
  • Page 39 2. POWER TRAIN ASSEMBLY 2. POWER TRAIN ASSEMBLY 1) 1) REMOVAL REMOVAL Wiring harness 70D9V2RI02 Mast Mast Refer to section on mast (Page 2-2)
  • Page 40 (2) (2) Service brake piping Service brake piping Disconnect the brake hydraulic hoses from the drive axle. (3) (3) Parking brake piping Parking brake piping Cutoff valve Disconnect parking brake hydraulic hoses Parking brake hose from the drive axle. Service brake hose Drive axle 100D9VRE20...
  • Page 41 (5) (5) Drive axle Drive axle ※ Before removing the drive axle unit, drain all of the oil from the axle. Transmission ① Attach a crane to the tilt cylinder notches on the dashboard and raise the truck. ② Loosen hexagonal bolts connecting drive axle to drive shaft.
  • Page 42 (6) (6) Inching linkage Inching linkage Remove the inching sensor cable. (7) (7) Transmission cooling piping Transmission cooling piping Disconnect cooling hose and connector Radiator from the transmission. ※ Make sure that the coolant be drained Make sure that the coolant be drained Transmission from the hose.
  • Page 43 2) 2) INSTALLATION INSTALLATION Installation is the reverse order to removal, but be careful of the following points. Tightening torque of the mounting bolts Bolt 4 for the transmission. Bolt 1 ·Bolt 1 : 5.5~8.3 kgf·m (39.8~60.0 lbf·ft) ·Bolt 2 : 5.5~8.3 kgf·m (39.8~60.0 lbf·ft) Bolt 2 Bolt 3 ·Bolt 3 : 5.5~8.3 kgf·m (39.8~60.0 lbf·ft)
  • Page 44 Tightening torque of mounting bolt for the drive axle. ·90~110 kgf·m (651~796 lbf·ft) ※ Apply loctite #277 on the thread before Apply loctite #277 on the thread before Transmission tightening. tightening. Drive axle Bolt Truck 100D9VRE23 Tightening torque of mounting bolt for drive shaft.
  • Page 45 3. ENGINE 3. ENGINE Remove the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL REMOVAL 50D9RE25 (1) (1) Engine hood Engine hood ① Cabin Crane - First, tilt the cabin ※ Refer to the operator's manual page 7-16. Refer to the operator's manual page 7-16.
  • Page 46 Lossen the bolts mounted on the engine flywheel housing. For details, see page 2-11. (3) (3) Engine accessory Engine accessory Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. ① Wiring harness to alternator and starter. ②...

  • Page 47: Radiator Hose

    (4) (4) Radiator hose Radiator hose Open the drain valve of the radiator and drain the cooling water, then remove the radiator hose. Engine Engine Engine Engine 100D9VRE34 (5) (5) Mounting bolt Mounting bolt Attach a crane to the engine hook and raise, then remove mounting bolts and nuts.

  • Page 48: Radiator Hoses

    (4) (4) Radiator hoses Radiator hoses Insert the radiator hoses securely and fit the clamps. Engine Engine Engine Engine 100D9VRE34 (5) (5) Exhaust pipe Exhaust pipe Insert the exhaust pipe to the engine securely and fit a clamp. 100D9VRE33 (6) (6) Air cleaner hose Air cleaner hose Engine...
  • Page 49 (8) (8) Engine accessory Engine accessory Install all wiring harnesses, cables and hoses around the engine, dashboard and frame. ① Wiring harness to alternator and starter. ② Wiring harness for oil pressure and engine water temperature gauges. ③ C a bl e s fo r m e t e r s , bu t t o n s a n d accelerator pedal.
  • Page 50 4. STEERING AXLE 4. STEERING AXLE 1) 1) REMOVAL REMOVAL Hose and pipe D503RE35 Mounting bolt Counterweight 100D9VRE40 (1) (1) Counterweight 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) : 4220 kg (9300 lb) ·Tightening torque : 100±15 kgf·m (723±108 lbf·ft) ※...

  • Page 51: Rear Wheel

    (2) (2) Rear wheel Rear wheel Remove mounting bolt and hub nut with socket wrench and then carefully take out the tire assembly. ·Tightening torque - Hub nut 66.3±5 kgf·m (480±36.2 lbf·ft) - Hub cap bolt 2.5±0.5 kgf·m (18.0±3.6 lbf·ft) ※...

  • Page 52: Maintenance

    GROUP 3 GROUP 3 MAINTENANCE FOR HOSE MAINTENANCE FOR HOSE 1) 1) MAINTENANCE MAINTENANCE The function and service life of hydraulic components depend to a great extent on how clean the hydraulic oil is. Therefore, it is very important to prevent dirt from entering the hydraulic system. Some simple advice to keep the hydraulic system clean: ·Always clean the area around parts before starting work.

  • Page 53: Section 3 Power Train System

    SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation ------------------------------------------------------------------------------------ 3-1 Group 2 Operation and maintenance ---------------------------------------------------------------------------------- 3-31 Group 3 Disassembly and assembly ------------------------------------------------------------------------------ 3-59...

  • Page 54: Group 1 Structure And Operation

    SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION GROUP 1 STRUCTURE AND OPERATION 1. STRUCTURE 1. STRUCTURE Drive axle Steering axle Transmission Engine Torque converter Propeller shaft 100D9V3PT01 The power train consists of the following components : ·Torque converter ·Transmission ·Drive shaft...

  • Page 55: Torque Converter

    2. TORQUE CONVERTER 2. TORQUE CONVERTER D503TM01 Turbine Pump Input shaft Stator Transmission pump The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the characteristics, and with it the favorable efficiency of a fluid clutch. The converter will be defined according to the engine power so that the most favorable operating conditions for each installation case are given.
  • Page 56 If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the turbine moment becomes equal to that of the pump moment. From this point on, the converter is working similar to a fluid clutch. A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the conversion range the moment upon the housing, and is released in the coupling range.
  • Page 57 3. TRANSMISSION 3. TRANSMISSION 1) 1) LAYOUT LAYOUT 50DS7ETM03 Flex plate for direct mount Central shaft/input shaft PTO 12 Transmission housing - rear part Converter Connection, PTO ; coaxial, 13 Transmission housing - front part Converter bell housing engine-dependent 14 Output flange Transmission pump Clutch shaft (KD) 15 Output shaft...

  • Page 58: Installation View

    2) 2) INSTALLATION VIEW INSTALLATION VIEW FRONT VIEW REAR VIEW 50DS7EPT26 Filter Converter Transmission mounting holes Direct mount via flex plate 10 Oil filter tube with oil dipstick Converter bell housing 11 Oil drain plug Transmission housing-front part 12 Output flange Transport bracket 13 Identification plate Transmission housing-rear part...
  • Page 59 3) 3) OPERATION OF TRANSMISSION OPERATION OF TRANSMISSION (1) (1) Gearbox diagram Gearbox diagram The multi-speed reversing transmission in countershaft design is power shiftable by hydraulically actuated multi-disk clutches. All gears are constantly meshing and carried on antifriction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 3-speed reversing transmission is equipped with 5 multi-disk clutches.
  • Page 60 (2) (2) Forward Forward In forward, forward clutch and 1st, 2nd, 3rd clutch are engaged. Forward clutch and 1st, 2nd, 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston. Transmission diagram 1st gear forward AN/KR KR/PTO Legend: AN = Input KV = Clutch forward...
  • Page 61 (3) (3) Reverse Reverse In reserve, reserve clutch and 1st, 2nd, 3rd clutch are engaged. Reverse clutch and 1st, 2nd, 3rd are actuated by the hydraulic pressure applied to the clutch piston. Transmission diagram 1st gear reverse AN/KR KR/PTO Legend: AN = Input KV = Clutch forward KR = Clutch reverse...

  • Page 62: Transmission Control

    4) 4) TRANSMISSION CONTROL TRANSMISSION CONTROL Transmission control see measuring points and oil circuit diagram see page 3-10. The transmission pump which is necessary for the oil supply of the converter and for the transmission control is located within the transmission on the engine-dependent input shaft. The pump feed rate is Q=45ℓ/min, at n =1500 min engine...
  • Page 63 · Hydraulic circuit Hydraulic circuit Gear-shift signal Turbine speed Output speed Engine speed Speed central gear chain Inch enable signal Inch pedal signal 1 Oil sump temperature (OPTION) Inch pedal signal 2 Oil temperature after the converter Converter Display Park brake feedback signal Lubrication Main pressure...
  • Page 64 5) 5) GEAR SELECTOR (DW-3) GEAR SELECTOR (DW-3) The gear selector is designed for the mounting on the steering column left side. By a rotative motion, the positions(speeds) 1 to 3 are selected by tilting the lever, the driving direction (Forward (F) - Neutral (N) - Reverse (R)).
  • Page 65 Gear selector (DW-3) Gear selector (DW-3) LEVER FOR MECHANICAL NEUTRAL INTERLOCK CODING GEAR SELECTOR OUTPUT FORWARD REVERSE NEUTRAL SPEED IN POSITION(NEUTRAL), F-R NOT SWITCHABLE TYPE PLATE CIRCUIT DIAGRAM SELECTOR GEAR POSITIONS A AD3(B3) B AD2(B2) C AD1(B1) C AD7(KD) F = Forward N = Neutral A ED1(+/VP) R = Reverse...
  • Page 66 6) 6) TRANSMISSION ERROR DISPLAY TRANSMISSION ERROR DISPLAY (1) (1) Function Function The display can be used with the gear selector. It indicates speed and driving direction as well as the activated inching. When driving in the automatic mode, a bar indicator gives additionally also information about the selected driving range;...

  • Page 67: Display During Operation

    (2) (2) Display during operation Display during operation Symbol Meaning Remarks Actual gear and direction F, N, R Central side shows actual gear 1, 2, 3 Right side shows actual direction Not neutral, waiting for neutral To engage a gear, first move shift selector to neutral (Central and right side) after power up or a severe fault position and again to F to R position...
  • Page 68 (3) (3) Display during AEB-Mode Display during AEB-Mode Symbol Meaning Remarks AEB-Starter is plugged at the diagnostic plug AEB-Starter-button is pressed KA..KE Calibrating clutch KC..KE, KV or KR KC, KD for 2 gear transmission KV, KR resp. KC, KD, KE for 3 gear transmission Wait for start, initialization of clutch _and Kx Kx, x : C, D, E, V, R...
  • Page 69 (4) (4) Definition of the error codes Definition of the error codes ① Introduction Introduction The error codes consists of two hexadecimal numbers. The first number shows the type of signal, the second number shows signal and the type of the error.
  • Page 70 Number Meaning of error code 3A hex Short circuit to battery voltage or open circuit at output speed input 3B hex Short circuit to ground or open circuit at output speed input 3C hex Logical error at output speed input 71 hex Short circuit to battery voltage at clutch KC 72 hex...
  • Page 71 Number Meaning of error code B1 hex Slippage at clutch KC B2 hex Slippage at clutch KD B3 hex Slippage at clutch KE B5 hex Slippage at clutch KV B6 hex Slippage at clutch KR D1 hex Short circuit to battery voltage at power supply for sensors D2 hex Short circuit to ground at power supply for sensors D3 hex...
  • Page 72 6) 6) ELECTRONIC CONTROL FOR POWER TRANSMISSION ELECTRONIC CONTROL FOR POWER TRANSMISSION (1) (1) Description of the basic functions Description of the basic functions The powershift transmission 3 WG-94 EC of series WG-90 is equipped with the electronic transmission control EST-65 specially developed for this purpose. The system process the driver command according to the following criteria: ·Gear determination depending on driving speed and load condition.
  • Page 73 70D9V3PS83 Inching pedal 11 Temperature measuring point after the Gear selector converter (No. 63) Display 12 Inductive sensor - turbine speed Optical warning 13 Inductive sensor - engine speed Switch for driving program 14 Temperature measuring point for the converter Manual/Automatic (No.
  • Page 74 (2) (2) Inching device Inching device This function is especially suitable for lift trucks. Without modifying the engine speed, it allows a continuously variable reduction of the driving speed to such a level that operation at a very low speed is possible. In this way, the driver can move the vehicle to a certain position with high accuracy.
  • Page 75 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS 4. TRANSMISSION MEASURING POINTS AND CONNECTIONS The measurement have to be carried out with hot transmission (about 80~95°C) 11 21 21 68 57 67 AN/KR KV AN/KR 4661 401 059 4661 301 059 50DS7ETM04 3-22...
  • Page 76 1) 1) MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE Port Description Size 11 + 2 bar Before the converter - opening pressure M10×1 16 + 3 bar Reverse clutch M10×1 16 + 3 bar Forward clutch M10×1 16 + 3 bar...
  • Page 77 6. DRIVE AXLE (KESSLER) 6. DRIVE AXLE (KESSLER) 1) 1) STRUCTURE (1/6) STRUCTURE (1/6) 100D9V3DA01 400 Differential & carrier assy 412 Bearing bushing 425 Hexagon screw 401 Drive pinion 413 Hexagon socket screw 427 Screw plug 402 Ring gear 414 Hexagon screw 428 Sealing ring 403 Differential housing 415 Tapered roller bearing...
  • Page 78 2) 2) STRUCTURE (2/6) STRUCTURE (2/6) 100D9V3DA02 150 Brake assy 261 Housing 273 Sealing ring 250 Friction disc 262 O-ring 278 Bleeding socket 251 Steel disc 263 O-ring 280 Bleeder valve 252 Clutch piston 266 Hexagon socket screw 281 Pipe 258 Gasket 269 Hex sockets crew 282 Hexagon screw with flange...
  • Page 79 3) 3) STRUCTURE (3/6) STRUCTURE (3/6) 100D9V3DA03 300 Planetary housing 318 Sleeve 333 Locking pin 304 O-ring 319 Screw 335 Ring gear 305 Screw plug 320 Thrust ring 336 Ring gear carrier 306 Sealing ring 322 Planetary gear 337 Retainer 309 Thrust washer 324 Thrust washer 338 Hexagon socket screw...
  • Page 80 4) 4) STRUCTURE (4/6) STRUCTURE (4/6) 100D9V3DA04 Axle housing 40 Axle shaft 50 Radial seal ring Breather 42 Wheel hub 53 Taper roller bearing Plug 43 Wheel stud 54 Taper roller bearing Seal 47 Disk 55 Spacer ring Screw plug 48 Hex nut 59 Nut Seal...
  • Page 81 5) 5) STRUCTURE (5/6) STRUCTURE (5/6) (615) (615) 110D9DR05 605 Lining set 612 Cap 623 Magetic 606 Bleeder valve 615 Pressure bolt 624 Tolerance ring 608 Circlip 616 Hex screw 625 O-ring 609 Dished plate spring 617 Castle nut 626 O-ring 610 Hex nut 618 Split pin 629 Socket screw...

  • Page 82: Operation

    6) 6) STRUCTURE (6/6) STRUCTURE (6/6) 110D9DR06 600 Parking brake 602 O-ring 604 Hex screw 601 Brake carrier 603 Disc plate 628 Hex screw 7) 7) OPERATION OPERATION Both sides of the housing are supported by the frame and the center is mounted on the transmission case through propeller shaft.

  • Page 83: Tire And Wheel

    6. TIRE AND WHEEL 6. TIRE AND WHEEL B507AX68 Wheel rim Lock ring Valve assembly Tire Side ring Wheel nut The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with the ground to gain the power which drives the machine. Various types of tires are available to suit the purpose.

  • Page 84: Group 2 Operation And Maintenance

    GROUP 2 OPERATION AND MAINTENANCE GROUP 2 OPERATION AND MAINTENANCE 1. OPERATION 1. OPERATION 1) 1) DRIVING PREPARATION AND MAINTENANCE DRIVING PREPARATION AND MAINTENANCE Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity.

  • Page 85: Cold Start

    - Upshifting in overrunning condition. - Upshifting in overrunning condition. In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if the speed of the vehicle on a downgrade should not be further increased. - Downshifting in overrunning condition. - Downshifting in overrunning condition.
  • Page 86 Now, the temperature must drop quickly(in about 2~3 minutes) to normal values. If this is not the case, there is a trouble pending, which must be eliminated prior to continue working. The monitoring of the oil temperature(behind the converter) is additionally on the temperature gauge which is located on the dashboard.
  • Page 87 2. MAINTENANCE 2. MAINTENANCE 1) 1) TRANSMISSION TRANSMISSION (1) (1) Oil level check Oil level check At the oil level check, the vehicle has to be secured against rolling with blocks. At the oil level check, the vehicle has to be secured against rolling with blocks. The oil level check must be carried out as follows : - Oil level check (weekly) - At horizontally standing vehicle...

  • Page 88: Filter Replacement

    (2) (2) Oil change and filter replacement intervals Oil change and filter replacement intervals ※ First oil change after 100 operating hours in service. First oil change after 100 operating hours in service. Every further oil change after 1000 operating hours in service, however at least once a year. Every further oil change after 1000 operating hours in service, however at least once a year.
  • Page 89 50DS7EPT19 Legend: Legend: 1 = Oil filler tube with oil dipstick 2 = Mounting provision for oil filler tube with oil dipstick (option) 3 = Oil drag plug 7/8" 14 UNF 2B 4 = Fine filter Oil dipstick MEASURED AT LOW COLD IDLING-NEUTRAL D507PT20...

  • Page 90: Drive Axle

    2) 2) DRIVE AXLE DRIVE AXLE (1) (1) Important remarks Important remarks ① For safety reasons, the operator should verify and service at regular intervals all of the bolted assemblies and all of the important safety locks such as : Wheel nuts Nuts of axle mounting bolts Bolts on the steering components and the brake system parts : if the screws are tightable, the...
  • Page 91 (3) (3) Drain oil Drain oil ※ Differential and carrier assembly, axle housing and hub assembly have a total oil space. Differential and carrier assembly, axle housing and hub assembly have a total oil space. Oil drain has to take place at the complete axle. Oil drain has to take place at the complete axle.

  • Page 92: Hub Assembly

    (4) (4) Oil fi lling and fi lling level Oil fi lling and fi lling level ※ Differential and carrier assembly, axle housing and hub assembly have a total oil space. Differential and carrier assembly, axle housing and hub assembly have a total oil space. All oil drain plugs have to be closed before filling with oil.

  • Page 93: Troubleshooting

    3. TROUBLESHOOTING 3. TROUBLESHOOTING 1) 1) TRANSMISSION TRANSMISSION (1) (1) GENERAL INSPECTION WHILE DRIVING GENERAL INSPECTION WHILE DRIVING Problem Problem Cause Cause Failure at the specific gear 1. Low oil pressure or no pressure. stage 1) No oil, low level or high oil viscosity. 2) Loose inching control valve connection, incorrect adjustment or damage.
  • Page 94 Problem Problem Cause Cause Slow clutch meshing or failure 1. Low oil pressure. 2. Low converter oil pressure. 3. Air mixed with oil 1) Air mixed through the pump input port. 2) Low oil level 4. Abnormal adjustment of inching valve linkage. Reverse gear shift failure 1.
  • Page 95 (2) (2) ABNORMAL NOISE CHECK LIST ABNORMAL NOISE CHECK LIST Problem Problem Cause Cause Noise only at neutral 1. Gear or bearing wear inside the pump. 2. Torque converter stator wear. 3. Low oil level. 4. Gear parts of engine and T/M pump's misalignment with that of converter housing and pump.
  • Page 96 (3) (3) PRESSURE TEST CHECK LIST PRESSURE TEST CHECK LIST Problem Problem Cause Cause FR/RR clutch low pressure Incorrect adjustment of inching valve linkage Inching spool sticked and open. Clutch and piston oil leakage. Regulator spring defect. Low oil pressure. Incorrect connection of cooler external line.
  • Page 97 Transmission fault codes Transmission fault codes Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Logical error at gear range signal Logical error at gear range signal TCU shifts transmission to Check the cables from TCU to shift T C U d e t e c t e d a w r o n g s i g n a l...
  • Page 98 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage or O.C. at S.C. to battery voltage or O.C. at No reaction, TCU uses Check the cable from TCU to the default temperature sensor...
  • Page 99 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Logical error at engine speed input Logical error at engine speed input OP mode : Substitute clutch Check the cable from TCU to the control sensor TCU measures a engine speed over a...
  • Page 100 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Logical error at internal speed input Logical error at internal speed input OP mode : Substitute clutch Check the cable from TCU to the control sensor TCU measures a internal speed over a...
  • Page 101 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Vehicle1 timeout Vehicle1 timeout TCU shifts to neutral Check vehicle controller · NN(because of shifting Check wire of CAN-Bus Time of CAN-message Vehicle1 from ·...
  • Page 102 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to ground at clutch KD S.C. to ground at clutch KD TCU shifts to neutral Check the cable from TCU to the OP mode : Limp home gearbox The measured resistance value of the...
  • Page 103 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage at clutch KV S.C. to battery voltage at clutch KV TCU shifts to neutral Check the cable from TCU to the OP mode : Limp home gearbox...
  • Page 104 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · O.C. at clutch KR O.C. at clutch KR TCU shifts to neutral Check the cable from TCU to the OP mode : Limp home gearbox The measured resistance value of the...
  • Page 105 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Slippage at clutch KV Slippage at clutch KV TCU shifts to neutral Check pressure at clutch KV · OP mode : Limp home Check main pressure in the system TCU calculates a differential speed at...
  • Page 106 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Overtemp converter output Overtemp converter output No reaction Cool down machine · OP mode : Normal Check oil level TCU measured a oil temperature at the ·...
  • Page 107 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage at display S.C. to battery voltage at display No reaction Check the cable from TCU to the OP mode : Normal display output...
  • Page 108 (5) (5) Measuring of resistance at actuator/sensor and cable Measuring of resistance at actuator/sensor and cable ① Actuator Actuator 76043PT19 = ∞ Open circuit Short cut to ground = R; R = 0, R = R or R = R, R (For S.C.

  • Page 109: Oil Leakage

    DRIVE AXLE DRIVE AXLE (1) (1) Noise and vibration Noise and vibration Locating fault and cause Locating fault and cause Measures Measures Shortage of oil Check oil level or refi ll lubricating oil. Inappropriate oil Replace the oil. Drive Damaged wheel bearing Replace the wheel bearing.
  • Page 110 Service brake Service brake ① Brake overheats. Brake overheats. Locating fault and cause Locating fault and cause Measures Measures Install brake cooling system if not already installed on truck. Overheating due to Inadequate coolant flow or heat excessive duty cycle exchange Re-analyze and re-size brake cooling system if necessary.
  • Page 111 ③ Brake does not release. Brake does not release. Locating fault and cause Locating fault and cause Measures Measures Truck does not move. Damaged hydraulic system Repair hydraulic system. Repair hydraulic system so pressure is less More than 0.14 MPa pressure than 0.14 MPa when brakes released and while applied when brakes released.

  • Page 112: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION DISASSEMBLY 1. TRANSMISSION DISASSEMBLY DISASSEMBLY DISASSEMBLY Transmission 3 WG-94 EC 50DS7ETM11 ① Attach transmission to the assembly truck by means of clamping angles (1) and holding fixtures (2). (S) Assembly truck 5870 350 000 (S) Holding fixtures...
  • Page 113 ③ Separate the fine filter (1) from the filter head by means of belt wrench. (S) Belt wrench 5870 105 005 50DS7ETM15 ④ Loosen the cylindrical screws (2) and separate the filter head (1) from the transmission housing. 50DS7ETM16 ⑤ Remove both O-rings (1) out of the annular groove of the filter head.
  • Page 114 2) 2) DISASSEMBLY PRESSURE CONTROLLER DISASSEMBLY PRESSURE CONTROLLER (PROPORTIONAL VALVES), INDUCTIVE (PROPORTIONAL VALVES), INDUCTIVE SENSOR, SPEED SENSOR (HALL SENSOR, SPEED SENSOR (HALL SENSOR), TEMPERATURE SENSOR, SENSOR), TEMPERATURE SENSOR, BREATHER AND SCREW PLUGS BREATHER AND SCREW PLUGS ① Remove all screw plugs with O-ring (1 and 2).

  • Page 115: Remove O-Rings

    ④ Loosen cylindrical screw (1) and remove speed sensor (2). 2 = Speed sensor-n output (Hall sensor) ※ Remove O-rings. 50DS7ETM21 ⑤ Remove breather (1). 50DS7ETM22 3-62...
  • Page 116 3) 3) DISASSEMBLY CONVERTER AND DISASSEMBLY CONVERTER AND CENTRAL SHAFT (PTO SHAFT) CENTRAL SHAFT (PTO SHAFT) ① Loosen cylindrical screws (1) and separate the flexplate (2) from the converter (3). 50DS7ETM23 ② Pull off converter (1) by hand. 50DS7ETM24 ③ Disengage the retaining ring (see arrow).
  • Page 117 ⑤ Pull the toothed disk (1) from the central shaft. 50DS7ETM27 ⑥ Press the ball bearing (1) from the central shaft (2). 50DS7ETM28 3-64...
  • Page 118 4) 4) DISASSEMBLY OF OUTPUT FLANGE DISASSEMBLY OF OUTPUT FLANGE ① Loosen the hexagon screws (1) and remove disk and O-ring (2 and 3). 50DS7ETM29 ② Pull output flange (1) off the output shaft by means of two-armed puller. 50DS7ETM30 ③...
  • Page 119 5) 5) DISASSEMBLY OF MAIN PRESSURE DISASSEMBLY OF MAIN PRESSURE VALVE AND CONVERTER SAFETY VALVE VALVE AND CONVERTER SAFETY VALVE ① Loosen screw plug (1) and remove main pressure valve (control pressure valve): Main pressure valve consists of: 1 = Screw plug with O-ring 2 = Piston 3 = Spacer rings 4 = Compression spring...
  • Page 120 6) 6) R E M O VA L O F C L U T C H E S A N D R E M O VA L O F C L U T C H E S A N D DISASSEMBLY OF OIL PRESSURE PUMP DISASSEMBLY OF OIL PRESSURE PUMP ①...
  • Page 121 ⑤ Use assembly lever to remove all bearing outer rings from the housing front part. ※ If, contrary to the ZF recommendation, the tapered roller bearings of clutches and output are not replaced, it is imperative to ensure the previous pairing (bearing outer ring/bearing inner ring).
  • Page 122 ⑩ Loosen bolted connection between converter bellhousing/transmission housing (1) and pressure oil pump/ transmission housing (2). 50DS7ETM42 ⑪ Press converter bellhousing off the housing equally by means of hexagon screws M10 (1). ※ Difficult disassembly due to fixing by cylindrical pins. 50DS7ETM43 ⑫...
  • Page 123 ⑭ Remove filter (1). 50DS7ETM46 ⑮ Remove O-ring (1). Loosen cylindrical screws (2). 50DS7ETM47 ※ Check oil pressure pump : In case of wear marks in the pump housing, stator hollow shaft or on the i n n e r a n d o u t e r r o t o r , t h e complete oil pressure pump is to be replaced.
  • Page 124 7) 7) DISASSEMBLY CLUTCHES : DISASSEMBLY CLUTCHES : 1 = Clutch KV(Clutch-forward) 2 = Clutch KR(Clutch-reverse and input) 3 = Clutch KD(Clutch-2nd gear) 4 = Clutch KE(Clutch-3rd gear) 5 = Clutch KC(Clutch-1st gear) 6 = Output 50DS7ETM50 (1) (1) Clutch KR/input Clutch KR/input ①...
  • Page 125 ④ Remove needle cage (1). 50DS7ETM54 ⑤ Remove axial bearing assy (1). 50DS7ETM55 ⑥ Disengage snap ring (1). 50DS7ETM56 ⑦ Remove end plate (1), disk package (2) and plate with cup springs (3) from the disk carrier. 50DS7ETM57 3-72...
  • Page 126 ⑧ Remove retaining ring-contact position of axial bearing (1). 50DS7ETM58 ⑨ Preload compression spr ing and disengage retaining ring (1). (S) Assembly aid 5870 345 114 50DS7ETM59 ⑩ Remove cup spring (1) and compression spring (2). 50DS7ETM60 ⑪ By means of compressed air (see arrow), press piston (1) off the shaft/disk carrier (see arrow) and remove it.
  • Page 127 ⑫ Remove both O-rings (1 and 2). 50DS7ETM62 ⑬ Disengage rectangular rings (1). 50DS7ETM63 ⑭ Pull tapered roller bearing (inner ring) off the shaft. (S) Grab sleeve 5873 001 026 (S) Basic tool 5873 001 000 50DS7ETM64 ※ The clutch (1) cannot be disassembled. It is supplied by the spare par ts service only as a complete assy which consists of :...
  • Page 128 (2) (2) Clutch KV Clutch KV ① Snap out rectangular ring (1). 50DS7ETM66 ② Pull off bearing inner ring with inner disk carrier (1). 50DS7ETM67 ③ Remove bearing inner ring (1), axial bearing assy (2) and inner disk carrier (3). 50DS7ETM68 ④...
  • Page 129 ⑤ Remove axial bearing assy (1). 50DS7ETM70 ⑥ Remove snap ring (1). 50DS7ETM71 ⑦ Remove end plate (1), disk package (2) and plate (3) from the disk carrier. 50DS7ETM72 ⑧ Remove retaining ring-contact position of axial bearing (1). 50DS7ETM73 3-76...
  • Page 130 ⑨ Preload compression spring and remove retaining ring (1). (S) Assembly aid 5870 345 114 50DS7ETM74 ⑩ Remove cup spring (1) and compression spring (2). 50DS7ETM75 ⑪ By means of compressed air (see arrow), press piston (1) off the shaft/disk carrier and remove it.
  • Page 131 ⑬ Snap out rectangular ring (1). 50DS7ETM78 ⑭ Pull tapered roller bearing (inner ring) off the shaft. (S) Grab sleeve 5873 000 029 (S) Basic tool 5873 000 000 50DS7ETM79 ※ The clutch (1) cannot be disassembled. It is supplied by the spare par ts service only as a complete assy which consists of : 1A = Retaining ring...
  • Page 132 Clutch KD Clutch KD ① Snap out rectangular ring (1). 50DS7ETM81 ② Pull tapered roller bearing (inner ring) off the shaft. (S) Grab sleeve 5873 000 029 (S) Basic tool 5873 000 000 50DS7ETM82 ③ Remove axial bearing assy (1) and inner disk carrier.
  • Page 133 ⑤ Remove axial bearing assy (1). 50DS7ETM85 ⑥ Remove snap ring (1). 50DS7ETM86 ⑦ Remove end plate (1), disk package (2) and cup spring (3) from the disk carrier. 50DS7ETM87 ⑧ Remove retaining ring-contact position of axial bearing (1). 50DS7ETM88 3-80...
  • Page 134 ⑨ Preload compression spring and remove snap ring (1). (S) Assembly aid 5870 345 114 50DS7ETM89 ⑩ Remove spring cup (1) and compression spring (2). 50DS7ETM90 ⑪ By means of compressed air (see arrow), press piston (1) off the shaft/disk carrier and remove it.
  • Page 135 ⑬ Snap out rectangular ring (1). 50DS7ETM93 ⑭ Pull tapered roller bearing (inner ring) off the shaft. (S) Rapid grip 5873 011 011 (S) Extractor set 5870 026 100 50DS7ETM94 ※ The clutch (1) cannot be disassembled. It is supplied by the spare par ts service only as a complete assy which consists of : 1A = Retaining ring...
  • Page 136 Clutch KE Clutch KE ① Snap out rectangular ring (1). 50DS7ETM96 ② Pull tapered roller bearing (inner ring) off the shaft. (S) Grab sleeve 5873 000 029 (S) Basic tool 5873 001 000 50DS7ETM97 ③ Remove retaining ring (1). 50DS7ETM98 ④...
  • Page 137 ⑤ Remove tapered roller bearing (1) and inner disk carrier (2). 50DS7ETM100 ⑥ Pull off bearing inner ring (1) and running disk (2). 50DS7ETM101 ⑦ Remove bearing inner ring (1) and running disk (2). 50DS7ETM102 ⑧ Disengage snap ring (1). 50DS7ETM103 3-84...
  • Page 138 ⑨ Remove end plate (1), disk package (2) and cup spring (3) from the disk carrier. 50DS7ETM104 ⑩ Preload compression spring and remove snap ring (1). (S) Assembly aid 5870 345 114 50DS7ETM105 ⑪ Remove spring cup (1) and compression spring (2).
  • Page 139 ⑬ Remove both O-rings (1 and 2). 50DS7ETM62 ⑭ Snap out rectangular ring (1). 50DS7ETM109 ⑮ Pull tapered roller bearing (inner ring) off the shaft. (S) Rapid grip 5873 011 011 (S) Basic tool 5873 001 000 50DS7ETM110 ※ The clutch (1) cannot be disassembled. It is supplied by the spare par ts service only as a complete assy which consists of :...
  • Page 140 (5) (5) Clutch KC Clutch KC ① Snap out rectangular ring (1). 50DS7ETM112 ② Pull off bearing inner ring with inner disk carrier (1). 50DS7ETM113 ③ Remove bearing inner ring (1), axial bearing assy (2) and inner disk carrier (3). 50DS7ETM114 ④...
  • Page 141 ⑤ Remove axial disk (1) and axial needle cage (2). 50DS7ETM116 ⑥ Disengage snap ring (1). 50DS7ETM117 ⑦ Remove end plate (1) and disk package (2) from the disk carrier. 50DS7ETM118 ⑧ Preload compression springs and remove snap ring (1). (S) Assembly aid 5870 506 128 50DS7ETM119...
  • Page 142 ⑨ Remove disk (1) and cup springs (2). 50DS7ETM120 ⑩ By means of compressed air (see arrow), press piston (1) off the shaft/disk carrier and remove it. Remove both O-rings. 50DS7ETM121 ⑪ Snap out rectangular ring (1). 50DS7ETM122 ⑫ Pull tapered roller bearing (inner ring) off the shaft.
  • Page 143 ※ The clutch (1) cannot be disassembled. It is supplied by the spare par ts service only as a complete assy which consists of: 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM124 3-90...

  • Page 144: Output Shaft

    (6) (6) Output shaft Output shaft ① Pull the bearing inner ring off the output shaft. (S) Grab sleeve 5873 000 029 (S) Basic tool 5873 000 001 50DS7ETM125 ② Rotate output shaft 180°and pull off bearing inner ring. (S) Grab sleeve 5873 002 035 (S) Rapid grip 5873 012 011...

  • Page 145: Transmission Assembly

    2. TRANSMISSION ASSEMBLY 2. TRANSMISSION ASSEMBLY REASSEMBLY OF CLUTCHES : REASSEMBLY OF CLUTCHES : Clutch KR/input Clutch KR/input ※ The clutch (1) is supplied by the spare parts service only as a complete assy which consists of: 1A = Ball 1B = Helical gear 1C = Disk carrier 50DS7ETM65...
  • Page 146 ④ Insert piston (1) into the disk carrier. ※ Pay a t t e n t i o n t o t h e i n s t a l l a t i o n position, see Figure. 50DS7ETM131 ⑤...
  • Page 147 ⑧ Mount plate assy with cup springs (1), with the open side showing towards the piston (see arrow). ※ Installation position plate-see below figure. 50DS7ETM135 ⑨ Fit plate (1) according to sketch (see arrow). 1 = Plate with cup springs 2 = Compression spring with spring cup and retaining ring 3 = Piston with O-rings...
  • Page 148 ⑫ Equally press on end plate with F (approx. 100N = 10kg) and set dial indicator to "zero". 50DS7ETM139 ⑬ Then press end plate against the snap ring (upwards) and read the disk clearance. ※ Disk clearance : 2.2 to 2.6 mm ※...
  • Page 149 Mount needle cage 40×45×17 (1) and oil it. 50DS7ETM143 Mount inner disk carrier until contact is obtained. Install inner disks by short ccw/cw rotations of the inner disk carrier (1). 50DS7ETM144 Mount axial washer 40×60×1 (1), axial needle cage 40×60×3 (2) and running disk (3) 40×60×3.5 and oil them.
  • Page 150 Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring 30×2 (2). Wear protective gloves. ※ A d j u s t b e a r i n g i n n e r r i n g a f t e r cooling-down.
  • Page 151 (2) (2) Clutch KV Clutch KV The clutch (1) is supplied by the spare parts service only as a complete assy which consists of : 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM149 ①...
  • Page 152 ④ Insert piston (1) into the disk carrier. ※ Pay a t t e n t i o n t o t h e i n s t a l l a t i o n position, see figure. 50DS7ETM76 ⑤...
  • Page 153 ⑧ Mount plate assy with cup springs (1), with the open side showing towards the piston (see arrow). ※ Installation position plate-see below figure. 50DS7ETM157 ⑨ Fit plate (1) according to sketch (see arrow). 1 = Plate with cup springs 2 = Compression spring with cup spring and retaining ring 3 = Piston with O-rings...
  • Page 154 ⑫ Equally press on end plate with F (approx. 100N = 10kg) and set dial indicator to "zero". 50DS7ETM161 ⑬ Then press end plate against the snap ring (upwards) and read the disk clearance. ※ Disk clearance : 2.2 to 2.6 mm ※...
  • Page 155 Mount needle cage 40×45×17 (1) and oil it. 50DS7ETM69 Mount inner disk carrier until contact is obtained. Install inner disks by short ccw/cw rotations of the inner disk carrier (1). 50DS7ETM166 Mount axial washer 40×60×1 (1), axial needle cage 40×60×3 (2) and running disk (3) 40×60×3.5 and oil them.
  • Page 156 Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring 30×2 (2). Wear protective gloves. ※ Adjust bearing inner ring after cooling-down. 50DS7ETM169 ※ Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.
  • Page 157 (3) (3) Clutch KD ※ The clutch (1) is supplied by the spare parts service only as a complete assy which consists of : 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM95 ①...
  • Page 158 ④ Insert both O-rings (1 and 2) into the piston grooves and oil them. 1 = 40×3 2 = 104.5×3 50DS7ETM62 ⑤ Insert piston (1) into the disk carrier. ※ Pay attention to the installation position, see figure. 50DS7ETM91 ⑥ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid.
  • Page 159 ⑧ By means of the assembly aid, preload compression spring under a hand- operated press until the retaining ring 40×1.75 (1) can be snapped in. (S) Assembly aid 5870 345 114 50DS7ETM89 ⑨ Cup spring (1) into the disk carrier. ※...
  • Page 160 ⑫ Cap spring (1) according to sketch (see arrow). 1 = Cup spring 2 = Compression spring with spring cup and retaining ring 3 = Inner clutch- and outer clutch disc 4 = End shim 5 = Piston with O-rings 6 = Clutch assy.
  • Page 161 Mount running disk 40×60×3.5 (1), axial needle cage 40×60×3 (2) and axial washer 40×60×1 (3) and oil them. ※ Fit running disk (1), with the chamfer showing towards the retaining ring. 50DS7ETM181 Mount needle cage 40×45×17 (1) and oil it. 50DS7ETM84 Mount inner disk carrier until contact is obtained.
  • Page 162 Heat up bearing inner ring (approx. 120°C). 50DS7ETM128 Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring 30×2 (2). Wear protective gloves. ※ A d j u s t b e a r i n g i n n e r r i n g a f t e r cooling-down.
  • Page 163 (4) (4) Clutch KE ※ The clutch (1) is supplied by the spare parts service only as a complete assy which consists of : 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM111 ①...
  • Page 164 ④ Insert both O-rings (1 and 2) into the piston grooves and oil them. 1 = 40×3 2 = 104.5×3 50DS7ETM62 50DS7ETM107 ⑤ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. (S) Assembly aid 5870 345 114 50DS7ETM188...
  • Page 165 ⑦ By means of the assembly aid, preload compression spring under a hand- operated press until the retaining ring 40×1.75 (1) can be snapped in. (S) Assembly aid 5870 345 114 50DS7ETM105 ⑧ Cup spring (1) into the disk carrier. ※...
  • Page 166 ⑪ Cap spring (1) according to sketch(see arrow). 1 = Cup spring 2 = Compression spring with spring cup and retaining ring 3 = Inner clutch-and outer clutch disc 4 = End shim 5 = Piston with O-rings 6 = Clutch assy 50DS7ETM192 ⑫...
  • Page 167 ⑮ Press in both bearing outer rings into the inner disk carrier (1) until contact is obtained. Then mount the bearing inner rings. 50DS7ETM196 ※ Setting of axial play of the inner disk carrier bearing±0.05 mm (see TM197 to TM202) : Determine dimension "X2"...
  • Page 168 Determine dimension "X1" from retaining ring (1) to running disk (2). → see below figure. Dimension X1 = 42.1 mm 50DS7ETM200 Legend : 1 = Retaining ring 35×2.0 2 = Running disk 35×52×3.5 3 = Compression spring with cup spring and retaining ring 4 = Disk package with end plate and snap ring...
  • Page 169 Mount bearing inner ring (1) until contact is obtained. ※ Different bearing sizes → see page 3-124 TM198. Wear protective gloves. ※ A d j u s t b e a r i n g i n n e r r i n g a f t e r cooling-down.
  • Page 170 Heat up bearing inner ring (approx. 120°C). 50DS7ETM128 Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring 30×2 (2). Wear protective gloves. ※ Adjust bearing inner ring after cooling-down. 50DS7ETM206 ※ Check closing and opening of the clutch by means of compressed air at the hole (see arrow).
  • Page 171 (5) (5) Clutch KC Clutch KC ※ The clutch (1) cannot be disassembled. It is supplied by the spare parts service only as a complete assy which consists of : 1A = Retaining ring 1B = Helical gear 1C = Disk carrier 1D = Shaft 50DS7ETM124 ①...
  • Page 172 ④ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. (S) Assembly aid 5870 345 114 50DS7ETM210 ⑤ Mount cup spring package (1) and disk (2). ※ Installation position of the cup springs, see below figure.
  • Page 173 ⑧ Install outer and inner disks alternately into the disk carrier (3) as shown in figure. Starting with an outer disk and ending with an inner disk. 1 = Outer disks (10 pcs) 2 = Inner disks (10 pcs) 3 = Clutch assy 50DS7ETM212 ⑨...
  • Page 174 ⑫ Mount axial needle cage 35×52×2 (1) and axial disk 35×52×1 (1) and oil them. 50DS7ETM116 ⑬ Mount needle cage 35×42×18 (1) and bush (2) and oil it. 50DS7ETM115 ⑭ Mount inner disk carrier until contact is obtained. Install inner disks by short ccw/cw rotations of the inner disk carrier (1).
  • Page 175 Heat up bearing inner ring (approx. 120°C). 50DS7ETM128 Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring 30×2 (2). Wear protective gloves. ※ Adjust bearing inner ring after cooling-down. 50DS7ETM218 ※ Check closing and opening of the clutch by means of compressed air at the hole (see arrow).
  • Page 176 (6) (6) Output Output ① Heat up bearing inner ring (approx. 120°C). 50DS7ETM128 ② Mount bearing inner ring (1) until contact is obtained. Wear protective gloves. ※ Adjust bearing inner ring after cooling- down. 50DS7ETM220 ③ Heat up bearing inner ring (approx. 120°C).
  • Page 177 REASSEMBLY OF OIL PRESSURE REASSEMBLY OF OIL PRESSURE P U M P A N D R E I N S TA L L AT I O N O F P U M P A N D R E I N S TA L L AT I O N O F CLUTCHES CLUTCHES (1) (1)
  • Page 178 ③ Fit stator hollow shaft (1). 50DS7ETM224 ④ Fix stator hollow shaft radially with two cylindrical screws (1). ※ Do not tighten the cylindrical screws - just tur n them in until contact is obtained and then turn them back by approx.
  • Page 179 ⑦ Fit two adjusting screws (S) and position converter bellhousing (1) equally until contact is obtained. ※ Pay attention to the hole pattern. (S) Adjusting screws (M10) 5870 204 007 50DS7ETM228 ⑧ Force the cylindrical pins 12×24 (1) into the holes (blind holes) until contact is obtained.
  • Page 180 ⑪ Position transmission pump with 3 cylindrical screws (1) M8×60 (3×120° offset position) equally until contact is obtained. ※ Do not damage (shear off) the O-ring. 50DS7ETM232 ⑫ Fix transmission pump with cylindrical screws M8×60 (1). Tightening torque (M8/8.8×60) ---------------- -------------------------------------------------- M = 23 Nm 50DS7ETM233...
  • Page 181 ⑭ Fix suction tube (1) with cylindrical screws M8×16 (2). Tightening torque M8/8.8×16 ---- M = 23 Nm ※ When reusing the cylindrical screws, they must be secured with Loctite no. 243. ※ New cylindrical screws are already provided with adhesive (microcapsule). The microcapsule bursts when the 50DS7ETM236 screw is turned in, wets screw and nut...
  • Page 182 ② Align and grease rectangular ring 30×2 (1). Position clutch KD (2). 50DS7ETM240 ③ Align and grease rectangular rings 50×2.5 (1). Position clutch KR- input (2). 50DS7ETM241 ④ Align and grease rectangular ring 30×2 (1). Position clutch KV (2). 50DS7ETM242 ⑤...
  • Page 183 ⑥ Align and grease rectangular ring 30×2 (1). Position clutch KE (2). 50DS7ETM244 ⑦ Align and grease rectangular rings (1). 50DS7ETM245 ⑧ Use the lifting device to carefully bring the transmission housing rear part into contact position. ※ Bolts (1) of screen sheet must be fixed into the pilot holes.
  • Page 184 ⑨ Hand-tighten the transmission housings crosswise with 2 cylindrical screws (1). Fit cylindrical pins 12×24 (2) centrically to the mounting face. Tighten the transmission housing front and rear part crosswise with 4 cylindrical screws M10 (1). Tightening torque ------------- M = 46 Nm 50DS7ETM247 Transmission rear part is not fixed to...
  • Page 185 REASSEMBLY OF OUTPUT FLANGE REASSEMBLY OF OUTPUT FLANGE ① Use driver tool to fit the shaft seal 70×100 ×10 (1) until contact position, with the sealing lip showing towards the oil sump. (S) Driver tool 5870 048 057 ※ Fill space between sealing lip and dust lip with grease.
  • Page 186 4) 4) R E A S S E M B LY O F C O N V E R T E R R E A S S E M B LY O F C O N V E R T E R SAFETY VALVE AND MAIN PRESSURE SAFETY VALVE AND MAIN PRESSURE VALVE...
  • Page 187 5) 5) REASSEMBLY OF CENTRAL SHAFT REASSEMBLY OF CENTRAL SHAFT (PTO) AND CONVERTER (PTO) AND CONVERTER ① Press tapered bearing (1) onto the central shaft (2) until contact is obtained. 50DS7ETM254 ② Press the toothed disk (1) onto the pump shaft until contact is obtained.
  • Page 188 ⑤ Mount converter (1) until contact is obtained. 50DS7ETM24 ⑥ Position 1 washer/each/thickness= 1.0mm (4EA) (1) onto the flexplate mounting webs (4EA). Place flexplates (2). ※ Pay a t t e n t i o n t o t h e i n s t a l l a t i o n position.
  • Page 189 6) 6) R E A S S E M B LY O F P R E S S U R E R E A S S E M B LY O F P R E S S U R E C O N T R O L L E R ( P R O P O R T I O N A L C O N T R O L L E R ( P R O P O R T I O N A L VALVES), INDUCTIVE SENSOR, SPEED...
  • Page 190 ④ Fix pressure controller-proportional valves-(1) with the cylindrical screws M6×12 (2). Tightening torque (M6/8.8×12) ----- M = 9.5 Nm 50DS7ETM263 ⑤ Mount all screw plugs (1 and 2) with O-rings. 1 = Screw plug M10x1 with O-ring 8×1.5 (24EA) Tightening torque (M10×1) --------- M = 6 Nm 2 = Screw plug 9/16-18 UNF with O-ring 11.9×2 (7EA)
  • Page 191 7) 7) REASSEMBLY OF FILTER, CLOSING REASSEMBLY OF FILTER, CLOSING COMPONENTS, OIL FILLER TUBE COMPONENTS, OIL FILLER TUBE WITH OIL DIPSTICK AND OIL DRAIN WITH OIL DIPSTICK AND OIL DRAIN PLUG PLUG ① Place O-rings 34.2×3 (1) into the holes and grease them.
  • Page 192 ③ Install O-ring 30×3 (1) onto the oil suction tube (2), grease it and fix it with cylindrical screws M8×16 (3) to the transmission housing. Mount oil dipstick (4). Tightening torque (M8/8.8×16) ----- M = 23 Nm 50DS7ETM268 ④ Fit oil drain plug 7/8-14 UN 2A (1). Tightening torque (7/8-14 UN 2A) --- M = 30 Nm Fix identification plate (2) by means of...
  • Page 193 Loctite. (16) The bolted or keyed assemblies safeties are to be checked according to instructions ; in case of doubt, consult Hyundai dealer. (17) Refill the oil after assembly. (18) Repair weldment is only allowed after consultation with Hyundai. 3-140...
  • Page 194 2) 2) USING OF LOCTITE AND OPERATING SUPPLIES USING OF LOCTITE AND OPERATING SUPPLIES Kind Type Color Application Loctite Blue Lightly locked screws Middle locked screws Green Highly locked screws Green Increased coefficient of friction in contact surfaces Orange Surface gasket White Special gasket Light-green...

  • Page 195: Tightening Torque

    4) 4) TIGHTENING TORQUE TIGHTENING TORQUE Unit : N·m (1) (1) Standard metric threads Standard metric threads Metric standard thread Screw Screw Screw Thread 10.9 12.9 1050 1220 1100 1550 1800 1450 2100 2450 (2) (2) Metric fine threads Metric fine threads Unit : N·m Metric fine thread Screw...
  • Page 196 (3) (3) Tightening torques of wheel nuts Tightening torques of wheel nuts Dimensions Phosphor blackened M20×1.5 470 Nm M22×1.5 650 Nm 3-143...
  • Page 197 5) 5) DISASSEMBLY OF DRIVE AXLE DISASSEMBLY OF DRIVE AXLE (1) (1) Disassembly of planetary gear Disassembly of planetary gear ① Drain the oil. See "Oil change" on page 3-37. ② Loosen and remove mounting bolts. ③ Carefully pull off planetary pot/lid. 100D9V3DA20 (2) (2) Disassembly of sun gear and axle shaft...
  • Page 198 (4) (4) Checking/Retightening the wheel Checking/Retightening the wheel bearing adjustment nut bearing adjustment nut ① Put the customer service tool on the wheel bearing adjustment nut and tighten to the specified tightening torque. Customer service tool : Wrench for wheel bearing adjustment nut (see above) Tightening torque for used bearings : 300 Nm...
  • Page 199 (7) (7) Planetary gear Planetary gear ① Insert O-ring into groove of the planetary housing. Sealing of the contact surface between planetary housing and wheel hub Multi-purpose grease prevents the O-ring from falling out during assembly. ② Align planetary housing so that it aligns with the corresponding boreholes in the wheel hub.

  • Page 200: Section 4 Brake System

    SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and Function ------------------------------------------------------------------------------------ 4-1 Group 2 Operational Checks and Troubleshooting ------------------------------------------------------ 4-26 Group 3 Tests and Adjustments ------------------------------------------------------------------------------------- 4-28 Group 4 Disassembly and reassembly ------------------------------------------------------------------------- 4-31...

  • Page 201: Group 1 Structure And Function

    SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE ※ The brakes are operated by a pressure compensated, closed center hydraulic system. Flow is supplied by a fixed displacement, gear type brake pump. 1) 1) SERVICE BRAKE SYSTEM SERVICE BRAKE SYSTEM...
  • Page 202 3) 3) FULL POWER HYDRAULIC BRAKE FULL POWER HYDRAULIC BRAKE SYSTEM SYSTEM Response time Response time ADVANTAGES - The full power hydraulic Full power brake actuation VS Full power brake actuation VS brake system has several advantages over Air/Hydraulic brake actuation Air/Hydraulic brake actuation traditional brake actuation systems.

  • Page 203: Hydraulic Circuit

    2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT Front axle Brake Brake switch Brake valve Charging pressure Brake sensor 120~125bar (1740~1810psi) Parking Parking sensor 90~110bar (1305~1595psi) Parking 25~45bar (363~653psi) (EPPR solenoid valve-opt) Cut-off valve Strainer 6bar (87psi) Hyd oil Strainer tank 100D9V4BS10...
  • Page 204 SERVICE BRAKE RELEASED SERVICE BRAKE RELEASED Front axle Brake Brake switch Brake valve Charging pressure Brake sensor 120~125bar (1740~1810psi) Parking Parking sensor 90~110bar (1305~1595psi) Parking 25~45bar (363~653psi) (EPPR solenoid valve-opt) Cut-off valve Strainer 6bar High pressure (87psi) Low pressure Hyd oil Strainer tank 100D9V4BS11...
  • Page 205 SERVICE BRAKE OPERATED SERVICE BRAKE OPERATED Front axle Brake Brake switch Brake valve Charging pressure Brake sensor 120~125bar (1740~1810psi) Parking Parking sensor 90~110bar (1305~1595psi) Parking 25~45bar (363~653psi) (EPPR solenoid valve-opt) Cut-off valve Strainer 6bar High pressure (87psi) Low pressure Hyd oil Strainer tank 100D9V4BS12...
  • Page 206 PARKING BRAKE RELEASED PARKING BRAKE RELEASED Front axle Parking brake switch Brake Brake switch Brake valve Charging pressure Brake sensor 120~125bar (1740~1810psi) Parking Parking sensor 90~110bar (1305~1595psi) Parking 25~45bar (363~653psi) (EPPR solenoid valve-opt) Cut-off valve Strainer 6bar High pressure (87psi) Hyd oil Strainer tank...
  • Page 207 PARKING BRAKE OPERATED PARKING BRAKE OPERATED Front axle Parking brake switch Brake Brake switch Brake valve Charging pressure Brake sensor 120~125bar (1740~1810psi) Parking Parking sensor 90~110bar (1305~1595psi) Parking 25~45bar (363~653psi) (EPPR solenoid valve-opt) Cut-off valve Strainer 6bar High pressure (87psi) Low pressure Hyd oil Strainer...
  • Page 208 5) 5) DO AEB WORK DO AEB WORK Please refer to page 7-91. ※...
  • Page 209 3. INCHING PEDAL AND LINKAGE 3. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the front axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force.

  • Page 210: Operation

    4. PARKING BRAKE SYSTEM 4. PARKING BRAKE SYSTEM (KESSLER) 1) 1) STRUCTURE STRUCTURE 100D7BS111 Housing Adjust screw Lining pad Pressure ring Bank of cup springs Lining pad Thrust bolt Piston Gliding bolt 2) 2) OPERATION OPERATION The two identical brake pads and slide freely on the guide bolt, which is fastened in the housing. The guide bolts are guided in an additional brake anchor plate which in turn is screwed onto the vehicle, i.e.
  • Page 211 3) 3) MOUNTING AND BASIC SETTING REGULATIONS MOUNTING AND BASIC SETTING REGULATIONS Basic brake setting is required after mounting new brake lining plates or brake disks, as well as during all repair stages and in the event of insufficient braking performance. 100D7BS112 Thrust bolt Screw cap...
  • Page 212 Turn the adjusting screw anticlockwise in order to set the following rated clearances. Model Adjusting screw Clearance (mm) Turns Min. FSG 90 Clearance Max. 100D-9V Min. FSG 110 Clearance M20 (SW 10) Max. 1 1/5 Hold the adjusting screw in position with a hexagonal socket wrench and lock with lock nut. ③...
  • Page 213 4) 4) EMERGENCY RELEASE OF THE PARKING BRAKE EMERGENCY RELEASE OF THE PARKING BRAKE After the failure of the pressure release the parking brake by using following manual procedure. 100D7BS117 Thrust bolt Screw cap Even surface Bank of cup springs Lock nut Socket wrench Adjusting screw...

  • Page 214: Maintenance And Repair Work

    5) 5) MAINTENANCE AND REPAIR WORK MAINTENANCE AND REPAIR WORK (1) (1) Maintenance and exchange of brake pads Maintenance and exchange of brake pads The brake pads themselves are maintenance free. All that is required here is a check for damaged parts, as well as inspection to ensure that the brake disk remains easy running.
  • Page 215 100D7BS114 Guide bolt Castellated nut Lining pad 6a Safety splint Lining pad 6b Safety clip Permanent magnet Depending on the free space available, release one of the two guide bolts, removing the safety ⑥ splint, unscrewing the castellated nut and pulling the guide bolt out of the brake anchor plate. Now, the brake lining pads can be removed tangentially to the brake disk.
  • Page 216 (2) (2) Changing the seal Changing the seal DETAIL A DETAIL B 100D7BS115 Piston Circlip Bank of cup spring Adjusting screw Seal Detail of the seal Lock nut Guide bolt Detail of the seal Housing Thrust bolt ※ Faulty seals must be exchanged in accordance with the instructions below. Stand the vehicle on an even surface and secure against rolling away.
  • Page 217 General General Any discovered defects or damage to parts not listed here must naturally be repaired or replaced using original parts. For any other information not contained in these instructions or for more detailed instructions, please contact Hyundai dealer. 4-17...
  • Page 218 5. BRAKE VALVE 5. BRAKE VALVE 1) 1) STRUCTURE STRUCTURE BL BR Hydraulic circuit Port Port name Port size P Main pressure port PF 3/8 T Drain port PF 3/8 BR Brake cylinder port PF 3/8 BL Pressure switch port PF 1/4 160D9VBS07 Valve body...

  • Page 219: Installation Requirements

    (1) (1) Purpose Purpose The purpose of the brake valve is to sensitively increase and decrease the braking pressure when the brake pedal is actuated. (2) (2) Ready position Ready position A connection is established between ports (BR) and ports (T) so that the wheel brakes ports (BR) are pressureless via the returns ports (T).
  • Page 220 6. CUT-OFF VALVE 6. CUT-OFF VALVE STRUCTURE STRUCTURE 130bar (1885psi) 95~110bar (1377~1595psi) Parking 35~45bar (507~652psi) Hydraulic circuit Block Solenoid valve Solenoid valve Coil Check valve Check valve Cutoff valve Relief valve Plug 100D9V4CV01 4-20...
  • Page 221 2) 2) TIGHTENING TORQUE TIGHTENING TORQUE Item Name Hex size Tightening torque Solenoid valve 27 mm 45 Nm Solenoid valve 27 mm 45 Nm Check valve 22 mm 40 Nm Check valve 22 mm 40 Nm Cutoff valve 27 mm 50 Nm Relief valve 27 mm...
  • Page 222 7. BRAKE ACCUMULATOR 7. BRAKE ACCUMULATOR 1) 1) STRUCTURE STRUCTURE Item Brake (2 EA) RCV (1 EA) Ø9 Diameter (d) 122 mm 90 mm Mounting height (a) 145 mm 120 mm Nominal volume 0.75ℓ 0.35ℓ Priming pressure 50 bar 15 bar Operating medium Operating pressure Max.
  • Page 223 (5) (5) Disposal of the accumulator Disposal of the accumulator Before the accumulator is scrapped, its gas filling pressure must be reduced. For this purpose, drill a hole through gas chamber (B) using a drill approx. 3 mm in diameter. The gas chamber is located on the side opposite the threaded port above the welding seam around the center of the accumulator.

  • Page 224: Pressure Switch

    8. PRESSURE SENSOR AND SWITCH 8. PRESSURE SENSOR AND SWITCH 1) 1) PRESSURE SENSOR PRESSURE SENSOR Structure Ref. label ·Tightening torque : 2.5 ~ 3.0 kgf·m (18 ~ 21.7 lbf·ft) Pin map Function + Supply Deutsch - Supply DT04-3P Output 70D9V4BS10 Thread Measuring range...
  • Page 225 2) 2) OPERATION OPERATION (1) (1) Purpose Purpose The pressure switches are used to visually or audibly warn the driver of the pressure within the system. Make contact / circuit closer Make contact / circuit closer (2) (2) The pressure switch can be fitted in the braking system or directly on one of its components. The system pressure acts on an absorption area within the switch, making an electrical contact as the pressure on that area is increased.

  • Page 226: Group 2 Operational Checks And Troubleshooting

    GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS 1) 1) BRAKE PIPING 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.

  • Page 227: Troubleshooting

    2. TROUBLESHOOTING 2. TROUBLESHOOTING Problem Problem Cause Cause Remedy 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.

  • Page 228: Group 3 Tests And Adjustments

    GROUP 3 TESTS AND ADJUSTMENTS GROUP 3 TESTS AND ADJUSTMENTS 1. AIR BLEEDING OF BRAKE SYSTEM 1. AIR BLEEDING OF BRAKE SYSTEM Air bleeding should be performed by two persons : One rides on truck for depressing and Air vent plug releasing brake pedal : the other person is on the ground and removes cap from air Vinyl tube...

  • Page 229: Brake Pedal

    2. ADJUSTMENT OF 2. ADJUSTMENT OF PEDALS PEDALS Inching pedal Brake pedal 70D9V10TA01 Brake stopper bolt Inching stopper bolt Inching sensor Brake storke limit bolt Brake&inching pedal interlock bolt 1) 1) Brake pedal Brake pedal · Adjust the brake stopper bolt (1) so that Brake pedal pedal height is "H".
  • Page 230 3. EMERGENCY RELEASE OF THE PARKING BRAKE 3. EMERGENCY RELEASE OF THE PARKING BRAKE After the failure of the pressure release the parking brake by using following manual procedure. 100D7BS117 Thrust bolt Screw cap Even surface Bank of cup springs Lock nut Socket wrench Adjusting screw...

  • Page 231: Group 4 Disassembly And Assembly

    GROUP 4 DISASSEMBLY AND ASSEMBLY GROUP 4 DISASSEMBLY AND ASSEMBLY 1. BRAKE VALVE 1. BRAKE VALVE 1) 1) STRUCTURE STRUCTURE BL BR Hydraulic circuit Port Port name Port size P Main pressure port PF 3/8 T Drain port PF 3/8 BR Brake cylinder port PF 3/8 BL Pressure switch port...
  • Page 232 2) 2) REASSEMBLY REASSEMBLY 9 23 24 (1) (1) Body assembly Body assembly Body Spool Plug Holder Spring Main spring 1 Spring retainer 1 Oil seal 110D7EBS50 DU bushing Rubber cover Plain washer Snap ring Spring retainer 2 Main spring 2 Install oil seal (9), plain washer (23), ①...
  • Page 233 Tighten plug (3) ③ - Tool : 19 mm spanner - Tightening torque : 14.0~16.5 kgf·m Press-in the DU bushing (11) with a ※ exclusive jig. Be careful of dust and scrap after ※ washing the parts. 110D7EBS53 Spring retainer (7, 27), main spring (6, ④...

  • Page 234: Section 5 Steering System

    SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM Group 1 Structure and Function -------------------------------------------------------------------------------------- 5-1 Group 2 Operational Checks and Troubleshooting -------------------------------------------------------- 5-12 Group 3 Disassembly and Assembly ------------------------------------------------------------------------------ 5-14...

  • Page 235: Group 1 Structure And Function

    SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE MCV (LS1) MCV (S) Steering wheel Return pipe Steering unit Steering cylinder 100D9VSS01 The steering system for this truck is composed of main pump, steering wheel assembly, steering unit, priority valve (built in MCV), steering cylinders, steering axle and piping.
  • Page 236 2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT Steering unit Main control valve 160~ 165bar Priority valve RCV and Pressure Cutoff valve sensor (opt) LS(X) OUTLET #2 OUTLET #1 #1: PISTON TYPE #2: GEAR TYPE INLET Main pump Strainer Hydraulic oil tank 100D9V5SS10 The hydraulic oil discharged from the pump flows to the priority valve built in the main control valve.
  • Page 237 1) 1) NEUTRAL NEUTRAL Steering unit Main control valve 160~ 165bar Priority valve High pressure RCV and Pressure Low pressure Cutoff valve sensor (opt) LS(X) OUTLET #2 OUTLET #1 #1: PISTON TYPE #2: GEAR TYPE INLET Main pump Strainer Hydraulic oil tank 100D9V5SS11 When the engine is running and the steering wheel is not being turned, the steering unit spool and...
  • Page 238 2) 2) LEFT OR RIGHT TURN LEFT OR RIGHT TURN Steering unit Main control valve 160~ 165bar Priority valve High pressure RCV and Pressure Cutoff valve sensor (opt) Low pressure RH turn LS(X) OUTLET #2 OUTLET #1 160~ 165bar #1: PISTON TYPE #2: GEAR TYPE INLET Main pump...
  • Page 239 3. STEERING UNIT 3. STEERING UNIT 1) 1) STRUCTURE STRUCTURE 70D9V5SS06 Dust seal ring 13 Cardan shaft 24 Model / Code label Housing and spool/sleeve 16 Distributor plate 30 Adjusting screw Ball 17 Gearwheel set 31 Spring Shaft seal 18 O-ring 32 Piston Bearing assembly 19 End over...

  • Page 240: Operation

    2) 2) OPERATION OPERATION Housing Pump return (tank) Left Right Pump in Wear plate Spacer Drive link Spool Shaft seal Bearing Sleeve Check valve End-cover Springs Rotorset (stator /rotor) 35D9VB5SS76 The steering unit is a closed center circuit and consists of a rotary valve (spool + sleeve set) and a metering gear set.
  • Page 241 3) 3) MANUAL STEERING (EMERGENCY) MANUAL STEERING (EMERGENCY) Pump return Left Right Pump in (tank) Drive Spool Gerotor Centering assembly springs Manual steering check valve Shaft seal Check Sleeve valve Pump pressure Metered flow Exhaust Intake Intake or Exhaust Inactive or Trapped 35D9VBSS77 When the engine is not running and the steering wheel is being turned, the priority divider valve spool is pushed against the end stop by spring force.
  • Page 242 4) 4) RELIEF VALVE PRESSURE TEST AND ADJUSTMENT RELIEF VALVE PRESSURE TEST AND ADJUSTMENT Test specification (1) (1) ·Enine speed : low idle rpm ·Oil temperature : 50 ± 5 ℃ (122 ± 9 ℉) ·Steering relief set pressure : 135 ~ 140 bar (1958 ~ 2031 psi) Pressure test and adjustment Pressure test and adjustment ①...
  • Page 243 4. PRIORITY VAVLVE 4. PRIORITY VAVLVE 1) 1) STRUCTURE STRUCTURE Priority valve (built in MCV) Hydraulic circuit 70D9V5SS07 2) 2) OPERATION OPERATION The oil from the hydraulic pump flows to the priority valve. The priority valve supplies a flow of oil to the steering system and lift, tilt system. The steering flow is controlled by the steering unit to operate the steering cylinder.
  • Page 244 5. STEERING AXLE 5. STEERING AXLE 1) 1) STRUCTURE STRUCTURE ※ Do not remove the stopper bolt unless necessary. Frame Wheel and tire 100D9VSA01 Steering axle 15 Shim 28 Boot 42 Grease nipple Axle knuckle 16 Retainer ring 29 Steering link 43 Hose clamp Taper roller bearing 17 Axle hub...
  • Page 245 2) 2) TIGHTENING TORQUE AND SPECIFICATION TIGHTENING TORQUE AND SPECIFICATION Stroke 149mm Hub nut 63.2±5 kgf.m (480±36.2 lbf.ft) 49.2 ~ 66.6 kgf.m (356 ~ 482 lbf.ft) 100D9VSA02 Type Unit Center pin support single shaft Structure of knuckle Elliott type Toe-in degree Camber degree...

  • Page 246: Group 2 Operational Checks And Troubleshooting

    If minimum turning radius is not within±100 mm (±4 in)of specified value, adjust turning angle stopper bolt. Min turning radius (Outside) 100D-9V 3965 (13' 0") Hydraulic pressure of power Remove plug from the LS port of the steering unit and install oil pressure gauge.
  • Page 247 Problem Problem Cause Cause Remedy Remedy ·The high and low pressure hoses are ·Inspect and correct. The oil pressure does connected reversely. not rise. ·The relief valve is faulty or not closed. ·Inspect and correct. ·The oil pump function is degraded or ·Inspect and correct or replace.

  • Page 248: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT 1. STEERING UNIT 1) 1) STRUCTURE STRUCTURE Tightening torque Item kgf·m lbf·ft 22, 23 3.1±0.6 22.3±4.3 0.1±0.01 0.074±0.07 2.6±0.5 18.8±3.6 70D9V5SS06 Dust seal ring 13 Cardan shaft 24 Model / Code label Housing and spool/sleeve 16 Distributor plate...
  • Page 249 TOOLS TOOLS Holding tool for the entire steering unit. Material: Appropriate metal or hard plastic. 35D9VB5SS68 Assembly tool for dust seal. Material: Free cutting steel. 35D9VB5SS69 Assembly tool for shaft seal, O-ring/Roto Glyd type: Code number: 11092408. 35D9VB5SS70 Torque wrench ·13 mm socket spanner ·2 mm, 7/64 inch (2.75 mm) allen key ·Torx Bit size T50...
  • Page 250 3) 3) TIGHTENING TORQUE TIGHTENING TORQUE L : Left port R : Right port T : Tank port P : Pump port LS : Load sensing port 25BX5SS90 Tightening torque Port Port size kgf·m lbf·ft L, P, R, T 3/4-16 UNF 43.4 7/16-20 UNF 14.5...
  • Page 251 4) 4) DISASSEMBLY DISASSEMBLY Screw out the plug (42) for relief valve using an 8 mm allen key. Sealing washer is crimped on the plug. 25BX5SS21 Screw out the adjusting screw (30) using a 6 mm allen key. 25BX5SS22 Remove the spring for relief valve (31). 25BX5SS23 Remove the piston for relief valve (32).
  • Page 252 Replace the unit in the holding tool on steering column end. Remove the screws (22 and 23) with washers (20) using a 13 mm ring spanner or top wrench. 35D9VB5SS09 Remove the end cover (19), sideways. 35D9VB5SS10 Lift the gearwheel set (17) off the unit. Remove the two o-rings (18).
  • Page 253 Remove the distributor plate (16). 35D9VB5SS13 (10) Screw out the ball stop (35) using a 2 mm allen key. 35D9VB5SS14 (11) Remove the o-ring (18) from housing. 35D9VB5SS15 (12) Remove the check valve (37) using a torx bit size T50. 35D9VB5SS16 5-19 5-19...
  • Page 254 Shake out the check valve ball (3), suction valve pins (34), balls (33 and 36). 35D9VB5SS17 (14) Place the housing with the ports facing down on the work bench. Ensure that the cross pin (11) in the spool and sleeve set (2) is in the horizontal position.
  • Page 255 (16) Press out the cross pin (11). 35D9VB5SS21 (17) Remove the ring (10). 35D9VB5SS22 (18) Carefully press the spool out of the sleeve. 35D9VB5SS23 (19) Press the neutral position springs (12) out of the slot of the spool. 35D9VB5SS24 5-21 5-21...
  • Page 256 (20) Remove dust seal (1) and shaft seal (Roto Glyd) (5) carefully with a screw driver or similar tool. 35D9VB5SS25 (21) The steering unit is now completely dismantled. ※ Clean all parts carefully in shellsol K or Clean all parts carefully in shellsol K or similar cleaner fluid.
  • Page 257 5) 5) ASSEMBLY ASSEMBLY Place the two flat neutral position springs in the slot. Place the curved springs between the flat ones and press them into place. 35D9VB5SS27 Configuration of spring set (12). There can be different numbers of curved springs depending on configuration of spring set.
  • Page 258 Line up the spring set (12). 35D9VB5SS31 Guide the ring (10) down over the sleeve. The ring should be able to move free of the springs. 35D9VB5SS32 Fit the cross pin (11) into the spool/sleeve. 35D9VB5SS33 Fit bearing races and needle bearing (7) as shown on the drawing below.
  • Page 259 Assembly pattern for standard bearing 1 Outer bearing race → 2 Needlebearing → 3 Inner bearing race → 4 Spool → 5 Sleeve. The inside chamfer on the inner bearing race must face the chest of the inner spool. 35D9VB5SS35 (11) Place the steering unit housing with the port face down on the work bench.
  • Page 260 (14) Press and turn the shaft seal (5) into position in the housing. 35D9VB5SS39 (15) 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. 35D9VB5SS40 (16) With a light turning movement, guide the...
  • Page 261 (18) Place the steering unit housing on the holding tool on the steering column end. Put the check valve ball (3) into the hole indicated by the circle. 35D9VB5SS43 (19) Place the ball for LS check valve (36) into the hole indicated by the circle. 35D9VB5SS44 (20) Screw the ball stop (35) into the LS check...
  • Page 262 (22) Place the pins (34) in the same two bolt holes. 35D9VB5SS47 (23) Insert the O-ring (18) in the grove on the housing. 35D9VB5SS48 (24) Place the distributor plate (16) so that the channel holes match the thread holes in the housing.
  • Page 263 (26) Place the 2 o-rings (18) in the two groves in the gear rim. Fit the gearwheel and rim (17) on the cardan shaft (13). Place the gear wheel side with all the deeper splines facing downwards. Only this side will fit on the cardan shaft due to all gear sets used in steering unit have timing securing: splines of gear wheel and cardan shaft can only be assembled with...
  • Page 264 (30) Screw in the check valve (37) into the P-port using a Torx Bit size T50. ·Tightening torque : 2.6±0.5 kgf·m (18.8±3.6 lbf·ft) 35D9VB5SS55 (31) Replace the unit in the holding tool on gear set end. Install the piston (32) to housing.
  • Page 265 (34) Screw in the plug (42) using a 8 mm allen key. ·Tightening torque : 6.6±0.5 kgf·m (47.7±3.6 lbf·ft) 25BX5SS39 (35) Place the dust seal ring (1) in the housing. 35D9VB5SS59 (36) Fit the dust seal ring in the housing using special tool for dust seal assembly and a plastic hammer.
  • Page 266 2. STEERING CYLINDER 2. STEERING CYLINDER STRUCTURE STRUCTURE 1) 1) ※ Specifications ·Cylinder bore : 85 mm (3.3 in) ·Outer diameter : 100 mm (3.9 in) ·Stroke(half) : 149.5 mm (5.9 in) ·Rod diameter : 55 mm (2.2 in) 35FQ-09001 1 Tube assy Back up ring 13 Lock washer...
  • Page 267 2) 2) DISASSEMBLY DISASSEMBLY ※ Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in & vice. Remove the cover by hook a wrench in the notch of cylinder head and turn counter-clockwise. Remove the cylinder rod and piston from the tube.
  • Page 268 Install the dust wiper (8) to the gland (4) using a special installing tool. Coat the dust wiper with grease slightly before installing. Using a special tool, install gland assembly into the cylinder tube (1). Special tool D507SE29 Using a hook spanner, install the gland (4) ass- Hook spanner embly, and tighten it with torque 60±6 kgf·m (434±43 lbf·ft).
  • Page 269 4. STEERING AXLE 4. STEERING AXLE 1) 1) STRUCTURE STRUCTURE ※ Do not remove the stopper bolt unless necessary. Frame Wheel and tire 100D9VSA01 Steering axle 15 Shim 28 Boot 42 Grease nipple Axle knuckle 16 Retainer ring 29 Steering link 43 Hose clamp Taper roller bearing 17 Axle hub...
  • Page 270 2) 2) CHECK AND INSPECTION CHECK AND INSPECTION , A2 50D9SE25 unit : mm (in) Criteria Check item Remedy Standard size Repair limit A1 OD of shaft 60 (2.4) 59.5 (2.3) Shaft A2 ID of bushing 60 (2.4) 59.5 (2.3) OD of king pin 50 (2.0) 49.8 (2.0)
  • Page 271 3) 3) DISASSEMBLY DISASSEMBLY ※ Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the balance weight part of the truck. Loosen the hub nut (56) and take off the steering wheel tire.
  • Page 272 4) 4) ASSEMBLY 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. Tighten the set bolt (38) of king pin (6). There is a notch in the middle of the king pin (6), make sure that this notch is on the set screw side.

  • Page 273: Section 6 Hydraulic System

    SECTION 6 HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function --------------------------------------------------------------------------------------- 6-1 Group 2 Operational checks and troubleshooting --------------------------------------------------------- 6-30 Group 3 Disassembly and assembly ------------------------------------------------------------------------------ 6-35...

  • Page 274: Group 1 Structure And Function

    SECTION 6 HYDRAULIC SYSTEM SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC SYSTEM OUTLINE 1. HYDRAULIC SYSTEM OUTLINE The hydraulic system consists of a variable displacement pump, a control valve (MCV), lift cylinders and tilt cylinders.
  • Page 275 MANUAL (UP) MAST HAND LEVER RETURN MAIN LIFT CYLINDER 32MPa VELOCITY 12V : 70D-9VB, 70/80D-9V (4640psi) FUSE 24V : 100D-9V OUTLET VALVE #1: PISTON TYPE #2: GEAR TYPE TS-MAST (FMBWO) SUCTION HYD. HAND PUMP INLET PUMP-PISTON LS (w/TANK) (w/ GEAR TYPE)
  • Page 276 MANUAL (UP) MAST HAND LEVER RETURN MAIN LIFT CYLINDER 32MPa VELOCITY 12V : 70D-9VB, 70/80D-9V (4640psi) FUSE 24V : 100D-9V OUTLET VALVE #1: PISTON TYPE #2: GEAR TYPE TS-MAST SUCTION (FMBWO) HYD. HAND PUMP INLET PUMP-PISTON LS (w/TANK) (w/ GEAR TYPE)
  • Page 277 3. WORK EQUIPMENT HYDRAULIC CIRCUIT 3. WORK EQUIPMENT HYDRAULIC CIRCUIT ※ The operating explain is based on the remote control lever type. 1) 1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION Tilt cylinder Lift...
  • Page 278 2) 2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION Tilt cylinder Lift cylinder VELOCITY ACCUMULATOR FUSE V/V (OPTIONAL) Cutoff valve Steering unit WEIGHT SENSOR (EH01) A5.1 CD-70 AUX3 (PUSH) B5.1...
  • Page 279 3) 3) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION Tilt cylinder Lift cylinder VELOCITY ACCUMULATOR FUSE V/V (OPTIONAL) Cutoff valve Steering unit WEIGHT SENSOR (EH01) A5.1 CD-70 AUX3 (PUSH) (PULL)
  • Page 280 4) 4) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION Tilt cylinder Lift cylinder VELOCITY ACCUMULATOR FUSE V/V (OPTIONAL) Cutoff valve Steering unit WEIGHT SENSOR (EH01) A5.1 CD-70 AUX3 (PUSH) (PULL)
  • Page 281 4. MAIN PUMP 4. MAIN PUMP 1) 1) STRUCTURE STRUCTURE 70D9V6HS06 Flow compensator Pressure port (out) B Pressure port (Outlet) Pressure compensator Suction port (in) S 10 Stud bolt and nut DEC valve Drain port D1 (not used) 11 24V coil Load sense (LS) port X Drain port D3 12 Label...
  • Page 282 2) 2) OPERATION OPERATION (1) (1) General General 1 Drive shaft 2 Sleeve (retaining ball) 3 Slider 4 Piston 5 Regualting piston 6 Pressure compensator (adusting screw, max. Pressure) 7 Flow compensator (adjusting screw, stand-by pressure) 4 10 70D9V6HS61 8 Swash plate 9 Regualting plate 10 Valve plate (distributor plate) 11 Connection plate...
  • Page 283 When the pistons are pulled out of the cylinder rotor (12), the cylinder and the space in the piston are filled with oil (suction phase). The oil is sucked through the outlets in the valve plate (1). When the pistons are pressed in, the oil is forced out at the bottom, through the valve plate (10). A small amount of oil is forced through the piston head and lubricates the slider and yoke.

  • Page 284: Checks And Adjustments

    3) 3) CHECKS AND ADJUSTMENTS CHECKS AND ADJUSTMENTS (1) (1) Margin pressure check Margin pressure check The margin pressure is the difference between the pressure at the B-Port and X-Port. If the mar- gin pressure is not within the range shown in the below table, the flow of hydraulic oil out of the variable displacement pump will be either too low or too high.
  • Page 285 (3) (3) Pressure compensator adjustment Pressure compensator adjustment Mark or measure the screw locations of the flow ① and pressure compensators. Be sure to count and note the number of turns Be sure to count and note the number of turns ※...

  • Page 286: Main Control Valve

    5. MAIN CONTROL VALVE 5. MAIN CONTROL VALVE 1) 1) STRUCTURE (4 SPOOL) STRUCTURE (4 SPOOL) Fork Lowering Speed Manual Lowering Valve Adjustment Valve Steering (LS1) Gauge (G) 2nd Relief Valve (DV2) Main Relief Valve (DV1) Pilot Drain (D) 70D9V6HS07A Tightening torque Port Port name...
  • Page 287 2) 2) FUNCTION FUNCTION (1) (1) Emergency fork lowering Emergency fork lowering In case that the mast can not be lowered due to a problem in the controller, activate the emergency lowering valve on the MCV assembly by rotating the valve (a). Manual override features are intended for Manual override features are intended for emergency use, not for continuous-duty...
  • Page 288 Cutoff solenoid for hydraulic blocking Cutoff solenoid for hydraulic blocking This device is a mast interlock that prevents the hydraulic functions of the RCV from being activated unless the driver is seated. In addition, it is a key lowering interlock device that prevents the fork from descending even when the ignition key is turned off.
  • Page 289 Hot hydraulic oil can cause serious burns to skin. Do not touch hydraulic components or oil Hot hydraulic oil can cause serious burns to skin. Do not touch hydraulic components or oil during test. Make sure hydraulic oil has cooled to safe temperature before installing or during test.
  • Page 290 6. EPPR VALVE (option) 6. EPPR VALVE (option) 1) 1) STRUCTURE (4 OR 5 SPOOL) STRUCTURE (4 OR 5 SPOOL) EHPR4 EHPR2 EHPR8 EHPR10 EHPR6 (20 pcs) (10 pcs) 20 TYP EHPR3 EHPR1 EHPR5 EHPR7 EHPR9 100D9V6EV01 6-17...
  • Page 291 Hydraulic circuit Hydraulic circuit EHPR2 EHPR4 EHPR8 EHPR6 EHPR10 EHPR3 EHPR9 EHPR5 EHPR1 EHPR7 100D9V6EV02 Tightening torque Hex. Port Port name Port size (mm) kgf·m lbf·ft 1, 2 Lift / Lower 3, 4 Tilt rod / head 5, 6 / 7, 8 / 9, 10 Aux 1, Aux 2 9/16-18 UNF 22.4...
  • Page 292 7. PRESSURE SENSORS 7. PRESSURE SENSORS 1) 1) LOAD PRESSURE SENSOR LOAD PRESSURE SENSOR Structure Ref. label ·Tightening torque : 2.5 ~ 3.0 kgf·m (18 ~ 21.7 lbf·ft) Pin map Function + Supply Deutsch - Supply DT04-3P Output 70D9V4BS10 Thread Measuring range Voltage Electircal...
  • Page 293 8. MAST ACCUMULATOR . MAST ACCUMULATOR 1) 1) STRUCTURE STRUCTURE ·Tightening torque : 2 kgf·m (14.7 lbf·ft) Valve protection cap Seal ring M28×1.5 16 mm Lift cylinder Accumulator 590 mm Pump PF 1/2 ø60 mm 35D9VB6HS52 35D9VB6HS59 Pre-charging pressure Parts No. Normal volume Weight at 20 ℃...
  • Page 294 2) 2) PRE-CHARGE PRESSURE PRE-CHARGE PRESSURE The accumulator is supplied pre-charged with nitrogen gas. The pre-fill pressure provided is indicated on the label of the accumulator shell or engraved on the surface of the top shell of the accumulator. A gas valve connection terminal is provided on the top of the accumulator to adjust the filling pressure (depending on the load or workplace conditions) as needed.
  • Page 295 4) 4) GAS RELEASE AND GAS RELEASE AND CHARGING CHARGING Release Loosen the plastic cap and loosen the M8 ① screw tightly locked to the gas valve connection Valve protection cap on the top of the accumulator with a 6 mm hex. wrench and lock it again.
  • Page 296 Charging The filling kit operation method was prepared The filling kit operation method was prepared ※ based on HYDAC product standards. based on HYDAC product standards. Accumulator gas pressure adjustment and Accumulator gas pressure adjustment and ※ charging kit must be purchased separately. charging kit must be purchased separately.
  • Page 297 Open the release valve and blow out nitrogen ⑩ Spindle Open : C.C.W ← gas in the FPU. Close : C.W → If there is gas in the charging hose and FPU, it If there is gas in the charging hose and FPU, it ※...

  • Page 298: Spring Pin

    9. REMOTE CONTROL VALVE 9. REMOTE CONTROL VALVE STRUCTURE STRUCTURE Tightening torque Hex. Port name Port thread (mm) kgf·m lbf·ft All port 9/16-18UNF 22.4 Bolt - tie 3SP M6 × 40L (8 EA) Bolt - tie 4SP M6 × 40L (4 EA) SW 5 M6 ×...
  • Page 299 2) 2) OPERATION OPERATION HYDRAULIC CIRCUIT (1) (1) Hydraulic functional principle Hydraulic functional principle Pilot devices with end position locks operate as direct operated pressure reducing valves. They basically comprise of control lever (A), two pressure reducing valves, body (3) and locks. Each pressure reducing valve comprises of a plunger kit (5), a metering spring (7) and a spring (11).
  • Page 300 10. LIFT CYLINDER 10. LIFT CYLINDER 1) 1) V MAST V MAST 14 15 11 10 13 8 3YFJ-07020 Tube assy Wear ring 11 Dust wiper Cushion seal 12 O-ring Piston Gland 13 O-ring Piston seal Du bushing 14 Spacer Back up ring 10 Rod seal 15 O-ring...
  • Page 301 11. FREE LIFT CYLINDER 11. FREE LIFT CYLINDER 1) 1) TS MAST TS MAST 16,17 15 14 13,12 3YFJ-17110 Retaining ring 15 Retaining ring Tube assy Set screw 16 O-ring Piston 10 Rod cover 17 Backup ring Piston seal 11 Rod bushing 18 O-ring Wear ring 12 U-packing...

  • Page 302: Tilt Cylinder

    12. TILT CYLINDER 12. TILT CYLINDER 21,20,19 10,9 14,13 3YFJ-08500 Tube assy 10 Back up ring 19 Hex bolt 11 O-ring 20 Hex nut Rod cover 12 Piston 21 Spring washer Pin bushing 13 O-ring 22 O-ring U-packing 14 Back up ring 23 Rod bushing Back up ring 15 Piston seal...

  • Page 303: Group 2 Operational Checks And Troubleshooting

    (screwed into inlet pipe). 35D9VB5SO19 CONTROL VALVE CONTROL VALVE 3) 3) Raise forks to maximum height and measure oil pressure. Check the oil pressure. Model Unit Pressure 210 ± 3 100D-9V (psi) (3050 ± 43) 6-30...
  • Page 304 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) SYSTEM SYSTEM Problem Problem Cause Cause Remedy 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 mast ·...
  • Page 305 Problem Problem Cause Cause Remedy Remedy High oil temperature ·Lack of hydraulic oil. ·Add oil. ·High oil viscosity. · Change to SAE10W, class CD engine oil. ·Oil filter clogged. ·Clean filter. Cylinder lowers considerably · Internal leakage of cylinder happens ·...
  • Page 306 2) 2) MAIN PUMP MAIN PUMP Problem Problem Cause Cause Remedy Remedy Unusual noises ·Insufficient air bleeding of the hydraulic ·Fill the axial piston pump, suction line system. for the hydraulic pump and the oil No or insufficient flow tank. ·Completely air bleed the pump and hydraulic system.
  • Page 307 3) 3) CYLINDER CYLINDER Problem Problem Cause Cause Remedy Remedy Oil leaks out from rod cover ·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.

  • Page 308: Group 3 Disassembly And Assembly

    GROUP 3 DISASSEMBLY AND ASSEMBLY GROUP 3 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP 1. MAIN PUMP 1) 1) STRUCTURE STRUCTURE 65 56 58 2 20 30 24 63 50 37 48 13 36 51 44 29 70D9V6HS12 Lock nut 24 Screw (M8×50) 47 Hub Lock nut 25 Washer...

  • Page 309: General Instruction

    ·Seal kit (101~118) 101101 106 106 101 101 106 106 70D9V6HS13 101 Washer 107 O-Ring 113 O-Ring 102 Washer 108 Seal 114 O-Ring 103 O-Ring 109 Seal 115 O-Ring 104 O-Ring 110 O-Ring 116 Seal 105 O-Ring 111 O-Ring 117 Seal 106 Seal 112 O-Ring 118 Shaft seal...

  • Page 310: Shaft Seal Replacement

    3) 3) SHAFT SEAL REPLACEMENT SHAFT SEAL REPLACEMENT Put the pump in vertical, with the shaft facing up. You need to find something suitable for the cover You need to find something suitable for the cover geometry, in order to put the pump in vertical geometry, in order to put the pump in vertical position.
  • Page 311 Clean the surface with compressed air. 70D9V6HS74 Put a thin layer of clean grease on the contact surface. 70D9V6HS75 Protect the shaft seal using a proper protection for the shaft end. 70D9V6HS76 Do not damage the shaft seal lip while assembling the seal on the shaft.
  • Page 312 Use a proper tool to push the shaft seal close to its seat. The shaft seal must be kept always perpendicular to the shat to not damage the seal lip. 70D9V6HS78 Be careful not to push the shaft seal inside the case.
  • Page 313 4) 4) COMPENSATOR SEALS REPLACEMENT COMPENSATOR SEALS REPLACEMENT Remove the screws of the compensators. 70D9V6HS81 Remove the pressure and the flow compensators. 70D9V6HS82 Remove the DEC (Displacement Electronic Control). 70D9V6HS83 Remove the O-ring seals. 70D9V6HS84 6-40...
  • Page 314 Insert the new O-ring seals. 70D9V6HS85 Remove nut and washer. 70D9V6HS86 Insert new washers. Tightening torque of nut and plug. ·Tightening torque : 1.5 kgf·m (10.9 lbf·ft) Keep attention to do not touch the limiter screws or Keep attention to do not touch the limiter screws or you will change the calibration of pressure and flow you will change the calibration of pressure and flow compensators.
  • Page 315 Insert the new O-ring seals. 70D9V6HS89 (10) Remove plug, nut and the O-ring seals. 70D9V6HS90 (11) Insert the new O-ring seals. Tightening torque of nut and plug. ·Tightening torque : 1.5 kgf·m (10.9 lbf·ft) Keep attention to do not touch the limiter screws or Keep attention to do not touch the limiter screws or you will change the calibration.
  • Page 316 (13) Insert the new O-ring seals on the compensator plane. 70D9V6HS93 (14) Remove the O.ring seals on DEC (Displacement Electronic Control) plane. 70D9V6HS94 (15) Insert the new O-ring seals on DEC (Displacement Electronic Control) plane. 70D9V6HS95 (16) Reassemble the flow and the pressure regulators. 70D9V6HS96 6-43...
  • Page 317 (17) Tighten the bolts with a torque wrench. ·Tightening torque : 1.5 kgf·m (10.9 lbf·ft) 70D9V6HS97 (18) Reassemble the DEC (Displacement Electronic Control). Tighten the bolts with a torque wrench. ·Tightening torque : 1.5 kgf·m (10.9 lbf·ft) Keep attention, in order to reassemble the torque Keep attention, in order to reassemble the torque limit in the right way, you need to spin the limiter, limit in the right way, you need to spin the limiter,...
  • Page 318 Use some aluminum protection on the vice to not Use some aluminum protection on the vice to not damage the machined surfaces. Put the pump in damage the machined surfaces. Put the pump in vertical position. Grab the pump by the pilot. vertical position.
  • Page 319 Remove the screws and washers from gear pump section. 70D9V6HS103 Remove the gear pump section. 70D9V6HS104 Remove the screws from the cover. 70D9V6HS105 (10) Remove gently the cover slipping the fingers between it and the case in order to keep the valve plate that could be attached to the cover.
  • Page 320 (11) Remove the seals from the cover. 70D9V6HS107 (12) Remove the O-rings from the body. 70D9V6HS108 (13) Remove plugs from the max and min displacement limiter and their seals. Keep attention to don’t touch the limiter screws or Keep attention to don’t touch the limiter screws or you will change the max or min displacement of you will change the max or min displacement of your pump.
  • Page 321 (15) Insert the new O-rings and reassemble the max and min displacement limiters. Tighten the plug M8 and the nut M8. ·Tightening torque : 1.5 kgf·m (10.9 lbf·ft) 70D9V6HS111 (16) Insert the new O-rings. 70D9V6HS112 (17) Remove the valve plate. 70D9V6HS113 (18) Use grease in order to attach valve plate to the...
  • Page 322 (19) Reassemble the hub and the cover. 70D9V6HS115 Put the pump in the vice. Use some aluminum Put the pump in the vice. Use some aluminum protection on the vice to not damage the machined protection on the vice to not damage the machined surfaces.
  • Page 323 (23) Reassemble the nut, washers and stud bolt. ·Tightening torque : 4.6 kgf·m (33.3 lbf·ft) 70D9V6HS119 (24) Reassemble the nut from stud bolt. 70D9V6HS120 (25) Remove the O-ring from the drain plugs. 70D9V6HS121 (26) Insert the new O-ring. 70D9V6HS122 6-50...
  • Page 324 (27) Insert the plug in the body. ·Tightening torque : 3.1 kgf·m (22.4 lbf·ft) 70D9V6HS123 (28) Reassemble the flow and the pressure regulators. 70D9V6HS124 (29) Tighten the bolts with a torque wrench. ·Tightening torque : 1.5 kgf·m (10.9 lbf·ft) 70D9V6HS125 6) 6) GEAR PUMP SEALS REPLACEMENT GEAR PUMP SEALS REPLACEMENT...
  • Page 325 Remove the nut from stud bolt from gear pump section. 70D9V6HS127 Remove the nut, washers and stud bolt from gear pump section. 70D9V6HS128 Remove the screws and washers from gear pump section. 70D9V6HS129 Remove the gear pump section. 70D9V6HS130 6-52...
  • Page 326 Remove thrust plates and gears from the housing. 70D9V6HS131 (10) Remove seal and anti-extrusion seal. 70D9V6HS132 (11) Insert new seal and anti-extrusion seal. 70D9V6HS133 (12) Remove rear cover. 70D9V6HS134 6-53...
  • Page 327 (13) Remove seal of the housing. 70D9V6HS135 (14) Insert new seal of the housing. 70D9V6HS136 (15) Reassemble rear cover. 70D9V6HS137 (16) Reassemble thrust plates and gears. 70D9V6HS138 6-54...
  • Page 328 (17) Reassemble the gear pump section. 70D9V6HS139 (18) Reassemble the screws and washers from gear pump section. Tighten the screws with a torque wrench. ·Tightening torque : 4.6 kgf·m (33.3 lbf·ft) 70D9V6HS140 (19) Reassemble the nut, washers and stud bolt from gear pump section.
  • Page 329 3. LIFT CYLINDER 3. LIFT CYLINDER 1) 1) STRUCTURE STRUCTURE (1) (1) V-mast V-mast · I.D×O.D×stroke (standard) 85×98×1475 mm (3.3×3.9×58.1 in) · Rod O.D : 60 mm (2.4 in) 3YFJ-07020P Tube assy Wear ring 11 Wiper ring Stop ring 12 O-ring Rod cover Piston 13 O-ring...
  • Page 330 (2) (2) TS-mast TS-mast · I.D×O.D×stroke (standard) 85×98×1463 mm (3.3×3.9×57.6 in) · Rod O.D : 60 mm (2.4 in) 3YFJ-07210P Tube assy Cushion ring 13 Wiper ring Retainer ring 14 O-ring Piston Stop ring 15 O-ring U-packing 10 Rod cover 16 Spacer Back up ring 11 Rod bushing...

  • Page 331: Retaining Ring

    (3) (3) Free lift Free lift (TS-mast) · I.D×O.D×stroke (standard) 95×108×767 mm (3.7×4.3×30.2 in) · Rod O.D : 70 mm (2.8 in) 3YFJ-17110P Tube assy Retaining ring 15 Retaining ring Set screw 16 O-ring Piston 10 Rod cover 17 Backup ring Piston seal 11 Rod bushing 18 O-ring...
  • Page 332 2) 2) DISASSEMBLY DISASSEMBLY 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.
  • Page 333 4. TILT CYLINDER 4. TILT CYLINDER 1) 1) STRUCTURE STRUCTURE · I.D×O.D×stroke : 115×134×307 mm (4.5×5.3×12.1 in) · Rod O.D : 60 mm (2.36 in) 3YFJ-08500P Tube assy 10 Back up ring 19 Hex bolt 11 O-ring 20 Hex nut Rod cover 12 Piston 21 Spring washer...
  • Page 334 2) 2) DISASSEMBLY 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 335: Section 7 Electrical System

    SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component location ------------------------------------------------------------------------------------------ 7-1 Group 2 Electrical circuit -------------------------------------------------------------------------------------------------- 7-3 Group 3 Cluster ---------------------------------------------------------------------------------------------------------------- 7-27 Group 4 Component specification ---------------------------------------------------------------------------------- 7-71 Group 5 Connector destination --------------------------------------------------------------------------------------- 7-72 Group 6 Troubleshooting ------------------------------------------------------------------------------------------------- 7-77...

  • Page 336: Group 1 Component Location

    GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 1. LOCATION 1 1. LOCATION 1 In/decrement switch Exhaust system cleaning switch Inching switch Rear wiper/washer switch Power switch Hazard switch (opt) Auto shift switch Parking brake switch Rear work lamp switch Top wiper/wahser switch (opt) Heated mirror switch (opt) Main light switch...
  • Page 337 2. LOCATION 2 2. LOCATION 2 100D9V7ES02 Wiper assembly 10 Beacon lamp 19 ECU Washer reservoir tank 11 Camera (opt) 20 TCU Head and turn signal lamp 12 License lamp (opt) 21 RMCU (opt) Radio and USB player 13 Rear wiper assembly 22 Battery Top wiper assembly (opt) 14 Rear combination lamp...

  • Page 338: Group 2 Electrical Circuit

    GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT ·ELECTRICAL CIRCUIT (1/3, CABIN TYPE, -#0006) ELECTRICAL CIRCUIT (1/3, CABIN TYPE, -#0006) MCV HARNESS ECU SERVICE ARMREST HARNESS F35 #14 G CONNECTOR 104 #18 Y TCU(TRANSMISSION CONTROL UNIT _ EC3a) RMCU HARNESS-AIRCON CABIN HARNESS (A~J 9P) FUSE BOX...
  • Page 339 ·ELECTRICAL CIRCUIT (2/3, -#0006) ELECTRICAL CIRCUIT (2/3, -#0006) PARKING PRESSURE BRAKE SWITCH FUEL FILTER G-SENSOR SENSOR SENSOR FAIL SW LOAD SENSOR TILT SWITCH FUEL TILTING MOTOR BRAKE MIRROR HEATER (MAST) HYD TEMP/PS AIRCON SENDOR S/W CAB TILT COOLING HEATER COMP BACK TEMP AIR CLEARNER...
  • Page 340 ·ELECTRICAL CIRCUIT (3/3, -#0006) ELECTRICAL CIRCUIT (3/3, -#0006) CABIN HARNESS A/CON CIRCUIT REAR VIEW WIPER MOTOR REAR WIPER MOTOR HEAD LAMP HEAD LAMP CAMERA ANTENA USB MP3 RADIO REAR SPEAKER CONDENSOR BEACON A/CON CONTROL SWITCH ASSY ROOM ROOM WORK LAMP R/DRYER LAMP LAMP LH...
  • Page 341 ·ELECTRICAL CIRCUIT (1/3, CABIN TYPE, #0007~0036) ELECTRICAL CIRCUIT (1/3, CABIN TYPE, #0007~0036) ECU SERVICE ARMREST HARNESS MCV HARNESS 104 #18 Y TCU(TRANSMISSION CONTROL UNIT _ EC3a) CONNECTOR RMCU HARNESS-AIRCON CABIN HARNESS (A~J 9P) FUSE BOX START KEY S/W RMCU SERVICE MACHINE DIAGNOSIS CONNECTOR RB RL WYRY YR WRWG B...
  • Page 342 ·ELECTRICAL CIRCUIT (2/3, #0007~0036) ELECTRICAL CIRCUIT (2/3, #0007~0036) PARKING PRESSURE BRAKE SWITCH G-SENSOR SENSOR FUEL FILTER SENSOR FAIL SW LOAD SENSOR FUEL TILT SWITCH TILTING MOTOR BRAKE (MAST) MIRROR HEATER HYD TEMP/PS SENDOR AIRCON COOLING S/W CAB TILT HEATER BACK COMP TEMP AIR CLEARNER...
  • Page 343 ·ELECTRICAL CIRCUIT (3/3, #0007~0036, OLD) ELECTRICAL CIRCUIT (3/3, #0007~0036, OLD) CABIN HARNESS A/CON CIRCUIT REAR VIEW REAR WIPER MOTOR HEAD LAMP HEAD LAMP WIPER MOTOR CAMERA ANTENA USB MP3 RADIO REAR SPEAKER CONDENSOR BEACON ROOM ROOM WORK LAMP R/DRYER LAMP A/CON CONTROL SWITCH ASSY LAMP LH LAMP RH...
  • Page 344 ·ELECTRICAL CIRCUIT (3/3, #0007~0036, NEW) ELECTRICAL CIRCUIT (3/3, #0007~0036, NEW) A/CON CIRCUIT CABIN HARNESS A/CON CONTROL SWITCH ASSY 1YFJ-91120 WIPER MOTOR REAR WIPER MOTOR REAR VIEW HEAD LAMP HEAD LAMP ANTENA CAMERA 24 23 USB MP3 RADIO REAR 29 30 SPEAKER CONDENSOR R/DRYER...
  • Page 345 ·ELECTRICAL CIRCUIT (1/4, CABIN TYPE, #0037-) ELECTRICAL CIRCUIT (1/4, CABIN TYPE, #0037-) MCV HARNESS ECU SERVICE ARMREST HARNESS 104 #18 Y CONNECTOR TCU(TRANSMISSION CONTROL UNIT _ EC3a) RMCU HARNESS-AIRCON CABIN HARNESS (A~J 9P) FUSE BOX START KEY S/W RMCU SERVICE MACHINE DIAGNOSIS CONNECTOR RB RL WYRY YR WRWG B...
  • Page 346 ·ELECTRICAL CIRCUIT (2/4, CANOPY TYPE, #0037-) ELECTRICAL CIRCUIT (2/4, CANOPY TYPE, #0037-) ECU SERVICE 104 #18 Y CONNECTOR TCU(TRANSMISSION CONTROL UNIT _ EC3a) RMCU OHG HARNESS (A~J 9P) FUSE BOX START KEY S/W RMCU SERVICE MACHINE DIAGNOSIS CONNECTOR INCHING SENSOR B BR X2(21P) X1(46P)
  • Page 347 ·ELECTRICAL CIRCUIT (3/4, #0037-) ELECTRICAL CIRCUIT (3/4, #0037-) PARKING PRESSURE BRAKE SWITCH G-SENSOR SENSOR FUEL FILTER SENSOR FAIL SW LOAD SENSOR FUEL TILT SWITCH TILTING MOTOR BRAKE (MAST) MIRROR HEATER HYD TEMP/PS SENDOR AIRCON COOLING S/W CAB TILT HEATER COMP TEMP BACK AIR CLEARNER...
  • Page 348 ·ELECTRICAL CIRCUIT (4/4, #0037-) ELECTRICAL CIRCUIT (4/4, #0037-) CABIN HARNESS A/CON CIRCUIT WIPER MOTOR REAR WIPER MOTOR REAR VIEW HEAD LAMP HEAD LAMP CAMERA ANTENA USB MP3 RADIO REAR SPEAKER CONDENSOR WORK LAMP R/DRYER BEACON ROOM ROOM A/CON CONTROL SWITCH ASSY LAMP LH LAMP RH LAMP...

  • Page 349: Power Circuit

    1. POWER CIRCUIT 1. POWER CIRCUIT The negative terminal of the battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal. 1) 1) OPERATING FLOW OPERATING FLOW Fuse box [CN-37 (No.35 →...
  • Page 350 POWER CIRCUIT POWER CIRCUIT TILT SWITCH TILTING MOTOR CAB TILT S/W HORN HIGH A/CON F07 #18 ALTERNATOR 103 #10 CN-74 CN-95 FUSIBLE LINK PRE-HEATER CR-24 16SQ 113 #18 G11 #18 ROOM 16SQ LAMP LH PREHEAT CL-1 RELAY ROOM LAMP RH START MOTOR CN-27 220 #12...
  • Page 351 2. STARTING CIRCUIT 2. STARTING CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Battery (+) terminal Start motor [CN-45 (B+)] Fusible link [CN-95] Alternator [CN-74 (B+)] I/conn [CN-3 (1)] Start switch [CS-2 (1)] Start relay [CR-23 (1)] Heater relay [CR-24] The engine can be started only when the gear selector lever is in neutral position. The engine can be started only when the gear selector lever is in neutral position.

  • Page 352: Starting Circuit

    STARTING CIRCUIT STARTING CIRCUIT CS-13 CAN_H* ALTERNATOR CN-130 CAN_L* 103 #10 KL15(IG) CN-74 KL30(B+) CAN_L CN-95 CAN_H FUSIBLE LINK CAN_T GEAR SELECTOR SW(CAN) PRE-HEATER CR-24 16SQ 113 #18 G11 #18 16SQ PREHEAT RELAY START MOTOR G8 #12 CN-45 106 #12 1.25BR 116 #18 START RY...

  • Page 353: Charging Circuit

    3. CHARGING CIRCUIT 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator release the start switch to the ON position. Charging current generated by operating the alternator flows into the battery. The current also flows from the alternator to each electrical component through the fusible link (CN-95) and the fuse box.
  • Page 354 CHARGING CIRCUIT CHARGING CIRCUIT TILT SWITCH TILTING MOTOR CN-56 GND(SENSOR?) 115 #18 ALTERNATOR TM AUTO2 SIG TM AUTO1 SIG 103 #10 SW PARKING PRESSURE CN-74 SW SEAT SW AIR INTAKE PRESS CN-95 SW ENG OIL PRESS FUSIBLE LINK HIGH BEAM SW ENG PREHEAT LAMP EPPR OUT1 PRE-HEATER...
  • Page 355 4. PREHEATING CIRCUIT 4. PREHEATING CIRCUIT Combustion chamber glow plugs are used in order to give satisfactory starting of low ambient temperatures. 1) 1) OPERATING FLOW OPERATING FLOW Battery (+) terminal Start motor [CN-45 (B+)] Preheat relay [CR-24] When you turn the start switch to the ON position, the preheat relay makes the preheater operated and the engine warm up lamp of the cluster turned ON.
  • Page 356 PREHEATING CIRCUIT PREHEATING CIRCUIT TILT SWITCH TILTING MOTOR FUEL HEATER ALTERNATOR 103 #10 CN-74 CN-95 FUSIBLE LINK PRE-HEATER CR-24 16SQ 113 #18 G11 #18 16SQ PREHEAT RELAY START MOTOR 220 #12 G8 #12 CN-45 106 #12 1.25BR 116 #18 START RY 102 #12 1.25B G11 #18...
  • Page 357 5. HEAD LIGHT AND REAR WORK LIGHT CIRCUIT 5. HEAD LIGHT AND REAR WORK LIGHT CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Head light Head light Fuse box (No.18) Main light switch [CS-39 (6)] Switch ON, 2nd step [CS-39 (5)] Multi function switch [CS-11 (8)] Multi function switch MIDDLE [CS-11 (7)] I/conn [CN-90 (9)]...
  • Page 358 HEAD LIGHT AND REAR WORK LIGHT CIRCUIT HEAD LIGHT AND REAR WORK LIGHT CIRCUIT CAB TILT S/W CL-15A 112 #18 REAR COMBI LAMP LH CL-15B 112 #18 CL-16A 112 #18 REAR COMBI CL-16B LAMP RH 112 #18 LICENCE LAMP 112 #18 CL-21 F18 #18 CS-74...
  • Page 359 6. WIPER AND WASHER CIRCUIT 6. WIPER AND WASHER CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Fuse box [No.22] Front wiper motor [CN-21 (8)] Wiper relay Hi [CR-4 (3)] Wiper relay Lo [CR-26 (1)] Multi function switch [CS-12 (6)] Rear wiper & washer switch [CS-3 (3, 6)] I/conn [CN-90 (27)] Rear wiper motor [CN-102 (3)] Fuse box [No.21]...
  • Page 360 2) 2) CHECK POINT CHECK POINT Engine Start switch Check point Voltage ① - GND (Front wiper switch power input) ② - GND (Rear wiper switch power input) ③ - GND (Top wiper switch power input) ④ - GND (Washer pump relay power input) ⑤...
  • Page 361 WIPER AND WASHER CIRCUIT WIPER AND WASHER CIRCUIT WASHER CN-102 PUMP 727 #18 F22 #18 726 #18 REAR WIPER MOTOR 707 #18 WIPER MOTOR F21 #18 706 #18 CN-70 F22 #18 REAR WIPER SWITCH RELAY RELAY RELAY RELAY INT WIPER FRONT WIPER Lo WASHER PUMP...
  • Page 362 GROUP 3 GROUP 3 CLUSTER CLUSTER STRUCTURE Like following figure, cluster is consisted of LCD and buttons. LCD will indicate the operation and abnormal status of truck to the driver in order to use and maintenance. Also, LCD allows to set and indicate the various modes, monitoring, and gadgets.
  • Page 363 2) 2) GAUGE GAUGE Operation screen Operating screen will be displayed if turn on the start switch. 70D9V3KY30A Speed meter Coolant temperature gauge Transmission oil temperature gauge Fuel gauge DEF gauge Clock Speed meter · It indicates the speed of truck and calibrated in miles per hour (mph) or kilometer per hour (km/h).
  • Page 364 (5) (5) DEF (Diesel Exhaust Fluid) gauge DEF (Diesel Exhaust Fluid) gauge · This gauge indicates the level of DEF. · Fill the DEF when the level is low. 70D9V3KY33 (6) (6) Transmission oil temperature gauge Transmission oil temperature gauge ·...

  • Page 365: Warning Lamps

    3) 3) WARNING LAMPS WARNING LAMPS 70D9V3KY35 ※ Warning and indicator lamp will display only items that were set as ON, and all warning and Warning and indicator lamp will display only items that were set as ON, and all warning and indicator except fuel level warning and coolant temperature warning will be displayed in order indicator except fuel level warning and coolant temperature warning will be displayed in order from the left of screen.

  • Page 366: Coolant Temperature Warning Lamp

    (1) (1) Fuel level warning lamp Fuel level warning lamp · Warning lamp will be displayed if fuel level is low. · Please refuel immediately if the lamp is ON. 35L93KY155 (2) (2) Coolant temperature warning lamp Coolant temperature warning lamp ·...
  • Page 367 · If the lamp lights on, stop the engine immediately and check the engine. ※ Please contact your Hyundai service center or local dealer. Please contact your Hyundai service center or local dealer. 35D9VB3KY15 (8) (8) Battery charge warning lamp Battery charge warning lamp ·...
  • Page 368 (11) (11) Communication error warning lamp Communication error warning lamp · This warning lamp will be lit up if the communication between cluster-CI and ECU is fail. · Please check the communication line if the warning lamp is lit up. 35D9VB3KY20 (12) (12)
  • Page 369 1. These lamps will be on when a manual (stationary) exhaust system cleaning is not performed 2. Stop the engine immediatary 3. Please contact your hyundai service center or local dealer The status of a manual (stationary) exhaust system cleaning when Flash the exhaust system cleaning switch has been activated.
  • Page 370 ※ Manual exhaust system cleaning Manual exhaust system cleaning ※ Manual exhaust system cleaning must be operated in a Manual exhaust system cleaning must be operated in a fireproof area. fireproof area. ※ To stop a manual exhaust system cleaning before it has To stop a manual exhaust system cleaning before it has completed, set to the exhaust system cleaning switch to the completed, set to the exhaust system cleaning switch to the...
  • Page 371 When this warning lamp lights ON, stop the engine immediately and and check the DEF level and related parts of the engine. ※ Please contact your Hyundai service center or local dealer. Please contact your Hyundai service center or local dealer. 50D9CD33...
  • Page 372 (21) (21) Transmission warning lamp Transmission warning lamp · If the lamp lights on, check the transmission. · If the red warning light is lit while driving, stop the engine and check the forklift. 70D9V3KY194 (22) (22) Seat belt reminder lamp Seat belt reminder lamp ·...

  • Page 373: Indicator Lamps

    4) 4) INDICATOR LAMPS INDICATOR LAMPS 70D9V3KY36 ※ Warning and indicator lamps will display only items that were set as ON, and all warning and Warning and indicator lamps will display only items that were set as ON, and all warning and indicator except turning indicator lamp and driving indicator lamp will be displayed in order indicator except turning indicator lamp and driving indicator lamp will be displayed in order from the left of screen.
  • Page 374 (1) (1) Consumables management indicator lamp Consumables management indicator lamp · Light up if consumables which must be replaced are exist. · The indicator lamp will light up only 3 minutes since start switch ON, and then light OFF. · Please check the consumables management list in maintenance menu.
  • Page 375 (6) (6) OPSS indicator lamp OPSS indicator lamp · Light up if driver leave seat during operation. · Truck driving and/or mast control will be blocked if lamp is lit up. ※ Please refer to page the operator manual 0-12 for details. Please refer to page the operator manual 0-12 for details.
  • Page 376 (10) (10) High beam indicator lamp High beam indicator lamp · This indicator is displayed when the vehicle's high beam is on. 70D9V3KY196 (11) (11) Shift mode indicator lamp 1 Shift mode indicator lamp 1 · This indicator shows the current vehicle's shift mode, A1 and A2 are indicated on vehicles with 2nd gear or higher.

  • Page 377: Information Display

    5) 5) INFORMATION DISPLAY INFORMATION DISPLAY Truck front/rear tilt Load weight Operation time Total trip distance Truck left/right tilt 70D9V3KY40 (1) (1) Mast front/rear tilt Mast front/rear tilt · Display the real time tilt of mast. 70D9V3KY41 (2) (2) Truck front/rear tilt Truck front/rear tilt ·...

  • Page 378: Operation Time

    (4) (4) Load weight Load weight (option) · Display the load weight. · Screen will display blurry if the weight sensor has not been mounted. 35D9VB3KY38 (5) (5) Total trip distance Total trip distance · Display total trip distance of the truck. ·...
  • Page 379 6) 6) BUTTONS BUTTONS (1) (1) Camera Camera · This switch displays rear camera images. (if the camera is mounted) 35D9VB3KY41 (2) (2) UP/Left UP/Left · This switch is used to move upward or leftward in menu or increase the value. 35D9VB3KY42 (3) (3) Down/Right...
  • Page 380 7) 7) MAIN MENU MAIN MENU (1) (1) Structure Structure Menus consist of main menu and sub-menu. Operation Screen Main Menu Screen Sub-Menu Screen 70D9V3KY42 Main menu screen Sub menu Explanation · · Model select Diesel, LPG · · Tilt setting Truck tilt initialize ·...

  • Page 381: Equipment Menu

    (2) (2) Equipment menu Equipment menu ① Model Select (a required setting) Model Select (a required setting) Check under the start switch ON status. Selection will be canceled if press the cancel button. ※ This is a required setting. Some functions may not be worked properly if you do not select This is a required setting.

  • Page 382: Check Functions

    ② Tilt Setting Tilt Setting Setting Setting (Check under the start switch ON status.) (Check under the start switch ON status.) ※ The tilt sensor has already been initialized when deliver the truck from factory. The tilt sensor has already been initialized when deliver the truck from factory. ※...
  • Page 383 d) d) Left or right truck tilt warning (red) Left or right truck tilt warning (red) · Stop : ±3.4°(1.5 ~ 5.0 tons) · Driving Truck weight Warning angles (red) ° ±20.3 1.5 ~ 2.0 tons ° ±20.8 2.2 ~ 3.3 tons °...
  • Page 384 b. b. Check functions Check functions Set the mode as active and start switch OFF. Upon start switch ON, the password screen pops up and starting is prohibited until the right. password has been offered. (But, driver still can start the vehicle if starts within 10 seconds from start switch OFF) Set the mode as 5 min of delay time and start switch OFF.
  • Page 385 Cylinder cross-section value Cylinder cross-section value unit : cm Model Mast type V-mast TS-mast V300~500 113.49 141.76 TS450~500 100D-9V V550~600 141.76 190.07 TS550~750 · · Truck that has not applied the Truck that has applied the weight weight sensor sensor (option) 70D9V3KY53 1.
  • Page 386 b. b. Unloaded status adjustment Unloaded status adjustment 1. Equipment 2. Password 3. Weight Sensor Setting 70D-9V 35D9VB3KY47 35D9VB3KY51 70D9V3KY56 Enter to Equipment menu Enter the password Choose Weight Sensor Setting 4. Load Weight Adjustment 5. Unloaded Status Adjustment 6. Instruction 70D9V3KY59 70D9V3KY60 35D9VB3KY71...
  • Page 387 c. c. Loaded status adjustment Loaded status adjustment ※ Must be prepared to lift up by locating the load on the fork before enter the weight. Must be prepared to lift up by locating the load on the fork before enter the weight. ※...
  • Page 388 d. d. Reset Reset Initialize the all values of 'Unloaded and Loaded Status Adjustment' that were entered previously. (Cylinder cross-sectional area is not initialized.) 1. Equipment 2. Password 3. Weight Sensor Setting 70D-9V 35D9VB3KY47 35D9VB3KY51 70D9V3KY56 Enter to Equipment menu Enter the password Choose Weight Sensor Setting...
  • Page 389 e. e. Weight Display Setting Weight Display Setting Enable to adjust the digit-number fo weight of main screen. 1. Equipment 2. Password 3. Weight Sensor Setting 70D-9V 35D9VB3KY47 35D9VB3KY51 70D9V3KY56 Enter to Equipment menu Enter the password Choose Weight Sensor Setting 4.
  • Page 390 f. f. Overload Alarm Overload Alarm 1. Equipment 2. Password 3. Weight Sensor Setting 70D-9V 35D9VB3KY47 35D9VB3KY51 70D9V3KY56 Enter to Equipment menu Enter the password Choose Weight Sensor Setting 4. Overload alarm 5. Select 6. Completion 70D9V3KY68 35D9VB3KY81 100D9VB3KY80 Enter to Overload alarm. Select ON or OFF.
  • Page 391 ⑥ FingerTips FingerTips Setting Setting (option) (option) 1. Equipment 2. Password 3. FingerTips Setting 35D9VB3KY47 35D9VB3KY51 70D9V3KY72 Enter to Equipment. Enter the password Choose FingerTips Setting and enter. a. a. Lever Position Setting Lever Position Setting 1. Lever Position Setting 2.
  • Page 392 ⑦ CSC (Curve Speed Control) Setting (if installed) CSC (Curve Speed Control) Setting (if installed) 1. Equipment 2. Password 3. CSC Setting 35D9VB3KY47 35D9VB3KY51 70D9V3KY80 Enter to Equipment. Enter the password Choose CSC setting and enter. 4. Select 5. Completion 70D9V3KY81 70D9V3KY82 Select ON or OFF.
  • Page 393 b. b. Speed Setting Speed Setting · In case of 1st gear → 2nd gear, it is possible to set up to 7 ~ 10 km/h. · In case of 2nd gear → 1st gear, it is possible to set up to 4 ~ 5 km/h. ※...
  • Page 394 ⑩ HAC (Hill Assist Control) Setting (if installed) (Hill Assist Control) Setting (if installed) If you are trying to drive in stop status on the hill, the truck does not move backward when the HAC setting is ON. 1. Equipment 2.
  • Page 395 ⑫ Zero Start Setting (if installed) Zero Start Setting (if installed) 1. Equipment 2. Password 3. Zero Start Setting 35D9VB3KY47 35D9VB3KY51 70D9V3KY98 Enter to Equipment. Enter the password Choose Zero Start Setting and enter. 4. Select Sensitivity 5. Setting Sensitivity 100D9V3KY99 100D9V3KY10 Change value using up/down...
  • Page 396 ⑭ ZF TCU ZF TCU Calibration Calibration Enable to calibrate the inching and clutch of the transmission. ※ Depending on the model, the initial conditions for calibration may be different or the procedure Depending on the model, the initial conditions for calibration may be different or the procedure may be automatically skipped.
  • Page 397 b. b. Clutch Calibration Clutch Calibration 2-1. ZF TCU Calibration 2. Password 3. ZF TCU Calibration 70D9V3KY127 35D9VB3KY51 70D9V3KY127 Choose ZF TCU Calibration Enter the password Choose ZF TCU Calibration and enter. and enter. ※ Conditions 4. Prepare for Calibration Conditions 1) Engine RPM 800 to 1100 2) T/M temperature 60℃...
  • Page 398 ⑮ Seat Belt Interlock (option) Seat Belt Interlock (option) 1. Equipment 2. Password 3. Seat Belt Interlock 35D9VB3KY47 35D9VB3KY51 70D9V3KY132 Enter to Equipment. Enter the password (applied Choose Seat Belt Interlock master password) and enter. 4. Select 5. Completion 70D9V3KY133 70D9V3KY134 Setting has been completed.
  • Page 399 (2) (2) Maintenance Maintenance ① Failure History ailure History 1. Maintenance 2. Password 3. Failure History 35D9VB3KY48 35D9VB3KY51 70D9V3KY138 Enter to Maintenance. Enter the password Choose Failure History and enter. 4. Engine or Transmission 5. History 6. Failure List 70D9V3KY139 70D9V3KY140 70D9V3KY141 Choose what needs to...
  • Page 400 7. Replacement 8. Confi rm 9. Change 70D9V3KY146 70D9V3KY147 70D9V3KY148 Select Replacement. Press enter button. Select Change. 10. Setting Cycle 11. Completion 70D9V3KY149 70D9V3KY150 C h a n g e p r o p e r l y t h e Setting has been completed.

  • Page 401: Display Setting

    (3) (3) Display setting Display setting ① LCD Brightness Adjustment rightness Adjustment · LCD brightness has two options. (Automatic and Manual modes) · Manual mode always keeps the selected brightness. · Brightness : Daytime 100%, Nighttime 50% · Daytime/Nighttime time zone : 06 ~ 18 1.

  • Page 402: Unit Setting

    b. b. Unit Setting Unit Setting 1. Unit Setting 2. Unit Setting Litst 3. Setting 70D9V3KY159 35D9VB3KY152 35D9VB3KY153 Select Unit Setting. Enable to set the unit of Set unit. speed, weight, temperature and pressure. c. c. Language Setting Language Setting 1.
  • Page 403 ④ Password Change. Password Change. · This function is to allow to change password from default password to user defined password. · Password length must be 5~10 digits. ※ Since, if you forget the password, you must request the A/S, do not forget the password. Since, if you forget the password, you must request the A/S, do not forget the password.
  • Page 404 ⑤ Consumables M Consumables Management anagement 1. Display Setting 2. Conusmables Management 3. List 35D9VB3KY49 70D9V3KY174 70D9V3KY143 Enter to Display Setting. Choose Consumables Man- agement and enter. 8) 8) CAUSES AND CORRECTION OF CLUSTER WARNING LAMP CAUSES AND CORRECTION OF CLUSTER WARNING LAMP Warning lamp types Symbol Warning and indicator lamp...
  • Page 405 Warning lamp types Symbol Warning and indicator lamp Causes and correction Battery charging Battery charging warning Battery is not being charged. warning lamp Please check alternator and wiring. Tilt lock indicator Tilt lock indicator lamp Auto-leveling is the operational status. (if installed) OPSS is working : 15 OPSS indicator...

  • Page 406: Group 4 Component Specification

    GROUP 4 COMPONENT SPECIFICATION GROUP 4 COMPONENT SPECIFICATION Part name Specification 24 V×80 AH Battery RC : 190 min CCA : 850 A LED work lamp 12~24 V, 20~27 W License lamp (opt) 24 V, 5 W LED rear combination lamp 24 V, LED (turn signal, tail, stop) 24 V, 26 W (high and low), 18 W (low) LED head and turn lamp...

  • Page 407: Group 5 Connector Destination

    GROUP 5 CONNECTOR DESTINATION GROUP 5 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-3 I/conn (frame-main harness) MG650943-5 CN-4 AMP/KET I/conn (frame-main harness) MG642292 MG652290 CN-6 Aircon harness 2-85262-1 CN-7 Fuel heater CN-12 I/conn (main-satety harness) 1897009-2 1897013-2 CN-13...
  • Page 408 Connector part No. Connector No. of Type Destination number Female Male CN-92 I/conn (monitor-main harness) 174262-2 174264-2 CN-98 DEUTSCH Resistor DT06-3S-EP06 DT04-3S-EP10 CN-102 Rear wiper motor 180900 CN-113 Warning buzzer MG610320 CN-125 ORBCOMM TNC-C-58 CN-125 DEUTSCH/- 12/1 I/conn (cabin harness-RMCU) DT06-12S TNJ-C-58 CN-125...
  • Page 409 Connector part No. Connector No. of Type Destination number Female Male ·Switch Switch CS-2 Start switch MG610281 MG620282 CS-3 CARLING Rear wiper switch 21HN-56300 CS-5 Center horn MG640322 CS-5A Center horn MG610320 CS-5B Center horn S820-105000 CS-10 CARLING Fuel warmer switch 21HN-56300 CS-11 Multi function switch...
  • Page 410 Connector part No. Connector No. of Type Destination number Female Male CR-15 Neutral signal relay CR-24 Glow controller relay F162210 CR-34 HELLA Travel cut relay 8JA003526-001 CR-35 HELLA Back up relay 8JA003526-001 CR-44 Cabin tilt relay coil relay 174352-2 CR-51 HELLA Attach cut relay 8JA003526-001...
  • Page 411 Connector part No. Connector No. of Type Destination number Female Male CN-155 Diagnosis connector MG610335 MG642554 CN-M1 DEUTSCH Lift down 963040-3 CN-M2 DEUTSCH Lift up 963040-3 CN-M3 DEUTSCH Tilt out 963040-3 CN-M4 DEUTSCH Tilt in 963040-3 CN-M5 DEUTSCH Aux 1 in 963040-3 CN-M6 DEUTSCH...

  • Page 412: Group 6 Troubleshooting

    GROUP 6 TROUBLESHOOTING GROUP 6 TROUBLESHOOTING Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy ·Faulty wiring. ·Check for loose terminal and Lamps dimming even at maximum engine speed. disconnected wire. ·Improper belt tension. ·Adjust belt tension. L a m p s f l i c k e r d u r i n g e n g i n e operation.
  • Page 413 SECTION 8 MAST SECTION 8 MAST Group 1 Structure ------------------------------------------------------------------------------------------------------------- 8-1 Group 2 Operational Checks and Troubleshooting -------------------------------------------------------- 8-4 Group 3 Adjustment ---------------------------------------------------------------------------------------------------------- 8-7 Group 4 Removal and Installation ----------------------------------------------------------------------------------- 8-9...

  • Page 414: Group 1 Structure

    SECTION 8 MAST SECTION 8 MAST GROUP 1 STRUCTURE GROUP 1 STRUCTURE 1. 2 STAGE MAST (V MAST) 1. 2 STAGE MAST (V MAST) Outer master Inner master Lift cylinder Lift cylinder Frame Carriage 100D9V8MS01 Outer mast Lift chain Chain sheave bearing Roller bearing Anchor bolt 10 Side roller bearing...

  • Page 415: Lock Plate

    2. 3 STAGE MAST (TS MAST) 2. 3 STAGE MAST (TS MAST) Frame 100D9V8MS02 Outer mast Middle mast 11 Retainer ring Shim Sheave 12 Tilt cylinder pin Load roller bearing Anchor bolt 13 Lock plate Side roller bearing Chain 14 Master mounting pin Inner mast 10 Sheave bracket 15 Joint pin...
  • Page 416 3. CARRIAGE, BACKREST AND FORK 3. CARRIAGE, BACKREST AND FORK 1) 1) SHAFT TYPE SHAFT TYPE Shaft type fork 100D9V8MS03 Carriage & backrest Side roller Retainer ring Hanger bar Fork 10 Spacer Fork retaining Wear plug 11 Spacer Roller Cover...

  • Page 417: Group 2 Operational Checks And Troubleshooting

    EX : ℓ=1200 mm (47 in) mm (in) STD Fork assy Applicable model Standard Limit 69FJ-71010G 100D-9V 75 (3.0) 68 (2.7) Thickness 100D9V8MS04 Set forks in middle and measure out of parallel and difference in height at the top of forks.
  • Page 418 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) MAST MAST Problem Problem Cause Cause Remedy 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.
  • Page 419 2) 2) FORKS FORKS Problem Problem Cause Cause Remedy Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear and reduces the thickness of the wear limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion...

  • Page 420: Group 3 Adjustment

    GROUP 3 ADJUSTMENT GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER 1. MAST LOAD ROLLER INNER/OUTER MAST ROLLER CLEAR- INNER/OUTER MAST ROLLER CLEAR- 1) 1) ANCE ADJUSTMENT ANCE ADJUSTMENT Outer mast Measure the clearance with the mast Inner mast Bring into overlap at near 480 mm (19 in).
  • Page 421 2) 2) CARRIAGE LOAD ROLLER CARRIAGE LOAD ROLLER Measure the clearance when the center of the carriage upper roller is 100 mm from Outer mast Carriage the top of the inner mast. Adjust plate screw Measure the clearance at upper, middle and lower rollers after loosen the adjust Bring screws from the side rollers.

  • Page 422: Group 4 Removal And Installation

    GROUP 4 REMOVAL AND INSTALLATION GROUP 4 REMOVAL AND INSTALLATION 1. FORKS 1. FORKS 1) 1) SHAFT TYPE SHAFT TYPE Lower the fork carriage until the forks are Fork retainer approximately 25 mm (1 in) from the floor. Release fork retainer and remove cover. Hanger bar Slide one hanger bar at a time out of carriage assembly.
  • Page 423 3. CARRIAGE ASSEMBLY 3. CARRIAGE ASSEMBLY CARRIAGE CARRIAGE 1) 1) With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is done to create slack in the load chains when the carriage is lowered. Lower the carriage all the way down to the floor.
  • Page 424 CARRIAGE LOAD ROLLER BEARING CARRIAGE LOAD ROLLER BEARING Carriage load Remove carriage as outlined in the roller bearing carriage removal paragraph. Retainer ring Using the plier, remove retaining rings from load roller bearing bracket. Using a plier, remove load roller bearings from load roller bearing bracket.
  • Page 425 3) 3) 3 STAGE MAST(TS MAST) 3 STAGE MAST(TS MAST) Remove the carriage assembly and move it to one side. Mast load roller Loosen and remove hexagon bolt secur- ing bottom cylinder from outer mast. Loosen and remove set bolts and nuts securing lift cylinders to middle mast.
  • Page 426 5. CHAIN 5. CHAIN 1) 1) CHAIN SHEAVE CHAIN SHEAVE Sheave Chain Place a sling around carriage and attach Joint pin Outer mast to an overhead hoist. Lift carriage high enough so that the tension on the chain over sheaves is relieved after the carriage is blocked.
  • Page 427 3) 3) SHEAVE SUPPORT SHEAVE SUPPORT (TS mas (TS mast) Remove the carriage assembly and move to one side. After removing bolt to securing sheave support assembly to free lift cylinder. Attach a sling to the sheave support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
  • Page 428 Rust and corrosion 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 429 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 430 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. 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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