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Hyundai 25L-9A Manual

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SECTION 1 GENERAL

SECTION 1 GENERAL

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

Group 2 Specifications ---------------------------------------------------------------------------------------------------- 1-5

Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-13

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

SECTION 3 POWER TRAIN SYSTEM

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation ----------------------------------------------------------------------------------- 3-1

Group 2 Troubleshooting ------------------------------------------------------------------------------------------------ 3-20

Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 3-26

SECTION 3 POWER TRAIN SYSTEM

SECTION 3 POWER TRAIN SYSTEM (Option, HD Transmission and Drive Axle)

Group 1 Structure and operation ----------------------------------------------------------------------------------- 3-88

Group 2 Disassembly and assembly ----------------------------------------------------------------------------- 3-102

Group 3 Maintenance and troubleshooting ------------------------------------------------------------------- 3-146

SECTION 4 BRAKE SYSTEM

SECTION 4 BRAKE SYSTEM

Group 1 Structure and function -------------------------------------------------------------------------------------- 4-1

Group 2 Operational checks and troubleshooting -------------------------------------------------------- 4-10

Group 3 Tests and adjustments ------------------------------------------------------------------------------------- 4-14

SECTION 5 STEERING SYSTEM

SECTION 5 STEERING SYSTEM

Group 1 Structure and function -------------------------------------------------------------------------------------- 5-1

Group 2 Operational checks and troubleshooting -------------------------------------------------------- 5-13

Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 5-15

SECTION 6 HYDRAULIC SYSTEM

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function -------------------------------------------------------------------------------------- 6-1

Group 2 Operational checks and troubleshooting -------------------------------------------------------- 6-41

Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 6-45

SECTION 7 ELECTRICAL SYSTEM

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location ----------------------------------------------------------------------------------------- 7-1

Group 2 Electrical circuit ------------------------------------------------------------------------------------------------- 7-3

(Option, HD Transmission and Drive Axle)

CONTENTS

CONTENTS

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Summary of Contents for Hyundai 25L-9A

Page 1 CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ---------------------------------------------------------------------------------------------------- 1-5 Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-13 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 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM...
Page 2 Group 3 Component Specification --------------------------------------------------------------------------------- 7-20 Group 4 Connector Destination -------------------------------------------------------------------------------------- 7-21 Group 5 Troubleshooting ------------------------------------------------------------------------------------------------ 7-26 SECTION 8 MAST SECTION 8 MAST Group 1 Structure ------------------------------------------------------------------------------------------------------------ 8-1 Group 2 Operational Checks and Troubleshooting ----------------------------------------------------- Group 3 Adjustment -------------------------------------------------------------------------------------------------------- 8-8 Group 4 Removal and Installation --------------------------------------------------------------------------------- 8-11...
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 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 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
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 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
Page 9 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
Page 10 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 11 SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety hints ------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ---------------------------------------------------------------------------------------------------- 1-5 Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-13...
Page 12 GROUP 1 SAFETY HINTS GROUP 1 SAFETY HINTS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. · Oil is a dangerous substance. Never handle oil, grease or oily clothes in places where there is any fire of flame.
Page 13 Be particularly careful when removing the radiator cap and the hydraulic oil tank filler cap, if this is done immediately after using the truck, 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, move the control levers to each position two or three...
Page 14 · Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail. It is very dangerous if someone slips while on the truck. D50ASF09 · When working with others, choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreed work.
Page 15 Way to use dipstick Push the dipstick fully into the guide, and then pull out. Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you consider the maintenance is too difficult, always request the HYUNDAI Forklift distributor to carry out...
Page 17 2. SPECIFICATIONS 25L9ASP01 Model Unit 25L-9A 30L-9A 33L-9A 35LN-9A Capacity kg (lb) 2500 (5000) 3000 (6000) 3300 (6500) 3500 (7000) Load center mm (in) 500 (24") Weight (Unloaded) kg(lb) 3888 (8570) 4282 (9440) 4395 (9690) 4535 (10000) Lifting height mm (ft-in) 3305 (10' 10")
Page 18 3. SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item Unit Specification Model HYUNDAI, L4KB [Theta] Type 4-cycle, vertical Cooling Method Water cooled Number of cylinders and arrangement 4 cylinders, In line Firing order 1-3-4-2 Cylinder bore X stroke mm (in) 88 97 (3.46 3.82)
Page 19 STEERING UNIT Item Unit Specification Type Load sensing/Non load reaction/Dynamic signal Capacity cc/rev Max. input pressure 22.7 Back pressure Input torque 1.5 0.2 POWER TRAIN DEVICES Item Specification Model KAPEC 280DB Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type...
Page 24 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 25 SECTION 2 REMOVAL AND INSTALLATION OF UNIT Group 1 Structure ------------------------------------------------------------------------------------------------------------ 2-1 Group 2 Removal and Installation of unit --------------------------------------------------------------- ------- 2-2...
Page 26 SECTION 2 REMOVAL & INSTALLATION OF UNIT SECTION 2 REMOVAL & INSTALLATION OF UNIT GROUP 1 STRUCTURE GROUP 1 STRUCTURE 13 14 16 17 25L9AOM23 Mast 10 Transmission 19 Radiator Lift cylinder 11 Torque converter 20 Muffler Steering unit 12 Engine 21 LPG tank Tilt cylinder 13 Air cleaner...
Page 27 GROUP 2 REMOVAL AND INSTALLATION OF UNIT Remove and install following units as explained in the flow chart. 1. MAST REMOVAL L15C3RE001 Forks Backrest Lower the fork carriage until the forks are ① approximately 25 mm (1 in) from the floor. Turn knob up and slide one fork at a time ②...
Page 28 While supporting lift chains, remove nuts ② Lift chain and split pin from the anchor bolt. Outer mast Split pin 25L9ARE05 Pull the chains out of the sheaves and ③ drape them over the front of the carriage. Mast Carriage Lift chain Block 22D9RE06...
Page 29 Piping ① Remove the return hoses and clamps attached to the cylinder. Band Remove hose assembly, valve and tee ② Hose clamp clamp from the lift cylinder. Put blind plugs in the piping immediately ※ after removing hoses. Return hose This prevents the hydraulic oil from flowing out and also prevents dust and Lift...
Page 30 Inner mast Using an overhead hoist raise the inner ① mast straight and carefully draw out of outer mast section. Inner mast Be careful the mast not to swing or fall. Outer mast 22D9RE10 Tilt cylinder pin Loosen the bolt and remove the tilt cylinder pin.
Page 31 INSTALLATION After assembling mast components totally without piping connections, install mast assembly to the equipment. Installation procedure for each of mast component is the reverse of the removal procedure. ※ Mast support cap Check the mast support cap and spring pin for wear. ①...
Page 32 2. POWER TRAIN ASSEMBLY REMOVAL Service Brake piping Parking brake piping 25L9ARE04A Mast Refer to section on mast (Page 2-2)
Page 33 Service brake piping Disconnect the service brake piping from Brake pipe the brake housing of drive axle. Brake valve Drive axle 25L9ARE12...
Page 34 Drive axle Crane Drain the axle oil from the drive axle ※ before the axle removal. Attach a crane to the tilt cylinder notches ① on the dashboard and raise the truck. Tilt cylinder Loosen hexagonal bolts (1) connection ② notch the drive shaft to the drive axle.
Page 35 Torque converter Remove the cover on top face of the ① torque converter housing then remove Cover the 8 mounting bolts installed on the engine flywheel. To rotate the flywheel, remove 1 mounting bolt, then insert a turning tool in the mounting hole. One man must turn the engine fan by hand Bolt (2) while the other turns the flywheel.
Page 36 INSTALLATION Installation is the reverse order to Bolt (1) removal, but be careful of the following points. Tightening torque Bolt (2) ·Bolt (1):5.9~8.9 kgf · m (42.7~64.4 lbf · ft) ·Bolt (2):2.7~4.1 kgf · m (19.5~29.7 lbf · ft) Bolt (5) ·Bolt (3):5.9~8.9 kgf ·...
Page 37 3. ENGINE Remove the torque converter, transmission and front axle inside the frame, then remove the engine assembly. REMOVAL D503RE25 Overhead guard Remove the wiring for rear combination lamp, working lamp, head lamp and flasher lamp on the stay of the overhead guard and then raise it together with the bonnet.
Page 38 Remove the torque converter housing cover, mounting bolts installed to flywheel housing. For details, see page 2-10. Engine accessory Engine assy Remove all wiring harnesses, cables and hoses around the engine, dashboard and frame. Wiring harness to alternator and starter. ①...
Page 39 Loosen the clamp and disconnect the ⑤ Engine hose to the air cleaner. Clamp Loosen the nut and disconnect the pipe ⑥ to the muffler. Air cleaner Muffler Exhaust pipe Engine 25L9ARE41 Radiator hose Radiator assy Open the drain valve of the radiator and drain the cooling water, then remove the radiator hose.
Page 40 Mounting bolt Attach a crane to the engine hook and raise, then remove mounting bolts. Raise the engine slightly, slide towards the radiator, then lift up. When sliding the engine, be careful of the ※ collision engine and radiator. Engine assy 25L9ARE24 INSTALLATION Installation is the reverse order of removal,...
Page 41 Fuel hoses Engine Insert the fuel hose securely and fit Clamp clamps. Air cleaner Muffler Exhaust pipe Engine 25L9ARE41 Air cleaner hose and exhaust pipe Regulator ① Align the exhaust pipe to the engine securely and tighten the nuts. ·Tightening torque : 4.0~6.0 kgf·m Hose (28.9~43.4 lbf·ft) Insert the air cleaner hose securely and...
Page 42 Hold the counterweight with hoist bars, and raise it with a crane. Remove the mounting bolts, raise slightly and move it slowly to rear side. ·Weight of counterweight (standard) 25L-9A : 1,307 kg (2,881 lb) 30L-9A : 1,596 kg (3,519 lb) 33L-9A : 1,866 kg (4,114 lb) ·Tightening torque : 199±29.9 kgf ·...
Page 43 Rear wheel Remove mounting bolt and hub nut with Mounting bolt socket wrench and then carefully take out the tire assembly. ·Tightening torque : 16.0~20.0 kgf · m Mounting bolt (116~145 lbf · ft) Hub cap 25L9ARE28 Hose Steering axle After draining out oil in the hoses, disconnect the hoses from the steering axle.
Page 44 SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation ----------------------------------------------------------------------------------- 3-1 Group 2 Troubleshooting ------------------------------------------------------------------------------------------------ 3-20 Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 3-26...
Page 45 SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN DIAGRAM STRUCTURE 25L9APT26 Engine Drive shaft Service brake Transmission Drive axle Parking brake...
Page 46 SPECIFICATION Item Specification Model KAPEC 280 DB Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.9 : 1 Type Power shift Gear shift (FR/RR) Transmission Control Electrical single lever type, kick-down system 1.308 : 1 Overhaul ratio 1.308 : 1 Type Front-wheel drive type, fixed location...
Page 47 2. TORQUE CONVERTER STRUCTURE 25L9APT03 Hexagon bolt Charging pump assembly Ball Plain washer Plug Air breather Flexible plate O-ring Inner oil strainer Torque converter assembly Torque converter housing Oil strainer spring Shaft Hexagon bolt O-ring Snap ring Torque converter cover Oil strainer plug Socket gear O-ring...
Page 48 OPERATION The torque converter is connected with a flywheel by a flexible plate, engine output is delivered from the flywheel to the flexible plate. The exterior of the torque converter is protected by the torque converter housing. The torque converter housing forms the oil path for the oil pump, it includes the oil strainer filtering sucked oil through this oil path and the oil level gauge measuring oil level of the transmission inside.
Page 49 3. TRANSMISSION STRUCTURE 15L7APT28 Control valve Output gear Torque converter Temperature sensor Turbine wheel Oil strainer Impeller wheel Idle gear Stator wheel Forward clutch pack Forward clutch gear Input shaft Oil pump Reverse clutch pack Reverse clutch gear...
Page 50 INSTALLATION VIEW 22D9PT05 1 Torque converter 5 Transmission oil filter 2 Control valve 6 Transmission output (Universal joint link part) 3 Oil level pipe and dipstick 4 Air breather OPERATION The torque converter is an automatic fluid drive. It transmits engine torque by means of hydraulic force. The torque converter leads and the power which is delivered rotated the charging pump.
Page 51 OPERATING MODES Forward Input Torque converter Clutch shaft Forward clutch gear Output gear Output 15L7APT29 Reverse Input Torque converter Clutch shaft Reverse clutch gear Output gear Output 15L7APT30...
Page 52 TRANSMISSION CASE AND CONTROL VALVE Structure 22D9PT07 Transmission case 11 Socket bolt Cylinder gear Oil seal 12 Oil gauge Idle gear Ball 13 Clamp Output gear Spring 14 Socket bolt Socket bolt O-ring 15 Flange bolt Dowel pin Plug 16 Control valve O-ring Plug 17 Gasket...
Page 53 Operation The transmission case includes the function of a control valve and an oil filter. The oil filter is charge of filtering sucked oil by an oil pump before transmitting sucked oil to a control valve and a torque converter. Oil transmitted through an oil filter delivers oil pressure to the piston of the forward and reverse clutch through the solenoid valve.
Page 54 CONTROL VALVE Operation 22D9TPT08 Modulation Forward clutch pressure check port Fwd/rev solenoid valve Reverse clutch pressure check port Inching spool Main pressure check port Main relief valve Parking solenoid valve Inching valve pressure check port The control valve consists of the main relief valve, solenoid valve, modulation valve and inching valve.
Page 55 Structure Main relief valve Modulation Inching valve pressure check port Forward clutch pressure check port Main pressure check port Reverse clutch pressure check port Parking solenoid valve Inching spool Solenoid valve 25L9APT22 1 Guide plug 11 Spring 21 Stopper 2 O-ring 12 Solenoid valve (fwd/rev) 22 Spring 3 Spring...
Page 56 CLUTCH Operation Reverse Forward 15L7APT31 Forward clutch plugging pressure delivery line ( Reverse clutch plugging pressure delivery line ( Clutch pack lubrication line ( When (forward/reverse) mode is selected through the solenoid valve of control valve, the flux flowed by the oil pump flows into forward (reverse) clutch pack in 10.5~14.9 kgf/cm (149~212 psi) of pressure through the oil path of transmission inside.
Page 57 Structure 10 11 22 23 17 18 10 11 22D9TPT11 1 Shaft 11 Quad ring 21 Spacer 2 Peek seal 12 Plate 22 Forward clutch gear 3 Small seal ring 13 Friction plate 23 Spacer 4 Reverse clutch gear 14 Plate 24 Ball bearing 5 Ball bearing 15 Snap ring...
Page 58 OUTPUT GEAR Operation The output gear is engaging the forward clutch gear and reverse clutch gear together. If a driver selects forward, the forward clutch gets plugging, the forward clutch gear revolves and the power of forward clutch gear is delivered to output gear. If a driver selects reverse, the reverse clutch gets plugging, the reverse clutch gear revolves and the power of reverse clutch gear is delivered to output gear.
Page 59 4. DRIVE AXLE INSTALLATION VIEW 25L9APT15 Carrier sub assembly Service brake Oil dipstick Drive axle housing STRUCTURE 22D9PT16 Piston shaft Axle shaft Wheel hub Ring gear Service brake Carrier sub assy Differential device Hub reduction Parking brake The drive axle is connected with the transmission output gear and universal joint. The power transferred by the universal joint is connected to the pinion shaft of drive axle, the pinion shaft delivers the power to the differential device through the ring gear.
Page 60 CARRIER ASSEMBLY Operation Carrier sub assembly include spiral bevel gear for transfer the power of transmission to axle. Also, including differential device for separate power of transmission to left/right axle shaft and parking brake. Sprial ring gear Differential device Parking brake Pinion shaft 25L9APT21 3-16...
Page 61 DIFFERENTIAL DEVICE Operation Since the ring gear is linked with the right of the differential case and the bolt, the power transferred to the ring gear makes the differential device revolve. And also, the left and right of the differential case are connected with the left and right of the axle shaft and the spline respectively, it delivers the power to the final drive.
Page 62 PARKING BRAKE (NEGATIVE BREAKE) Operation In case of start switch OFF at truck, active parking brake from parking spring push parking piston, and then piston pressured friction plate. It has force distribution. In case of start switch ON at truck, the main pressure at control valve on transmission main pressure supply to parking brake port, and then released pressure at piston and friction plate finally the parking brake is released.
Page 63 Structure 25L9APB03 1 Parking spline Quad ring - S 13 Taper roller bearing 2 Plate Quad ring - L 14 Oil seal 3 Friction plate Brake piston 15 U-joint flange 4 Piston housing 10 Parallel pin 16 Taper roller bearing nut 5 Elbow 45 11 Parking spring 12 Parking cover...
Page 64 GROUP 2 TROUBLESHOOTING 1. TRANSMISSION Trouble symptom Probable cause Remedy 1. Output does not go up 1) Torque converter - Torque converter oil The oil is in short supply. Replenish oil. The oil that is not regulated is used. Change the oil to regular oil. The air has mixed into oil.
Page 65 Trouble symptom Probable cause Remedy 2. Power is not transmitted 1) Torque converter The flexible plate is broken. Change the flexible plate. The oil is in short supply. Replenish oil. The shaft and spline are worn. Change the shaft and the spline. The gear is broken.
Page 66 Trouble symptom Probable cause Remedy 4. Clutch or converter oil pressure is too high 1) Torque converter Viscosity of oil is too high (at cold time). Warm up the torque converter if the temperature of torque converter oil is below outside air temperature. The oil that is not regulated is used.
Page 67 2. DRIVE AXLE Trouble symptom Probable cause Remedy 1. Noise and vibration 1) Drive axle Lubricating oil shortage. Check oil level and refill lubricating oil. Using different lubricating oil. Change lubricating oil. Maladjustment or detect of wheel Change wheel bearing. bearing.
Page 68 Trouble symptom Probable cause Remedy 2. Oil leakage 1) External leakage Excess of oil. Check oil level. Set of oil amount. Using different oil. Change oil. Blocking air breather. Washing or change air breather. Damaged of hub oil seal. Disassemble, check and change. Leakage at pinion shaft.
Page 69 Trouble symptom Probable cause Remedy 4. Brake does not apply 1) Service brake. - Low or no pressure Empty fluid reservoir. Fill reservoir to correct level with to brake. specified fluid. Damaged hydraulic system. Check hydraulic system. Leakage of brake actuation fluid. Refer to "Brake leaks actuation fluid"...
Page 70 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF TRANSMISSION DISASSEMBLING OF TRANSMISSION ASSY Drain the transmission oil. Remove the drain plug at T/C housing. Lay the wood plate (or plastic plate) on the workshop's table (bottom). And put the T/M assy on the wood plate (or plastic plate) : For an (dis) assembly at the time of damage prevent.
Page 71 Remove the socket gear. Next remove the snap-ring at socket gear. 22D9TTM005 Removal the oil pump sub assy. Remove the hexagon bolt (M8 1.25P 38L), and then remove the copper washer. 15L7ATM006 Use a plastic mallet to decomposition. 22D9TTM007 Remove the O-ring at pump sub assy. 22D9TTM008 Remove the oil seal, pump case, drive gear, driven gear, stator shaft and bolt plate.
Page 72 Removal the control valve sub assy. Remove the hexagon bolt (M8 1.25P 60L). 22D9TTM010 Remove the part slowly with hit the end side softly. Using a plastic hammer . Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.
Page 73 (10) Remove the cooler (in/out) plug.(M16) 22D9TTM015 (11) Remove the air breather. 22D9TTM016 (12) Remove the hexagon bolt, and then remove the T/ C cover. 15L7ATM017 (13) Remove the oil level gauge. 15L7ATM018 (14) Remove the socket bolt, and then remove the clamp.
Page 74 (15) Remove the socket bolt, and then remove the pipe. Next remove the O-ring at the pipe. 15L7ATM020 (16) Remove the socket bolt, and then remove the speed sensor. 22D9TTM021 (17) Lay the T/M assy without damage to the T/C housing.(engine mounting surface) 22D9TTM022 (18)
Page 75 (19) Remove the plug.(PT 1/8 4EA, PT3/8 4EA) 22D9TTM024 (20) Remove the socket bolt (T/M case + T/C housing fastening bolt) 4 socket bolt exclusions. 15L7ATM025 15L7ATM026 (21) To turn over T/M assy without damage to the T/M case. (main pump mounting surface) Next remove the 4 socket bolt.
Page 76 (22) Remove the part slowly with hit the end side softly. Using a plastic hammer. 15L7ATM028 (23) Remove the T/C housing. 15L7ATM029 (24) Gear assemblies arrangements. 15L7ATM030 (25) Remove the O-ring. 15L7ATM031 Remove the output gear assy. (26) 15L7ATM032 3-32 3-32...
Page 77 (27) Remove the idle gear assy. 15L7ATM033 (28) Remove the clutch gear assy. Store each gear assembly in separate box. 15L7ATM034 (29) Remove the oil seal. 15L7ATM035 3-33 3-33...
Page 78 DISASSEMBLING OF GEAR ASSEMBLIES Disassembling clutch gear assy. 22D9TTM036 Remove the peek seal and seal ring. 22D9TTM037 Pull out the bearing (#6207) and spacer from the shaft. 22D9TTM038 Pull out the forward clutch sub assy and space. 22D9TTM039 3-34 3-34...
Page 79 Pull out the bearing (#6911) from the shaft. 22D9TTM040 Pull out the reverse clutch sub assy and remove the O-ring. 22D9TTM041 Forward clutch sub assy. 22D9TTM042 Remove the forward clutch gear sub, and then remove the spacer. 22D9TTM043 3-35...
Page 80 Remove the snap ring, and then remove the bearing. 15L7ATM044 Remove the snap ring, and then remove the back plate, friction disk, and steel plate. 15L7ATM045 Remove the wire ring, and then remove the back plate and spring. When you remove the wire-ring, it might be shot out by impact of spring.
Page 81 Remove the reverse clutch gear sub. 22D9TTM048 Remove the snap ring, and then remove the bearing. 15L7ATM049 Remove the snap ring, and then remove the back plate, friction disk, and steel plate. 15L7ATM050 Remove the wire ring, and then remove the back plate and spring.
Page 82 Disassembling of Idle gear assy. 15L7ATM052 Pull out the bearing, and then remove the idle gear upper (lower). 15L7ATM053 Disassembling of output gear assy. 15L7ATM054 3-38 3-38...
Page 83 Remove the seal ring, oil seal and sealing cap. 15L7ATM055 Pull out the bearing. 15L7ATM056 3-39 3-39...
Page 84 2. ASSEMBLY OF TRANSMISSION ASSEMBLING OF GEAR ASSEMBLIES Assemble the part with reverse the aforementioned disassemble procedure. Assembling of clutch gear assembly. Forward clutch drum sub assembly. In drum internal groove O-ring assembly. Spread grease on seal ring. 22D9TTM057 In piston groove glyd ring assembly. Spread grease on glyd ring.
Page 85 First insert steel plate, and then insert friction disk alternately. Next insert the back plate, and then assemble the snap ring. 15L7ATM061 Assemble the bearing, and then assemble the snap ring alternately. 15L7ATM062 Arrange serration of the friction disk, and then assemble the spacer, clutch gear sub.
Page 86 Reverse clutch drum sub assembly. Do work as the same way like forward clutch drum sub assembly procedure 1) Assemble the bearing, and then assemble the snap ring alternately. 15L7ATM065 Arrange serration of the friction disk, and then assemble the clutch gear sub. 22D9TTM066 Reverse clutch drum sub assembly.
Page 87 Assemble the bearing. - Used method of heating bearing. All bearings should never be heated above 120 C. 15L7ATM069 Assemble the forward clutch drum sub assy and space at the shaft sub assy. 22D9TTM070 Assemble the spacer and bearing. - Used method of heating bearing. 22D9TTM071 Assemble the peek seal and seal ring.
Page 88 Assembling of output gear assembly. Assemble the bearing. - Used method of heating bearing All bearings should never be heated above 120 C. 15L7ATM074 Assemble the oil seal, seal ring and sealing cap. Spread loctite #609 on the out wheel of oil seal, spread grease on inside wheel of oil seal.
Page 89 Assembling of idle gear assembly. Press the idle gear upper and idle gear lower at the idle gear shaft, and then assemble the bearing. - Used method of heating bearing All bearings should never be heated above 120 C. 15L7ATM077 Idle gear assy.
Page 90 ASSEMBLING OF TRANSMISSION ASSY Press the oil seal. Spread loctite #592 on the out wheel of oil seal, spread grease on inside wheel of oil seal. 15L7ATM079 Assemble the clutch gear assy. When you insert the shaft after install the seal ring in the shaft, please insert the shaft with turning it into the shaft side and hole side of shaft for prevent the damage of shaft.
Page 91 Press the lock-pins. After the assembling, please check whether you can turn the input (output) gear lightly by your hand. 15L7ATM084 Spread loctite #5127 on T/C housing space. 15L7ATM085 Assemble the T/C housing. 15L7ATM086 Assemble the part slowly with hit the end side softly.
Page 92 (11) Turn over T/M assy without damage to the T/C housing.(engine mounting surface) Next assemble the socket bolts. Socket bolt (M10 1.5p 40 mm) 16EA Tightening torque : 6.5~7.0 kgf m (47~50.5 lbf ft) Spread loctite #277 on socket bolt. 15L7ATM089 (12) Assemble the socket bolts.
Page 93 (15) Assemble the O-ring at the plug. Insert the oil strainer, spring ,and then assemble O-ring+plug assy. Plug tightening torque : 8~10 kgf m (58~72 lbf ft) Spread grease on O-ring. 15L7ATM093 (16) Assemble the speed sensor, next assemble the socket bolts.
Page 94 (20) Assemble the T/C cover and hexagon bolts. Hexagon bolt (M8 1.25p 16 mm) Tightening torque : 3.2~3.6 kgf m (23~26 lbf ft) Spread loctite #277 on socket bolt. 15L7ATM098 (21) Assemble the air breather. Tightening torque : 3.0~4.0 kgf m (21.5~29 lbf ft) Spread loctite #577 on air breather.
Page 95 (25) Assemble the hex bolt. Hexagon bolt (M8 1.25p 60 mm) 10EA Tightening torque : 3.2~3.6 kgf m (23~26 lbf ft) 22D9TTM103 (26) Assemble the drive gear, driven gear and stator shaft at the pump case and assemble the bolt plate and then oil seal.
Page 96 (30) Insert the PTO shaft. 15L7ATM107 (31) Install the flexible plate at the torque converter, and then install the hexagon bolt and washer. Hexagon bolt (3/8-24UNF-2B) Tightening torque : 3.0~3.5 kgf m (21.6~25.3 lbf ft) Spread loctite #277 on hexagon bolt 15L7ATM108 (32) Insert the T/C sub assy at the T/M sub assy.
Page 97 3. DISASSEMBLY OF DRIVE AXLE DISASSEMBLY Disassembling of drive axle assy. 15L7ADA001 Remove bolts of hub sub assembly. To avoid serious personal injury and possible damage to components, be very careful when using lifting devices during removal and disassembly procedures. Inspect to make sure that neither lifting strap is damaged.
Page 98 Disassemble in order of special bolt return spring. 22D9TDA006 Remove the brake pistion. Caution of the quad ring damage. 22D9TDA007 After remove retaining ring, pull out left axle shaft. (Do work as the same way like right axle shaft) Use a brass, leather or rubber mallet for assembly and disassembly procedures.
Page 99 (10) Remove all each parts in order of thrust washer planet gear needle bearing thrust washer. Check to be sure that the needle roller quantity. (19 EA/1 gear) 22D9TDA011-1 22D9TDA011-2 22D9TDA011 Thrust washer (1) Thrust washer (2) (11) Disassemble the set screw. When hard to disassemble by loctite, heating the set screw on 1 min by heating device.
Page 100 (14) Extract carrier housing with bearing. 22D9TDA014 (15) Remove bolts and spring wahser. 22D9TDA015 (16) Remove flange hub, shim, spacer and O-ring. If you do not replace the bearing or spacer, disassemble and reassemble the shim to accept. 22D9TDA016 (17) Extract the fixing bolt of carrier assembly.
Page 101 (18) Extract carrier assembly. Using lifting device. 22D9TDA018 (19) Fix carrier assembly to a jig. 22D9TDA019 (20) Remove carrier cap bolt. 22D9TDA020 (21) Extract the carrier cap (apply marking a match). 22D9TDA021 (22) Remove adjusting ring of both sides bearing cup. Using dedicated fixtures and brass drift punch.
Page 102 (23) Extract differential assembly. 22D9TDA023 (24) After turn over carrier assy and fix it, remove nut. 22D9TDA024 (25) Remove U-joint flange. 22D9TDA025 (26) Remove carrier case cover bolts. Disassemble slowly and follow the No. in regular. It prevent to jump out the cover by inner spring 22D9TDA026 (27) Extract carrier case cover assembly.
Page 103 (28) Remove spring and guide pin. 22D9TDA028 (29) Disassemble the piston. When disassembling, apply oil or air pressure at brake port. Caution of damage on quad ring 22D9TDA029 (30) Remove the O-ring 22D9TDA030 (31) Disassemble the pinion shaft. Hit the pinion shaft by rubber hammer. To avoid personal injury and possible damage to component.
Page 104 (32) Disassemble shim, spacer, and bearing. If do not replace the spacer and bearing, it use original shim. 22D9TDA032 (33) Remove the O-ring. 22D9TDA033 (34) Extract piston housing. 22D9TDA034 (35) Remove parking friction plate and separate plate. 22D9TDA035 (36) Remove spline parking. 22D9TDA036 3-60 3-60...
Page 105 (37) Remove bearing cup and shim. 22D9TDA037 (38) Bearing cup and shim parts. 22D9TDA038 3-61 3-61...
Page 106 ASSEMBLY Carrier sub assembly Differential device assembly Prepare parts for assembly of differential. 22D9TDA138 Fix differential case RH and spiral ring gear with bolt. After paste loctite #277 on spiral of bolt. Confirm torque : 7.1~7.6 kgf m 22D9TDA139 Assemble the carrier sub of a sequential development.
Page 107 Adjusting shim and pinion shaft assembly Fix carrier case to the jig. Read the following information before installing new gear set in the carrier. Always inspect the gear set for correct marks to make sure the gears are a matched set. 22D9TDA036A The locations of the gear set marks are shown in right figure.
Page 108 Decide thickness of shim by gauge and measuring apparatus (Standard gap between bearing and carrier case step : A) (Mounting distance (MD) of pinion shaft : B) Thickness of shim X = A - B + Carrier case bearing step depth ex1) A=0.35, B=-0.1, Bearing step depth= +0.1 X=0.35 + 0.1 + 0.1 = 0.55 mm 22D9TDA038A...
Page 109 Set a ball. 15L7ADA043 Equip jig for fixing. 15L7ADA044 Fasten the ball. 15L7ADA045 Put into spacer. 22D9TDA047 Decide thickness of shim by depth gauge (thickness : A) If there is no set work-related replacement parts required. Re-use the existing parts. Thickness of shim = A - (0.03 ~ 0.06) A : short distance between the bearing assembly and spacer...
Page 110 Assemble shim. 22D9TDA052 Assemble bearing. Bearing cup is assembled using a dedicated jig. Put heated bearing inner ring, and control heating temperature 100 C or less. 22D9TDA053 Assemble of parking sub assembly Assemble spline parking. 22D9TDA054 Assemble O-ring 22D9TDA055 Assemble in order of separate plate (plate friction plate).
Page 111 Assemble the piston housing. (paste loctite #5127) 22D9TDA057 Example of paste loctite. 22D9TDA057A Assemble O-ring, air bleeder and elbow 45 . (when assemble O-ring, paste oil or greace). Tightening torque of elbow 45 : 3.8~4.2 kgf·m Tightening torque of air bleeder : 1.5~2.0 kgf·cm 22D9TDA058 Attention of direction on assembly.
Page 112 Assemldy direction : Top of parking release : Assembly of guide pin 22D9TDA059A Guide pin + spring assembly. 22D9TDA060 Parking cover + oil seal assembly. (Match the parking position tap and cover hole) 22D9TDA061 Assemble bolt. Paste loctite #5127 on side assembling. Paste loctite #277 on bolt, tightening torque 3~ 4 kgf m.
Page 113 Follow the direction at the cover assembly symmetry, for proper seating of the spring. 22D9TDA062A Check the performance of parking brake. The following procedure describes how to test brake oil leakage, return state of piston. Remove residual air in brake line. Actuate the piston at least five times with 10 bar.
Page 114 Preload measurement. (Spec : 10~19 kgf cm) If preload is over the spec, follow the procedure. (refer to page 3-65, 3-66) Adjust the thickness of shim. Always remember that the hydraulic oil circuit is under pressure. When carring out inspection and maintenance, release the pressure first.
Page 115 Adjusting the gear set backlash Assemble differential sub in carrier case. 22D9TDA076 Sub-assembly differential carrier case de suffren. Threaded steel ball assembly for positioning. 22D9TDA077 Fit carrier cap with steel ball. Bolt : paste loctite #277 Confirm torque : 11.7~13.1 kgf m 22D9TDA078 Fasten bearing adjust ring.
Page 116 When the ring gear away from the pinion shaft will Backlash reduction methods increase the backlash. 22D9TDA082 How to increase backlash 22D9TDA081 Adjusting tooth contact pattern of the gear set After assembling, adjust pattern of the gear and pinion shaft figure. If pattern is not adjusted, take a measure as measuring backlash again and then reassemble.
Page 117 Rotate ring gear forward and backward so that the 6 marked teeth go past the drive pinion six time to get a good contact pattern. Compare the contact patterns. In new gear sets, a good contact pattern is toward the toe of the tooth, and centered between the top and bottom of the tooth.
Page 118 If the contact patterns require adjustment along the width of tooth (top/bottom), follow steps If the contact patterns require adjustment along the length of tooth (toe/heel), follow steps High pattern : A high contact pattern indicates that the pinion was installed too shallow into the carrier.
Page 119 Fix spring pin with ring bearing adjust. And assemble them. 15L7ADA094 After completion of the pattern adjustment, the spring pin assembly. Adjust the bearing ring to be fixed. 22D9TDA096 15L7ADA095 3-75 3-75...
Page 120 Assemble of carrier assembly Paste sealant on axle housing. (Loctite #5127) 22D9TDA097 Assemble carrier assembly on axle housing. 22D9TDA098 Fasten bolt. Assemble bolt after spread loctite #277. Confirm torque : 6.1~6.5 kgf m 22D9TDA099 3-76 3-76...
Page 121 Traveling brake system assembly Axle shaft assembly Insert snap ring on the axle shaft. 22D9TDA100 After put the ball bearing, fix it with snap ring. 22D9TDA101 After put axle shaft into axle housing fix with snap ring. 22D9TDA102 Brake piston assembly Assemble ring (Quad ring + Back up ring) at piston brake.
Page 122 Assemble the piston. Match assembly tap of special bolt and position of sleeve. Before assemble Quad ring coating oil or grease. 22D9TDA105 Assemble return spring and special bolt. Paste loctite #277. Tighten torque :1.8~2.0 kgf m 22D9TDA106 Example) Paste loctite on speical bolt. If paste loctite too much on sleeve &...
Page 123 Hub assembly Hub sub assembly Assemble hub bolt. (Use jig and press) 22D9TDA110 Assemble direction example. Careful assemble with head of bolt and hub flange. 22D9TDA110A If you do not press or dedicated fixtures. Assemble the hub nuts, hub bolt assembly can be tightened.
Page 124 Assemble O-ring coated grease at wheel shaft. 22D9TDA113 Assemble flange hub and wheel shaft. Paste loctite #5127 Confirm torque : 6.0~7.0 kgf m Bolt : Spread loctite #277 22D9TDA114 Fix spacer. 22D9TDA115 Assemble oil seal at carrier housing. Oil seal with loctite #592. 15L7ADA116 Assemble bearing cup at carrier housing.
Page 125 Assemble bearing cup at upper side of carrier ⑨ housing. 22D9TDA118 Hub + wheel shaft assemble in grease charge. ⑩ ·Charge amount : Grease outer ring of wealth space 60~80%. Recommend Grease : Shell Retinax 0419 22D9TDA118A Assemble the carrier housing on flange hub and ⑪...
Page 126 Pressurize bearing cone. Before assembling, paste axle oil on roller of bearing cone. 22D9TDA122 Assemble planet carrier. 22D9TDA123 Assemble the locknut to confirm the bearing preload. Use designated jig or brass drift punch. Loosen and tighten repeatedly 2~3 time with 35~38 kgf m If there is no parts replacement from bearing, shaft, housing and spacer, initially assembled shims can...
Page 127 Fasten lock nut. Spread the Loctite #277 on screw. Confirm torque : 3.5~3.8 kgf m Mate lock nut slot and planet carrier's hole. Preload : 40~50 kgf cm 22D9TDA124B Fasten set screw. Spread the Loctite #277. Confirm torque : 105~150 kgf cm 22D9TDA124C Assemble in order of washer needle bearing...
Page 128 Assemble of hub sub assembly Paste loctite #5127 on axle housing. About 3 mm wide circle around the front of the application. 22D9TDA127 Assemble the hub assembly on the axle housing. Lifting device or the guide bolts. Field, using the following guide bolt. Can be easily assembled.
Page 129 The rest part assembly Assemble O-ring and fitting bleeder for LH and Confirm torque : 3.8~4.2 kgf m 22D9TDA129 Assemble bleeder and cap. Screw : Assemble after spread loctite #577. Confirm torque : 1.5~2.0 kgf m 22D9TDA130 Assemble air breather. Screw : Assemble after spread loctite #577.
Page 130 Put in dipstick. Fill axle oil as much as standard. Standard between the upper limit and the lowest limit. 22D9TDA135 22D9TDA134 Assemble dipstick gauge. 22D9TDA136 Finish drive axle assembly. 22D9TDA137 3-86 3-86...
Page 131 Functional test of hydraulic apply brake The following procedure describes how to test the hydraulic apply brake system only. To perform this test, use a device that allows you to observe possible leaks through oil seals and that also allows you to verify that the piston return system works correctly .
Page 132 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM (Option, HD Transmission and Drive Axle) (Option, HD Transmission and Drive Axle) Group 1 Structure and operation ----------------------------------------------------------------------------------- 3-88 Group 2 Disassembly and assembly ---------------------------------------------------------------------------- 3-102 Group 3 Maintenance and troubleshooting ------------------------------------------------------------------- 3-146...
Page 133 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND OPERATION GROUP 1 STRUCTURE AND OPERATION 1. POWER TRAIN DIAGRAM 1. POWER TRAIN DIAGRAM 1) 1) STRUCTURE STRUCTURE 25L9APT26 Engine Drive shaft Service brake Transmission Drive axle Parking brake 3-88...
Page 134 2) 2) SPECIFICATION SPECIFICATION Item Specification Model KAPEC 280DK Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.90 Type Power shift Gear shift(FWD/REV) Transmission Control Solenoid On/Off type 1.4375 Overhaul ratio 1.4375 Type Front-wheel drive type, fixed location Axle Gear ratio 11.568 : 1...
Page 135 2. TRANSMISSION 2. TRANSMISSION STRUCTURE STRUCTURE 1) 1) 25D9HDI3PS174 Control valve PTO shaft 11 Reverse clutch shaft Torque converter Charging pump 12 Output shaft Turbine wheel Forward clutch pack 13 Parking brake Impeller wheel Forward clutch shaft Stator 10 Reverse clutch pack 3-90...
Page 136 25L9A3PS02 Torque converter Control valve PTO pump mounting Torque converter housing Speed sensor Temp sensor Output (Universal joint link part) 3-91...
Page 137 2) 2) OPERATION OPERATION The torque converter acts as a fluid coupling to smoothly transfer engine power to the trans- mission. It also increases the torque by the force applied to the stator while oil is circulating inside the torqueconverter. The engine power transferred through the flexible plate is then transferred to the impeller on the torque converter in order to drive the oil pump.
Page 138 4) 4) CLUTCH CLUTCH Forward clutch Reverse clutch 1 Pressure line 2 Lubrication line 25D9V3PS10 Gear shift refers to the action of shifting the vehicle from neutral to forward/reverse. When forward or reverse is decided by the vehicle's shift lever, the corresponding electric signal switches the forward/reverse solenoid to the ON state.
Page 139 5) 5) POWER FLOW POWER FLOW Forward Input Torque converter Forward clutch shaft Input Forward clutch gear Output gear Output Ouput 25D9V3PS11 3-94...
Page 140 Reverse Input Torque converter Forward clutch shaft Input Forward drum gear Reverse drum gear Reverse clutch shaft Clutch gear Ouput Output gear Output 25D9V3PS12 3-95...
Page 141 6) 6) CONTROL VALVE CONTROL VALVE Structure 25L9A3PS06 25L9A93PS07 Main relief Main pressure check port Forward solenoid valve Inching Reverse solenoid valve Modulation Forward clutch pressure check port Parking brake solenoid valve Reverse clutch pressure check port Function Item Function Main relief Maintains constant clutch pressure.
Page 142 Hydraulic circuit Hydraulic circuit Control Valve Solenoid Vavle (for Clutch) TC IN Relief Valve Inchin Valve Accumulator Torque Converter Main Relief Valve Solenoid Valve (for Parking) Oil Cooler Oil Filter Transmission Lubricating Charging Pump Strainer ① The charging pump of the transmission draws oil in the transmission through the strainer, and the oil is delivered to the torque converter through the main relief valve to form the main pressure of the forward and reverse clutch.
Page 143 Parking brake Parking brake The transmission includes a parking brake. 25L9A3PS13 ① Parking brake operation The parking spring pushes the piston to squeeze Spring the plate, causing parking brake force by friction force. Piston Friction Plate 25L9A3PS14 ② Parking brake release Hydraulic Pressure Hydraulic pressure is applied to the piston from...
Page 144 3. DRIVE AXLE . DRIVE AXLE 1) 1) STRUCTURE STRUCTURE 25D9V3PS102 Pinion shaft Axle shaft Ring gear Service brake Differential device Hub reduction 2) 2) OPERATION OPERATION The drive axle is connected with the transmission output gear by drive shaft assembly. The power transferred by the drive shaft assembly is connected to the pinion shaft of drive axle, the pinion shaft delivers the power to the differential device through the ring gear.
Page 145 Carrier sub assembly Carrier sub assembly Structure Structure 25D9V3PS104 Lock nut 11 T/R bearing 21 Spider O-ring 12 Pinion shaft 22 Diffsub assembly Flange yoke 13 Diff side gear 23 Adjust screw Oil seal 14 Thrust washer 24 Carrier cap Carrier case 15 Hex bolt 25 Lock plate...
Page 146 Performance property Since the ring gear is linked with the right of the differential case and the bolt, the power transferred to the ring gear makes the differential device revolve. And also, the differential case are connected with the left and right of the axle shaft and the spline respectively, it delivers the power to the final drive.
Page 147 GROUP 2 DISASSEMBLY AND ASSEMBLY GROUP 2 DISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY OF TRANSMISSION 1. DISASSEMBLY OF TRANSMISSION DISASSEMBLY OF TRANSMISSION ASSEMBLY DISASSEMBLY OF TRANSMISSION ASSEMBLY 1) 1) Disassembly the transmission assembly. 25D9HDI3PS14 Loosen the drain plug and discharge the oil before starting the parts disassembly.
Page 148 ② Loosen the hex bolts and separate the flexible Flexible plate plate. Hex bolt 25D9V3PS18 ③ Loosen the socket bolt and remove the spring washer and the speed sensor. Speed sensor Spring washer Socket bolt 25L9A3PS19 Remove the oil filter and oil filter adaptor. Oil filter adaptor Oil filter 25LC93PS19...
Page 149 ② Remove the control valve and gasket. Control valve assembly Gasket 25D9HDI3PS21 (7) (7) Disassembly of parking piston Disassembly of parking piston Parking piston sub ① Loosen the socket bolts (M8×25L, 8 EA). Return spring ※ Disassemble slowly and follow the number. It pre- Disassemble slowly and follow the number.
Page 150 Loosen the hex bolts and remove the washers, charging pump and gasket. Hex. bolt Pump sub assembly Washer Pup gasket 25L9A3PS25 (10) Loosen the magnetic plug and remove the spring and suction filter. Suction filter Spring Magetic plug 25L9A3PS26 (11) Remove the output shaft.
Page 151 (14) Remove the reverse clutch. Reverse clutch 25D9V3PS30 (15) Loosen the socket bolts and remove the parking Parking gear assembly Socket bolt gear assembly. ·M8×25 L : 6 EA 25D9V3PS31 (16) Remove the plates (6 EA) and discs (5 EA), parallel Plate pins (4 EA).
Page 152 Remove the piston ring and peek seals. Piston ring Peek seal 25L9A3PS34 Remove the bearings and thrust spacer. Bearing Thrust spacer Bearing 25D9V3PS35 Remove the clutch gear, needle bearing, and thrust Clutch gear washer. Needle bearing Thrust washer 25D9V3PS36 Remove retaining ring, pressure plate, plates and Retaing ring discs.
Page 153 Disassemble snap ring, spring plate and spring Snap ring from shaft. Spring plate Snap ring can bounce by the force of the spring, so Snap ring can bounce by the force of the spring, so Spring fix the spring and remove it. Pay attention to safety fix the spring and remove it.
Page 154 (10) Remove the peek seals. Peek seal 25D9V3PS41 (11) Remove the bearings and thrust spacer. Bearing Thrust spacer Bearing 25D9V3PS42 (12) Remove the clutch gear, needle bearing, and thrust Clutch gear washer. Needle bearing Thrust washer 25D9V3PS43 (13) Remove retaining ring, pressure plate, plates and Retaing ring discs.
Page 155 (14) Remove the snap rings, spring plate and spring. Snap ring Snap ring can bounce by the force of the spring, so Snap ring can bounce by the force of the spring, so Spring plate fix the spring and remove it. Pay attention to safety fix the spring and remove it.
Page 156 Remove the dust seal and piston ring. Dust seal Piston ring 25D9V3PS48 Remove the bearings. Bearing 25D9V3PS49 4) 4) DISASSEMBLY OF CHARGING PUMP DISASSEMBLY OF CHARGING PUMP Disassemble charging pump. 25D9V3PS50 Remove the oil seal and O-ring. Oil seal O-ring 25D9V3PS51 3-111...
Page 157 Remove the pump case, drive and driven gear. Pump case Drive gear Driven gear Stator shaft 25D9V3PS52 5) 5) DISASSEMBLY OF PARKING GEAR ASSEMBLY DISASSEMBLY OF PARKING GEAR ASSEMBLY Disassemble parking gear assembly. 25D9V3P53 Remove the snap rings, bearings, spacer, and Parking drive Snap ring parking gear.
Page 158 2. ASSEMBLY OF TRANSMISSION 2. ASSEMBLY OF TRANSMISSION REASSEMBLY OF CLUTCHES REASSEMBLY OF CLUTCHES 1) 1) Insert the D-ring into the piston groove and oil it. D-ring Piston 25D9V3PS56 Insert the O-ring into the shaft groove and oil it. O-ring 25D9V3PS57 Assemble the piston sub assembly.
Page 159 After assembling the plate, disc and pressure plate, Retaining ring the retaining ring is assembled. Pressure plate Disc Plate 25D9V3PS60 Measure clearance between the back plate and Thickness gauge retaining ring using thickness gauge. ※ Replace the retaining ring if the measured value is Replace the retaining ring if the measured value is out of spec.
Page 160 Assemble the other bearing. Bearing 25D9V3PS64 (10) Assemble the peek seals on the groove of the Peek seal clutch shaft. 25D9V3PS65 (11) Insert the snap ring into the groove of the clutch Needle bearing shaft. Apply oil to the thrust washer and assemble. Assemble the clutch gear.
Page 161 (10) Assemble the other bearing. Bearing 25D9V3PS68 (11) Assembly the peek seals on the groove of the Peek seal clutch shaft. 25D9V3PS69 2) 2) REASSEMBLY OF OUTPUT SHAFT REASSEMBLY OF OUTPUT SHAFT Assemble the bearings. 25D9V3PS70 Assembly the piston ring in the groove of the shaft. Piston ring 25D9V3PS71 3-116...
Page 162 Assemble the dust seal and grease the seal rib. Dust seal 25D9V3PS72 3) 3) RESSEMBLY OF CHARGING PUMP RESSEMBLY OF CHARGING PUMP Assemble the oil seal and grease the seal rib. Oil seal 25D9V3PS73 Assemble the drive and driven gear. Drive gear Driven gear Dowel pin...
Page 163 4) 4) ASSEMBLY OF PARKING GEAR ASSEMBLY ASSEMBLY OF PARKING GEAR ASSEMBLY Assemble the bearings, spacer, snap ring. Snap ring Beaing Spacer 25D9V3PS76 Assemble the parking gear and snap ring. Snap ring Parking ring 25D9V3PS77 Assemble the snap rings and the parking drive Snap ring gear.
Page 164 Press in parallel pins (4 EA). Parallel pin 25D9V3PS80 Assemble the discs (5 EA) and plates (6 EA). Plate Disc 25L9A3PS81 Assemble the parking gear assembly and the sock- Socket bolt et bolts (M8×25L, 6 EA). Parking gear ※ Apply Loctite #277 on socket bolt. Apply Loctite #277 on socket bolt.
Page 165 Installl the forward clutch. ※ Forward clutch Grease the peeks seal and align them. Grease the peeks seal and align them. Piston ring Peek seal 25L9A3PS84 Install the output shaft. ※ Grease the piston ring seal and align it. Grease the piston ring seal and align it. Output shaft Piston ring 25L9A3PS85...
Page 166 (10) Assemble the suction filter, spring, magnetic plug and O-ring. ※ Grease the O-ring before assembling. Grease the O-ring before assembling. ·Tightening torque : 4.1 ~ 4.9 kgf·m Suction filter (29.7 ~ 35.4 lbf·ft) Spring Magnetic plug & O-ring 25L9A3PS88 (11) Assemble the gasket, charging pump, washer, and hex bolt (M8×45L, 5 EA).
Page 167 (14) Assemble parking piston subassembly, return spring, parking cover, and socket bolts (M8×25L, 6 Parking piston subassembly EA). Return spring ※ Parking cover Apply Loctite #277 on socket bolt. Apply Loctite #277 on socket bolt. ·Tightening torque : 3.1 ~ 3.6 kgf·m (22.4 ~ 26.04 lbf·ft) Socket bolt 25D9V3PS92...
Page 168 (18) Assemble the snap rings (2 EA) in the socket gear. Snap ring Assemble the PTO shaft and socket gear. PTO shaft Socket gear 25L9A3PS96 (19) Assemble the flexible plate and hex bolts (3/8-24- Flexible plate UNF, 6EA). ※ Apply Loctite #277 on hex bolt. Apply Loctite #277 on hex bolt.
Page 169 (22) Assemble the drain plug. ※ Apply Loctite #277 on hex bolt. Apply Loctite #277 on hex bolt. ·Tightening torque : 4.1 ~ 4.9 kgf·m (29.7 ~ 35.4 lbf·ft) Drain plug 25D9V3PS15 (23) Assemble the oil level gauge. Oil level gauge 25D9V3PS16 (24) Before putting the transmission into operation, fill it...
Page 170 3. DISASSEMBLY OF . DISASSEMBLY OF DRIVE AXLE DRIVE AXLE 1) 1) DIS DISASSEMBLY ASSEMBLY Disassemble drive axle assembly. 25D9V3PS105 Disassemble carrier hsg. sub assembly. 25D9V3PS106 Disassemble disc, opposing plate. 25D9V3PS107 Disassemble axle shaft. 25D9V3PS108 3-125...
Page 171 Disassemble special bolt, return spring. Return spring Special bolt 25D9V3PS109 Brake piston sub assembly 25D9V3PS110 Disassemble bolt, carrier sub assembly. 25D9V3PS111 Disassemble Bolt, lock plate. Lock plate Bolt 25D9V3PS112 3-126...
Page 172 Disassemble bolt, plain washer. Bolt Plain washer 25D9V3PS113 (10) Dissassemble carrier cap, steel ball. Steel ball Carrier cap 25D9V3PS114 (11) Disassemble adjust screw. Adjust screw 25D9V3PS115 (12) Disassemble differential sub assembly. Differential sub assembly 25D9V3PS116 3-127...
Page 173 (13) Dissassemble carrier cap, steel ball. Spacer Shim T/R bearing Oil seal O-ring Flange yoke Lock nut 25D9V3PS117 (14) The Lock nut from the decomposition order. Pinion shaft 25D9V3PS118 (15) Disassemble Pinion shaft. Thrust washer Spacer 2 Snap ring 25D9V3PS119 (16) Disassemble planetary gear, needle roller Spacer 1...
Page 174 (17) Disassemble set screw, hub lock nut and PL carrier 25D9V3PS121 (18) Disassemble bolt, wheel shaft and T/R bearing. Bolt T/R bearing Wheel shaft 25D9V3PS122 (19) Disassemble hub sub assembly, carrier Hub sub assembly housing. Carrier housing 25D9V3PS123 3-129...
Page 175 3.ASSEMBLY OF .ASSEMBLY OF DRIVE AXLE DRIVE AXLE 1) 1) ASSEMBLY OF ASSEMBLY OF DIFFERENTIAL DEVICE DIFFERENTIAL DEVICE Make preparation for diffdrential assembly. 25D9V3PS124 Assemble Ring gear by Bolt. ※ Spread loctite #277. Spread loctite #277. loctite #277 ·Tightening torque : 10.2 ~ 11.2 kgf·m (73.8 ~ 81.0 lbf·ft) Bolt Ring gear...
Page 176 The THK of shim will be decided of measured value of gauge & machine. ① Dimensional drawings of the alphabet (mm) Backlash a : 107 b : 25.25 c : Engraved value d : 132.75 e : 33.75 f : 32.5 g : 1.75 ②...
Page 177 Turn carrier case a one-eighty (180˚) and fix it on jig. Special bolt 25D9V3PS132 Assemble pinion shaft on spacer. Spacer 25D9V3PS133 Assemble pinion shaft, and assemble Master bearing shim & master bearing sort of shim : 0.1, 0.15, 0.3 mm Shim 25D9V3PS134 Assemble oil seal, flange yoke, O-ring and...
Page 178 (10) Turn carrier case a one-eighty (180˚) and Differencial assemble differencial assembly on carrier assembly case. 25D9V3PS136 (11) Assemble hex bolt on carrier cap. Loctite #277 ※ Spread loctite #277 on the bolt. Spread loctite #277 on the bolt. Hex bolt ·Tightening torque : 11.7 ~ 12.5 kgf·m Spring washer (84.6 ~ 90.4 lbf·ft)
Page 179 Measure Backlash. Indicator ※ Backlash of pinion & ring gear : 0.18~0.23 mm ※ If it is wrong backlash, you can adjust value as moving each step. Rotate ring ※ If ring gear takes from pinion shaft far, the value of backlash will be increased. If ring gear takes from pinion shaft close, the value of backlash will be decreased.
Page 180 4) ) MEASUREMENT OF TOOTH CONTACT PATTERN MEASUREMENT OF TOOTH CONTACT PATTERN ※ After assemble , adjust pattern of the gear After assemble , adjust pattern of the gear Spiral bevel gear set pattern and pinion shaft figure. If pattern is not and pinion shaft figure.
Page 181 Compare the contact patter n with illustrations. ※ The good contact pattern of gearset is The good contact pattern of gearset is appeared what the length of tooth has appeared what the length of tooth has had. had. Good hand-rolled pattern 35D9VB3PS179 High pattern 35D9VB3PS180...
Page 182 (4) (4) If you need control contact pattern to If you need control contact pattern to adjust THK of tooth (top/bottom), you adjust THK of tooth (top/bottom), you should obey steps ①-②. should obey steps If you need control contact pattern to If you need control contact pattern to adjust THK of tooth (toe/heel), you should adjust THK of tooth (toe/heel), you should...
Page 183 ④ ④ Toe pattern Move pattern toward toe Increase the gearset backlash (within Tighten adjusting ring this side specified range) to move contact pattern toward heel and away from toe. Refer to "Adjusting the gearset back lash". Increase backlash Loosen adjusting ring this side 35D9VB3PS175 Fix spring pin to adjusted Ring bearing.
Page 184 Assemble original taper roller bearing & oil seal. Original taper roller bearing Oil seal 25D9V3PS145 Spread grease on seal rip and assemble flange yoke. Flange yoke Grease 25D9V3PS146 (10) spread grease on O-ring assemble O-ring and spread loctite #277 on lock nut and O-ring tighten it.
Page 185 5) ) ASSEMBLY OF HUB ASSEMBLY OF HUB Press hub bolt into hub. Adjust screw 25D9V3PS149 Press hub outer oil seal. Before assemble, spread grease at inside hub. ※ Grease : Shell Retinax 0434 - 60 ~ 80 % Grease : Shell Retinax 0434 - 60 ~ 80 % spread spread 25D9V3PS150...
Page 186 Press bearing cup into carrier housing Carrier housing both side. Bearing cup Bearing cup 25D9V3PS153 Press T/R bearing and P.L carrier sub assembly. P.L carrier T/R bearing 25D9V3PS154 Fastening hub lock nut and assemble the set screw. ※ Spread loctite #277. Spread loctite #277.
Page 187 Assemble spacer 2, thrust washer, snap Thrust washer ring. Spacer 2 Snap ring 25D9V3PS157 6) ) ASSEMBLY OF DRIVE AXLE ASSEMBLY OF DRIVE AXLE Press dowel pin on axle housing. Dowel pin 25D9V3PS158 Spread loctite #5127 on axle housing and assemble carrier sub assembly.
Page 188 Assemble piston sub. 25D9V3PS161 Return spring, Sprecial bolt. ※ Spread loctite #277 on the bolt. Spread loctite #277 on the bolt. Return spring ·Tightening torque : 3.1 ~ 3.5 kgf·m Special bolt (22.4 ~ 25.3 lbf·ft) 25D9V3PS162 Assemble axle shaft. Axle shaft 25D9V3PS163 Assemble brake disc pack...
Page 189 Spread loctite #5127 on axle housing and Loctite #5127 assemble carrier hsg. sub assembly. ※ Spread loctite #277. Spread loctite #277. ·Tightening torque : 10.2 kgf·m (73.8 lbf·ft) Loctite #277 25D9V3PS165 Assemble oil level gauge & air breather Oil level gauge on axle housing.
Page 190 (12) Complete drive axle assembly. 25D9V3PS169 3-145...
Page 191 GROUP 3 GROUP 3 MAINTENANCE AND MAINTENANCE AND TROUBLESHOOTING TROUBLESHOOTING 1. 1. MAINTENANCE MAINTENANCE TRANSMISSION TRANSMISSION Recommend oils Recommend oils The property that needs for auto transmission oil. ·It has suitable viscosity at the height temperature. ·It has suitable fluidity at the low temperature. ·It has excellent oxidation stability.
Page 192 Period of overaul Period of overaul ① As for the overhaul, we recommend either every 5 years or 7000 hours coming early to be done as a limit. ② Please change the oil seal, rubber such as O-ring, and gasket, copper gasket, if it has damaged. ③...
Page 193 Test ① Operation check Operation check · Please change the change lever to「N」position and hold this position, then please change the engine speed from low idle to high idle, and check the below condition. · The abnormal sound dose not occur. ·...
Page 194 ③ Stall torque output test Stall torque output test · Before testing, install a brace on the vehicle's tires and pay attention to prevent front and rear collisions. ※ When the torque converter is stall condition, heat generate suddenly inside of the torque When the torque converter is stall condition, heat generate suddenly inside of the torque converter.
Page 195 Oil levle gauge and part of oil filling Drain plug 25D9V3PS170 25D9V3PS171 Side drain plug 25D9V3PS172 ② ② Oil change Oil change Park the truck on flat ground. Block the wheels to prevent the truck moving during maintenance. Park the truck on flat ground. Block the wheels to prevent the truck moving during maintenance. Do not work under the truck supported only jacks for safe.
Page 196 ④ Snap ring, disc, opposing plate : Change the part that exceeds the wear limits. Snap ring, disc, opposing plate : Change the part that exceeds the wear limits. Item Part no. Standard Limit HA30-60220 Disc t=2.5 t=2.2 (Service brake) HA30-60200 Opposing plate t=2.5...
Page 197 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) TRANSMISSION TRANSMISSION (1) (1) Output does not go up Output does not go up Defects and causes Defects and causes Measures Measures Lack of oil supply Replenish the oil. Oil use that does not fit the Change to recommended oil.
Page 198 (2) (2) Power is not transmitted Power is not transmitted Defects and causes Defects and causes Measures Measures Flexible plate breakage Change the flexible plate. Lack of oil supply Replenish the oil. Spline wear Change the torque converter. Drive/Driven gear damage Change the charging pump.
Page 199 (5) (5) Clutch or converter oil pressure is too low Clutch or converter oil pressure is too low Defects and causes Defects and causes Measures Measures Lack of oil supply Replenish the oil. Oil use that does not ﬁ t the regulations Change to recommended oil.
Page 200 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 201 (2) (2) Oil leakage Oil leakage Locating fault and cause Locating fault and cause Measures Measures Excess supply of oil Check oil level. set of oil amount. Inappropriate oil Replace the oil. Blocking air breather Cleaning, replace the air breather Damaged hub oil seal Replace the hub oil seal.
Page 202 SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and function -------------------------------------------------------------------------------------- 4-1 Group 2 Operational checks and troubleshooting -------------------------------------------------------- 4-10 Group 3 Tests and adjustments ------------------------------------------------------------------------------------- 4-14...
Page 203 SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE There are two brake systems, the foot brake system and the parking brake system. The foot brake adopts the brake system of oil type at drive axle. Oil pressure is generated in maximum 60 through brake oil input path of the left and right drive kgf/cm...
Page 204 3. BRAKE PEDAL AND PIPING 3. BRAKE PEDAL AND PIPING STRUCTURE STRUCTURE (1) (1) Non-booster type Non-booster type Inching cable T/M inching link assy Transmission Drive axle 25L9ABS01 Brake pedal Pressure switch Reservoir tank assembly Service brake piping Brake valve assy Parking brake piping 3-way block Pressure switch...
Page 205 (2) (2) Booster type Booster type Inching cable i v i d t a n f l o u l i c d r a T/M inching link assy Drive axle Transmission 25L9ABS01A Brake pedal Pressure switch Reservoir tank assembly Service brake piping Brake valve assy Parking brake piping...
Page 206 4. INCHING PEDAL AND LINKAGE 4. INCHING PEDAL AND LINKAGE The brake pedal serves to actuate the hydraulic brakes on the drive axle. At the beginning of the pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic clutch to neutral and turn off the driving force.
Page 207 5. WET DISK BRAKE ( 5. WET DISK BRAKE (SERVICE SERVICE) 1) 1) STRUCTURE STRUCTURE 22D9HPT20 Drive axle housing Plate Planet carrier Square ring (S) Friction plate 10 Thrust washer Square ring (B) Planet gear 11 Back up ring (S) Brake piston Retaining ring 12 Back up ring (B)
Page 208 6. BRAKE VALVE (NON-BOOSTER TYPE, STD) 6. BRAKE VALVE (NON-BOOSTER TYPE, STD) 1) 1) STRUCTURE STRUCTURE A - A 12 14 13 15 22D9BS04 Rod assy Union 13 Spring Boot Elbow 14 Spring seat Snap ring O-ring 15 Spring seat Body 11 Secondary cup Piston...
Page 209 7. BRAKE VALVE ( 7. BRAKE VALVE (BOOSTER TYPE, OPT BOOSTER TYPE, OPT) 1) 1) STRUCTURE STRUCTURE 20 19 18 17 20D7BS03 Front housing 11 Seal 21 Check ball Rear housing 12 Seal 22 O-ring Push rod 13 Seal 23 Check spring Bellows 14 Seal 24 Cage...
Page 210 2) 2) DISASSEMBLY DISASSEMBLY Remove push rod (3), bellows (4), air vent (25) and bolt (28). 20D7BS04 Remove front housing (1), rear housing (2), servo spring (10), servo piston (9) and master piston (5). 20D7BS05 Remove relief plug (18) with O-ring (19), relief spring (17), shim (16) and relief piston (15).
Page 211 3) 3) INSPECTION AND ASSEMBLY INSPECTION AND ASSEMBLY Clean all parts thoroughly and lubricate the parts either with mineral or with hydraulic oil, according to their use destination. All single parts are to be checked for damage and replaced, if required. Assembly is in opposite order to disassembly.
Page 212 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 1. OPERATIONAL CHECKS 1) 1) GENERAL INFORMATION GENERAL INFORMATION Brake system generate small metal wear particles at a fairly steady rate, especially during the break-in period. If these fine, but hard particles are allowed to circulate in the lubricant, along with external moisture and dirt, internal components will wear at a much faster rate than normal.
Page 213 Oil capacity and using oil ① Oil volume is approximately 5.6 liters. Actual volume will vary by axle model and configuration. ② Using Hyundai Genune axle oil (If use incorrect axle oil, the product has noise and burn-out at component). 4) 4) MAINTENANCE...
Page 214 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) BRAKE SYSTEM BRAKE SYSTEM Problem Cause Remedy ·Hydraulic system leaks oil. ·Repair and add oil. Insufficient braking force ·Hydraulic system leaks air. ·Bleed air. ·Disk worn. ·Replace. ·Brake valve malfunctioning. ·Repair or replace. ·Hydraulic system clogged. ·Clean.
Page 215 2) 2) BRAKE SYSTEM OF THE DRIVE AXLE BRAKE SYSTEM OF THE DRIVE AXLE Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 1. Inoperation of 1. Inoperation of brake brake ·Non-inject or lack of brake oil ·Check oil level, set correct oil volume 1) Service brake ·Damage of brake seal ·Replace piston seal.
Page 216 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 releasing brake pedal : the other person is Air vent plug on the ground and removes cap from air vent plug on wheel cylinder.
Page 217 3. 3. PARKING BRAKE RELEASE PARKING BRAKE RELEASE In case of malfunction of transmission, it's hard to supply pressure at parking brake. Using function of parking force release at carrier sub assembly of drive axle, it is possible to tow the truck.
Page 218 SECTION 5 STEERING SYSTEM Group 1 Structure and function -------------------------------------------------------------------------------------- 5-1 Group 2 Operational checks and troubleshooting -------------------------------------------------------- 5-13 Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 5-15...
Page 219 SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE NON-BOOSTER TYPE Steering wheel Hydraulic tank Steering unit Steering cylinder Priority valve 25L9ASS01 The steering system for this truck is composed of steering wheel assembly, steering unit, steering cylinder, steering axle, priority valve and pipings. The steering force given to the steering wheel enters the steering unit through the steering column.
Page 220 BOOSTER TYPE Steering wheel Hydraulic tank Steering unit Steering cylinder Dual flow divider Hydraulic oil tank 25L9ASS02 The steering system for this truck is composed of steering wheel assembly, steering unit, steering cylinder, steering axle, dual flow divider and pipings. The steering force given to the steering wheel enters the steering unit through the steering column.
Page 221 2. HYDRAULIC CIRCUIT · NON-BOOSTER TYPE (PRIORITY VALVE) 25L9ASS03 Gear pump with priority valve Return filter Steering unit 10 Hydraulic tank Steering cylinder 11 Priority valve Suction strainer 17 Pressure/temperature sensor...
Page 222 · BOOSTER TYPE (DUAL FLOW DIVIDER) Brake valve 25L9ASS04 Gear pump Return filter Steering unit 10 Hydraulic tank Steering cylinder 11 Dual flow divider Suction strainer 17 Pressure/temperature sensor...
Page 223 NEUTRAL Descriptions are based on the non booster type (priority valve). 25L9ASS05 The steering wheel is not being operated so control spool (G) does not move. The oil from hydraulic gear pump (1) moves the priority valve spool (D) to the left. Oil flow into LS port to the hydraulic tank (10).
Page 224 LEFT TURN 25L9ASS06 When the steering wheel is turned to the left, the spool (G) within the steering unit (4) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool (G) within the steering unit (3) through the spool (D) of priority valve in gear pump (1) and flows to the gerotor(H).
Page 225 RIGHT TURN 25L9ASS07 When the steering wheel is turned to the right, the spool (G) within the steering unit (3) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool (G) within the steering unit (3) through the spool (D) of priority valve in gear pump (1) and flows to the gerotor(H).
Page 226 3. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing 14 Bearing race 24 Plate spring Ball 15 Bore screw 25 P-port check valve.
Page 227 OPERATION The steering unit is composed of the control valve (rotary valve) and the metering device. The control valve controls the flow of oil from the pump in the interior of the unit depending on the condition of the steering wheel. The metering device is a kind of hydraulic motor composed of a stator and a rotor. It meters the required oil volume, feeds the metered oil to the power cylinder and detects cylinder’s motion value, that is, cylinder’s motion rate.
Page 228 4. STEERING AXLE STRUCTURE 25L9ASS08 Steering axle 18 Hub bolt 37 Upper cover Knuckle-RH 20 Hub cap Lower cover Knuckle-LH 21 Steering link 39 Hex bolt Special bolt 22 Steering cylinder 40 Spring wahser King pin 23 Spherical plain bearing 41 Shim (0.1t) Taper roller bearing 24 Steer link pin...
Page 229 STRUCTURE (KIA GEORGIA only) 25L9ASS08-1 Steering axle 18 Steering link 34 Hex bolt Knuckle-RH 19 Steering cylinder 35 Spring washer Knuckle-LH 20 Spherical plain bearing 36 Shim (0.1t) Special bolt 21 Steer link pin 37 Shim (0.15t) King pin 22 Plain washer 38 Shim (0.3t) Taper roller bearing 23 Grease nipple...
Page 230 TIGHTENING TORQUE AND SPECIFICATION Stroke 86 mm Stroke 86 mm Apply loctite #277 49.5~66.5 kgf m (358~481 lbf ft) 25L9ASS09 Type Unit Center pin support single shaft Structure of knuckle Elliott type Toe-in degree Camber degree Caster degree King pin angle degree Max steering angle of wheels (Inside/Outside) degree...
Page 231 Fit bar and a piece of chalk at outside edge of counterweight to mark line of turning radius. If minimum turning radius is not within 100 mm ( 4 in) of specified value, adjust turning angle stopper bolt. Min turning radius (Outside) 25L-9A 2076 mm (82 in) 33L-9A 2136 mm (84 in) 30L-9A...
Page 232 Problem Cause Remedy Steering wheel turns unsteadily. Lockout loosening. Retighten. Metal spring deteriorated. Replace. Steering system makes Gear backlash out of adjustment. Adjust. abnormal sound or vibration. Lockout loosening. Retighten. Air in oil circuit. Bleed air. Abnormal sound heard when Valve steering wheel is turned fully Faulty.
Page 233 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT STRUCTURE 25-3 25-2 25-4 25-1 20D7SS06 Dust seal 11 O-ring 21 Housing Retaining ring 12 Rolled screw 22 Spool Cap seal 13 Gerotor set 23 Sleeve Thrust bearing 14 Bearing race 24 Plate spring Ball 15 Bore screw 25 P-port check valve...
Page 234 TOOLS Holding tool. 5-69(1) Assembly tool for O-ring and kin-ring. 5-69(2) Assembly tool for lip seal. 5-69(3) Assembly tool for cardan shaft. 5-69(4) 5-16...
Page 235 Assembly tool for dust seal. 5-70(1) Torque wrench 0~7.1 kgf m (0~54.4 lbf ft) 13 mm socket spanner 6, 8 mm and 12 mm hexagon sockets 12 mm screwdriver 2 mm screwdriver 13 mm ring spanner 6, 8 and 12 mm hexagon socket spanners Plastic hammer Tweezers 5-70(2)
Page 236 DISASSEMBLY Disassemble steering column from steering unit and place the steering unit in the holding tool. Screw out the screws in the end cover(6- off plus one special screw). 5-72(1) Remove the end cover, sideways. 5-72(2) Lift the gearwheel set(With spacer if fitted) off the unit.
Page 237 Remove distributor plate. 5-73(1) Screw out the threaded bush over the check valve. 5-73(2) Remove O-ring. 5-73(3) Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool.
Page 238 Take ring, bearing races and thrust bearing from sleeve and spool. The outer (Thin) bearing race can sometimes "stick" in the housing, therefore check that it has come out. 5-74(1) (10) Press out the cross pin. Use the special screw from the end cover. 5-74(2) A small mark has been made with a pumice stone on both spool and sleeve...
Page 239 (12) Press the neutral position springs out of their slots in the spool. 5-75(1) (13) Remove dust seal and O-ring. 5-75(2) Disassembling the pressure relief valve (14) Screw out the plug using an 8 mm hexagon socket spanner. Remove seal washers. D353SE10 (15) Unscrew the setting screw using an 8 mm...
Page 240 (16) Shake out spring and piston. The valve seat is bonded into the housing and cannot be removed. D353SE12 (17) T h e p r e s s u r e r e l i e f v a l v e i s n o w disassembled.
Page 241 ASSEMBLY Assemble spool and sleeve. When assembling spool and sleeve only one of two possible ways of positioning the spring slots is correct. There are three slots in the spool and three holes in the sleeve in the end of the spool / sleeve opposite to the end with spring slots.
Page 242 Press the springs together and push the neutral position springs into place in the sleeve. 5-77(2) Line up the springs and center them. 5-77(3) Guide the ring down over the sleeve. The ring should be able to rotate free of the springs.
Page 243 Fit bearing races and needle bearing as shown on below drawing. 5-78(2) Assembly pattern for standard bearings Outer bearing race Thrust bearing Inner bearing race Spool Sleeve 5-78(3) Installation instruction for O-ring (10) Turn the steering unit until the bore is horizontal.
Page 244 (11) Grease O-ring with hydraulic oil and place them on the tool. 5-79(1) 5-79(2) (12) Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.
Page 245 (14) Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore. 5-80(1) Installation instructions for lip seal (15) Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
Page 246 (17) Press and turn the lip seal into place in the housing. 5-81(1) (18) With a light turning movement, guide the spool and sleeve into the bore. Fit the spool set holding the cross pin horizontal. 5-81(2) (19) The spool set will push out the assembly tool guide.
Page 247 (21) Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing. 5-82(1) (22) Grease the O-ring with mineral oil approx. viscosity 500 cSt at 20 ˚C. 5-82(2) (23) Place the distributor plate so that the...
Page 248 (25) Place the cardan shaft as shown - so that it is held in position by the mounting fork. 5-83(1) (26) Grease the two O-rings with mineral oil approx. viscosity 500 cSt at 20 C and place them in the two grooves in the gear rim.
Page 249 (29) Place the end cover in position. 5-84(1) (30) Fit the special screw with washer and place it in the hole shown. 5-84(2) (31) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. Tightening torque : 3.0 0.6 kgf m (21.7...
Page 250 (33) Fit the dust seal ring in the housing. 5-85(1) (34) Press the plastic plugs into the connection ports. Do not use a hammer! 5-85(2) 5-32...
Page 251 2. STEERING CYLINDER STRUCTURE Type 1 Serial number : xxxxD 25L9ASS10 Tube assembly Rod seal Wear ring DD-bushing 10 Lock washer Rod cover O-ring 11 Spacer Dust wiper Piston seal 12 O-ring 5-33...
Page 252 Type 2 Serial number : SxxxxG 25L9ASS11 Tube assembly Rod seal Piston seal Rod assembly Dry bearing 10 Wear ring Rod cover O-ring Dust wiper O-ring 5-34...
Page 253 DISASSEMBLY Before disassembling steering cylinder, release oil in the cylinder first. Put wooden blocks against the cylinder tube, then hold in a vice. Remove the rod cover by hook a wrench in the notch of cylinder head and turn counter- clockwise.
Page 254 Install the dust wiper to the gland using a special installing tool. Coat the dust wiper with grease slightly before installing. Set a special tool the cylinder, gland assembly into the cylinder tube. D353SE29 Using a hook spanner, install the gland assembly and tighten it with torque 60 6 kgf m (434 43 lbf ft).
Page 255 3. STEERING AXLE STRUCTURE 25L9ASS08 Steering axle 18 Hub bolt 37 Upper cover Knuckle-RH 20 Hub cap Lower cover Knuckle-LH 21 Steering link 39 Hex bolt Special bolt 22 Steering cylinder 40 Spring wahser King pin 23 Spherical plain bearing 41 Shim (0.1t) Taper roller bearing 24 Steer link pin...
Page 256 CHECK AND INSPECTION A1,A2 25L9ASS12 unit : mm (in) Criteria Check item Remarks Standard size Repair limit OD of shaft 55 (2.2) 54.5 (2.1) Shaft ID of bushing 55 (2.2) 55.5 (2.2) OD of king pin 35 (1.4) 34.5 (1.4) Replace OD of steering cylinder pin 20 (0.8)
Page 257 DISASSEMBLY Servicing work on the knuckle part can be carried out without removing the axle assy from chassis. The work can be done by jacking up the counter weight part of the truck. Loosen the hub nut (54) and take off the steering wheel tire.
Page 258 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 special bolt (4) and washer (35) of king pin (5).
Page 259 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function -------------------------------------------------------------------------------------- 6-1 Group 2 Operational checks and troubleshooting -------------------------------------------------------- 6-41 Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 6-45...
Page 260 SECTION 6 HYDRAULIC SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC CIRCUIT Non boosted brake + travel OPSS V-MAST 2nd relief valve Lift lock (tilt, aux) Needle valve (emergency) LIFT TILT AUX1 WORK(AUX2) Load sensing Main relief valve (lift) Hydrostator (unloading) Tilt lock '1A'...
Page 261 Non boosted brake + travel/mast OPSS V-MAST Lift lock 2nd relief valve Needle valve (tilt, aux) (emergency) LIFT TILT AUX1 WORK(AUX2) OPS (seat) Lifting, Tilt, Aux Load sensing SOL-A SOL-B OPS (seat) Lowering Main relief valve (lift) Hydrostator (unloading) Tilt lock '1A' '1A' '1A'...
Page 262 Boosted brake + travel OPSS V-MAST VF-MAST VS-MAST Lift lock 2nd relief valve (tilt, aux) Needle valve (emergency) LIFT TILT AUX1 WORK(AUX2) Load sensing Main relief valve (lift) Hydrostator (unloading) Tilt lock Front axle TF-MAST QF-MAST TS-MAST 25L9AHS03 Hydraulic gear pump Return filter 15 Load sensor Main control valve...
Page 263 Boosted brake + travel/mast OPSS V-MAST VS-MAST VF-MAST Lift lock 2nd relief valve (tilt, aux) Needle valve (emergency) LIFT TILT AUX1 WORK(AUX2) OPS (seat) Lifting, Tilt, Aux Load sensing SOL-A SOL-B OPS (seat) Lowering Main relief valve (lift) Hydrostator (unloading) Tilt lock Front axle TF-MAST...
Page 264 Fingertip control (non boosted brake) V-MAST AUX 1 AUX 2 TILT Emergency Lifting Main relief Lowering '1A' '1A' '1A' QF-MAST TS-MAST TF-MAST '1A' '1A' VF-MAST VS-MAST 25L9AHS05 Hydraulic gear pump Suction strainer 13 Free lift cylinder Main control valve Return filter 14 Load sensor Steering unit Down safety valve...
Page 265 Fingertip control (boosted brake) V-MAST VF-MAST VS-MAST AUX 2 TILT AUX 1 Emergency Lifting Main relief Lowering Front axle TF-MAST QF-MAST TS-MAST 25L9AHS06 Hydraulic gear pump Suction strainer 13 Free lift cylinder Main control valve Return filter 14 Load sensor Steering unit Down safety valve 15 Flow regulator...
Page 266 WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION The operation explanations are based on the non boosted brake type. V-MAST 2nd relief valve (tilt, aux) Lift lock LIFT TILT AUX1 WORK(AUX2) OPS (seat) Lifting, Tilt, Aux Load sensing SOL-A SOL-B OPS (seat)
Page 267 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION V-MAST 2nd relief valve (tilt, aux) Lift lock LIFT WORK(AUX2) TILT AUX1 OPS (seat) Lifting, Tilt, Aux Load sensing SOL-A SOL-B OPS (seat) Lowering Steering system Main relief valve (lift) Hydrostator (unloading) Tilt lock...
Page 268 WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION V-MAST 2nd relief valve (tilt, aux) Lift lock LIFT WORK(AUX2) TILT AUX1 OPS (seat) Lifting, Tilt, Aux Load sensing SOL-A SOL-B OPS (seat) Lowering Steering system Main relief valve (lift) Hydrostator (unloading) Tilt lock...
Page 269 WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION V-MAST 2nd relief valve (tilt, aux) Lift lock LIFT TILT AUX1 WORK(AUX2) OPS (seat) Lifting, Tilt, Aux SOL-A SOL-B OPS (seat) Lowering Steering system Main relief valve (lift) Hydrostator (unloading) Tilt lock INLET 25L9AHS10...
Page 270 2. HYDRAULIC GEAR PUMP STRUCTURE (Booster brake) 5 12 9 10 11 13 14 20D7HS14 Housing Drive gear 13 Oil seal Body Idle gear 14 Snap ring Rear cover Side plate 15 Bolt Bushing 10 O-ring 16 Washer O-ring 11 Back up ring 12 Side plate OPERATION This pump comprises of a housing (1), a body (2) and a rear cover (3) bolted together.
Page 271 STRUCTURE (Non booster brake) 29,30 2 7 9 10 11 1 13 14 SECTION B - B" 20L7HS07 Housing 11 Back up ring 21 Spring Body 12 Side plate 22 Plug Priority valve body 13 Oil seal 23 O-ring Bushing 14 Snap ring 24 Adjust screw O-ring...
Page 272 3. DUAL FLOW DIVIDER (BOOSTER TYPE BRAKE) SECTION "A-A" SECTION "B-B" 22D9HHS14-1B Body End plug 13 Spring BF spool LS plug 14 Orifice SF spool BF plug 15 Orifice BF spool 10 Relief plug 16 Shim Spring 11 Tank plug O-ring 12 Piston 6-13...
Page 273 4. MAIN CONTROL VALVE STRUCTURE 4 spool, with OPSS AUX 2 AUX 1 TILT LIFT 25L9AHS11 Lift block 43 Auxiliary block 61 Solenoid valve 31 Solenoid valve 45 Work block 62 Bolt 33 Tilt block 60 PT block Port Port name Port size Remark Inlet port...
Page 274 Lift block assy 31 33 (NON-OPSS) 31 (OPSS) SECTION A - A' 25L9AHS12 Lift block 12 Check spring 23 End plug Lift spool 13 Control seat 24 Plug Lock plug 14 O-ring 25 O-ring O-ring 15 Back up ring 26 Cage Return spring 16 Stop ring 27 O-ring...
Page 275 Tilt block assy SECTION J - J' SECTION B - B' 25L9AHS13 O-ring 14 O-ring 33 Tilt block Return spring 15 Back up ring 34 Tilt spool Spring seat 16 Stop ring 35 Tilt piston Plate 17 Bolt 36 O-ring 25 O-ring 37 Lock spring O-ring...
Page 276 Auxiliary 1 block assy SECTION J - J' SECTION C - C' 25L9AHS14 Lock plug 13 Control seat 29 O-ring O-ring 14 O-ring 30 O-ring Return spring 15 Back up ring 39 Ball Spring seat 16 Stop ring 40 LS inner spring Plate 17 Bolt 41 LS spring...
Page 277 Auxiliary 2 block assy SECTION J - J' SECTION D - D' 25L9AHS15 Lock plug 13 Control seat 29 O-ring O-ring 14 O-ring 30 O-ring Return spring 15 Back up ring 39 Ball Spring seat 16 Stop ring 40 LS inner spring Plate 17 Bolt 41 LS spring...
Page 278 Inlet section assy 47 Unloading spool 48 Spring 49 Work plug 50 O-ring 51 Relief seat 52 Relief poppet 53 Relief spring 54 Control screw 55 Relief plug 56 O-ring 57 Lock nut 58 O-ring 59 Cage plug SECTION E - E' 25L9AHS16 6-19...
Page 279 INLET SECTION OPERATION Structure and description Secondary relief valve Main relief valve Unloading spool 25L9AHS17 Operation Secondary relief valve To neutral passage Main relief valve To neutral passage To neutral passage Main relief valve Secondary relief valve Unloading spool Unloading spool To load check valve 25L9AHS18 Oil flows from P (pump) port to hydraulic oil tank (T) by pushing unloading spool.
Page 280 LIFT SECTION OPERATION Lift position Inlet poppet 25L9AHS19 When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the inlet poppet and flow into lift cylinder port (1A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
Page 281 Lower position Inlet poppet 25L9AHS20 When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (1A) In lift lower position the fork drops due to its own weight.
Page 282 TILT SECTION OPERATION Tilt forward position Tilt lock spool Inlet poppet 25L9AHS21 When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The oil supplied from the pump pushes up the inlet poppet and flow into tilt cylinder port (2B). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage.
Page 283 Tilt backward position Tilt lock spool Inlet poppet 25L9AHS22 When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the inlet poppet and flows into tilt cylinder port (2A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage.
Page 284 MAIN RELIEF VALVE Pressure setting A good pressure gauge must be installed Relief plug Relief seat Lock nut O-ring in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit.
Page 285 5. MAIN CONTROL VALVE (finger tip, 4-spool) Lifting solenoid valve AUX 1 TILT AUX 2 LIFT Lowering solenoid valve 25L9AHS25 Port Port name Port size Tightening torque Inlet port 1 1/16-12 UN 9.5 kgf·m (68.7 lbf·ft) Tank port 1 1/16-12 UN 9.5 kgf·m (68.7 lbf·ft) Lift port 1 1/16-12 UN...
Page 286 PARTS LIST Assembly 10 9 3-1-1 25L9AHS26 Main block assy 4.1 Adapter Plain washer 1A Solenoid valve 4.2 Socket head screw Plain washer Tilt block assy Auxiliary 2 block assy Tension rod 3.1 Adapter 5.1 Adapter 10 Tension rod 3.3.1 Socket head screw 5.2 Socket head screw 100 Sect/sect seal kit Auxiliary 1 block assy...
Page 287 Main block 9.2 9 25L9AHS27 Connection block 9-1 Ball 18 Tapped plug Main relief valve 9-2 O-ring 20 Solenoid valve Controller spool 10 Dampening 21 Tapped plug Tapped plug 11 Orifice 100 O-ring Plug 13 Gab filter screw 101 O-ring Plug 14 Gab filter screw 102 Sect/sect seal kit...
Page 288 Tilt and aux block (1/2) Orifice Spring cap Spring Spring Spring cap Disc Flat head screw Housing Flange 10 Socket head screw 11 Spacer 12 Housing 13 Hex head screw 14 Socket head screw 15 Spool 16 Socket head screw 17 Proportional twin solenoid 18 Spring 19 Controller spool...
Page 289 Tilt and aux block (2/2) 25L9AHS29 Spool valve body Spring 118 Seal kit Tapped plug Controller spool 200 O-ring Shuttle valve 100 O-ring 201 O-ring 3-1 Ball 101 O-ring 3-2 O-ring 102 O-ring 6-30...
Page 290 Emergency drain Ball Socket head screw Type plate Socket head screw 100 O-ring 25L9AHS30 Auxiliary relief valve 1A Pressure limiting valve Valve cone Spring Screw Seal nut Cap nut 25L9AHS32 6-31...
Page 291 Solenoid valve Cartridge AMP coil Washer Lock washer 100 O-ring 101 O-ring 102 O-ring 25L9AHS31 6-32...
Page 292 EMERGENCY LOWERING In case of the mast cannot be lowered due to a problem in the controller, active the emergency lowering valve on the valve block with hexagonal wrench. Turn off the electric emergency switch. Rotate counter clockwise the emergency lowering valve using hexagonal wrench and lower the mast and the load carriage slowly.
Page 293 6. LIFT CYLINDER V-MAST D255HS18 Tube assembly Wear ring 11 O-ring Retaining ring 12 Guide Piston Gland 13 DU bushing Piston seal Dust wiper 14 Spacer Back up ring 10 Rod seal 15 O-ring VF AND VS-MAST 5, 6 8, 9 11, 12 14, 15 22B9FHS20...
Page 294 TF AND TS-MAST 15, 16 14 17 18 19 13 20 10 7 8, 9 4, 5 3 6 11, 12 22B9FHS21 Tube assembly Spacer 15 Dust wiper Retaining ring 16 Retaining ring Piston 10 Stop ring 17 Rod bushing U-packing 11 Cushion seal 18 Spacer...
Page 295 QF-MAST (RH) 10 24 23 22 21 25 26 27 8 11 10 15, 16 12, 13 14 19 20 6, 7 4, 5 17, 18 22B9FHS23 Tube assembly 10 Set screw 19 Cushion seal 11 Piston 20 Retaining ring Rod end 12 Back up ring 21 Rod cover...
Page 296 7. TILT CYLINDER TYPE 1 23 19 18 20, 21, 22 12, 13 14, 15 10, 11 22B9FHS24 Tube assembly 10 U-packing 19 Spherical bearing 11 Back up ring 20 Hexagon bolt Piston 12 Dust wiper 21 Spring washer Piston seal 13 Snap ring 22 Lock nut Wear ring...
Page 297 12 Retaining ring Piston Set screw 13 O-ring Piston seal Rod cover 14 Back up ring Wear ring 10 U-packing TF-MAST (25L-9A) 11, 12 10 13, 14 25L9AHS35 Tube assembly Check valve 11 Dust wiper Retaining ring 12 Retaining ring...
Page 298 12 Retaining ring Piston Set screw 13 O-ring Piston seal Rod cover 14 Back up ring Wear ring 10 U-packing TS-MAST (25L-9A) 11, 12 13, 14 25L9AHS37 Tube assembly Check valve 11 Dust wiper Retaining ring 12 Retaining ring Piston...
Page 299 QF-MAST 11, 12 13, 14 25L9AHS38 Tube assembly Check valve 11 Dust wiper Retaining ring 12 Retaining ring Piston Set screw 13 O-ring Piston seal Rod cover 14 Back up ring Wear ring 10 U-packing 6-40...
Page 300 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS CHECK ITEM Check visually for deformation, cracks or damage of rod. Set mast vertical and raise 1 m from ground. Wait for 10 minutes and measure hydraulic drift(amount forks move down and amount mast tilts forward).
Page 301 2. TROUBLESHOOTING SYSTEM Problem Cause Remedy Large fork lowering speed. Seal inside control valve defective. Replace spool or valve body. Oil leaks from joint or hose. Replace. Seal inside cylinder defective. Replace packing. Large spontaneous tilt of Tilting backward : Check valve defec- Clean or replace.
Page 302 HYDRAULIC GEAR PUMP Problem Cause Remedy Pump does not develop full System relief valve set too low or Check system relief valve for proper pressure. leaking. setting. Oil viscosity too low. Change to proper viscosity oil. Pump is worn out. Repair or replace pump.
Page 303 LIFT CYLINDER Problem Cause Remedy Oil leaks out from gland Foreign matters on packing. Replace packing. through rod. Unallowable score on rod. Smooth rod surface with an oil stone. Unusual distortion of dust seal. Replace dust seal. Chrome plating is striped. Replace rod.
Page 304 GROUP 3 DISASSEMBLY AND ASSEMBLY 1. HYDRAULIC GEAR PUMP (BOOSTER TYPE) Tools required Metric socket set Internal snap ring pliers Shaft seal sleeve Torque wrench It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continu- ing.
Page 305 Lift and remove end cover. PUMP 03 Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts. PUMP 04 (10) Remove rear bearing block from drive and idler shafts. PUMP 05 (11) Remove idler shaft from bearing block.
Page 306 (12) Remove drive shaft from mounting flange. There is no need to protect the shaft seal as it will be replaced as a new item. PUMP 07 (13) Remove the front bearing block. PUMP 08 (14) Turn mounting flange over, with shaft seal up, and remove the retaining ring with proper snap ring pliers.
Page 307 (17) Remove seals from both bearing blocks and discard. PUMP 11 INSPECT PARTS FOR WEAR Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be replaced as new items. Check drive shaft spline for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway.
Page 308 Inspect bearing blocks for excessive wear or scoring on the surfaces which are in contact with the gears. Also inspect the bearings for excessive wear or scoring. Inspect the area inside the gear housing. It is normal for the surface inside the gear housing to show a clean "wipe"...
Page 309 ASSEMBLY New seals should be installed upon reassembly of pump. Install new shaft seal in mounting flange with part number side facing outboard. Press the seal into the seal bore until the seal reaches the bottom of the bore. Uniform pressure must be used to prevent misalignment or damage to the seal.
Page 310 Insert the drive end of the drive shaft through the bearing block with the seal side down, and the open side of the E-seal pointing to the intake side of the pump. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal.
Page 311 (13) Gently slide the gear housing over the rear bearing block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place with hands, do not force or use any tool. Check to make sure the intake port in the housing in on the same side as the open end of the E-seal and that the marked lines on the mounting flange and gear...
Page 312 (17) Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts. Tighten torque : 3.0~4.0 kgf m (22~29 lbf ft) (18) Remove pump from vise. (19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution.
Page 313 2. HYDRAULIC GEAR PUMP (NON-BOOSTER TYPE) STRUCTURE 15L7MHS06A Housing 11 Back up ring 21 Spring Body 12 Side plate 22 Plug Body (priority valve) 13 Oil seal 23 O-ring Bushing 14 Snap ring 24 Adjust screw O-ring 15 Bolt 25 O-ring 16 Washer 26 Plug bolt Drive gear...
Page 314 DISASSEMBLY Clamping pump Clamping pump in a vice with pump shaft facing up. (Do not chuck the aluminum parts such as body and housing.) Mark V by permanent marker pen. This will assure proper reassembly. PUMP101 Housing Loosen 8 bolts and remove housing. Pry off snap ring for hole and remove oil seal from housing.
Page 315 Body and rear cover Loosen the vice and remove body and bronze side plate from rear cover. Remove O-ring from rear cover. Disassemble pin from body. PUMP105 Priority valve Loosen the plug at the side of drive gear, be careful not to bounce out spring. Take out spring.
Page 316 ASSEMBLY Preparation Clean all parts and dry them with compressed air thoroughly. Check the permanent mark. Apply grease O-ring, oil seal, E-type ring and side plate lightly. Priority valve Suction Discharge Relief valve : if disassembled Fit O-ring on plug and adjust screw. Tighten plug for port of gage mounting.
Page 317 Rear cover and body Assemble pin into body. Suction Discharge Assemble O-ring on the groove of rear cover. Place the bronze face of side plate contact with gear on rear cover. Insert side plate into body and adjust pin by pressing after adjusting pin hole of PUMP108 rear cover and pin of body.
Page 318 Housing Press fit oil seal with same direction as drawing carefully and fit snap ring. Fit O-ring into groove of housing. Insert drive gear into housing and combine housing with body pressing lightly after confirmed pin position. Tighten bolt with washer zigzag lightly, be careful not to leave O-ring its place.
Page 319 3. MAIN CONTROL VALVE Remove bolt (1) to separate the valve section. Bolt torque (1) : 28.9~33.3 lbf ft (39~45Nm) 20D7MCV01 Divide the valve body. Aux2 Aux1 Tilt Lift T-cover 20D7MCV02 Remove dust cap (3) and bolt (2) from the valve body.
Page 320 Remove O-ring seals (5) from the valve body. 20D7MCV05 Remove tilt spool (6) from the valve body. 20D7MCV06 Remove lift spool (7) from the valve body. Remove lock poppet (8) from the valve body. Remove normal close solenoid valve (9, Opt) from the valve body.
Page 321 Remove relief plugs (15), springs (14) and poppets (13). Relief plugs torque (15) : 2.5 kgf m 20D7MCV09 Remove normal open solenoid valve (16, Opt) from the valve body. 20D7MCV10 Assembly procedure of the main control valve is the reverse order of the removal procedure. 6-62...
Page 322 3-1. MAIN CONTROL VALVE (FINGERTIP, OPT) STRUCTURE AUX 2 AUX 1 TILTING MAIN Main section Aux 2 section Tilt section Aux 1 section (lifting and lowering) 3-1-1 25L7AFT01 Tightening torque - Item (3-1-1, 4-2, 5-2,10) : 0.97 kgf·m (7.0 lbf.ft) - Item (9) : 2.35 kgf·m (16.9 lbf.ft) Main block...
Page 323 MAIN SECTION 25L7AFT02 Flow rate : 100 lpm Maximum pressure : 250 bar Lifting and lowering valve Main section EMP solenoid valve EMP 31V lifting valve AMP coil Cartridge 25L7AFT04 EMP 31V Tightening torque lowering valve 25L7AFT05 6.12 kgf·m (44.2 lbf·ft) 25L7AFT03 When it can’t control lifting &...
Page 324 3-way controller 9 bar spring 25L7AFT06 25L7AFT07 During unloading, supplied oil by the pump return to tank keeping 9 bar of system pressure. 6-62-3...
Page 325 Pressure Reducing valve & G damping screw Pressure reducing valve Pressure reducing valve controls valve actuation by suppling internal control oil. Use flat screw driver. Tightening torque 0.71 kgf·m (5.2 lbf·ft) 25L7AFT08 G damping screw G damping increased throttling effect of load sensing line. Tightening torque 1.02 kgf·m (7.4 lbf·ft) 25L7AFT09A...
Page 326 Pressure relief valve 25L7AFT10 Use with a 12 mm spanner. Tightening torque (2) 1.43 kgf·m (10.3 lbf·ft) 25L7AFT11 Use with a 3 mm wrench. Tightening torque (1) 1.43 kgf·m (10.3 lbf·ft) = Pressure increases = Pressure decreases 25L7AFT12 Rotating clockwise to increase setting pressure with a wrench. 80 bar increase and decrease per 1 turn.
Page 327 Emergency lowering valve and shuttle valve Emergency lowering valve 25B9UFT14 When need to force lowering, rotate counter clockwise increasingly with emergency lowering valve. Shuttle valve 25L7AFT15 Transfer bigger load pressure through shuttle valve. Use a flat screw driver. 6-62-6...
Page 328 TILT SECTION 25L7AFT16 Flow rate : 40 lpm Load holding pressure : 210 bar Proportional directional valve 25L7AFT17 Counter balance valve block Valve section block 6-62-7...
Page 329 Disassembly valve section Disassemble spool All block type, 40lpm Disassemble coil 25L7AFT18 AMP 4 pin coil Disassembling process Release spring cap. 25L7AFT19 Release spring cap completely. 25L7AFT20 Release lever block. 25L7AFT21 Pull out spool. 25L7AFT22 6-62-8...
Page 330 2 way controller and shuttle valve 2 way controller (6 bar) 6 bar spring 25L7AFT24 2 way controller make it keep 6 bar regardless of load change between in and out of spool. Shuttle valve 25L7AFT25 Transfer bigger load pressure through shuttle valve. Fix 4 mm bolt and pull out.
Page 331 Counter balance valve Counter balance valve needs during tilting out operation. Tightening torque 61-250 bar = Pressure increases 3.06 kgf·m (22.1 lbf·ft) = Pressure decreases 25L7AFT28A 6-62-10...
Page 332 AUXILIARY SECTION 25L7AFT29 Flow rate : 40 lpm Pressure limit aux section : 140 bar Proportional directional valve Valve section block 25L7AFT30 Ancillary block 6-62-11...
Page 333 2 way controller and shuttle valve 2 way controller (6 bar) 6 bar spring 25L7AFT24 2 way controller make it keep 6 bar regardless of load change between in and out of spool. Shuttle valve 25L7AFT25 Transfer bigger load pressure through shuttle valve. Fix 4 mm bolt and pull out.
Page 334 Second relief valve Controlling individual section pressure, rotating clockwise to increase setting pressure with wrench. 80 bar increase and decrease per 1 turn. Relief valve 25L7AFT26 25L7AFT27 Use with a 12 mm spanner. Use with a 3 mm wrench. Tightening torque (1) Tightening torque (2) 1.43 kgf·m (10.3 lbf·ft) 1.43 kgf·m (10.3 lbf·ft)
Page 335 ADD SECTION PART Disassembly Tightening torque 0.97 kgf·m (7.0 lbf·ft) Tightening torque 2.35 kgf·m (16.9 lbf·ft) 40B9HS02 When it needs to disassemble HMPL valve, it’s possible to release tension rod sets. 6-62-14...
Page 336 4. LIFT CYLINDER (V-mast) STRUCTURE · Specification (V330, standard) Unit : mm (in) Model Stroke Rod O.D 25L-9A 50 (2.0) 58 (2.3) 1630 (64.2) 40 (1.4) 30/33L-9A 55 (2.2) 63 (2.5) 1630 (64.2) 45 (1.8) Down safety valve 20D7HS19 Tube assy...
Page 337 DISASSEMBLY Hold the cylinder tube in a vice, loosen Guide the cylinder head and remove it. Remove the spacer from the cylinder tube and knock out the bushing. Hook a wrench in the hole in the retainer at the piston end and turn. Lever up the edge of the guide, then turn the guide in again and the guide can be removed.
Page 338 5. TILT CYLINDER STRUCTURE Type 1 Serial number : XXXD I.D×O.D×stroke (standard) 75×86×129 mm (3.0x2.4×5.1 in) Rod O.D : 35 mm (1.4 in) 25L9AHS42 Tube assembly 10 U-packing 19 Spherical bearing 11 Back up ring 20 Hexagon bolt Piston 12 Dust wiper 21 Spring washer Piston seal 13 Stop ring...
Page 339 Type 2 Serial number I.D×O.D×stroke 75×86×129 mm (3.0x2.4×5.1 in) Rod O.D : 35 mm (1.4 in) 25L9AHS43 Tube assembly 10 O-ring 19 Socket screw 11 Back up ring 20 Rod eye Gland 12 Lock washer 21 Spherical bearing DU-bushing 13 Piston 22 Hexagon bolt Rod seal 14 Piston seal...
Page 340 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 341 SECTION 7 ELECTRICAL SYSTEM Group 1 Component location ------------------------------------------------------------------------------------------ 7-1 Group 2 Electrical circuit -------------------------------------------------------------------------------------------------- 7-3 Group 3 Component specification ---------------------------------------------------------------------------------- 7-20 Group 4 Connector destination --------------------------------------------------------------------------------------- 7-21 Group 5 Troubleshooting ------------------------------------------------------------------------------------------------- 7-26...
Page 342 SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 25L9AEL01 Head lamp Back buzzer Rear view camera (opt) Turn signal lamp Blue spot (opt) 10 Rear combination lamp Cluster Rear work lamp (opt) 11 Radio and USB player (opt) High horn Beacon lamp (opt) 12 Battery...
Page 343 2. LOACTION 2 25L9AEL02 Multi function switch Horn switch Machine control valve Start switch Forward-reverse lever 10 12V socket (opt) Parking brake switch Switch board 11 Master switch (opt) Hazard switch (opt) Cluster...
Page 344 GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT ·ELECTRICAL CIRCUIT (1/6, FRAME, 25L-9A : ~#0496, 30L-9A : ~#0314, 33L-9A : ~#067, 35LN-9A : ~#0136) ELECTRICAL CIRCUIT (1/6, FRAME, 25L-9A : ~#0496, 30L-9A : ~#0314, 33L-9A : ~#067, 35LN-9A : ~#0136)
Page 345 ·ELECTRICAL CIRCUIT (1/6-1, FRAME, 25L-9A : ~#0602, 30L-9A : ~#0364, 33L-9A : ~#076, 35LN-9A : ~#0178) ELECTRICAL CIRCUIT (1/6-1, FRAME, 25L-9A : ~#0602, 30L-9A : ~#0364, 33L-9A : ~#076, 35LN-9A : ~#0178) 7-3-1...
Page 346 ·ELECTRICAL CIRCUIT (1/6-2, FRAME, 25L-9A : ~#0649, 30L-9A : ~#0406, 33L-9A : ~#079, 35LN-9A : ~#0196) ELECTRICAL CIRCUIT (1/6-2, FRAME, 25L-9A : ~#0649, 30L-9A : ~#0406, 33L-9A : ~#079, 35LN-9A : ~#0196) 7-3-2...
Page 347 ·ELECTRICAL CIRCUIT (1/6-3, FRAME, 25L-9A : #0650~, 30L-9A : #0407~, 33L-9A : #080~, 35LN-9A : #0197~) ELECTRICAL CIRCUIT (1/6-3, FRAME, 25L-9A : #0650~, 30L-9A : #0407~, 33L-9A : #080~, 35LN-9A : #0197~) 7-3-3...
Page 348 ·ELECTRICAL CIRCUIT (2/6, DASHBOARD, 25L-9A : ~#0181, 30L-9A : ~#0115, 33L-9A : ~#035, 35LN-9A : ~#0043) ELECTRICAL CIRCUIT (2/6, DASHBOARD, 25L-9A : ~#0181, 30L-9A : ~#0115, 33L-9A : ~#035, 35LN-9A : ~#0043) TO OHG(CABIN) HARNESS-LH TO OHG(CABIN) HARNESS-RH REAR WORK LAMP S/W...
Page 349 ·ELECTRICAL CIRCUIT (2/6-1, DASHBOARD 25L-9A : ~#0228, 30L-9A : ~#0134, 33L-9A : ~#0038, 35LN-9A : ~#0050) ELECTRICAL CIRCUIT (2/6-1, DASHBOARD 25L-9A : ~#0228, 30L-9A : ~#0134, 33L-9A : ~#0038, 35LN-9A : ~#0050) 7-4-1...
Page 350 ·ELECTRICAL CIRCUIT (2/6-2, DASHBOARD 25L-9A : ~#0496, 30L-9A : ~#0314, 33L-9A : ~#0067, 35LN-9A : ~#0136) ELECTRICAL CIRCUIT (2/6-2, DASHBOARD 25L-9A : ~#0496, 30L-9A : ~#0314, 33L-9A : ~#0067, 35LN-9A : ~#0136) 7-4-2...
Page 351 ·ELECTRICAL CIRCUIT (2/6-3, DASHBOARD 25L-9A : ~#0522, 30L-9A : ~#0343, 33L-9A : ~#0074, 35LN-9A : ~#0143) ELECTRICAL CIRCUIT (2/6-3, DASHBOARD 25L-9A : ~#0522, 30L-9A : ~#0343, 33L-9A : ~#0074, 35LN-9A : ~#0143) 7-4-3...
Page 352 ·ELECTRICAL CIRCUIT (2/6-4, DASHBOARD 25L-9A : #0522~, 30L-9A : #0343~, 33L-9A : #0074~, 35LN-9A : #0143~) ELECTRICAL CIRCUIT (2/6-4, DASHBOARD 25L-9A : #0522~, 30L-9A : #0343~, 33L-9A : #0074~, 35LN-9A : #0143~) 7-4-4...
Page 353 ·ELECTRICAL CIRCUIT (3/6, CABIN WITH A/C, 25L-9A : ~#0181, 30L-9A : ~#0115, 33L-9A : ~#0035, 35LN-9A : ~#0043) ELECTRICAL CIRCUIT (3/6, CABIN WITH A/C, 25L-9A : ~#0181, 30L-9A : ~#0115, 33L-9A : ~#0035, 35LN-9A : ~#0043) * LEC DIAGRAM OF CABIN HARNESS-RH...
Page 354 ·ELECTRICAL CIRCUIT (3/6-1, CABIN WITH A/C, 25L-9A : #0182~, 30L-9A : #0116~, 33L-9A : #0036~, 35LN-9A : #0044~) ELECTRICAL CIRCUIT (3/6-1, CABIN WITH A/C, 25L-9A : #0182~, 30L-9A : #0116~, 33L-9A : #0036~, 35LN-9A : #0044~) 7-5-1 7-13...
Page 355 ·ELECTRICAL CIRCUIT (4/6, OVERHEAD GUARD, 25L-9A : ~#0181, 30L-9A : ~#0115, 33L-9A : ~#0035, 35LN-9A : ~#0043) ELECTRICAL CIRCUIT (4/6, OVERHEAD GUARD, 25L-9A : ~#0181, 30L-9A : ~#0115, 33L-9A : ~#0035, 35LN-9A : ~#0043) * ELEC DIAGRAM OF OHG HARNESS-RH...
Page 356 ·ELECTRICAL CIRCUIT (4/6-1, OVERHEAD GUARD, 25L-9A : ELECTRICAL CIRCUIT (4/6-1, OVERHEAD GUARD, 25L-9A : 25L-9A : #0182~, 30L-9A : #0116~, 33L-9A : #0036~, 35LN-9A : #0044~) 25L-9A : #0182~, 30L-9A : #0116~, 33L-9A : #0036~, 35LN-9A : #0044~) 7-6-1 7-15...
Page 357 ·ELECTRICAL CIRCUIT (5/6, FRAME, FINGERTIP, 25L-9A : ~#0496, 30L-9A : ~#0314, 33L-9A : ~#0067, 35LN-9A : ~#0136) ELECTRICAL CIRCUIT (5/6, FRAME, FINGERTIP, 25L-9A : ~#0496, 30L-9A : ~#0314, 33L-9A : ~#0067, 35LN-9A : ~#0136) HYD PS TEMP SENSOR LOAD SENSOR...
Page 358 ·ELECTRICAL CIRCUIT (5/6-1, FRAME, FINGERTIP, 25L-9A : ~#0602, 30L-9A : ~#0364, 33L-9A : ~#0076, 35LN-9A : ~#0178) ELECTRICAL CIRCUIT (5/6-1, FRAME, FINGERTIP, 25L-9A : ~#0602, 30L-9A : ~#0364, 33L-9A : ~#0076, 35LN-9A : ~#0178) 7-7-1...
Page 359 ·ELECTRICAL CIRCUIT (5/6-2, FRAME, FINGERTIP, 25L-9A : ~#0649, 30L-9A : ~#0406, 33L-9A : ~#0079, 35LN-9A : ~#0196) ELECTRICAL CIRCUIT (5/6-2, FRAME, FINGERTIP, 25L-9A : ~#0649, 30L-9A : ~#0406, 33L-9A : ~#0079, 35LN-9A : ~#0196) 7-7-2...
Page 360 ·ELECTRICAL CIRCUIT (5/6-3, FRAME, FINGERTIP, ELECTRICAL CIRCUIT (5/6-3, FRAME, FINGERTIP, 25L-9A : #0649~, 30L-9A : #0406~, 33L-9A : #0079~, 35LN-9A : #0196~ 25L-9A : #0649~, 30L-9A : #0406~, 33L-9A : #0079~, 35LN-9A : #0196~) 7-7-3...
Page 361 ·ELECTRICAL CIRCUIT (6/6, FINGERTIP) ELECTRICAL CIRCUIT (6/6, FINGERTIP) ARMREST HARNESS EMERGENCY STOP SWITCH(FOR MCV) 120 AWG18 234 AWG18 120 AWG18 234 AWG18 245 AWG20 CS-10 246 AWG20 M17 AWG20 114 AWG20 AUX ENABLE SWITCH 121 AWG18 121 AWG20 N14 AWG20 420 AWG20 120 AWG18 CN-16...
Page 362 ·ELECTRICAL CIRCUIT (ECM HARNESS) ELECTRICAL CIRCUIT (ECM HARNESS)
Page 363 GROUP 2 ELECTRICAL CIRCUIT (OPTION, HD TRANSMISSION AND DRIVE AXLE) GROUP 2 ELECTRICAL CIRCUIT (OPTION, HD TRANSMISSION AND DRIVE AXLE) ·ELECTRICAL CIRCUIT (1/5, FRAME) ELECTRICAL CIRCUIT (1/5, FRAME) AIRCON AIRCON-HARNESS COMP. LOAD SPEED 100 #10 R SENSOR TILT SENSOR(T/M) 222 #20 Br LEVER POWER BACKUP...
Page 364 ·ELECTRICAL CIRCUIT (2/5, FRAME, WOODWARD) ELECTRICAL CIRCUIT (2/5, FRAME, WOODWARD) AIRCON AIRCON-HARNESS COMP. SPEED LOAD 100 #10 R SENSOR(T/M) TILT SENSOR 222 #20 Br BACKUP LEVER POWER 100 #10 R ALARM CLEANER SWITCH SOCKET EMPTY SWITCH SWITCH CN-45 START MOTOR KNOB HORN SWITCH 4-HORN CN-37...
Page 365 ·ELECTRICAL CIRCUIT (3/5, FRAME, FINGERTIP) ELECTRICAL CIRCUIT (3/5, FRAME, FINGERTIP) AIRCON AIRCON-HARNESS COMP. SPEED 100 #10 R SENSOR(T/M) LOAD 222 #20 Br POWER BACKUP SENSOR CLEANER SOCKET ALARM EMPTY SWITCH 100 #10 R SWITCH CN-45 START MOTOR TO HARNESS-ARMREST 120 #18 R CN-74 EM S/W 234 #18 Gr...
Page 366 ·ELECTRICAL CIRCUIT (4/5, FRAME, FINGERTIP, WOODWARD) ELECTRICAL CIRCUIT (4/5, FRAME, FINGERTIP, WOODWARD) AIRCON SPEED AIRCON-HARNESS COMP. SENSOR(T/M) LOAD 100 #10 R SENSOR 222 #20 Br BACKUP POWER ALARM CLEANER EMPTY SOCKET SWITCH 100 #10 R SWITCH CN-45 TO HARNESS-ARMREST 120 #18 R EM S/W 234 #18 Gr VALVE POWER...
Page 367 ·ELECTRICAL CIRCUIT (5/5, DASHBOARD) ELECTRICAL CIRCUIT (5/5, DASHBOARD) TO:HARNESS OHG(CABIN)-LH TO:HARNESS OHG(CABIN)-RH STEERING COLUMN SW REAR WORK LAMP LPG CUT OFF S/W HAZARD SWITCH STEERING COLUMN SWITCH(JM01,AN00) (JM01,AN01 or JM02) FLASHER COMBI.SWITCH GEAR SELECTOR 2-TRH UNIT F/SOL R/SOL DO-1 6-TLH HEAD LAMP SWITCH CS-2 101 #10 W...
Page 368 MEMORANDUM...
Page 369 1. POWER CIRCUIT The negative terminal of the battery is grounded to the truck chassis. When the start switch is in the off position, the current flows from the positive battery terminal. OPERATING FLOW Battery (+) Start motor [CN-45 (B+)] Fuse box [CN-36] Fuse box [No.1] I/conn [CN-3 (1)]...
Page 370 100 #10 100 #10 TO AIRCON CN-45 HARNESS FLASHER UNIT HORN START SWITCH B BR START MOTOR CN-74 TO: PSI (BP) ALTERNATOR CN-2 231 #20 231 #20 104 #20 104 #20 105 #20 105 #20 113 #20 113 #20 CN-3 101 #10 101 #10 INTERFACE 1 (FUEL KIT)
Page 371 2. STARTING CIRCUIT OPERATING FLOW Battery (+) terminal Start motor [CN-45 (B+)] I/conn [CN-2 (2)] Start relay [CR-23 (87)] Fuse box [CN-36] Fuse box [CN-36 (No.1)] I/conn [CN-3 (1)] Start switch [CS-2 (1)] The engine can be started only when the gear selector lever is in neutral position. When start switch is in ON position Start switch ON [CS-2 (1)] I/conn [CN-3 (2)]...
Page 372 100 #10 222 #20 100 #10 START SWITCH B BR CN-45 START MOTOR CN-74 TO: PSI (BP) CN-2 231 #20 231 #20 ALTERNATOR F.N.R CONTROLLER CS-11 1-SIG2(Or) 2-SIG1(Y) MICOM 3-+5V(R) CN-38 4-5V GND(B) 5-GND(B) 6-VCC(8~32V) CS-13 1-REV(Or) CN-3 2-N(Gr) 101 #10 101 #10 M17 AWG20 M17 AWG20...
Page 373 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator release the start switch to the ON position. Charging current generated by operating alternator flows into the battery. The current also flows from alternator to each electrical component through the fuse box. OPERATING FLOW Warning flow Alternator [CN-74 (1)]...
Page 374 100 #10 222 #20 100 #10 START SWITCH B BR CN-45 START MOTOR CN-74 TO: PSI (BP) CN-2 231 #20 231 #20 ALTERNATOR CN-3 101 #10 101 #10 103 #10 103 #10 CN-1 107 #20 107 #20 M11 #20 3W/300 345 #20 222 #20 222 #20...
Page 375 4. HEAD LIGHT AND REAR WORK LIGHT CIRCUIT OPERATING FLOW Head light Fuse box [CN-36 No.18] I/conn [CN-2 (7)] Multi function switch [CS-12 (3)] Multi function switch ON [CS-12 (5)] I/conn [CN-2 (6)] Head lamp relay [CR-13 (1 4)] I/conn [CN-2 (15)] I/conn [CN-6 (12)] I/conn [CN-14A (1)] LH Head lamp ON [CL-3A (1)]...
Page 376 100 #10 100 #10 START KEY S/W B BR CN-45 START MOTOR CN-2 CR-13 202 #20 202 #20 G #20 118 #20 118 #18 203 #18 128 #20 HEAD LAMP RELAY 203 #18 CN-3 101 #10 103 #10 MAIN EARTH CL-21 G #20 204 #20...
Page 377 6. FRONT WIPER AND WASHER CIRCUIT OPERATING FLOW Fuse box [CN-36 (No.26)] I/conn [CN-2 (12)] Front wiper & washer switch [CS-3 (3, 5)] I/conn [CN-6 (7)] Wiper motor [CN-21 (3)] Front wiper & washer switch ON (1st step) Front wiper & washer switch [CS-3 (2)] I/conn [CN-6 (3)] Front wiper motor [CN-21 (4)] Front wiper motor operating...
Page 378 100 #10 100 #10 START SWITCH B BR CN-45 START MOTOR CN-2 125 #18 125 #18 CN-3 101 #10 103 #10 CN-14A CL-17 204 AWG20 ILLUMINATION CN-6 TURN 213 AWG20 213 AWG20 GROUND G AWG18 212 AWG20 212 AWG20 FRONT TURN-LH 125 AWG20 125 AWG20 MAIN EARTH...
Page 379 GROUP 3 COMPONENT SPECIFICATION Part name Specification Remark Battery 12V 96HA RC : 130 min CCA : 630A Work lamp 12V, 55W License lamp 12V, 3.4W 2 Combination lamp 12V, 21W (T/S) 12V, 10W (Back) 12V, 5W (Tail) 12V, 21W (Stop) Head lamp 12V, 55W Flasher lamp...
Page 380 GROUP 4 CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn (Dashboard harness-frame harness) 936421 936429 CN-2 I/conn (Dashboard harness-frame harness) 2-85262-1 368301-1 CN-3 Bi-Fuel extension MG610335 CN-5 I/conn (RH OHG harness-frame harness) MG610346 MG640348 CN-5 I/conn (RH cabin harness-dashboard harness)
Page 381 Connector part No. Connector No. of Type Destination number Female Male CN-65 Back buzzer MG640322 CN-71 Seat heat MG620042 CN-71 DEUTSCH Parking solenoid DT06-2S CN-83 A/C condensor fan PB625-02027 CN-113 OPSS buzzer MG610320 CN-113 Fuel system interface connection 174352-2 CN-122 DEUTSCH Forward solenoid DT06-2S...
Page 382 Connector part No. Connector No. of Type Destination number Female Male Lamp CL-1 Room lamp MG610392 CL-1 Room lamp (ring terminal) S820-106000 CL-3 DEUTSCH Head lamp DT06-6S CL-3 Head lamp MG652520 CL-7 DEUTSCH Beacon lamp DT06-2S DT04-2P CL-14 Front turn lamp 936187-3 CL-15 DAEDONG...
Page 383 FINGERTIP HARNESS ONLY Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn (Dashboard harness-frame harness) 936428 CN-2 I/conn (Dashboard harness-frame harness) 368301-1 CN-3 I/conn (Frame harness-dashboard harness) MG652934-5 CN-13 Fuel system interface connection 368050-1 CN-18 Power output 174352-2 CN-28 Hydraulic temperature sensor...
Page 384 Connector part No. Connector No. of Type Destination number Female Male Lamp CL-21 License lamp ST750018-3 ST750036-3 Diode DO-1 AMP/QPL Diode 174352-2 21HK-95440 DO-2 AMP/QPL Diode 174352-2 21HK-95440 DO-3 AMP/QPL Diode 174352-2 21HK-95440 DO-4 AMP/QPL Diode 174352-2 21HK-95440 DO-5 AMP/QPL Diode 174352-2 21HK-95440...
Page 385 GROUP 5 TROUBLESHOOTING Trouble symptom Probable cause Remedy Lamps dimming even at Faulty wiring. Check for loose terminal and discon- maximum engine speed. nected wire. Lamps flicker during engine Improper belt tension. Adjust belt tension. operation. Charge lamp does not light Charge lamp defective.
Page 386 SECTION 8 MAST SECTION 8 MAST Group 1 Structure ------------------------------------------------------------------------------------------------------------ 8-1 Group 2 Operational Checks and Troubleshooting ------------------------------------------------------ 8-5 Group 3 Adjustment -------------------------------------------------------------------------------------------------------- 8-8 Group 4 Removal and Installation ---------------------------------------------------------------------------------- 8-11...
Page 387 SECTION 8 MAST SECTION 8 MAST GROUP 1 STRUCTURE GROUP 1 STRUCTURE 1. 2 STAGE MAST (V MAST) 1. 2 STAGE MAST (V MAST) TILT CYLINDER CARRIAGE LIFT CYLINDER 22D9MS01 Outer mast Anchor bolt 11 Bushing Inner mast Chain sheave bearing 12 Roller Roller Snap ring...
Page 388 2. 2 STAGE MAST (VF MAST) 2. 2 STAGE MAST (VF MAST) TILT CYLINDER LIFT CYLINDER CARRIAGE FREE LIFT CYLINDER 22D9MS02 Outer mast Shim (0.5, 1.0t) 11 Bushing Inner mast Roller 12 Sheave Chain Shim (0.5, 1.0t) 13 Sheave bracket Anchor bolt Tilt cylinder pin Back up liner...
Page 389 3. 3 STAGE MAST (TF MAST) 3. 3 STAGE MAST (TF MAST) TILT CYLINDER LIFT CYLINDER CARRIAGE FREE LIFT CYLINDER 22D9MS21 Outer mast Roller 11 Sheave Middle mast Shim (0.5, 1.0t) 12 Tilt cylinder pin Inner mast Back up liner 13 Support cap Chain Shim (0.5, 1.0t)
Page 390 4. CARRIAGE, BACKREST AND FORK 4. CARRIAGE, BACKREST AND FORK 22D9MS03 Backrest Load roller Fork assembly Carriage Side roller Extension fork...
Page 391 EX :ℓ= 1050 mm (41.3 in) mm (in) STD Fork assy Applicable model Standard Limit Thickness 64HN-21030 25L-9A 45 (1.8) 40 (1.6) 64HN-31020 30/33L-9A 45 (1.8) 40 (1.6) D507FK01 Set forks in middle and measure out of parallel and difference in height at top of forks.
Page 392 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) MAST MAST Problem Problem Cause Cause Remedy Remedy ·Deformed mast or carriage. ·Disassemble, repair or replace. Forks fail to lower. ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump Fork fails to elevate and cylinders in section 6, hydraulic system.
Page 393 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 394 GROUP 3 ADJUSTMENT GROUP 3 ADJUSTMENT 1. MAST LOAD ROLLER (V, VF MAST) 1. MAST LOAD ROLLER (V, VF MAST) 1) 1) INNER/OUTER MAST ROLLER INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480 mm. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the clearance between the...
Page 395 2. MAST LOAD ROLLER (TF MAST) 2. MAST LOAD ROLLER (TF MAST) 1) 1) INNER AND MIDDLE MAST ROLLER INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT CLEARANCE ADJUSTMENT Measure the clearance with the mast overlap at near 480 mm. Shift the inner mast to one side to bring the roller into contact with the outer mast and the middle mast, and adjust the clearance between the roller side face...
Page 396 3) 3) CARRIAGE LOAD ROLLER CARRIAGE LOAD ROLLER Outer mast Adjust Bring into Measure the clearance when the center of screw contact the carriage upper roller is 100 mm from the top of the inner mast. Measure the clearance at upper, middle Side and lower rollers after loosen the adjust roller...
Page 397 GROUP 4 REMOVAL AND INSTALLATION GROUP 4 REMOVAL AND INSTALLATION 1. FORKS 1. FORKS Lower the fork carriage until the forks are Rolled pin approximately 25 mm (1 inch) from the floor. Knob Turn the knob up and slide forks, one by one, toward the center of the carriage Spring where a notch has been cut in the bottom...
Page 398 2) 2) SIDE ROLLER SIDE ROLLER Side roller Remove carriage as outlined in the carriage assembly and removal paragraph. Loosen and remove nuts, adjust screws and side rollers from carriage side pate. Thoroughly clean, inspect and replace all worn or damaged parts. Reverse the above procedure to assembly.
Page 399 4) 4) MAST LOAD ROLLER AND BACK UP MAST LOAD ROLLER AND BACK UP LINER LINER (1) (1) 2 stage mast (V mast) 2 stage mast (V mast) ① Remove the carriage assembly and Chain move them to one side. ②...
Page 400 (2) (2) 2 stage mast (TF mast) 2 stage mast (TF mast) ① Remove free lift chain connected between carriage and free lift cylinder. ② Remove the carriage assembly and move them to one side. ③ bolt Loosen and remove hexagon bolts and Chain washers securing lift cylinders to inner mast.
Page 401 (2) (2) 3 stage mast (TF mast) 3 stage mast (TF mast) ① Remove the carriage assembly and move to one side. ② Loosen and remove hexagon bolt securing bottom cylinder from outer mast. ③ Loosen and remove bolts and special washers securing lift cylinders to middle mast.
Page 402 5) 5) ELEVATING MAST ELEVATING MAST (1) (1) Inner mast (V, VF mast) Inner mast (V, VF mast) ① After completing all necessary steps for load rollers and back up liner removal use an overhead hoist and sling or chain around upper crossmember of the inner mast section. ②...
Page 403 6) 6) CHAIN CHAIN Chain sheave (V, VF mast) Chain sheave (V, VF mast) (1) (1) Chain Outer mast ① Place a sling around carriage and attach to an overhead hoist. Lift carriage high enough so that the tension on the chain Inner mast over sheaves is relieved after the carriage is blocked.
Page 404 (3) (3) Chain wheel bearing support (TF mast) Chain wheel bearing support (TF mast) ① Remove the carriage assembly and move to one side. ② After removing bolt to securing chain wheel bearing support assembly to free lift cylinder. After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support assembly straight up and off of free lift cylinder.
Page 405 ② ② 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 406 ⑧ ⑧ Chain wear scale Chain wear scale The chain can be checked for wear or stretching with the use of a chain wear scale. Stretching of a chain is due to the elongation of the pitch holes and wearing of the pin O.D. The greatest amount of stretching occurs at the areas of the chain that flex over the sheaves most frequently.
Page 407 ③ Adjustment Adjustment Chain adjustments are important for the following reasons : ·Equal loading of chain. ·Proper sequencing of mast. ·Prevent over-stretching of chains. ·Prevent chains from jumping off sheaves if they are too loose. ④ Adjustment procedure Adjustment procedure ·With mast in its fully collapsed and vertical position, lower the fork to the floor.

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