35 45D-7E+Training

Service Training
We build a better future

(35/40/45D-7E, 50D-7AE)
1
Introduction Hyundai’s production plant (Ulsan)
2
3
- 35/40/45D-7E, 50D-7AE model introduction.
- Engine: HMC D4DD

- Rated Power: 95 hp/2300 rpm.
- Max Torque: 35 Kgm/1600 rpm
- Noise level (dBA): 106.1 Lwa
84.0(Left)/85.9(Right) Lpa
- Vibration level: 0.361 m/s2
- Max speed: 27.7km/h(35D-7E)
26.7km/h(40/45D-7E)
26.6km/h(50D-7AE)
- Fuel consumption:
140.2g/ps.hr(at 1700rpm)
4
5
- 35/40/45D-7E, 50D-7AE T/M, Axle, Converter
6
- Basic Torque converter Theory.
- A torque converter is a large doughnut shaped device that is mounted between the
engine and the transmission. It consists of three internal elements that work together to
transmit power to the transmission.
- The three elements of the torque converter are the Pump, the Turbine, and the Stator.
1. The pump is mounted directly to the converter housing which in turn is bolted directly
to the engine's crankshaft and turns at engine speed.
2. The turbine is inside the housing and is connected directly to the input shaft of the
transmission providing power to move the vehicle.
3. The stator is mounted to a one-way clutch so that it can spin freely in one direction but
not in the other.
- Each of the three elements have fins mounted in them to precisely direct the flow of oil
through the converter
- With the engine running, transmission fluid is pulled into the pump section and is pushed
outward by centrifugal force until it reaches the turbine section which starts it turning.
- The fluid continues in a circular motion back towards the center of the turbine where it
enters the stator.
- If the turbine is moving considerably slower than the pump, the fluid will make contact
with the front of the stator fins which push the stator into the one way clutch and prevent
it from turning.
- With the stator stopped, the fluid is directed by the stator fins to re-enter the pump at a
"helping" angle providing a torque increase.
- As the speed of the turbine catches up with the pump, the fluid starts hitting the stator
blades on the back-side causing the stator to turn in the same direction as the pump and
turbine.
- As the speed increases, all three elements begin to turn at approximately the same
speed.
- Converter can be tested in 2 ways: A. Inlet – Outlet pressure test
B. Stall test: If the converter is working, engine

RPM will drop under load conditions at full
acceleration.
7
- 35/40/45D-7E, 50D-7AE Transmission
Hydraulic pump
1 Torque converter
2 Input shaft
3 (3) P.T.O gears
4 Pump assembly T/M
T/M oil pump
5 Gear (RR, 2 stage)
6 Clutch (RR, 2 stage) 11,9L - DEXRON 3
7 Clutch drum (RR)
8 Clutch piston
15 Output shaft
9 Valve assembly
16 Clutch drum (FR)
10 Clutch (RR, 1 stage)
17 Clutch (FR, 2 stage)
11 Gear (RR, 1 stage)
18 Gear (Output, 2 stage)
12 Gear (FR, 1 stage)
19 Gear (FR, 2 stage)
13 Clutch (FR, 1 stage)
20 Counter shaft
14 Gear (Output, 1 stage)
9
For detailed disassembling and assembling info please check service manual!!!
 Rated flow: 37,4 l/rpm
 Main relief pressure: 7-15 Bar
 T/C relief pressure: 0,8-7,2 Bar
 Clutch pressure: 7-15 Bar
 Residual pressure: Max. 0,3Bar
( Clutch release condition )
 Coil Current/Voltage: 0.7A/24V
 Resistance At 20℃: 39.3Ω
10
1 Cylinder clutch (RR) 5 Gear (Out., 2nd stage) 1 T/C input port pressure 5 RR 1st stage pressure
2 Gear (RR, 2nd stage) 6 Gear (FR, 1st stage) 2 Main line pressure 6 RR 2nd stage pressure
3 Gear (RR, 1st stage) 7 Gear (FR, 2nd stage) 3 FR 2nd stage pressure 7 T/C output port pres.
4 Gear (Out, 1st stage) 8 Gear clutch (FR) 4 FR 1st stage pressure
11
Charging pump
Clutch pistons and discs
Transmission Ass’y
Assembly
Clutch drum
Transmission clutch
- 35/40/45D-7E, 50D-7AE Check Port
T/M
Pump
T/C Inlet pres. check
Hydro.
Breather Pump
Inlet relief valve
T/C outlet pres. check
Outlet relief valve
13
13
- 35/40/45D-7E, 50D-7AE Check Port
RR 2de
RR 1ste Stage
FR2de FR 1ste Stage Main
stage Stage Line
14
14
- 35/40/45D-7E, 50D-7AE Inching Adjustment
15
- 35/40/45D-7E, 50D-7AE Air Breather
There is external air breather in 3.5~5 ton class

engine forklift. Instead of that, T/M is breathing
Through dip stick tube , which has small hole in top.
16
- 35/40/45D-7E, 50D-7AE Drive Axle
17
1 Sun gear 6 Hub assy. 11 Pinion shaft

2 Planetary gear 7 Disk brake (See brakes) 12 Spider
3 Inner gear 8 Drive shaft 13 Pinion gear
4 Inner gear carrier 9 Differential carrier 14 Dif. side gear
5 Tapered bearing 10 Ring gear
18
20
21
- 35/40/45D-7E, 50D-7AE Brake System
22
- Drive axle oil: Mobilfluid 424 (10.5ℓ)
- Brake oil tank (3): ONLY AzollaZS10

or SAE 10W Hydraulic oil.
1 Brake pedal & bracket assembly

2 Parking lever assembly
3 Reservoir tank assembly
4 Brake valve
23
From reservoir tank
To Drive Axle
45Bar
From brake pedal
From brake pump
24
- 35/40/45D-7E, 50D-7AE Service Brake System
Service piston adjusting bolt (4EA)
Brake piston
This is the bolt that keeps the distance between brake piston and brake discs.
25
Piston and bushing that locates in the middle of bolt are
very tightly assembled like one piece. When piston moves
to left, bushing also moves to left. But, bushing will be
stopped by bolt head as the bolt are fixed with housing.
Let’s think about the condition that brake discs become worn
out. Then, the distance between disc plate and piston will be
increased, which will also request piston to travel more for
brake activation. But like I said, before piston moves to left
more, travel distance for bushing is quite limited and will
soon stopped. In this stage, piston will be slipped on bushing
in order to move left more for brake activation thanks to brake
oil pressure.
(Even though bushing and piston are assembled as one
piece, it still have very little clearance and piston will move
anyway.)
When piston returns by its spring, it will not perfectly return

to the initial position, but to the point that piston should stay
to keep certain distance between piston and disc plates.
In this way, distance between piston and disc plates can be
kept regardless of disc wear. So, as much as disc become
worn out, the more space “A” will be.
■ Disc replacement procedure

1. Untighten the bolts. (4EA)
2. You can have bushing and piston that are
assembled together.
3. Make the piston move to the right so that it can
be flat with bushing. (See left drawing)
★ If not, like , there will have any clearance.
27
- 35/40/45D-7E, 50D-7AE Parking Brake System
■ Adjustment of Parking Brake

1. Open rubber plug
2. Adjuster should be turned according to arrow
direction until shoe touches brake drum
3. Adjuster should be turned opposite direction
of the arrow sign by four clicks
At this case, lining clearance is 0.1~0.25mm
4. Check drum drag after operating several times
(Repeat from beginning if drag is occurred)
29
30
- 35/40/45D-7E, 50D-7AE Hydraulic System
31
- Down control valve situated in MCV.

- Down safety valve integrated inside outer lifting cylinder.
- Steering pressure relief vale build-in outside for easier access.
- Separated lift / tilt and auxiliary relief valve.
- Fixed main, auxiliary and steering pressure checkpoints on MCV.
- Separate hydraulic pressure and brake booster pressure pumps
on T/M and Engine
- Lift and tilt spools standard equipped with external OPSS solenoids
(24V on diesel and 12V on LPG models)
32
1 Hydraulic gear pump

2 Main control valve
3 Steering unit
4 Priority valve
5 Brake valve
6 Check valve
7 Steering cylinder
8 Tilt cylinder
9 Lift cylinder
10 Suction filter
11 Return filter
12 Down safety valve
13 Down control valve
14 Hydraulic oil tank
- Steering: 125Bar
- Main: 35D-7E = 175Bar
40D-7E = 195Bar
45D-7E = 210Bar
50D-7AE = 215Bar
- Auxiliary: ±150Bar
- Brake valve: 45Bar
33
- The OPSS solenoid

mechanically blocks
the lift and tilt
levers when seat
switch is open. On
diesel models 24V
and on LPG models
12V are assembled.
34
V-Mast TF-Mast
37
- 35/40/45D-7E, 50D-7AE Electric System
38
Insert electrical diagram.
39
① Parking brake pilot lamp

② Left turning pilot lamp
2 3 4 5 6 7 8
③ Fuel low level warning lamp
④ Engine oil pressure warning lamp
⑤ T/M oil temperature gauge
⑥ Battery charging warning lamp 1
1
2
⑦ Air cleaner warning lamp 1
⑧ Work lamp pilot lamp 1

1 4
⑨ Water in fuel warning lamp
⑩ Pre-heater pilot lamp 9
1
⑪ Coolant temperature lamp 5
⑫ Fuel gauge 1
0
⑬ Hour meter 1
3
⑭ Seat belt warning lamp
⑮ Engine checking warning lamp
40
Fuse
42
44
- 35/40/45D-7E, 50D-7AE D4DD Engine
Engine model – D4DD-C7
General type – 4-cyl. in line, 4 stroke, common rail system, turbocharged,

electronically controlled
Maximum output – 100 ps/2300 rpm
Maximum torque – 38kGm/160 rpm

1600 rpm
Compression pressure – 26 atm (20 atm limit)/200 rpm
Valve clearance (cold) – 0.4 mm
Gears timing system
Oil specification – API CF-4 or more / SAE10W-30, total capacity 9 liters
Maintenance recommendation:
•Oil check – 10 hours/daily
•Oil + filter change – 250h
• hours/monthly
45
INTAKE AIR PRESSURE SENSOR (BOOST PRESSURE SENSOR)
46
INTAKE AIR TEMPERATURE SENSOR
AIR TEMPERATURE SENSOR

(WITH BOOST SENSOR)
47
Check point for MAP SENSOR
1 2 3 4
1 : Signal for intake pressure
2 : Power supply
3 : Signal for intake temperature
4 : Ground
COOLANT TEMPERATURE AND OIL PRESSURE SENSORS
Gauge unit WATER

(CLUSTER) SENSOR
49
CRANKSHAFT AND CAMSHAFT POSITION SENSOR
CRANKSHAFT POSITION SENSOR - NE SENSOR
50
Cam Position Sensor (Hole Sensor Type)
IC Chip
Permanent
magnet
AIR GAP :
1±0.5mm
Condition Voltage
Idle 1.0V ∼ 2.0V
Cam position sensor senses top dead center on the compression stroke of cylinder #1,
#4 and reverse it to pulse signal for ECU so that ECU can determine the fuel injection
order.
Crank Position Sensor (Magnetic Type)
Air gab : 0.5~1.1 mm

Sensor Wave
It determines injection timing. All the engine pistons are

connected to crank shaft by connecting rods. Thus, sensor
in crank shaft can provide all the piston position information.
Revolution speed is defined with rpm of crank shaft.
Input signal for ECU is from crank shaft position sensor
which uses magnetic.
(58EA)
RAIL PRESSURE SENSOR
RAIL
RAIL
PRESSURE
PRESSURE
SENSOR
SENSOR
53
Flow damper RAIL PRESSURE SENSOR
P1091 P1092
P1093 P1094 When engine stops,
From common rail

To injector
(Input)
(Output)
When damping, Orifice

Pressure
limit valve
P0088 P2293
Rail pressure sensor
※P0XXX: Error code
P0192 P0193 P0194
Piston that contains orifice absorbs the fuel pressure
Shocks In common rail.
Pressure limit valve
When fuel leaks,
Dead Volume 11cc

Flow damper orifice Ø 0.76
Pressure limit valve 221MPa(2,210bar)
If there is any fuel leakage at injector area, piston and ball move
Rail pressure sensor 180 Mpa(1,800bar)
to the right with pressure by excessively leaked fuel and the ball
blocks the passage to stop the fuel leak and protect the system
in the end.
SUPPLY CONTROL VALVE(SCV) AND FUEL TEMP. SENSOR
Fuel
temperature
sensor
measures fuel
temperature and
sends the
information to
ECM.
And then ECM
adjusts the fuel
injection quantity
based on this
signal
55
SUPPLY CONTROL VALVE(SCV) AND FUEL TEMP. SENSOR
Output Rotating direction Anti-clockwise

Input
Plunger diameter Ø 8.5
Numbers of plunger 2
Cam lift 8.8mm

SCV Fuel discharge rate 1000㎣ [1cc]/rev
Voltage 24V
Supply
(To rail) Fuel temp. sensor Embeded
Feed Pump
Fuel temp.
sensor
CH No.1: SCV Voltage wave

CH No.2: SCV Current wave
ACCELERATION PEDAL, ECU AND ATMOSPHERIC PRESSURE SENSOR
Atmospheric pressure sensor, located inside ECM

(Engine Control Module) converts atmospheric
pressure to current and sends it to ECM.
With this signal, the status of the vehicle and the fuel
ignition timing are controlled so that the vehicle
performance is improved
57
Engine rpm
Coolant
temperature
Battery
voltage
Rail pressure
(Real)
Rail pressure
(Target)
SCV operating
current
SCV target
current
SCV duty
value
COMPONENTS OVERVIEW
13
59
INJECTORS AND ELECTRONIC FUEL PUMP
Hold diameter
Solenoid (￠0.16)×4
× Numbers of hole
Fuel discharge rate

1100
Valve (cc/min)
Nozzle stroke 0.35

Orifice
Resistance 0.3~0.6Ω
Edge Sac. Volume 0.19 ㎜3

filter Piston
Packing tip
Nozzle
60
INJECTORS (OPERATION)
Solenoid
Current Current Current

valve
From
common rail
Pressure control Pressure control Pressure control

chamber chamber chamber
Piston
Injecting Injecting Injecting

Nozzle quantity
quantity quantity
Before injection Injection After injection

Multi-injection
Mechanical injection Common rail injection
Pre-injection
It is for better combustion by injecting the fuel into the cylinder before the
main injection. W-Engine can reduce the vibration and explosion noise/surging
thanks to pre-injection. As a result, Nox emission will be reduced.
Pre-injection
Main injection
Voltage
Injecting time Injecting time
Current
Injection quantity : Nozzle diameter X Injecting time X Injecting pressure

X Injection number X battery voltage
INJECTORS AND ELECTRONIC FUEL PUMP
65
- 35/40/45D-7E, 50D-7AE HCE-DT TOOL
HCE DIAGNOSTIC TOOL SYSTEM INFORMATION
Item Contents Remarks
Above the MS XP  Above the MS XP Operating System

Operation
System  Korean, English, French, Deutsch, Italic,
Language 16 Languages
Spanish, etc
 With HRDT 2.0

7-Series excavator
 Machine&(Electronic)Engine Diagnosis
9S-Series excavator  Machine&(Electronic)Engine Diagnosis
Diagnosis 9-Series Wheel Loader  Machine&(Electronic)Engine Diagnosis
35/40/45D, 50D-7(A)E
Fork Lift (Large size) Engine Diagnosis
50/60/70/80 Ton Class
Engine Diagnosis  Cummins, MHI, YANMAR, HYUNDAI(G/H) Electronic type E/G
66
HCE DIAGNOSTIC TOOL COMPONENTS
ITEM CONTENTS Note
Program CD
Install DVD  HCE-DT Software Installation CD(DVD)
Manual Manual  User Manual
67
HCE DIAGNOSTIC TOOL COMPONENTS
ITEM Contents Note
System Voltage  7 ~ 35V
Communication to  RS-232
Vehicle  CAN – Version 2.0 (500, 250K-Version 1.0)
 USB
Communication to PC
 Wireless LAN
Memory  32Mbyte Internal Memory
68
HCE DIAGNOSTIC TOOL BASIC COMPONENTS
ITEM CONTENTS Note
16 PIN Main
 Main Connector
Connector
 Power supply for VCI

Trigger module
 Trigger signal
USB CABLE  For PC communication (Wire connection)
16 PIN Connector  for forklifts 50/60/70 and 80D-7E
9 PIN Connector  for forklifts 180/250D-7E To check !!!!!!
69
HCE DIAGNOSTIC TOOL CONNECTION
70
HCE DIAGNOSTIC TOOL INITIAL SCREEN
Choice sequence:
VIN FORKLIFTALL
COMMONENGINE
71
HCE DIAGNOSTIC TOOL MENUS
1. DIAGNOSIS –
Trouble shooting screens
2. Sensor data
graph Analysis
3. Running
data Analysis
72
1
Main Menus Contents
* Machine&(Electronic)Engine Diagnosis – Excavator/Wheel
Error Code loader
display * Engine Diagnosis – Fork Lift
- 9(and 7A) Series MCU, CMS, MHI, Yanmar, HMC(G/H), ZF TM
Error Current(Active) / History(Inactive) Code display

Status - 9(and 7A) Series MCU, CMS, MHI, Yanmar, HMC(G/H), ZF TM
Error Detail Error happening number count, Elapsed time, etc

Diagnosis
display - 9 Series MCU, CMS, MHI, Yanmar, HMC(G/H), ZF TM
Function
Pause Sensor data display at the time when error happen
Frame - 9 Series MCU, CMS, MHI, Yanmar, HMC(G/H), ZF TM
Error Code All or partial error code deletion (w. Service Password)
delete - 9 Series MCU, ZF TM, CMS, MHI, Yanmar, HMC(G/H), ZF TM
Guide support for the Error Code

Error Code
- 9(and 7A) Series MCU, CMS, MHI, Yanmar Engine
Guide
73
1
Excavator example 74
2
Item Content
* Excavator(Including 7(A) Series)

- Machine Status1, Machine Status2, Analog Signal 1,
Analog Signal 2, Digital Input, Digital Output, Engine Data
* Wheel loader
Monitoring
- Gauge, Warning/Indicator Lamp, Hour meter, Clock/Wiper,
(Real time)
Vehicle Travel, Vehicle Status 1, Vehicle Status 2, WL Analog
Signal, Engine Data, Vehicle Distance, Weighing System Status
Sensor data Weighing System Data1,2,3
Analysis * Fork Lift(HMC Engine)
Graph, Monitorig data Text/Graph Display and Analysis

Text Display - Graph data : Max. 8 Graphs
- Text data : max. 48 Items
Pause and
Move
Monitoring data save into the PC memory.

Data save
- Real time data save into the PC(No time limit)
75
2
※ Graph selection :
Max. 8 Graphs
3
Item Content
Monitoring data save into the Communication
converter without PC communication connection.
- Memory size : Max. 32Mbyte
- Data selection
Monitoring - Saving time
data saving on : 10Min., 30Min., 1Hour data saving( Max. 32Mbyte)
Running Memory - Saving type
data ＊Manual : Trigger button active when Error happen.
Analysis * Fault Code Trigger : Automatic trigger when Error
code
(Data Saving)
happen
통Data copy to PC from Communication convertor,

PC Save and
and then Analysis.
Analysis
- Text and Graph display for the saved data
77
3
84
- 35/40/45D-7E, 50D-7AE Maintenance
85
- 35/40/45D-7E, 50D-7AE Maintenance
86
87
- Questions or remarks.
90

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Service Training

We build a better future

- Engine: HMC D4DD

B. Stall test: If the converter is working, engine

 Rated flow: 37,4 l/rpm

 Main relief pressure: 7-15 Bar

 T/C relief pressure: 0,8-7,2 Bar

 Clutch pressure: 7-15 Bar

 Residual pressure: Max. 0,3Bar

( Clutch release condition )

 Coil Current/Voltage: 0.7A/24V

 Resistance At 20℃: 39.3Ω

T/C Inlet pres. check

Inlet relief valve

T/C outlet pres. check

Outlet relief valve

There is external air breather in 3.5~5 ton class

1 Sun gear 6 Hub assy. 11 Pinion shaft

- Drive axle oil: Mobilfluid 424 (10.5ℓ)

- Brake oil tank (3): ONLY AzollaZS10

1 Brake pedal & bracket assembly

From reservoir tank

From brake pedal

From brake pump

Service piston adjusting bolt (4EA)

When piston returns by its spring, it will not perfectly return

■ Disc replacement procedure

■ Adjustment of Parking Brake

- Down control valve situated in MCV.

1 Hydraulic gear pump

- The OPSS solenoid

Insert electrical diagram.

① Parking brake pilot lamp

⑧ Work lamp pilot lamp 1

Engine model – D4DD-C7

General type – 4-cyl. in line, 4 stroke, common rail system, turbocharged,

Maximum output – 100 ps/2300 rpm

Maximum torque – 38kGm/160 rpm

Compression pressure – 26 atm (20 atm limit)/200 rpm

Valve clearance (cold) – 0.4 mm

Gears timing system

Oil specification – API CF-4 or more / SAE10W-30, total capacity 9 liters

AIR TEMPERATURE SENSOR

Gauge unit WATER

CRANKSHAFT POSITION SENSOR - NE SENSOR

Idle 1.0V ∼ 2.0V

Air gab : 0.5~1.1 mm

It determines injection timing. All the engine pistons are

From common rail

When damping, Orifice

Dead Volume 11cc

Output Rotating direction Anti-clockwise

Cam lift 8.8mm

CH No.1: SCV Voltage wave

Atmospheric pressure sensor, located inside ECM

Fuel discharge rate

Nozzle stroke 0.35

Edge Sac. Volume 0.19 ㎜3

Current Current Current