Service Manual: Forklift Diesel

SERVICE MANUAL
Forklift Diesel
15D/ 18D/ 20DA-7E
HYUNDAI FORKLIFT TRUCK
Kiều Văn Trung

Tell: 0936.359.363
SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Group 3 Periodic Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
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.
As preparation in case of fire, always know
the location and directions for use of fire
extinguishers and other fire fighting equipment.
D35ASF01
· Wear well-fitting helmet, safety shoes and

working clothes. When drilling, grinding or
hammering, always wear protective goggles.
Always do up safety clothes properly so that
they do not catch on protruding parts of
machines. Do not wear oily clothes.
When checking, always release battery plug.
D35ASF02
· Flames should never be used instead of

lamps. Never use a naked flame to check
leaks or the level of oil or electrolyte.
D35ASF03
· Exhaust gas is dangerous. Provide adequate

ventilation when working a closed space.
D35ASF04
1-1
Be particularly careful when removing the
radiator cap and the hydraulic oil tank filler
cap, if this is done immediately after using
the machine, there is a danger that boiled
oil may spurt out.
· The procedure for releasing the hydraulic
pressure is as follows : lower the fork to the ground,
and stop the engine(Motor), move the control
levers to each position two or three times.
D35ASF05
· When working on top of the machine, be

careful not to lose your balance and fall.
D35ASF06
· Hand a caution sign in the operator's compartment

(For example Do not start or Maintenance in
progress).
This will prevent anyone from starting or
moving the machine by mistake.
It is extremely dangerous to try to check
the fan belt tension while the engine is
running.
D35ASF07
When inspecting the engine is running parts, or

near such parts, always stop the engine first.
Before checking or servicing accumulator or
piping, depress brake pedal repeatedLy to
release pressure.
· Park the machine on firm, flat ground.
Lower the fork to the ground and stop the
engine.
Return each lever to NEUTRAL and apply
D35ASF08
the brake lock.
1-2
· Immediately remove any oil or grease on the
floor of the operator's compartment, or on the
handrail. It is very dangerous if someone
slips while on the machine.
OIL
D35ASF09
· When working with others, choose a group

leader and work according to his instructions.
Do not perform any maintenance beyond the
agreed work.
D35ASF10
· Unless you have special instructions to the

contrary, maintenance should always be
carried out with the engine stopped. If
maintenance is carried out with the engine
running, there must be two men present : one
sitting in the operator's seat and the other one
performing the maintenance. In such a case,
never touch any moving part.
· Always remember that the hydraulic oil circuit

is under pressure. When feeding or draining
the oil or carrying out inspection and
maintenance, release the pressure first.
D35ASF11
1-3
· Thoroughly clean the machine. In particular, be careful to clean the filler caps, grease fittings and the
area around the dipsticks. Be careful not to let any dirt or dust into the system.
· Always use HYUNDAI Forklift genuine parts for replacement.
· Always use the grades of grease and oil recommended by HYUNDAI Forklift.
Choose the viscosity specified for the ambient temperature.
· Always use pure oil or grease, and be sure to use clean containers.
· When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into
the oil.
· Before draining the oil, warm it up to a temperature of 30 to 40。C .
· After replacing oil, filter element or strainer, bleed the air from circuit.
· When the strainer is located in the oil filler, the strainer must not be removed while adding oil.
· When changing the oil filter, check the drained oil and filter for any signs of excessive metal particles
or other foreign materials.
· When removing parts containing O-ring, gaskets or seals, clean the mounting surface and replace
with new sealing parts.
· After injecting grease, always wipe off the oil grease that was forced out.
· Do not handle electrical equipment while wearing wet places, as this can cause electric shock.
· During maintenance do not allow any unauthorized person to stand near the machine.
· Be sure you fully understand the contents of the operation. It is important to prepare necessary tools
and parts and to keep the operating area clean.
· When checking an open gear case there is a risk of dropping things in. Before removing the covers to
inspect such cases, empty everything from your pockets. Be particularly careful to remove wrenches
and nuts.
· 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 it.
1-4
GROUP 2 SPECIFICATIONS
1. GENERAL LOCATIONS
16
9 8
10
1 11
2
13
3
12
4
14
6
7
15
15D7EOM54
1 Mast 7 Forks 13 Counterweight

2 Lift chain 8 Overhead guard 14 Rear wheel
3 Lift cylinder 9 Turn signal lamp 15 Front wheel
4 Backrest 10 Head lamp 16 Rear combination lamp
5 Tilt cylinder 11 Operator's seat
6 Lift bracket 12 Bonnet
1-5
2. SPECIFICATIONS
C' C
D
R
A
E
I
M'
H
W
B
J
K
F
T
G L
15D7ESP01
Model Unit 15D-7E 18D-7E 20DA-7E

Capacity kg 1500 1750 2000
Load center R mm 500 ← ←
Weight(Unloaded) kg 2850 3020 3166
Lifting height A mm 3300 ← ←
Free lift B mm 145 ← 150
Fork Lifting speed(Unload/Load) mm/sec 650/620 650/610 650/600
Lowering speed(Unload/Load) mm/sec 450/500 ← ←
L×W×T L,W,T mm 900×100×35 ← 900×100×40
Tilt angle (forward/backward) C/C’ degree 6/10 ← ←
Mast Max height D mm 4332 ← ←
Min height E mm 2155 ← ←
Travel speed km/h 19.5 ← ←
Body Gradeability degree 19.8 17.9 16.8
Min turning radius(Outside) F mm 1985 2013 2050
Max hydraulic pressure kgf/cm2 190 ← ←
ETC Hydraulic oil tank ℓ 30 ← ←
Fuel tank ℓ 38 ← ←
Overall length G mm 2233 2263 2303
Overall width H mm 1070 ← ←
Overhead guard height I mm 2110 ← ←
Ground clearance J mm 120 ← ←
Wheel base K mm 1410 ← ←
Wheel tread front/rear M, M' mm 910/890 ← ←
1-6
3. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Unit Specification
Model - KUBOTA V2203-M-E3B

Type - 4-cycle, in-line overhead valve
Cooling Method - Water cooling
Number of cylinders and arrangement - 4 cylinders, in line
Firing order - 1-3-4-2
Combustion chamber type - In direct injection
Cylinder bore X stroke mm(in) 87×92.4(3.4 ×3.6)
Piston displacement cc(cu in) 2197(134.1)
Compression ratio - 22.6
Rated gross horse power ps/rpm 41.9/2400
Maximum gross torque at rpm kgf·m/rpm 14.3/1600
Engine oil quantity ℓ(U.S.gal) 9.5(2.5)
Dry weight kg(lb) 211(465)
High idling speed rpm 2600±50
Low idling speed rpm 850±50
Rated fuel consumption g/ps.hr 180
Starting motor V-kW DENSO12V, 2.0kW
Alternator V-A DENSO 12V, 40A
Battery V-AH 12V, 75AH
Fan belt deflection mm(in) 7~9(0.28~0.35)
(2) MAIN PUMP
Type - Gear
Capacity cc/rev 26
Maximum operating pressure bar 210
Rated speed (Max/Min) rpm 3000/500
(3) MAIN CONTROL VALVE

Type - Sectional
Operating method - Mechanical
Main relief valve pressure bar 190/150
Flow capacity lpm 80
1-7
(4) POWER TRAIN DEVICES
Item Specification
Model KAPEC 280 27 613/G7

Torque converter Type 3 Element, 1 stage, 2 phase
Stall ratio 2.9 : 1
Type Full auto, power shift
Gear shift(FR/RR) 1/1
Transmission Control Electrical single lever type, kick-down system
FR 2.137 : 1
Overhaul ratio
RR 2.214 : 1
Type Front-wheel drive type, fixed location
Axle Gear ratio 6.5 : 1
Gear Ring & pinion gear type
Q'ty(FR/RR) 2/2
Wheels
Front(drive) 6.50-10-12 PR
Rear(steer) 5.00-8-10 PR
Brakes Travel Front wheel, wet disc brake

Parking Ratchet, band brake type
Steering Type Hydro static, power steering

Steering angle 81°to both right and left angle, respectively
1-8
4. TIGHTENING TORQUE OF MAJOR COMPONENTS
No Item Size kgf·m lbf·ft
1 Engine mounting bolt, nut M12×1.25 12.3±2.4 89±17.4

2 Engine Radiator mounting bolt, nut M 8×1.25 2.5±0.5 18.1±3.6
3 Torque converter mounting bolt M10×1.25 6.9±1.4 50±10
4 Hydraulic MCV mounting bolt, nut M10×1.5 6.9±1.4 50±10
5 system Steering unit mounting bolt M10×1.5 4.0±0.5 29±3.6
6 Transmission mounting bolt, nut M16×2.0 7.5 54
7 Drive axle mounting bolt, nut M20×1.5 62.5±9.5 452±69
Power
8 train Steering axle mounting bolt, nut M20×2.5 58±8.5 420±61
system Front wheel mounting nut
9 M14×1.5 17.5±1.5 127±10.8
10 Rear wheel mounting nut M12×1.5 10±1 72±7.2
11 Counterweight mounting bolt M30×3.5 60±5 434±36
12 Others Operator's seat mounting nut M 8×1.25 2.5±0.5 18.1±3.6
13 Head guard mounting bolt M12×1.75 6.2 44.8
1-9
5. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12×1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.0 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36×4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 8×1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10×1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12×1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14×1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36×3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562
1-10
2) PIPE AND HOSE(FLARE TYPE)
Thread size(PF) Width across flat(mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
3) PIPE AND HOSE(ORFS TYPE)
Thread size(UNF) Width across flat(mm) kgf·m lbf·ft
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253
4) FITTING
Thread size(PF) Width across flat(mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
1-11
6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Capacityℓ(U.S.gal) Ambient temperature 。
C (。
F)
Service Kind of
point fluid -20 -10 0 10 20 30 40
15D/18D/ 20DA-7E
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil Engine oil 9.5
pan (2.5)
SAE 10W-30
SAE 15W-40
Torque ATF 10
converter ATF DEXRON III
transmission Engine oil (2.6)
Axle Gear oil 5 SAE 80W-90/API GL-5(DRY), MOBILFLUID 424(WET)

(1.3)
ISO VG32
26(6.9)
Hydraulic Hydraulic
Option ISO VG46
tank oil
32(8.4)
ISO VG68
ASTM D975 No.1

Fuel tank Diesel fuel 38
(10.0)
ASTM D975 No.2
Fitting NLGI No.1

Grease -
(Grease nipple)
NLGI No.2
Brake
reservoir Brake oil 0.5 DOT 3(DRY), AZOLLA ZS10(Hydraulic oil, ISO VG10 : WET)
tank (0.13)
Radiator
Antifreeze:Water 9.4 Ethylene glycol base permanent type
50:50 (2.48)
NOTES :
① SAE numbers given to engine oil should be selected according to ambient temperature.
② For engine oil used in engine oil pan, use SAE 10W oil when the temperature at the time of
。C , even if the ambient temperature in daytime is expected to rise
engine start up is below 0。
to 10。C or more.
③ any engine oil of API service class CF is used instead of class CH4 engine oil, the
If
frequency of oil change must be doubled.
1-12
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 degrees
of wear at time of periodic maintenance; therefore, even if no apparent wear is found, always replace
with new parts within the prescribed period of replacement(or earlier if trouble is found).
※ Replacement of consumable service parts in not covered under warranty.
No Description Period of replacement
1 Master cylinder and wheel cylinder caps, dust seals Every 1 year
2 Brake hose or tube Every 1 or 2 years
3 Brake reservoir tank and tube Every 2 to 4 years
4 Power steering hose Every 2 years
5 Stop lamp switch(oil pressure type) Every 2 years
6 Fuel hose Every 2 to 4 years
7 Rubber parts of power steering Every 2 to 4 years
8 Lift chain Every 2 to 4 years
9 Hose of load handling Every 1 or 2 years
1-13
SECTION 2 REMOVAL AND INSTALLATION OF UNIT
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
SECTION 2 REMOVAL & INSTALLATION OF UNIT
GROUP 1 STRUCTURE
15DRE01
1 Mast 9 Hydraulic pump 17 Counterweight

2 Lift cylinder 10 Transmission 18 Muffler
3 Steering unit 11 Torque converter 19 Seat
4 Main control valve 12 Engine 20 Overhead guard
5 Tilt cylinder 13 Rear wheel 21 Air cleaner
6 Fork 14 Steering cylinder 22 Steering wheel
7 Front wheel 15 Steering axle
8 Drive axle 16 Radiator
2-1
GROUP 2 REMOVAL AND INSTALLATION OF UNIT
Remove and install following units as explained in the flow chart.
1. MAST
1) REMOVAL
(1) Forks
① Lower the fork carriage until the forks are
approximately 25mm(1in) from the floor.
② Turn knob up and slide one fork at a time
toward the center of the carriage where a
notch has been cut in the bottom plate for
easy removal.
③ Remove only one fork at a time.
※ On larger forks it may be necessary to
use a block of wood.
15DRE02
(2) Backrest(If necessary)

① Remove bolts securing backrest to fork
carriage. Lift backrest straight up and
remove it from carriage.
15DRE03
(3) Carriage
① With the mast vertical, raise the carriage
high enough to place blocks under the
load forks. This is done to create slack in
the load chains when the carriage is
lowered. Lower the carriage all the way
down to the floor. Make sure the carriage
is level, this will prevent any binding when
the mast is raised. 20D7RE04
2-2
② While supporting lift chains, remove the
nuts and split pin from the chain anchor
bolts of stationary upright.
15DRE05
③ Pull the chains out of the sheaves and

drape them over the front of the carriage.
15DRE06
④ Slowly raise inner mast upright until mast

clears top of fork carriage. Move carriage
to work area and lower the mast.
Make sure that carriage remains on
floor and does not bind while mast is
being raised.
※ Inspect all parts for wear or damage.
Replace all worn or damaged parts.
15DRE07
2-3
(4) Piping
① Remove the return hoses and clamps
attached to the cylinder.
② Remove hose assembly, velocity fuse
valve(1) and tee from the lift cylinder.
※ Put blind plugs in the piping immediately
after removing hoses.
This prevents the hydraulic oil from
flowing out and also prevents dust and
dirt from getting in.
③ Disconnect hose assembly from the
connector(2).
15DRE08
(5) Lift cylinder

① Loosen the nuts and remove stud bolts
securing the lift cylinders to inner mast.
② Bind the lift cylinder with overhead hoist
rope and pull up so that the rope has no
slack or binding.
Make sure that the lift cylinder be
tightened firmly for safety.
③ Loosen and remove hexagon bolts and
clamps securing cylinder to outer mast.
④ Using an overhead hoist, slowly raise the
inner mast high enough to clear lift
cylinder.
⑤ Using an overhead hoist, draw out lift
cylinder carefully and put down on the
work floor.
15DRE09
2-4
(6) Inner mast
① Using an overhead hoist raise the inner
mast straight and carefully draw out of
outer mast section.
Be careful the mast not to swing or fall.
15DRE10
(7) Tilt cylinder pin

(8) Mast support cap
① Attach a crane to the stay at the top of
the outer mast, and raise enough to
sustain jacked up machine.
※ This operation is carried out from under
the machine, so use a pit, or if there is no
pit, jack up the machine and loosen with
on impact wrench.
② Remove the mounting bolts from the cap
then slowly raise the outer mast.
15DRE11
2-5
2) INSTALLATION
After assembling mast components totally without piping connections, install mast assembly to the
equipment.
※ Installation procedure for each of mast component is the reverse of the removal procedure.
(1) Mast support cap
① Check the mast support cap and spring pin for wear.
② Jack up the machine so that the front is raised and then using an overhead hoist assemble outer
mast to drive axle unit.
③ Tighten mounting bolts to mast support cap. Apply loctite #277.
·Tightening torque : 19.9~26.9kgf·m(144~195lbf·ft)
(2) Tilt cylinder pin
Hold the mast with a crane, operate the tilt control lever and align the holes, then knock the pin.
(3) Lift cylinder installation and adjustment
① Assemble the lift cylinder inside the outer
mast, then tighten the stopper bolt. If the
cylinder assembly has been replaced,
adjust as follows so that the left and right
cylinders are synchronized at the
maximum lifting height.
② Assemble the cylinder rod to the inner
mast, and check the left-to-right play of
the mast at the maximum lifting height.
※ If play is to LEFT, install adjustment shim
to LEFT cylinder.
※ If play is to RIGHT, install adjustment
L15C3RE12
shim to RIGHT cylinder.
·Shim thickness : 1.0mm(0.04in)
2-6
2. POWER TRAIN ASSEMBLY
1) REMOVAL
D503RE04
(1) Mast
Refer to section on mast (Page 2-2)
2-7
(2) Brake piping
Disconnect the brake piping from the
brake housing of drive axle.
15DRE12
(3) Parking brake cable

Disconnect parking brake cable from the
transmission.
Transmission
Parking brake
cable
20D7RE13
2-8
(4) Drive axle
① Attach a crane to the tilt cylinder notches
on the dashboard and raise the machine.
② Loosen hexagonal bolts (1) connection
drive axle to the transmission.
③ Put the block under the drive axle and
support under the drive axle with a truck.
④ Remove drive axle mount bolts (2) from
the frame and then slowly pull out the
truck with drive axle to the front.
⑤ Remove drive shaft assy from
transmission.
20D7RE14
(5) Inching linkage

Clevis pin
Remove the clevis pin from the
transmission control valve.
Inching pedal
Transmission
control valve
20D7RE15
(6) Transmission cooling piping

① Disconnect cooling hose from the
transmission.
Radiator
assy
※ Make sure that the coolant be drained
from the hose.
Transmission assy Hose
Hose
20D7RE16
2-9
(7) Torque converter
① Remove the cover on top face of the
torque converter housing then remove
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
while the other turns the flywheel.
15DRE17
(8) Mounting bolts holding to flywheel

housing
① Remove transmission assembly from the
engine flywheel housing by loosening the
8 mounting bolts.
15DRE18
② Using a moving truck slowly pull out

transmission assembly to the front.
15DRE19
2-10
2) INSTALLATION
(1) Installation is the reverse order to removal,
but be careful of the following points.
(2) Tightening torque
·Bolt (1) : 5.5~8.3kgf·m (39.8~60lbf·ft)
·Bolt (2) : 2.7~4.1kgf·m (19.5~29.7lbf·ft)
·Bolt (3) : 5.5~8.3kgf·m (39.8~60lbf·ft)
·Bolt (4) : 57~72kgf·m (412~521lbf·ft)
·Bolt (5) : 7.5kgf·m (54.2lbf·ft)
15DRE21
2-11
3. ENGINE
Lever the torque converter, transmission and front axle inside the frame, then remove the engine
assembly.
1) REMOVAL
D503RE25
(1) 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.
20D7RE22
2-12
(2) Remove the torque converter housing
cover, mounting bolts installed to flywheel
housing.
For details, see page 2-10.
(3) Engine accessory
Remove all wiring harnesses, cables and
hoses around the engine, dashboard and
frame.
① Wiring harness to alternator and starter.
② Wiring harness for oil pressure and
engine water temperature gauges.
③ Hoses to fuel tank and air cleaner.
④ Exhaust pipe.
(4) Radiator hose
Open the drain valve of the radiator and
drain the cooling water, then remove the
15DRE23
radiator hose.
(5) 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.
15DRE24
2-13
2) INSTALLATION
Installation is the reverse order of removal,
but be careful of the following points.
(1) Tighten the engine mounting bolts and
nuts.
(2) Tighten the engine mounting bracket bolts.
※ Do not remove the bolts unless necessary.
Loctite is coated over the threads of bolt.
So, once the bolts were removed, coat
them with loctite (#243) when installing.
※ Before installing the bolts, loctite in the
holes should be removed by a tap.
15DRE25
(3) Tightening torque
·Bolt (1) : 5.5~8.3kgf·m (39.8~60lbf·ft)
(2) : 10~15kgf·m (72~109lbf·ft)
(3) : 10~15kgf·m (72~109lbf·ft)
·Nut (4) : 11~16kgf·m (79.6~116lbf·ft)
(4) Radiator hoses
·Distance to insert hose : 35mm (1.4in)
(5) Air cleaner hose

① Insert the air cleaner hose securely and
fit a clamp.
② Distance to insert hose
·Air cleaner hose : 35mm (1.4in)
·Engine end : 25mm (1in)
15DRE26
2-14
4. STEERING AXLE
1) REMOVAL
15DRE27
(1) Counterweight
Hold the counterweight with hoist bars, and raise it with a crane.
Remove the mounting bolts, raise slightly and move it slowly to rear side.
·Weight of counterweight(standard)
15D-7E : 735kg(1620lb)
18D-7E : 894kg(1970lb)
20DA-7E : 1035kg(2280lb)
·Tightening torque :
55~65kgf·m(398~470lbf·ft)
2-15
(2) Rear wheel
Remove mounting bolt and hub nut with
socket wrench and then carefully take out
the tire assembly.
15DRE28
(3) Hose
Drain hydraulic oil in the hoses and
cylinder before removing them.
Loosen connector and then disconnect
the hoses.
15DRE29
(4) Mounting bolt

Put a block under the steering axle, block
on a truck, and raise the frame with a
crane. Remove the mounting bolts
installing to the frame, and pull out to the
rear.
There are shims between the block and
steering axle to prevent play.
·Tightening torque :
49.5~66.5kgf·m(358~481lbf·ft) 15DRE30
2-16
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-21
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-25
SECTION 3 POWER TRAIN SYSTEM
GROUP 1 STRUCTURE AND OPERATION
1. POWER TRAIN DIAGRAM
1) STRUCTURE
15DPT01
1 Engine 3 Drive shaft 5 Brake

2 Transmission 4 Drive axle
3-1
2) SPECIFICATION
Item Specification
Model KAPEC 280 27 613/G7

Torque converter Type 3 Element, 1 stage, 2 phase
Stall ratio 2.9 : 1
Type Full auto, power shift
Gear shift(FR/RR) 1/1
Transmission Control Electrical single lever type, kick-down system
FR 2.137 : 1
Overhaul ratio
RR 2.214 : 1
Type Front-wheel drive type, fixed location
Axle
Gear ratio 6.5 : 1
Gear Ring & pinion gear type
Quantity(FR/RR) 2/2
Wheels Front(drive) 6.50-10-12PR
Rear(steer) 5.00-8-10PR
Travel Front wheel, Wet disc brake
Brakes
Parking Ratchet, band brake type
Type Hydro static, power steering
Steering
Steering angle 81°to both right and left angle, respectively
3-2
2. TORQUE CONVERTER
1) STRUCTURE
6
5
4
2
1
9
10
7
16
11
13
12
14
15
20D7PT03
1 Bolt 9 Bolt
2 Plate 10 Torque converter housing cover
3 Flexible plate 11 Temperature sensor
4 Torque converter assembly 12 Inner oil strainer
5 Bolt 13 Oil strainer spring
6 O-ring 14 O-ring
7 Oil level gauge 15 Oil strainer plug
8 Oil level gauge guide 16 Torque converter housing
3-3
2) 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.
3) TORQUE CONVERTER HYDRAULIC CIRCUIT
Torque converter assy

Torque
converter
P T
Inlet port S Outlet port

To control valve
Inlet pressure Outlet pressure
detector port F G detector port
Main relief valve
C I To cooler
Gear pump
A D H
Drain Drain
Strainer
20D7PT04
3-4
3. TRANSMISSION
1) STRUCTURE
1 12 6 5 4 2
13
14
15
9
10
11
20D7PT28
1 Control valve 9 Output gear

2 Torque converter 10 Temperature sensor
3 Turbine shaft 11 Oil input path
4 Impeller shaft 12 Parking drum
5 Stator 13 Forward clutch
6 Forward clutch gear 14 Input shaft
7 Oil pump 15 Reverse clutch
8 Reverse clutch gear
3-5
2) INSTALLATION VIEW
1 4 3 6 7 5
2 8 20D7PT05
1 Torque converter 5 Oil level pipe and dipstick

2 Temperature sensor 6 Air breather
3 Control valve 7 Transmission oil filter
4 Parking brake link lever 8 Transmission output (Universal joint link part)
3) OPERATION
The flywheel of engine transmits a power to torque converter through flexible plate.
The torque converter consists of an impeller wheel connected to the input side, a turbine connected
to the output side and a stator wheel.
The power delivered from engine make the impeller wheel of the torque converter revolve, an
impeller blade generate a fluid energy through being full of fluid in torque converter, this energy give
torque to turbine wheel.
Flow of the fluid flowing through revolving turbine wheel is changed by stator, this course causes
opposite torque at stator and it is added to the turbine.
As the result of this, the output torque brings torque increase within the compass of stall capability.
When the truck starts running or goes to the uphill, a torque converter transmits a torque increased
against engine torque to power transmission system of the transport.
When the truck runs at regular speed without increase speed, high torque is not required and
output torque is gradually reduced.
Since the engine and transmission are connected through the fluid, return vibrations and shocks
from the drive axle is absorbed, safety of the transmission is secured.
Whether or not the truck travels, the engine continually operates and torque is converted
automatically according to load.
This system makes the drive operation much easier and work can be performed much more
efficiently.
Output power of the torque converter is transmitted to the input shaft, forward clutch or a reverse
clutch works according to gear choice of a driver.
The clutch power chosen at this time is connected to the output gear through the clutch gear.
3-6
4) OPERATING MODES
(1) Forward (2) Reverse
INPUT INPUT
OUTPUT OUTPUT
20D7PT29 20D7PT30
3-7
5) OIL PUMP AND SPACER
(1) Structure
T/C output pressure

check port
T/C output pressure
control valve T/C input pressure
5 check port
4 T/C input pressure
3 control valve
2 12 13
1
14
15
16
11
10
8 9
7
6
17
20D7PT06
1 Oil seal 10 Lock bolt

2 Oil pump case bush 11 O-ring
3 Bolt 12 Bolt
4 Plug 13 Plug
5 Oil pump case 14 O-ring
6 Driven gear 15 Spring
7 Drive gear bush 16 Ball
8 Drive gear 17 Spacer
9 Stator shaft
(2) Operation
The oil pump is located on the spacer side. It is in charge of the function of clutching internal oil of
the transmission through control valve and the function of sucking oil for oil supply of the torque
converter and lubrication function of a clutch.
Oil pump choose gear pump, supplies oil in control valve and torque converter through the oil path
between a spacer and a transmission case.
The relief valve located on the top of a spacer can maintain regularly input oil pressure and output
oil pressure.
3-8
6) TRANSMISSION CASE, CONTROL VALVE, OIL PUMP AND PARKING BRAKE
(1) Structure
4
5 8
9
3
13
7
12
10
2
1
20
11
7
23
22
21 15
25
24
14
18 16
17
19
20D7PT07
1 Oil filter 10 Parking brake connector (Small) 18 Parking bracket

2 Oil filter bolt 11 Band brake 19 Bolt
3 Bolt 12 Air breather 20 Bolt
4 Pipe 13 O-ring 21 Snap ring
5 Washer 14 Nut 22 Parking lever
6 Control valve 15 Parking brake control shaft 23 Oil seal
7 Plug 16 Bolt 24 Parking return spring
8 Cam shaft 17 Oil seal 25 Stoper pin
9 Parking brake connector (Large)
3-9
(2) Operation
The transmission case includes the function of a control valve, an oil filter and a parking brake.
The oil filter is charge of filtering sucked oil by an oil pump before transmitting sucked oil to a
control valve and a torque converter.
Oil transmitted through an oil filter delivers oil pressure to the piston of the forward and reverse
clutch through the solenoid valve.
At this time, the solenoid valve is in charge of the important function of transmitting oil pressure for
forward and reverse through an electric signal by the forward and reverse selection lever of the
truck.
Oil pressure chosen for forward or reverse by the solenoid valve is transmitted to the forward
clutch through the formed oil path between transmission case or the reverse clutch through the
pipe of transmission outside.
Parking brake works by the band brake installed on parking drum which is linked to the output
shaft of the forward clutch.
3-10
7) CONTROL VALVE
(1) Structure
Main relief function charge
Modulation function charge

14
8
2 15
Main valve pressure
detecting port 7
Forward clutch pressure 9 16
detecting port 10
Inching valve pressure 6 17
detecting port 38 11
12 18
5
13
19
4 Reverse clutch pressure

detecting port
20
21
22
3 To cooler
2
37
29 From cooler
1 23
35
30 24
25
26
27
28
31 36
32
33
34
Inching function charge
Change of direction function charge
20D7PT08
1 Stoper 10 O-ring 20 Plug 29 Valve

2 O-ring 11 Spring 21 Washer 30 Spring
3 Spring 12 Nut 22 Nipple 31 Spool
4 Plug 13 Stoper 23 Spring 32 Plate
5 Bolt 14 Plug 24 Valve 33 Snap ring
6 Spring 15 Piston 25 O-ring 34 Oil seal
7 Piston 16 Valve 26 Plate 35 Solenoid valve
8 Plug 17 Spring 27 Washer 36 Gasket
9 Plug 18 Stoper 28 Bolt 37 Body
38 Orifice
3-11
(2) Operation
The control valve mainly consists of the main relief valve, inching valve, accumulator valve and
directional valve.
The discharged oil from the gear pump enters main relief valve of the control valve and its
pressure is adjusted 10.8~14.9kgf/cm2 (154~212psi).
The oil adjusted pressure by the main relief valve is decided on the direction of forward or reverse
by the solenoid valve.
The decided oil is delivered the power transferred from the torque converter to drive axle through
the oil path between spacer and transmission case, the pipe of transmission outside and reverse
clutch.
The remaining oil appropriating clutch pressure flows into the torque converter through the input
pressure control valve in torque converter of the top of space.
At this time, the oil pressure input to the torque converter is adjusted 4~7kgf/cm2 (57~100psi), the oil
pressure output from the torque converter is adjusted below 7kgf/cm2 (100psi).
The oil in charge of increasing torque in the torque converter flows from the torque converter,
enters the radiator, after refrigerated, it is in charge of clutch lubrication through the lubrication oil
path of the clutch shaft.
The pressure detecting valve and built in accumulator provide a soft plugging when changing
gears.
The pressure detecting valve allows the accumulator to absorb the small shocks of rapid pressure
build up and quick release during gear changes.
When full pressure builds up, the pressure detecting valve shuts the accumulator off and allows it
to empty, so it is ready to function again during gear change.
The inching valve permits the clutch to partially disengage, so that engine rpm can be increased
for lifting while travel speed remains low.
(3) Oil pressure circuit diagram
Reverse clutch Forward clutch
Control valve
F
R
Directional
valve
P3
Accumulator
valve
1.2 1.6
P2
Inching valve Pedal

P1
Main relief
Engine
valve
13.2 cc/rev
2
10.8~14.9 kgf/cm
To torque converter
20D7PT09
3-12
8) FORWARD CLUTCH
(1) Operation
Clutch pack plugging Clutch pack lubrication line

pressure delivery line (From control valve)
(From control valve)
1 2 3 4 5
20D7PT31
1 Drum gear 3 Friction plate and plate 5 Forward shaft

2 Clutch piston 4 Clutch gear
When forward mode is selected through the solenoid valve of control valve, the flux flowed by the
oil pump flows into forward clutch pack in 9~14.2kgf/cm2 (128~202psi) of pressure through the oil
path of transmission inside.
This oil make plugging of clutch pack by giving pressure at the piston of clutch pack.
At this time, the drum gear of clutch pack is always revolving while connected with the turbine
shaft of torque converter.
According to be plugging, the clutch gear is connected and revolved with drum gear, this power is
delivered with linking output gear in touch with clutch gear.
3-13
(2) Structure
4 24
3
27
29
18 19
8 9
21 28
12
5
20
15
17
11
10
25
26
7
23
22
14
16
13
20D7PT11
1 Forward clutch gear 11 Thrust needle bearing 21 Forward drum gear

2 Forward shaft 12 Thrust washer 22 Snap ring
3 Piston 13 Spring 23 Thrust washer
4 Piston ring 14 Snap ring 24 O-ring
5 Friction plate 15 Seal ring 25 Parking drum
6 Plate 16 Spring cover 26 Snap ring
7 Spacer 17 Taper roller bearing 27 AV-Seal
8 Seal ring 18 Taper roller bearing 28 Side plate
9 Snap ring 19 Needle bearing 29 Ring
10 Needle bearing 20 Bush
3-14
9) REVERSE CLUTCH
(1) Operation
Clutch pack plugging Clutch pack lubrication line

pressure delivery line (From control valve)
(From control valve)
5 1 2 3 4
20D7PT32
1 Reverse drum gear 3 Friction plate and plate 5 Reverse shaft

2 Clutch piston 4 Clutch gear
When reverse mode is selected through the solenoid valve of control valve, the flux flowed by the
oil pump flows into the oil path of reverse shaft in 9~14.2kgf/cm2 (128~202psi) of pressure through
the oil path of transmission outside.
This oil make plugging of reverse clutch pack by giving pressure at the piston of clutch pack.
At this time, the reverse drum gear is revolving against forward drum gear with engaging forward
drum gear.
According as the clutch is plugging, the reverse clutch gear revolves.
The reverse clutch gear is connected with output gear, the power transferred from engine is
delivered to output of the transmission.
3-15
(2) Structure
4
3
24
2
25
10
8 19
21
11
9
26
5 14
12 17
20
13
7
23
22
16
18
15
20D7PT13
1 Reverse clutch gear 10 O-ring 19 Taper roller bearing

2 Reverse shaft 11 Snap ring 20 Taper roller bearing
3 Piston 12 Needle bearing 21 Reverse drum gear
4 Piston ring 13 Thrust needle bearing 22 Snap ring
5 Friction plate 14 Thrust washer 23 Thrust washer
6 Plate 15 Clutch spring 24 O-ring
7 Spacer 16 Snap ring 25 AV-Seal
8 Seal ring 17 Seal ring 26 Side plate
9 Rivet 18 Spring cover
3-16
10) OUTPUT GEAR
(1) 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.
(2) Structure
4 2
1
2
20D7PT14
1 Output gear 3 Oil seal

2 Taper roller bearing 4 Output gear cover
3-17
4. DRIVE AXLE
1) INSTALLATION VIEW
1 2 3 4 5
20D7PT15
1 Carrier assembly 3 Traveling brake 5 Oil level gage

2 Drive axle housing 4 Hub
2) STRUCTURE
4 3 4
5 6 1 2 6
20D7PT16
1 Piston shaft 3 Differential device 5 Hub

2 Ring gear 4 Axle shaft 6 Traveling brake
The drive axle is connected with the transmission output gear and universal joint.
The power transferred by the universal joint is connected to the pinion shaft of drive axle, the
pinion shaft delivers the power to the differential device through the ring gear.
The power transferred to the differential gear is delivered to final drive through the axle shaft.
3-18
3) CARRIER ASSEMBLY
(1) Operation
The pinion shaft is supported by the taper roller bearing in the carrier case and the bolt at the end
of a pinion shaft and transfers the power which is delivered from the universal joint to the ring gear
assembled from bolts at a differential device.
This power makes the differential device run.
Since the differential device is connected with an axle shaft and a spline, the power transferred to
differential device is delivered to final drive through the axle shaft.
(2) Structure
6 15
17 7
4
25
25
24 17
23 3
23
19 16
18 20
8 21
9 22
10
12 1
14
11
13
20D7PT18
1 Carrier case 9 Shim 17 Bearing control ring bolt

2 Spiral ring gear 10 Shim 18 Spacer
3 Pinion shaft 11 Universal joint flange 19 Shim
4 Carrier cap 12 Oil seal 20 Shim
5 Differential device 13 Nut 21 Shim
6 Cap bolt 14 O-ring 22 Shim
7 Washer 15 Cotter pin 23 Taper roller bearing
8 Shim 16 Bolt 24 Ball
25 Bearing
3-19
4) DIFFERENTIAL DEVICE
(1) 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.
If the load concerning in the left and right of the final drive is different, the shock is transferred to
the drive axle, the differential gear in the differential device runs, the power transferred to the
differential device adjusts the delivering rate to the left and right axle shaft.
Consequently, it guarantees for safety of drivers.
(2) Structure
5
7
3 2
4
4
1
6
20D7PT19
1 Differential case (Left) 4 Differential gear 7 Pinion

2 Differential case (Right) 5 Thrust washer 8 Bolt
3 Thrust washer 6 Washer 9 Spider
3-20
GROUP 2 TROUBLESHOOTING
Trouble symptom Probable cause Remedy

1. Excessive oil
temperature rise ·Improper oil level. ·Check oil level. Add or drain oil as
1) Torque converter necessary.
·Impeller interfering with surroundings. ·After draining oil from oil tank and tra-
nsmission, check and replace interfe-
ring parts.
·Stator and free wheel malfunctioning. ·Check engine (stalling) speed.
If necessary, replace.
·Air sucked in. ·Check the inlet side joint or pipe.
If necessary, retighten joint or repla-
ce gasket.
·Water intruding into transmission ·Check drained oil.
case. If necessary, change oil.
·Bearing worn or seizing. ·Disassemble, inspect, repair or repla-
ce.
·Gauge malfunctioning. ·Check and, if necessary, replace.
2) Transmission ·Clutch dragging. ·Check to see whether or not machi-
ne moves even when transmission is
placed in neutral position. If so, repl-
ace clutch plate.
·Bearing worn or seized. ·Disassemble, check and replace.
2. Noise operation
1) Torque converter ·Cavitation produced. ·Change oil, replace parts leaking air.
·Flexible plate damaged. ·Listen to rotating sound at lowspeed
operation. If necessary, replace flex-
ible plate.
·Bearing damaged or worn. ·Disassemble, check and replace.
·Gear damaged. ·Disassemble, check and replace.
·Impeller interfering with surroundings. ·Check impeller or check drained oil
for mixing of foreign matter.
If necessary, change oil.
·Bolt loosening. ·Disassemble and check. If necessa-
ry, retighten or replace.
·Spline worn. ·Disassemble, check and replace.
·Noise gear pump operation. ·Disassemble, check and replace.
2) Transmission ·Dragging caused by seizing clutch. ·Check to see whether or not machine
moves even when transmission is in
neutral position. If so, replace clutch
·Bearing worn or seizing. plate.
·Gear damaged. ·Disassemble, check and replace.
·Bolt loosening. ·Disassemble, check and replace.
·Disassemble, check and retighten or
replace.
·Spline worn. ·Disassemble, check and replace.
3-21
3. Low output power
1) Torque converter ·Insufficient hydraulic pressure :
- Low oil level. - Check oil level and add oil.
- Air sucked in. - Check joints and pipes.
If necessary, retighten joint or repla-
ce packing.
- Oil filter clogging. - Check and replace.
- Oil pump worn. - Check oil pressure. If necessary rep-
(Low delivery flow) lace pump.
- Regulator valve coil spring fatigu- - Check spring tension. If necessary,
ed. replace.
- Control valve spool malfunctioning. - Disassemble, check and repair or re-
place.
- Piston or O-ring worn. - Disassemble, check measure and re-
place.
·Stator free wheel cam damaged. - Check stalling speed.
(Increased engine load will cause ex-
cessive drop of stalling speed.)
- Check oil temperature rise.
If any, replace free wheel.
2) Transmission ·Flexile plate deformed ·Replace flexible plate.
·Stator free wheel seizing. - Check temperature plate.
(No-load will cause temperature rise)
- Replace free wheel if a drop of start-
ing output is found.
·Impeller damaged for interfering with - Check drained oil for foreign matter.
the surroundings. If any, change oil.
·Use of poor quality of oil or arising of - Check and change oil.
air bubbles.
- Air sucked in from inlet side. - Check joints and pipes.
If necessary, retighten joint or replace
packing.
- Low torque converter oil pressure - Check oil pressure.
accelerates generation of air bub-
bles.
- Oil mixing with water. - Check drained oil and change oil.
- Inching rod out of adjustment. - Check and adjust.
·Clutch slipping
- Lowering of weight. - Check oil pressure.
- Piston ring or O-ring worn. - Disassemble, check, measure and
replace.
- Clutch piston damaged. - Disassemble, check and replace.
- Clutch plate seizing or dragging. - Check to see whether or not machine
moves even when transmission is in
neutral position. If so, replace.
3-22
4. Unusual oil pressure
1) Oil pressure is high ·Control valve malfunctioning. (1)Check for spool operation.
If necessary, replace valve.
(2)Check for clogging of small hole in
valve body. If necessary, clean or
repair.
·Cold weather. (high oil viscosity) ·When atmospheric temp is below fr-
eezing point
(when normal oil pressure is recover-
ed if heated to 60 ~ 80。C), change
oil.
·Use of improper oil. ·Check and change oil.
2) Oil pressure is low ·Gear pump malfunctioning(worn). ·Disassemble, check and replace.
·Oil leaks excessively :
(1)Control valve oil spring defective. ·Check spring tension (see spring sp-
ecification).
If necessary replace.
(2)Control valve spool defective. ·Disassemble, check, and repair or re-
place valve.
·Air sucked in. ·Check joints and pipes. If necessary,
retighten joint or replace packing.
·Low oil level. ·Check oil level and add oil.
·Oil filter clogging. ·Check and replace.
3) Transmission ·Oil leaks excessively. ·Disassemble, check (piston ring and
O-ring for wear and other defects),
and replace.
5. Power is not transmitted
1) Torque converter ·Clutch plate damaged. ·Check for damage by listening to ab-
normal sounds at a low converter sp-
eed and replace.
·Low oil level. ·Check oil level and add oil.
·Oil pump driving system faulty. ·Disassemble and check for wear of
pump gear, shaft and spline.
Replace defective parts.
·Shaft broken. ·Check and replace.
·Lack of oil pressure. ·Check oil pump gear for wear and for
oil suction force.
If necessary, replace pump.
2) Transmission ·Low oil level. ·Check oil level and add oil.
·Inching valve and link lever improper- ·Check measure and adjust.
ly positioned.
·Forward/reverse spool and link lever ·Check and adjust.
improperly positioned.
·Clutch fails to disengage :
(1)Clutch case piston ring defective. ·Disassemble, check and replace.
(2)Main shaft plug slipping out. ·Disassemble, check and repair or re-
place.
·Clutch seizing. ·Check to see whether or not machine
moves even then transmission is in
neutral position. If so, replace.
·Shaft broken off. ·Disassemble, check(main shaft, etc.),
and replace.
·Clutch drum damaged (spring groove). ·Disassemble, check and replace.
·Clutch snap ring broken. ·Disassemble, check and repair or re-
place.
3-23
6. Power is not transmitted ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or
(Continue) age to clutch. replace.
·Shaft spline worn. ·Disassemble, check and replace.
7. Oil leakage ·Oil leaks from oil seal. ·Disassemble and check for wear of
(Transmission and torque seal lips and mating sliding surfaces
converter) (pump boss, coupling etc.)
Replace oil seal, pump boss, coupl-
ing, etc.
·Oil leaks from case joining surfaces. ·Check and retighten or replace pack-
ing.
·Oil leaks from joint or pipe. ·Check and repair or replace gasket.
·Oil leaks from drain plug. ·Check and retighten or gasket.
·Oil leaks from a crack. ·Check and replace cracked part.
3-24
GROUP 3 DISASSEMBLY AND ASSEMBLY
1.TRANSMISSION
1) DISASSEMBLY
① Transmission assembly set.
20D7TM001
② Disconnect torque converter.
20D7TM002
③ Extract PTO shaft.
20D7TM003
④ Remove control valve bolt.
20D7TM004
3-25
⑤ Extract control valve.
20D7TM005
20D7TM006
⑥ Extract oil filter.
20D7TM007
⑦ Remove snap ring.
20D7TM008
⑧ Remove parking lever.
20D7TM009
3-26
⑨ Remove snap ring.
20D7TM010
⑩ Remove bolt.
20D7TM011
⑪ Remove out wheel bolt.
20D7TM012
⑫ Remove bolt on the back side of filter.
20D7TM013
⑬ Remove bolt.
20D7TM014
3-27
⯾ Connect disassembly bolt.
20D7TM015
⯿ Disassemble torque converter housing.
20D7TM016
⬼ Disassemble spacer.
20D7TM017
⬽ After disassemble.
20D7TM018
⬾ Disassemble output gear assembly set.
20D7TM019
3-28
⬿ Disassemble connection.
20D7TM020
⭀ Extract band brake.
20D7TM021
⭁ Disassemble forward clutch gear.
20D7TM022
⭂ Disassemble reverse clutch gear.
20D7TM023
⭃ After disassemble.
20D7TM024
3-29
2) ASSEMBLY
(1) Assembly of transmission case outside part
Plug assembly
※ Before assemble taper plug, spread loctite #577.
① Assemble the upper part taper plug of hydraulic pipe.
20D7TM025
② Assemble installation part taper plug of control valve.
20D7TM026
③ Assemble space installation part.
20D7TM027
④ Assemble the left taper plug.
20D7TM028
3-30
⑤ Confirm torque.
·Tightening torque : 3.5~4.5 kgf·m
(25~33 lbf·ft)
20D7TM029
Oil seal pressurizer of cam shaft

① Spread sealant on oil seal.
※ Spread loctite #592 on the out wheel of oil seal.
Spread grease on inside wheel of oil seal.
20D7TM030
② Pressurize oil seal.
20D7TM031
Assembly of filter assembly bolt

① Spread sealant on oil seal.
※ Spread loctite #277 on filter assembly bolt.
20D7TM032
② Confirm assembly and torque.

(25~33 lbf·ft)
20D7TM033
3-31
(2) Assembly of transmission case inside
Assembly of bearing and parking control shaft
① Pressurize R part of bearing out wheel.
※ R part : Installation part of reverse clutch gear.
20D7TM034
② Pressurize O part of bearing out wheel.

※ O part : Installation part of output gear assembly.
20D7TM035
③ Pressurize F part of bearing out wheel.

※ F part : Installation part of forward clutch gear.
20D7TM036
④ Assemble adjustment shaft.
20D7TM037
3-32
⑤ Assemble nut.
20D7TM038
⑥ Spread grease on bearing out wheel.

※ When installing taper roller bearing, make sure
whether or not it is close.
※ Spread grease in taper roller bearing.
20D7TM039
Assembly of forward / reverse clutch pack

① Confirm seal ring of reverse clutch.
※ Spread grease on seal ring of clutch pack.
20D7TM040
② Spread oil on seal ring of reverse clutch.
20D7TM041
③ Assemble reverse clutch at transmission.
20D7TM042
3-33
④ Confirm seal ring of forward clutch.
20D7TM043
⑤ Spread oil on seal ring of forward clutch.
20D7TM044
⑥ Assemble forward clutch at transmission.

※ After finishing assembly, make sure whether or not
revolution of forward/reverse clutch pack is good.
20D7TM045
Assembly of parking brake system

① Fix small connection in PBB.
20D7TM046
② Set in parking drum.
20D7TM047
3-34
③ Spread grease on cam shaft.
20D7TM048
④ Fix large connection in cam shaft.
20D7TM049
⑤ Fit large connection in PBB.
20D7TM050
⑥ Assemble an eccentric shaft in PBB.
20D7TM051
Assembly of output gear assembly

① Assembly output gear.
20D7TM052
3-35
② Confirm gear revolution condition.
20D7TM053
(3) Assembly of spacer sub assembly

Assembly of oil pump
① Assemble O-ring of charging pump.
※ Spread grease at O-ring surface.
20D7TM054
② Spread sealant on charging pump.

※ Spread loctite #5127 at stator shaft lower in oil pump.
20D7TM055
③ Spread sealant on the whole surface.
20D7TM056
④ Fix charging pump in spacer.
20D7TM057
3-36
⑤ Spread sealant on hexagon bolt.
※ Spread loctite #242 at bolt.
20D7TM058
⑥ Confirm assembly and torque.

(25~29 lbf·ft)
20D7TM059
Assembly of inlet and outlet of pressure adjustment

valve in torque converter and pressure checking port
① Fix steel ball in spacer.
20D7TM060
② Fix spring.
20D7TM061
③ Spread sealant on plug and O-ring.

※ Spread loctite #277 at plug and bolt.
20D7TM062
3-37
④ Confirm torque.
(25~33 lbf·ft)
20D7TM063
⑤ Spread sealant on hex bolt.
20D7TM064
⑥ Confirm torque.
(25~33 lbf·ft)
20D7TM065
Assembly of bearing cup

※ After measuring the transmission case, spacer and
each clutch pack and estimating a proper amount of
shim.
Insert a proper amount of shim before assembling
bearing cup.
Make sure whether or not it is close with the lower of
bearing cup.
20D7TM066
① Pressurize F part of bearing out wheel.
② Pressurize R part of bearing out wheel.
20D7TM067
3-38
③ Pressurize O part of bearing out wheel.
20D7TM068
(4) Assembly of torque converter housing sub assembly

Assembly of temperature sensor and O-ring
① Spread loctite #577 on temperature sensor.
20D7TM069
② Confirm assembly and torque.

(22~29 lbf·ft)
20D7TM070
③ Assemble O-ring and spread grease.
20D7TM071
Oil strainer assembly

① Fix spring in strainer.
20D7TM072
3-39
② Fix strainer in torque converter housing.
20D7TM073
③ Temporarily assemble plug.
20D7TM074
④ Confirm torque.
·Tightening torque : 8~10 kgf·m
(58~72 lbf·ft)
20D7TM075
(5) Assembly of sub assembly

Assembly of transmission case and spacer sub assembly
① Spread oil.
20D7TM076
② Fix O-ring.
20D7TM077
3-40
③ Spread loctite #5127 on transmission case.
20D7TM078
④ Pressurize lock pin.
20D7TM079
⑤ Assemble space.
20D7TM080
⑥ Confirm gear revolution condition.
20D7TM081
Torque converter assembly

① Spread loctite #5127 on space.
20D7TM082
3-41
② Work roller.
※ Pay attention to tear O-ring of torque converter and oil
pump.
20D7TM083
③ Fit torque converter housing in space.
20D7TM084
④ Spread loctite #277 on bolt.
20D7TM085
⑤ Temporarily assemble bolt.
20D7TM086
⑥ Confirm torque.
(40~47 lbf·ft)
20D7TM087
3-42
(6) Transmission outside assembly
Fastening of transmission case bolt
① Revolve 90。.
20D7TM088
② Spread sealant on socket bolt.
20D7TM089
③ Temporarily assemble at transmission case.
20D7TM090
④ Confirm torque.
20D7TM091
⑤ Spread sealant on hexagon bolt.

※ Spread loctite #277 on bolt.
20D7TM092
3-43
⑥ Confirm torque.
(40~47 lbf·ft)
20D7TM093
Oil filter assembly

① Temporarily assemble filter.
20D7TM094
② Confirm fastening.
(5.8~8.7 lbf·ft)
20D7TM095
Parking brake part assembly

① Assemble snap ring.
20D7TM096
② Spread loctite #277 on support pin.
20D7TM097
3-44
③ Temporarily assemble support pin.
20D7TM098
④ Confirm torque.
(14~22 lbf·ft)
20D7TM099
⑤ Fix parking lever.
20D7TM100
⑥ Assemble snap ring.
20D7TM101
⑦ Fix spring and spread loctite #277 on bolt.
20D7TM102
3-45
⑧ Temporarily assemble parking bracket.
20D7TM103
⑨ Confirm torque.
(4.3~5.8 lbf·ft)
20D7TM104
The way to adjusting parking brake

① Tighten the adjustment shaft and loosen the shaft a 3/4 revolution.
·Tightening torque : 0.65kgf·m (4.7lbf·ft)
② Tighten the nut.
·Tightening torque : 3kgf·m (221lbf·ft)
Spread loctite #592 Position eccentric shaft

as figure
Nut
Adjustment shaft
20D7PT33
Pipe offering oil path of reverse clutch assembly

① Prepare reverse pipe.
20D7TM105
3-46
② Spread loctite #577 on nipple plug.
20D7TM106
③ Temporarily assemble oil pressure pipe and seal

washer at the same time.
20D7TM107
④ Spread sealant on nipple plug.
20D7TM108
⑤ Temporarily assemble oil pressure pipe and seal

washer at the same time.
20D7TM109
⑥ Confirm torque.
(25~29 lbf·ft)
20D7TM110
3-47
Oil seal output gear assembly
① Spread loctite #592 on the out wheel of oil seal.
20D7TM111
② Pressurize oil seal.
20D7TM112
③ Spread grease on inside wheel of oil seal.
20D7TM113
Control valve assembly

① As assembling, use guide pin at two spot.
Fix guide pin.
20D7TM114
② Assemble control valve assembly.
20D7TM115
3-48
③ Assemble hex bolt and confirm torque.
(22~29 lbf·ft)
20D7TM116
Air breather and oil level gauge guide pipe assembly

① Assemble air breather.
Air breather
※ Spread loctite #577 on air breather.
20D7TM117
② Spread sealant on oil level gauge guide.

※ Spread loctite #608 on pipe.
20D7TM118
③ Pressurize guide.
20D7TM119
3-49
2. DRIVE AXLE
1) DISASSEMBLY
① Drive axle.
20D7AXLE001
② Remove the bolt of axle shaft.
20D7AXLE002
③ Extract the left axle shaft.
20D7AXLE003
④ Extract the right axle shaft.
20D7AXLE004
3-50
⑤ Remove the bolt of plate / nut.
20D7AXLE005
⑥ Extract the nut.
20D7AXLE006
⑦ Extract the plate.
20D7AXLE007
⑧ Extract the hub bearing.
20D7AXLE008
⑨ Extract the hub.
20D7AXLE009
3-51
⑩ Remove the bolt of flange shaft.
20D7AXLE010
⑪ Extract the flange shaft.
20D7AXLE011
⑫ Disassemble the piston brake.
20D7AXLE012
⑬ Disassemble the carrier assembly.
20D7AXLE013
⑭ Fix the carrier assembly.
20D7AXLE014
3-52
⯿ Remove the bolt of carrier cap.
20D7AXLE015
⬼ Extract the carrier cap.
20D7AXLE016
⬽ Remove the left adjusting cap of bearing cup.
20D7AXLE017
⬾ Remove the right adjusting cap of bearing cup.
20D7AXLE018
⬿ Disassemble the differential assembly.
20D7AXLE019
3-53
§ After disassemble the carrier.
20D7AXLE020
2) ASSEMBLY
(1) Assembly of carrier assembly
Differential device assembly
¤ Assemble spider and the differential pinion.
20D7AXLE021A
¤Ł Assemble the washer and the differential gear.
20D7AXLE022
¤Ø Assemble the spider and the differential.
20D7AXLE023A
3-54
④ Assemble the washer and the differential gear.
20D7AXLE024
⑤ Assemble the differential case.
20D7AXLE025
⑥ Fix the bolt.
20D7AXLE026
⑦ Confirm the differential gear backlash.

※ Adjust backlash of differential gear within 0.015mm.
20D7AXLE027
⑧ Assemble the ring gear.
20D7AXLE028
3-55
⑨ Assemble the bearing of differential.
20D7AXLE029
(2) Assembly of carrier sub assembly

Adjusting shim and pinion shaft assembly
① Fix the carrier case.
20D7AXLE030
② Measure a gap(A) for deciding an amount of shim

with feeler gauge.
※ Determine shim X.
·X = A±Mounting distance (MD) of pinion gear
Ex 1) A = 0.5, MD value = - 0.2
X = 0.5 + 0.2 = 0.7mm
Ex 2) A = 0.5, MD value = + 0.2 20D7AXLE031
X = 0.5 - 0.2 = 0.3mm
③ Select the shim and assemble.
20D7AXLE032
④ Pressurize the bearing cup.
20D7AXLE033
3-56
⑤ Pressurize the bearing cone into the pinion shaft.
20D7AXLE034
⑥ Fix the pinion shaft.
20D7AXLE035
⑦ Set the ball.
20D7AXLE036
⑧ Fix the fixing jig.
20D7AXLE037
⑨ Fix the ball.
20D7AXLE038
3-57
⑩ Revolve the carrier case in 180。.
20D7AXLE039
⑪ Fix the spacer.
20D7AXLE040
⑫ Shim measuring gauge 1 insert.
20D7AXLE041
⑬ Shim measuring gauge 2 insert.
20D7AXLE042
⑭ Put the shim measuring block.
20D7AXLE043
3-58
⯿ Measure a gap (B).
⚰ Determine shim X.
♼X = B - End play (0.03~0.06)
Ex 1) B = 0.5,
X = 0.5 - (0.03~0.06) = 0.47~0.44mm
20D7AXLE044
⬼ Remove the pinion shaft.
20D7AXLE045
⬽ Assemble the bearing cup.
20D7AXLE046
⬾ Assemble and fit the pinion.
20D7AXLE047
⬿ Assemble the shim.
20D7AXLE048
3-59
⭀ Fix the bearing cone.
20D7AXLE049
Assembly of carrier sub assembly

⯱ Pressurize the oil seal.
20D7AXLE050
⯲ Fix the U-joint flange.

⚰ Assemble U-joint flange in preload 0.01~0.19 kgf♼m.
20D7AXLE051
⯳ Fix the O-ring.
20D7AXLE052
⯴ Temporarily assemble the nut.

⚰ Spread loctite #242 on nut.
20D7AXLE053
3-60
⑤ Fasten the torque.
(117~138 lbf·ft)
20D7AXLE054
⑥ Confirm the preload.
20D7AXLE055
⑦ Perform the calking.

Calking
40
20D7PT34
⑧ Assemble the differential sub in case.
20D7AXLE057
⑨ Fix the steel ball.

Paint marking(Both sides)
20D7PT35
3-61
⑩ Temporarily assemble the carrier cap.
20D7AXLE059
⑪ Fasten the torque.

※ Spread loctite #277 on bolt.
·Tightening torque : 26.8~32 kgf·m
(194~231 lbf·ft)
20D7AXLE060
Adjust backlash
① Assemble the RING BRG ADJUST.
20D7AXLE062
② Adjust the RING BRG ADJUST.
20D7AXLE063
③ Measure backlash.
20D7AXLE064
3-62
④ Fasten RING BRG ADJUST.
20D7AXLE065
⑤ Measure backlash again.

※ Backlash of pinion shaft and ring gear is 0.15~0.2mm
(0.006~0.008 in)
※ If backlash is wrong, carry out adjusting work.
Adjust the left / right of RING BRG ADJUST by one
and one clip.
20D7AXLE066
⑥ Fit position.
20D7AXLE067
⑦ Assemble cotter pin.

Paint marking(Both sides)
20D7PT35
※ After assembling, adjust pattern of the gear and Drive side(Forward) Coast side (Reverse)
pinion shaft as figure. 60

% 60
%
Heel Heel
If pattern is not adjusted, take a measure as 40% 40
%
measuring backlash again and then reassemble.
75%
40
40~
~7
5%
Toe Toe
20D7PT37
3-63
Assembly of carrier assembly
① Pressurize lock pin into drive axle.
20D7AXLE069
② Spread sealant on the installation surface of carrier.
20D7AXLE070
③ Fix assembly guide bar.
20D7AXLE071
④ Fit carrier at drive axle housing.

※ Spread loctite #5127 on drive axle housing.
20D7AXLE072
⑤ Spread loctite #277 on the spring washer bolt.
20D7AXLE073
3-64
⑥ Temporarily assemble bolt and confirm torque.
(43~51 lbf·ft)
20D7AXLE074
(2) TRAVELING BRAKE SYSTEM ASSEMBLY

Piston assembly
① Fix large quad ring into brake.
20D7AXLE075
② Fix small quad ring into brake.

※ When assembling quad ring, pay attent to chopping.
20D7AXLE076
③ Spread oil on the piston.
20D7AXLE077
④ Fix piston into drive axle housing.
20D7AXLE078
3-65
⑤ Set assembly jig.
20D7AXLE079
⑥ Assemble close to drive axle housing.
20D7AXLE080
⑦ Pressurize lock pin.
20D7AXLE081
⑧ Measure projection degree of piston.

※ Manage projection degree of piston in 0.6~0.9mm.
20D7AXLE082
Friction plate and plate assembly

① Pressurize oil seal into flange.
20D7AXLE083
3-66
② Assemble snap ring at socket.
20D7AXLE084
③ Fix socket gear into flange shaft.
20D7AXLE085
④ Fix plate into socket gear.
20D7AXLE086
⑤ Fix friction plate into socket gear.
20D7AXLE087
⑥ Fix friction plate and confirm the direction.
20D7AXLE088
3-67
⑦ Assemble snap ring at socket.
20D7AXLE089
⑧ Measure stepped pulley between flange and plate

and record.
※ Manage stepped pulley of flange 0.6~0.9mm.
20D7AXLE090
Flange shaft assembly

① Select flange shaft.
20D7AXLE091
② Spread loctite # 5127.
20D7AXLE092
③ Spread on the whole surface of flange shaft.
20D7AXLE093
3-68
④ Fit flange into drive axle housing.
20D7AXLE094
⑤ Spread loctite #242 on bolt.
20D7AXLE095
⑥ Fasten bolt.
·Tightening torque : 9~11.5 kgf·m
(65~83 lbf·ft)
20D7AXLE096
(3) Hub assembly

Hub sub assembly
① Pressurize bolt.
20D7AXLE097
② Put a bearing cup on the upper and lower of hub.
20D7AXLE098
3-69
③ Pressurize bearing cup.
20D7AXLE099
④ Spread grease on the bearing of flange.
20D7AXLE100
⑤ Fix bearing into hub.
20D7AXLE101
⑥ Spread grease in the oil seal.
20D7AXLE102
⑦ Spread sealant on the outside of oil.
20D7AXLE103
3-70
⑧ Pressurize oil seal.
20D7AXLE104
⑨ Spread grease on the bearing of axle.
20D7AXLE105
⑩ Fix bearing into hub.
20D7AXLE106
⑪ Spread grease on hub.
20D7AXLE107
Hub assembly
① Spread grease on the flange shaft.
20D7AXLE108
3-71
② Fix hub.
20D7AXLE109
③ Fix plate.
20D7AXLE110
④ Fix nut.
20D7AXLE111
⑤ Fasten torque and loosen.

(152~181 lbf·ft)
20D7AXLE112
⑥ Adjust preload.
·0.6~0.8 kgf·m
20D7AXLE113
3-72
⑦ Fit the position of plate, nut and hole.
20D7AXLE114
⑧ Spread loctite #277.
20D7AXLE115
⑨ Confirm torque.
(5.8~11 lbf·ft)
20D7AXLE116
Axle shaft assembly

① Spread loctite #5127 on axle shaft.
20D7AXLE117
② Fix into hub.
20D7AXLE118
3-73
③ Close to hub.
20D7AXLE119
④ Spread loctite #277 on bolt.

(43~51 lbf·ft)
20D7AXLE120
⑤ Fasten torque.
20D7AXLE121
The rest part assembly

① Assemble the air breather into LH.
20D7AXLE122
② Assemble the air breather into RH.

※ Spread loctite #577 on the air breather.
·Tightening torque (LH, RH) : 1.5~2 kgf·m
(11~14 lbf·ft)
20D7AXLE123
3-74
③ Assemble hanger bolt.
20D7AXLE124
④ Fix dipstick.
20D7AXLE125
⑤ Assemble the magnetic plug.

※ Spread loctite #577 on plug.
Loctite #577
20D7PT36
3-75
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
There are two brake systems, the foot brake system and the hand brake system.
The foot brake adopts the brake system of oil type at drive axle.
Oil pressure is generated in maximum 60kgf/cm2 through brake oil input path of the left and right drive
axle housing, this pressure allows the piston brake to advance and compresses a friction plate and
a plate.
So when the transportation travels, it is possible to brake.
The parking brake works by the hand brake installed on parking drum which is linked to the output
shaft of the forward clutch.
2. SPECIFICATION
1) DISK BRAKE
Item Specification
Type Wet disk brake
Master cylinder diameter (Non boosted) 33mm (1.3in)
Pedal height 160mm
Pedal adjustment
Play 1~3mm
Brake oil Azola ZS10 (SAE 10W hydraulic oil)
2) PARKING BRAKE
Item Specification
Type Ratchet, internal expanding mechanical type
Parking lever stroke / Cable stroke 12.1。/ 11.5mm
4-1
3. BRAKE PEDAL AND PIPING
1) STRUCTURE
15DBS01
1 Brake pedal 3 Reservoir tank assembly

2 Parking lever assembly 4 Brake master cylinder
4-2
4. INCHING PEDAL AND LINKAGE
The brake pedal serves to actuate the hydraulic brakes on the drive axle. At the beginning of the
pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic
clutch to neutral and turn off the driving force. By treading the pedal further, the brake is applied.
Idle stroke : 1~3mm

342.5 5mm
160mm
+ m
20m
15~
Floor plate
Control valve
33mm(1.3in)
Inching spool
T/M
20D7BS02
4-3
5. WET DISK BRAKE
1) STRUCTURE
1 2 3 4 6 7 9
5 8
20D7PT20
1 Drive axle housing 4 Piston brake 7 Socket gear

2 Square ring 5 Plate 8 Snap ring
3 Square ring 6 Friction plate 9 Flange shaft
2) OPERATION
Sealed up structure of hydraulic disk brake system secures good brake performance even in the
high humid or dusty area.
Because it is possible to use the brake semi-permanently, there is no need to replace or change the
lining as drum type brake do.
Major components are 6 plates (5), 5 friction plates (6), piston brake (4), and brake housing.
Braking force is applied by restricting the drive force from drive shaft and spline collar.
4-4
6. BRAKE MASTER CYLINDER
1) STRUCTURE
19 11 12 13
20 18 1 5 10 4 9 2 3 6 7 14 8 17 16 15
D205SBS04
1 Body 8 Boot 15 Head

2 Piston 9 Spacer 16 Head pin
3 Secondary cup 10 Spring seat 17 Nut
4 Primary cup 11 Union 18 Seat
5 Spring 12 Union bolt 19 Cap
6 Plate 13 Washer 20 Cap
7 Snap ring 14 Rod
2) DISASSEMBLY
(1) Remove the master cylinder boot(8) and remove the rod(14).
(2) Remove the snap ring(7) and take out the plate(6), the piston(2), the piston primary cup(4), and
piston spring(5).
(3) Specification of master cylinder.
·Cylinder bore diameter : 22.22mm
·Piston stroke : 35mm
3) INSPECTION
(1) Clean and check these components.
※ Use isopropyl alcohol or brake fluid for washing the components. Do not use gasoline,
kerosene or any other mineral oils. When using alcohol, do not leave rubber parts in the
liquid for more than 30 seconds.
(2) Inspect the inside wall of the master cylinder, and if any faults are found, replace the cylinder assembly.
(3) Replace the boot(8), the primary cup(4), piston(2), if deformation or any other defect is found.
4) ASSEMBLY
※ Prior to assembly make sure again of no contaminant of the components. Apply a thin coat
of brake oil to the components.
·Assembly is in opposite order to disassembly.
4-5
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
1) BRAKE PIPING
(1) Check pipes, hoses and joints for damage, oil leakage or interference.
(2) Operate brake pedal and check operating force when pedal in depressed. Check also change in
operating force, and change in position of pedal when pedal is kept depressed.
2) PARKING BRAKE
2
(1) Operating force of parking lever is 35~40 1
kgf·m(253~290lbf·ft).
(2) Check that parking brake can hold
machine in position when loaded on 20%
slope. If there is no slope available, travel
at low speed and check braking effect of
parking brake.
D35AtA19
4-6
2. TROUBLESHOOTING
Problem cause Remedy
Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil.
·Hydraulic system leaks air. ·Bleed air.
·Disk worn. ·Replace.
·Brake valve malfunctioning. ·Repair or replace.
·Hydraulic system clogged. ·Clean.
Brake acting unevenly. ·Tires unequally inflated. ·Adjust tire pressure.
(Machine is turned to one ·Brake out of adjustment. ·Adjust.
side during braking.) ·Disk surface roughened. ·Repair by polishing or replace.
·Wheel bearing out of adjustment. ·Adjust or replace.
Brake trailing. ·Pedal has no play. ·Adjust.
·Piston cup faulty. ·Replace.
·Brake valve return port clogged. ·Clean.
·Wheel bearing out of adjustment. ·Adjust or replace.
Brake chirps ·Brake trailing. ·See above. Brake trailing.
·Piston fails to return. ·Replace.
·Disk surface roughened. ·Repair by polishing or replace.
Brake squeaks ·Disk surface roughened. ·Repair by polishing or replace.
·Excessively large friction between ·Clean and apply brake grease.
disk plate.
Large pedal stroke ·Brake out of adjustment. ·Adjust.
·Hydraulic line sucking air. ·Bleed air.
·Oil leaks from hydraulic line, or lack ·Check and repair or add oil.
of oil.
Pedal dragging. ·Twisted push rod caused by improp- ·Adjust.
erly fitted brake valve.
·Brake valve seal faulty. ·Replace.
4-7
GROUP 3 TESTS AND ADJUSTMENTS
1. AIR BLEEDING OF BRAKE SYSTEM
1) Air bleeding should be performed by two
persons :
One rides on truck for depressing and
releasing brake pedal : the other person is
on the ground and removes cap from air
Air vent plug
vent plug on wheel cylinder.
2) Block the front wheel securely and apply
parking brake.
3) Start the engine.
4) Attach a vinyl tube to air vent plug and
immerse other end of tube into a vessel
filled with hydraulic oil. Vinyl tube
5) Loosen air vent plug by turning it 3/4 with a
wrench. Depress brake pedal to drain oil
mixed with air bubbles from plug hole. Vessel
6) Depress brake pedal until no air bubbles
come out of air vent plug hole.
7) After completion of air bleeding, securely
tighten air vent plug. Install cap on plug. 20D7BS09
2. ADJUSTMENT OF PEDAL
1) BRAKE PEDAL
(1) Pedal height from floor plate
Adjust with stopper bolt.
·Pedal height : 160mm (6.3in)
(2) Play Idle stroke : 1~3mm
Adjust with rod of master cylinder.
·Play : 1~3mm (0.04~0.1in) Pedal height
160mm
Floor plate
20D7BS10
4-8
(3) Micro switch for parking brake (if equipped)
o
① After assembling parking brake and Lever stroke 12.1
parking cable, put the parking brake lever
released.
② Loosen the nut for parking brake plate to
play up and down.
③ Move up the plate so that the stopper can Micro switch
be contacted with the pin and then
Rachet
reassemble nut.
Nut
·Micro switch stroke when parking
brake is applied : 2~3mm (0.08 ~ 0.1in)
Parking cable
20D7BS08
2) INCHING PEDAL
(1) Pedal height from floor plate
Adjust with stopper bolt.
·Pedal height : 160mm (6.3in) Inching stroke
15~20mm
(2) Adjust bolt so that brake pedal interconn-
ects with inching pedal at inching pedal
stroke 15~20mm(0.6~0.8in) Pedal height
160mm
Floor plate
20D7BS11
4-9
SECTION 5 STEERING SYSTEM
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
SECTION 5 STEERING SYSTEM
1. OUTLINE
15DSS01
The steering system for this machine is composed of steering wheel assembly, priority valve
steering unit, steering cylinder, steering axle and pipings. The steering force given to the steering
wheel enters the steering unit through the steering column. The required oil flow is sensed by the
function of the control section of the unit, and pressurized oil delivered from the hydraulic pump is
fed to the steering cylinder. The force produced by the steering cylinder moves the knuckle of
steering tires through the intermediate link.
The axle body is unit structure having steering knuckles installed to its both ends by means of
kingpins. Hub and wheel are mounted through bearing to spindle of knuckle.
5-1
2. HYDRAULIC CIRCUIT
15L7SS02
1 Hydraulic gear pump 5 Steering cylinder

2 Priority valve 8 Suction strainer
4 Steering unit 12 Hydraulic tank
5-2
1) NEUTRAL
15L7SS03
The steering wheel is not being operated so control spool(G) does not move.
The oil from hydraulic gear pump(1) enters port P of priority valve(2) and the inlet pressure oil
moves the spool(D) to the left.
Oil flow into LS port to the hydraulic tank(12).
So, the pump flow is routed to the main control valve.
5-3
2) LEFT TURN
15L7SS04
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(4)
through the spool(D) of priority valve(2) and flows to the gerotor(H).
Oil flow from the gerotor(H) flows back into the spool(G) where it is directed out of the left work
port(L).
Oil returned from cylinder returns to hydraulic tank(12).
When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
15L7SS05
When the steering wheel is turned to the right, the spool(G) within the steering unit(4) 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(4)
through the spool(D) of priority valve(2) and flows to the gerotor(H).
Oil flow from the gerotor(H) flows back into the spool(G) where it is directed out of the right work
port(R).
Oil returned from cylinder returns to hydraulic tank(12).
When the above operation is completed, the machine turns to the right.
5-5
3. STEERING UNIT
1) STRUCTURE
1
2
18
11
3
14
25-3 4
25-2 14
25-4 5 22
25-1 15
6
23
21
24
8
16
10 24
7
10
19
13
20
17
9
12
20D7SS06
1 Dust seal 11 O-ring 21 Housing

2 Retaining ring 12 Rolled screw 22 Spool
3 Cap seal 13 Gerotor set 23 Sleeve
4 Thrust bearing 14 Bearing race 24 Plate spring
5 Ball 15 Bore screw 25 P-port check valve
6 Pin 16 Drive 25-1 Plug
7 Spacer 17 End cap 25-2 Poppet
8 Center spring 18 Gland bushing 25-3 Spring seat
9 Washer 19 Plate 25-4 Spring
10 O-ring 20 Cap screw
5-6
2) 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.
When the steering wheel is turned, the spool turns, the oil path is switched and the oil is fed into the
metering device. As a result, the rotor is caused to run by oil pressure, and the sleeve is caused to run
through the drive shaft and cross pin. Therefore, when the spool is turned, the spool turns by the
same value in such a manner that it follows the motion of the spool. Steering motion can be
accomplished when this operation is performed in a continuous state.
If the hoses of the steering system are incorrectly connected, the steering wheel can turn very
rapidly when the engine is started. Keep clear of the steering wheel when starting the engine.
The centering spring for the spool and sleeve is provided to cause the valve to return to the neutral
position. It is therefore possible to obtain a constant steering feeling, which is transmitted to the hands
of the driver. Return to the center position occurs when the steering wheel is released.
5-7
4. STEERING AXLE
1) STRUCTURE
15DSS07
1-1 Steering axle wa 1-16 King pin washer 1-31 Lock plate
1-2 Knuckle-RH 1-17 Needle bearing 1-32 Hex bolt
1-3 Knuckle-LH 1-18 Thrust bearing 1-33 Steering cylinder
1-4 Wheel hub 1-19 Shim (0.13t) 1-34 Link
1-5 Hub bolt 1-20 Shim (0.25t) 1-35 Grease nipple
1-6 Oil seal 1-21 Clevis pin 1-36 King pin
1-7 Taper roller bearing 1-22 Thrust washer 1-37 Block
1-8 Taper roller bearing 1-23 Bearing 1-38 Bushing
1-9 Plain washer 1-24 Plain washer 1-39 Hub nut
1-10 Split pin 1-25 Split pin 2 Hex bolt
1-11 Castle nut 1-26 Clevis pin 3 Spring washer
1-12 Hub cap 1-27 Special bolt 4 Shim (1.0t)
1-13 Oil seal 1-28 Spring washer 5 Shim (0.5t)
1-14 Grease nipple 1-29 Hex bolt
1-15 Retaining ring 1-30 Hex nut
5-8
2) TIGHTENING TORQUE AND SPECIFICATION
15DSS08
Type Unit Center pin support single shaft

Structure of knuckle - Elliott type
Toe-in degree 0
Camber degree 1
Caster degree 0
King pin angle degree 0
Max steering angle of wheels(Inside/Outside) degree 80.8 / 56
Tread mm(in) 910 (35.8)
5-9
Check item Checking procedure
Steering wheel · Set rear wheels facing straight forward, then turn steering wheel to left and right.
30-60mm Measure range of steering wheel movement before rear wheel starts to move.
(1.2-2.4 in)
Range should be 30~60mm at rim of steering wheel. If play is too large, adjust
at gear box.
Test steering wheel play with engine at idling.
Knuckle · Check knuckle visually or use crack detection method. If the knuckle is bent, the
tire wear is uneven, so check tire wear.
Steering axle · Put camber gauge in contact with hub and measure camber.
If camber is not within 1±0.5°; rear axle is bent.
· Ask assistant to drive machine at minimum turning radius.
· Fit bar and a piece of chalk at outside edge of counterweight to mark line of
turning radius.
· If minimum turning radius is not within±100mm (±4in)of specified value, adjust
turning angle stopper bolt.
Min turning radius(Outside)
15D-7E 1985mm (78in)
18D-7E 2013mm (79in)
20DA-7E 2050mm (81in)
Hydraulic pressure of power Remove plug from outlet port of flow divider and install oil pressure gauge.
steering Turn steering wheel fully and check oil pressure.
※ Oil pressure :100~105kgf/cm2 (1420~1490psi)
2. TROUBLESHOOTING
Problem Cause Remedy
Steering wheel drags. ·Low oil pressure. ·Check lockout. Repair.
·Bearing faulty. ·Clean or replace.
·Spring spool faulty. ·Clean or replace.
·Reaction plunger faulty. ·Replace.
·Ball-and-screw assembly faulty. ·Clean or replace.
·Sector shaft adjusting screw excessi- ·Adjust.
vely tight.
·Gears poorly meshing. ·Check and correct meshing.
·Flow divider coil spring fatigued. ·Replace.
Steering wheel fails to return ·Bearing faulty. ·Clean or replace.
smoothly. ·Reaction plunger faulty. ·Replace.
·Ball-and-screw assy faulty ·Clean or replace.
·Gears poorly meshing. ·Check and correct meshing.
5-10
Steering wheel turns unstea- ·Lockout loosening. ·Retighten.
dily. ·Metal spring deteriorated. ·Replace.
Steering system makes abn- ·Gear backlash out of adjustment. ·Adjust.
ormal sound or vibration. ·Lockout loosening. ·Retighten.
·Air in oil circuit. ·Bleed air.
Abnormal sound heard when Valve
steering wheel is turned fully ·Faulty. (Valve fails to open.) ·Adjust valve set pressure and check
for specified oil pressure.
Piping
·Pipe(from pump to power steering ·Repair or replace.
cylinder) dented or clogged.
Piping makes abnormal Oil pump
sounds. ·Lack of oil. ·Add oil.
·Oil inlet pipe sucks air. ·Repair.
·Insufficient air bleeding. ·Bleed air completely.
Valve or valve unit makes Oil pump
abnormal sounds. ·Oil inlet pipe sucks air. ·Repair or replace.
Valve
·Faulty. (Unbalance oil pressure) ·Adjust valve set pressure and check
specified oil pressure.
Piping
·Pipe(from pump to power steering) ·Repair or replace.
dented or clogged.
·Insufficient air bleeding. ·Bleed air completely.
Insufficient or variable oil flow. ·Flow control valve orifice clogged. ·Clean
Insufficient or variable dischar- Piping
ge pressure. ·Pipe(from tank to pipe) dented or ·Repair or replace.
clogged.
Steering cylinder head ·Packing foreign material. ·Replace
leakage (Piston rod) ·Piston rod damage. ·Grind surface with oil stone.
·Rod seal damage and distortion. ·Replace
·Chrome gilding damage. ·Grind
Steering cylinder head thread ·O-ring damage. ·Replace
(A little bit leak is no problem)
Welding leakage ·Cylinder tube damage. ·Tube replace.
Rod ·Tube inside damage. ·Grind surface with oil store.
·Piston seal damage and distortion ·Replace
Piston rod bushing inner ·Bushing wear. ·Replace
diameter excessive gap
5-11
1. STEERING UNIT
1) STRUCTURE
1
2
18
11
3
14
25-3 4
25-2 14
25-4 5 22
25-1 15
6
23
21
24
8
16
10 24
7
10
19
13
20
17
9
12
20D7SS06
1 Dust seal 11 O-ring 21 Housing

2 Retaining ring 12 Rolled screw 22 Spool
3 Cap seal 13 Gerotor set 23 Sleeve
4 Thrust bearing 14 Bearing race 24 Plate spring
5 Ball 15 Bore screw 25 P-port check valve
6 Pin 16 Drive 25-1 Plug
7 Spacer 17 End cap 25-2 Poppet
8 Center spring 18 Gland bushing 25-3 Spring seat
9 Washer 19 Plate 25-4 Spring
10 O-ring 20 Cap screw
5-12
2) TOOLS
(1) Holding tool.
5-69(1)
(2) Assembly tool for O-ring and kin-ring.
5-69(2)
(3) Assembly tool for lip seal.
5-69(3)
(4) Assembly tool for cardan shaft.
5-69(4)
5-13
(5) Assembly tool for dust seal.
5-70(1)
(6) Torque wrench 0~7.1kgf·m

(0~54.4lbf·ft)
13mm socket spanner
6, 8mm and 12mm hexagon sockets
12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon socket spanners
Plastic hammer
Tweezers 5-70(2)
3) TIGHTENING TORQUE
L : Left port
R : Right port
T : Tank
P : Pump
D353SE23
Port Size Torque [kgf·m(lbf·ft)]

L 3/4 UNF - 16 13 (94)
R 3/4 UNF - 16 13 (94)
T 3/4 UNF - 16 13 (94)
P 3/4 UNF - 16 13 (94)
Mounting bolt M10×1.5 5.0 ±1.0 (36±7.2)
5-14
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).
5-72(1)
(2) Remove the end cover, sideways.
5-72(2)
(3) Lift the gearwheel set(With spacer if fitted)

off the unit.
Take out the two O-rings.
5-72(3)
(4) Remove cardan shaft.
5-72(4)
5-15
(5) Remove distributor plate.
5-73(1)
(6) Screw out the threaded bush over the

check valve.
5-73(2)
(7) Remove O-ring.
5-73(3)
(8) Take care to keep the cross pin in the

sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and thrust
bearing will be pushed out of the housing
together.
5-73(4)
5-16
(9) Take ring, bearing races and thrust
bearing from sleeve and spool. The outer
(Thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.
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
close to one of the slots for the neutral
position springs(See drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position
springs are disassembled.
5-74(3)
(11) Carefully press the spool out of the sleeve.
5-74(4)
5-17
(12) Press the neutral position springs out of
their slots in the spool.
5-75(1)
(13) Remove dust seal and O-ring.
5-75(2)
Disassembling the pressure relief valve

(14) Screw out the plug using an 8mm hexagon
socket spanner.
Remove seal washers.
D353SE10
(15) Unscrew the setting screw using an 8mm

hexagon socket spanner.
D353SE11
5-18
(16) Shake out spring and piston. The valve
seat is bonded into the housing and cannot
be removed.
D353SE12
(17) The pressure relief valve is now disassem-

bled.
D353SE13
5-19
5) ASSEMBLY
(1) 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. Place the slots and 5-76(1)
holes opposite each other so that parts
of the holes in the sleeve are visible
through the slots in the spool.
(2) Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place (see
assembly pattern).
5-76(2)
(3) Line up the spring set.
5-76(4)
(4) Guide the spool into the sleeve. Make

sure that spool and sleeve are placed
correctly in relation to each other.
5-77(1)
5-20
(5) Press the springs together and push the
neutral position springs into place in the
sleeve.
5-77(2)
(6) Line up the springs and center them.
5-77(3)
(7) Guide the ring down over the sleeve.

※ The ring should be able to rotate free of
the springs.
5-77(4)
(8) Fit the cross pin into the spool / sleeve.
5-78(1)
5-21
(9) Fit bearing races and needle bearing as
shown on below drawing.
5-78(2)
※ Assembly pattern for standard bearings

1
1 Outer bearing race 2
2 Thrust bearing 3
3 Inner bearing race
4 Spool
5 Sleeve 4
5
5-78(3)
Installation instruction for O-ring

(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
5-78(4)
5-22
(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.
5-79(3)
(13) Press and turn the O-ring into position in

the housing.
5-79(4)
5-23
(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.
5-80(2)
5-80(3)
(16) Guide the assembly tool right to the

bottom.
5-80(4)
5-24
(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. The O-ring are now in position.
5-81(3)
(20) Turn the steering unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.
5-81(4)
5-25
(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

channel holes match the holes in the
housing.
5-82(3)
(24) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.
5-82(4)
5-26
(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. Fit the gearwheel and rim on the
cardan shaft.
5-83(2)
(27) Important
Fit the gearwheel(Rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
5-83(3)
(28) Fit the spacer, if any.
5-83(4)
5-27
(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 ± 0.6kgf·m
(21.7 ± 4.3lbf·ft)
5-84(3)
(32) Place the dust seal ring in the housing.
5-84(4)
5-28
(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)
5-29
2. STEERING CYLINDER
1) STRUCTURE
6
9
10
7
4
8
3
11
8
12 7
5
10
9
6
15L7SS11
1 Tube assembly 5 Gland 9 O-ring

2 Rod 6 DU bushing 10 Lock washer
3 Piston seal 7 Rod seal 11 Spacer
4 Wear ring 8 Dust wiper 12 O-ring
5-30
2) DISASSEMBLY
※ Before disassembling steering cylinder, release oil in the cylinder first.
(1) Put wooden blocks against the cylinder tube, then hold in a vice.
(2) Remove the gland by hook a wrench in the notch of cylinder head and turn counter-clockwise.
(3) Remove the cylinder rod and piston from the tube.
(4) Check wear condition of the sealing parts. If there are some damage, replace with new parts.
3) CHECK AND INSPECTION mm(in)

Criteria
Check item Remedy
Standard size Repair limit
Clearance between 0.064~0.137 0.180 Replace
piston & cylinder tube (0.0025~0.0054) (0.0070) piston seal
cylinder rod & bushing (0.0009~0.0044) (0.0049) bushing
Seals, O-ring Damage Replace
Cylinder rod Dents Replace
Cylinder tube Biting Replace
4) ASSEMBLY
(1) Install a new piston seal the groove on the piston.
※ Be careful not to scratch the seal too much
during installation or it will not seat properly.
D353SE27
(2) Install the rod seal to the position in the gland

applying a slight coat with grease prior to install.
D353SE28
5-31
(3) Install the dust wiper to the gland using a special
installing tool. Coat the dust wiper with grease
slightly before installing.
(4) Set a special tool the cylinder, gland assembly
into the cylinder tube.
D353SE29
(5) Using a hook spanner, install the gland

assembly, and tighten it with torque 45±4.5
kgf·m(325±33lbf·ft).
D353SE30
(6) After the gland assembly was installed to the

cylinder tube, calk at the tube end into the groove
on the gland to prevent screw loosening.
※ If it need calking again, never using previous
calking position.
D353SE31
(7) Move the piston rod back and forth several times for the full distance of its stroke. This helps to
seat the ring and seals before applying full hydraulic pressure to the cylinder.
(8) Install cylinder into trail axle.
(9) While idling the engine with the rear wheels off the ground, operate the steering wheel left and
right alternately.
※ Then, repeat the above operation at gradually increasing engine rpm. This releases air
from the system and completes preparation for operation.
(10) Stop the engine, lower the floating rear wheels, and check pump joints for oil leaks and looseness
and retighten, them as required.
5-32
3. STEERING AXLE
1) STRUCTURE
※ Do not remove the stopper bolt unless necessary.
15DSS07
1-1 Steering axle wa 1-16 King pin washer 1-31 Lock plate
1-2 Knuckle-RH 1-17 Needle bearing 1-32 Hex bolt
1-3 Knuckle-LH 1-18 Thrust bearing 1-33 Steering cylinder
1-4 Wheel hub 1-19 Shim (0.13t) 1-34 Link
1-5 Hub bolt 1-20 Shim (0.25t) 1-35 Grease nipple
1-6 Oil seal 1-21 Clevis pin 1-36 King pin
1-7 Taper roller bearing 1-22 Thrust washer 1-37 Block
1-8 Taper roller bearing 1-23 Bearing 1-38 Bushing
1-9 Plain washer 1-24 Plain washer 1-39 Hub nut
1-10 Split pin 1-25 Split pin 2 Hex bolt
1-11 Castle nut 1-26 Clevis pin 3 Spring washer
1-12 Hub cap 1-27 Special bolt 4 Shim (1.0t)
1-13 Oil seal 1-28 Spring washer 5 Shim (0.5t)
1-14 Grease nipple 1-29 Hex bolt
1-15 Retaining ring 1-30 Hex nut
5-33
2) CHECK AND INSPECTION
15DSS10
unit : mm(in)
Criteria
No. Check item Remarks
Standard size Repair limit
A1 OD of shaft 50(1.9) 49.5(1.9)
A Shaft
A2 ID of bushing 50(1.9) 50.5(1.9)
B OD of king pin 35(1.4) 34.5(1.4) Replace
C OD of steering cylinder pin 17(0.6) 16.5(0.6)
D1 OD of pin 17(0.6) 16.5(0.6)
D Knuckle D2 ID of bushing 17(0.6) 16.5(0.6) Replace
Vertical play - - Adjust with shims
·OD : Outer diameter
·ID : Inner diameter
5-34
3) 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. Hub nut
(1) Loosen the hub nut and take off the steering
wheel tire.
D353SE24
(2) Remove Hub cap.

(3) Pull out split pin and remove slotted nut.
(4) Using the puller, take off the hub together with
the roller bearing.
※ Be very careful because just before the hub
comes off, tapered roller bearing will fall out.
(5) After hub is removed take off the inner race of
roller bearing.
(6) Pull out oil seal.
※ Don't use same oil seal twice.
(7) Repeat the same procedure for the other side.
Moreover, when disassembling is completed,
part the slotted nut in the knuckle to protect the
threaded portion.
15DSS09
(8) Loosen special bolt (1-27) and spring washer (1-

28).
(9) Pry out the retaining ring (1-15) and remove
washer(1-16) and oil seal (1-13).
(10) Push out the king pin (1-36) without damaging
the knuckle arm (1-3).
(11) If defect is observed in bearing (1-18), pull it out
by using extractor.
(12) Remove spilt pin (1-25), plain washer(1-24) and
link pin(1-26).
15DSS12
5-35
4) ASSEMBLY
※ In reassembling, have all parts washed, grease
applied to lubricating parts, and all expendable
items such as oil seal and spring washers
replaced by new ones.
Perform the disassembly in reverse order.
(1) Tighten the special bolt (1-27) and washer (1-28)
of king pin (1-36).
(2) There is a notch in the middle of the king pin (1-
36), make sure that this notch is on the special
bolt side.
(3) Do not hammer to drive in bearing (1-18)
because it will break.
Always use drive-in tool.
Be sure that the fixed ring of the bearing is
placed in position facing the knuckle (1-3).
(4) Hub
① Mount oil seal(1-6) and inner race of tapered
roller bearing(1-7) on the knuckle. The bearing
should be well greased before assembling.
② Install the outer race of the bearing(1-8) in the
wheel center and assemble to the knuckle.
③ Tighten nut(1-11) and lock with split pin(1-10). In
locking with split pin, locate the hole for the split
pin by turning the nut back 1/6 of a turn.
15DSS13
Adjust the preload of bearing.
④ Mount the hub cap(1-12).
Bearing should be well greased before assem-
bling.
5-36
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-27
SECTION 6 HYDRAULIC SYSTEM
1. HYDRAULIC CIRCUIT (NON OPSS / TRAVEL OPSS)
5 6
7
L R
4 10 9
1A 2A 2B 3A 3B 4A 4B
T 3
T LS P
P
19MPa
2 LS CF EF
LIFT TILT
10MPa
AUX1 AUX2
T
15MPa
E/G
1
11
8 12
15L7HS01
1 Hydraulic gear pump 7 Lift cylinder

3 Main control valve 9 Down control valve
4 Steering unit 10 Down safety valve
5 Steering cylinder 11 Return filter
6 Tilt cylinder 12 Hydraulic tank
6-1
HYDRAULIC CIRCUIT (TRAVEL WITH MAST OPSS)
5 6
7
L R
4 9
10
1A 2A 2B 3A 3B 4A 4B
T 3
T LS P
P
19MPa
2 LS CF EF AUX1
LIFT TILT
10MPa
AUX2
T
15MPa
E/G 1
11
8 12
15L7HS02
1 Hydraulic gear pump 7 Lift cylinder

3 Main control valve 9 Down control valve
4 Steering unit 10 Down safety valve
5 Steering cylinder 11 Return filter
6 Tilt cylinder 12 Hydraulic tank
6-2
1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION
7 6
10 9
1A 2A 2B 3A 3B 4A 4B
T 3
Steering system
P
19MPa
2 LS CF EF
LIFT TILT
10MPa
AUX1 AUX2
T
15MPa
E/G 1
11
Return line
8 12
15L7HS03
When the lift control lever is pulled back, the spool on the first block moves to lift position.
The oil from hydraulic gear pump(1) flows into main control valve(3) through the priority valve(2)
and then goes to the large chamber of lift cylinder(7) by pushing the load check valve of the spool.
The oil from the small chamber of lift cylinder(7) returns to hydraulic oil tank(12) at the same time.
When this happens, the fork goes up.
6-3
2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION
7 6
10 9
1A 2A 2B 3A 3B 4A 4B
T 3
Steering system
LOWER
P
19MPa
2 LS CF EF
TILT
10MPa
AUX1 AUX2
T
P 15MPa
E/G 1
11
Return line
8 12
15L7HS04
When the lift control lever is pushed forward, the spool on the first block moves to lower position.
The work port(1A) and the small and the large chamber of lift cylinder are connected to the return
passage, so the fork will be lowered due to its own weight.
6-4
3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION
7 6
10 9
1A 2A 2B 3A 3B 4A 4B
T 3
Steering system
P 19MPa
2 LS CF EF
LIFT TILT
10MPa
AUX1 AUX2
T
15MPa
P
E/G 1
11
Return line
8 12
15L7HS05
When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward
position.
and then goes to the large chamber of tilt cylinder(6) by pushing the load check valve of the spool.
The oil at the small chamber of tilt cylinder(6) returns to hydraulic tank(12) at the same time.
When this happens, the mast tilt forward.
6-5
4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION
7 6
10 9
1A 2A 2B 3A 3B 4A 4B
T 3
Steering system
P
19MPa
2 LS CF EF
LIFT TILT
10MPa
AUX1 AUX2
T
15MPa
P
E/G 1
11
Return line
8 12
15L7HS06
When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward
position.
and then goes to the small chamber of tilt cylinder(6) by pushing the load check valve of the spool.
The oil at the large chamber of tilt cylinder(6) returns to hydraulic tank(12) at the same time.
When this happens, the mast tilts backward.
6-6
2. HYDRAULIC GEAR PUMP
1) STRUCTURE
15DHS06
1 Front cover 6 Bushing block 11 Lip seal

2 Rear cover 7 Dry bearing 12 Snap ring
3 Gear housing 8 Channel seal 13 Socket head bolt
4 Drive shaft gear 9 Square seal 14 Plain washer
5 Driven gear 10 Dowel pin
2) OPERATION
This pump comprises of an end cover, a body, bushings and a mounting flange bolted together.
The gear journals are supported in plane bearings within pressure balanced bushings to give high
volumetric and mechanical efficiencies.
6-7
3. PRIORITY VALVE
1) STRUCTURE
15DHS15
1 Body 5 End plug 9 Orifice

2 Spool 6 Spool 10 O-ring
3 End plug 7 Bushing 11 End plug
4 Spring 8 Spring 12 Control screw
6-8
4. MAIN CONTROL VALVE
1) STRUCTURE (4 Spool - NON OPSS / TRAVEL OPSS)
1A 2A 3A 4A
2B 3B 4B
6 7 1 2 3 5 4
15L7HS07
Port name Size
Inlet port 7/8-14UNF

Outlet port 7/8-14UNF
Work port 3/4-16UNF
1 Inlet block assy 5 Auxiliary block assy

2 Lift block assy 6 Long bolt
3 Tilt block assy 7 Nut
4 Outlet block assy
6-9
2) INLET SECTION OPERATION
(1) Operation
INLET
P WORK SECTION
19MPa
15L7HS08
The inlet section contains the pump inlet connection as well as a diagnostic inlet pressure gage port
(new feature to be included).
6-10
3) LIFT SECTION OPERATION
(1) Lift position
LIFT
1A
1A
15L7HS09
When the operator shifts the lever backwards, the spool is extended out of the valve, and this opens
the internal fluid passages that lift the mast. Oil flows through the high pressure parallel cavity, past
the load check valve, through the spool metering notches, past the lift lock check valve, and to the
head side of the lift cylinder.
6-11
(2) Lower position
LIFT
1A
1A
15L7HS10
When the seated operator shifts the lever forwards, the spool retracts into the valve, and the oil is
directed from the cylinder, past the lift lock check valve, past the spool metering notches, and to the
common tank cavity.
6-12
4) TILT SECTION OPERATION
(1) Tilt forward position
TILT
2B 2A
2A 2B
15L7HS11
When the seated operator shifts the level forward, pressure is applied to the head of the tilt cylinder,
and the forks tilt forward. Oil is past the spool metering notches, and towards the cylinder head.
Simultaneously, the high pressure acts upon the end of the tilt lock plunger to move it towards the
spring end of the spool.This plunger movement opens additional spool metering notches which
control oil flow from the rod end of the cylinder to the tank return line.
6-13
(2) Tilt backward position
TILT
2B 2A
2A 2B
15L7HS12
When the seated operator shifts the lever back, the high pressure oil from the parallel passage is
directed past the load check valve, past the spool metering notches, and to the rod side of the
cylinder.
Exhaust oil from the head side of the cylinder is directed past the spool metering notches to tank.
6-14
5) STRUCTURE (4 SPOOL - TRAVEL WITH MAST OPSS)
2A 3A 4A
2B 3B 4B
16 17 11 12 13 15 15 14
15L7HS57
Port name Size
Inlet port 7/8-14UNF

Outlet port 7/8-14UNF
Work port 3/4-16UNF
11 Inlet block assy 15 Auxiliary block assy

12 Lift block assy 16 Long bolt
13 Tilt block assy 17 Nut
14 Outlet block assy
6-15
6) INLET SECTION OPERATION (TRAVEL WITH MAST OPSS)
(1) Operation
INLET
P WORK
19MPa SECTION
SOL V/V
15L7HS58
When the operator is not seated, the solenoid valve is in the normally open position, which helps
divert flow from the pump directly to the outlet to tank. In this manner, oil pressure and flow are not
able to reach the portions of the valve which control the vehicle functions, so their operation is
prevented.
Pressure is limited by the main relief valve.
6-16
7) LIFT SECTION OPERATION (TRAVEL WITH MAST OPSS)
(1) Lift position
LIFT
NEEDLE
V/V
1A
LIFT LOCK V/V
SOL V/V "B"
1A
15L7HS59
When the operator shifts the lever backwards, the spool is extended out of the valve, and this opens
the internal fluid passages that lift the mast. Oil flows through the high pressure parallel cavity, past
the load check valve, through the spool metering notches, past the lift lock check valve, and to the
head side of the lift cylinder.
6-17
(2) Lower position
LIFT
1A
NEEDLE
V/V
LIFT LOCK V/V
SOL V/V "B"
1A
15L7HS60
When the seated operator shifts the lever forwards, the spool retracts into the valve, and the oil is
directed from the cylinder, past the lift lock check valve, past the spool metering notches, and to the
common tank cavity.
6-18
(3) Secondary lower position
LIFT
NEEDLE V/V
NEEDLE
V/V
LIFT LOCK V/V
SOL V/V "B"
1A
15L7HS61
Secondary lowering method : A secondary lowering method is available in the event of the loss of
engine power that is needed to energize the normally closed solenoid valve.
· Important Note : Before opening the secondary needle valve, make sure personnel and
equipment are safely positioned to avoid accidents. Be careful to operate this secondary valve
slowly, as heavy loads may be suspended.
· A manual valve (needle valve) is located on the lift section, and it can be operated by opening the
vehicle cowling and rotating the manual valve (needle valve) counterclockwise with a wrench.
Open the manual valve (needle valve ) approximately 2~3 turns (do not rotate more than 4
turns). Then shift the lift spool slowly for controlled lowering. This should be just enough for slow,
controlled movement of the mast.
· Pressure is limited by the main relief valve.
6-19
8) OUTLET SECTION OPERATION
(1) Operation
OUTLET
150k
15L7HS62
The outlet section contains the tank port and the secondary relief valve (with built-in anti-cavitation
feature).
6-20
5. LIFT CYLINDER
D155HS13
1 Tube assembly 6 Wear ring 11 O-ring

2 Rod 7 Retaining ring 12 Guide
3 Piston 8 Gland 13 DU bushing
4 Piston seal 9 Dust wiper 14 Spacer
5 Back up ring 10 Rod seal 15 O-ring
6. TILT CYLINDER
15DHS14
1 Tube assembly 9 DU bushing 17 Washer

2 Rod 10 U-packing 18 Eye
3 Piston 11 Back up ring 19 Bushing
4 Piston seal 12 Dust wiper 20 Hex bolt
5 Wear ring 13 Stop ring 21 Spring washer
6 O-ring 14 O-ring 22 Lock nut
7 Nylon nut 15 Back up ring 23 Grease nipple
8 Gland 16 O-ring
6-21
7. FREE LIFT CYLINDER
D155HS15
1 Tube assembly 6 Check valve 11 Dust wiper

2 Rod 7 Ring retaining 12 Snap ring
3 Piston 8 Set screw 13 O-ring
4 Piston seal 9 Gland 14 Back up ring
5 Wear ring 10 Rod seal
6-22
1) CHECK ITEM
(1) Check visually for deformation, cracks or
Within 100mm(3.91in)
damage of rod.
(2) Set mast vertical and raise 1m from
(after 10min)
ground. Wait for 10 minutes and measure
hydraulic drift(amount forks move down
and amount mast tilts forward).
·C Check condition 20D7HS16
- Hydraulic oil : Normal operating temp
- Mast substantially vertical.
- Rated capacity load.
·Hydraulic drift
Within 5 (after 10min)
- Down(Downward movement of forks)
: Within 100mm (3.9in)
- Forward(Extension of tilt cylinder)
: Within 5。
(3) If the hydraulic drift is more than the
specified value, replace the control valve
or cylinder packing.
Check that clearance between tilt cylinder
bushing and mounting pin is within
20D7HS17
standard range.
mm (in)
Standard Under 0.6 (0.02)
2) HYDRAULIC OIL
(1) Using dipstick, measure oil level, and oil if
necessary.
(2) When changing hydraulic oil, clean
suction strainer(screwed into outlet port
pipe) and line filter(screwed into inlet pipe).
Line filter uses paper element, so replace
periodically(every 6 months or 1000
hours) 15DHS16
3) CONTROL VALVE
(1) Raise forks to maximum height and
measure oil relief pressure.
Check that oil relief pressure is 190kgf/cm2.
(2702psi)
6-23
2. TROUBLESHOOTING
1) SYSTEM
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.
mast. tive.
·Tilting forward : tilt lock valve defect- ·Clean or replace.
ive.
·Seal inside cylinder defective. ·Replace seal.
Slow fork lifting or slow mast ·Lack of hydraulic oil. ·Add oil.
tilting. ·Hydraulic oil mixed with air. ·Bleed air.
·Excessive restriction of oil flow on ·Clean filter.
pump suction side.
·Relief valve fails to keep specified ·Adjust relief valve.
pressure.
·Poor sealing inside cylinder. ·Replace packing.
·High hydraulic oil viscosity. ·Change to SAE10W, class CF engine
oil.
·Mast fails to move smoothly. ·Adjust roll to rail clearance.
·Oil leaks from lift control valve spool. ·Replace spool or valve body.
·Oil leaks from tilt control valve spool. ·Replace spool or valve body.
Hydraulic system makes ·Excessive restriction of oil flow pump ·Clean filter.
abnormal sounds. suction side.
·Gear or bearing in hydraulic pump ·Replace gear or bearing.
defective.
Control valve lever is locked ·Foreign matter jammed between sp- ·Clean.
ool and valve body.
·Valve body defective. ·Tighten body mounting bolts uniform-
ly.
High oil temperature. ·Lack of hydraulic oil. ·Add oil.
·High oil viscosity. ·Change to SAE10W, class CF engine
oil.
·Oil filter clogged. ·Clean filter.
6-24
2) HYDRAULIC GEAR PUMP

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.
Pump will not pump oil. ·Reservoir low or empty. ·Fill reservoir to proper level.
·Suction strainer clogged. ·Clean suction strainer.
Noisy pump caused by ·Oil too thick. ·Change to proper viscosity.
cavitation. ·Oil filter plugged. ·Clean filters.
·Suction line plugged or too small. ·Clean line and check for proper size.
Oil heating. ·Oil supply low. ·Fill reservoir to proper level.
·Contaminated oil. ·Drain reservoir and refill with clean oil.
·Setting of relief valve too high or too ·Set to correct pressure.
low.
·Oil viscosity too low. ·Drain reservoir and fill with proper
viscosity.
Foaming oil. ·Low oil level. ·Fill reservoir to proper level.
·Air leaking into suction line. ·Tighten fittings, check condition of
line.
·Wrong kind of oil. ·Drain reservoir, fill with non-foaming
oil.
Shaft seal leakage. ·Worn shaft seal. ·Replace shaft seal.
·Worn shaft in seal area. ·Replace drive shaft and seal.
3) MAIN RELIEF VALVE

Can’t get pressure ·Poppet D, E or K stuck open or ·Check for foreign matter between
contamination under seat. poppets D, E or K and their mating
parts. Parts must slide freely.
Erratic pressure ·Pilot poppet seat damaged. ·Replace the relief valve.
·Clean and remove surface
marks for free movement.
Pressure setting not correct ·Normal wear. Lock nut & adjust ·See ★How to set pressure on work
screw loose. main relief.
Leaks ·Damaged seats. ·Replace the relief valve.
·Worn O-rings. ·Install seal and spring kit.
·Parts sticking due to contamination. ·Disassemble and clean.
★ A good pressure gauge must be installed in the line which is in communication with the main relief. A
load must be applied in a manner to reach the set pressure of the main relief unit.
Then, follow these steps:
· Loosen lock nut.
· Set adjusting nut to desired pressure setting.
· If desired pressure setting cannot be achieved, add or remove shims as required.
· Tighten lock nut.
· Retest in similar manner as above.
6-25
4) LIFT CYLINDER

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.
Oil leaks out from cylinder ·O-ring damaged. ·Replace O-ring.
gland thread.
Rod spontaneously retract. ·Scores on inner surface of tube. ·Smooth rod surface with an oil stone.
·Unallowable score on the inner ·Replace cylinder tube.
surface of tube.
·Foreign matters in piston seal. ·Replace piston seal.
Wear(clearance between ·Excessive clearance between ·Replace wear ring.
cylinder tube and wear ring) cylinder tube and wear ring.
Abnormal noise is produced ·Insufficient lubrication of anchor pin or ·Lubricate or replace.
during tilting operation. worn bushing and pin.
·Bent tilt cylinder rod. ·Replace.
6-26
1. HYDRAULIC GEAR PUMP
※ Tools required
·Metric socket set
·Internal snap ring pliers
·Shaft seal sleeve
·Torque wrench
(1) It is very important to work in a clean work
area when repairing hydraulic products.
Plug ports and wash exterior of pump with
a proper cleaning solvent before continu-
ing.
(2) Remove port plugs and drain oil from
pump.
(3) Use a permanent marker pen to mark a
line across the mounting flange, gear
housing and end cover. This will assure
proper reassembly and rotation of pump.
(4) Remove key from drive shaft if applicable.
PUMP 01
(5) Clamp mounting flange in a protected jaw

vise with pump shaft facing down.
(6) Loosen the four metric hexagon head
bolts.
(7) Remove pump from vise and place on
clean work bench, remove the four hexagon
head bolts and spacers applicable.
PUMP 02
6-27
(8) Lift and remove end cover.
PUMP 03
(9) 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.
PUMP 06
6-28
(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.
PUMP 09
(15) Remove the oil seal from mounting flange,

be careful not to mar or scratch the seal
bore.
(16) Remove the dowel pins from the gear
housing. Do not lose pins.
PUMP 10
6-29
(17) Remove seals from both bearing blocks
and discard.
PUMP 11
2) INSPECT PARTS FOR WEAR

(1) Clean and dry all parts thoroughly prior to
inspection. It is not necessary to inspect
the seals as they will be replaced as new
items.
(2) Check drive shaft spline for twisted or
broken teeth, check keyed drive shaft for
broken or chipped keyway. No marks or
grooves on shaft in seal area, some
discoloration of shaft is allowable.
(3) Inspect both the drive gear shaft and idler
gear shafts at the bearing points and seal
area for rough surfaces and excessive
wear.
PUMP 12
(4) Inspect gear face for scoring or excessive

wear. If the face edge of gear teeth are
sharp, they will mill into the bearing blocks.
If wear has occurred, the parts are
unusable.
PUMP 13
6-30
(5) Inspect bearing blocks for excessive wear
or scoring on the surfaces which are in
contact with the gears. Also inspect the
bearings for excessive wear or scoring.
(6) Inspect the area inside the gear housing.
It is normal for the surface inside the gear
housing to show a clean "wipe" on the
inside surface on the intake side. There
should not be excessive wear or deep
scratches and gouges. PUMP 14
※ General information
It is important that the relationship of the
mounting flange, bearing blocks and gear
housing is correct. Failure to properly
assemble this pump will result with little or
no flow at rated pressure.
※ This pump is not bi-rotational.
6-31
3) ASSEMBLY
※ New seals should be installed upon
reassembly of pump.
(1) Install new shaft seal in mounting flange
with part number side facing outboard.
Press the seal into the seal bore until the
seal reaches the bottom of the bore.
Uniform pressure must be used to prevent
misalignment or damage to the seal.
PUMP 15
(2) Install retaining ring in groove in seal bore

of mounting flange.
PUMP 16
(3) Place front and back bearing blocks on a

clean surface with the E-seal grooves
facing up. Apply a light coating of
petroleum jelly in the grooves. Also coat
the E-seal and backup with the petroleum
jelly, this will help keep the seals in place
during assembly.
PUMP 17
(4) Place the E-seals, flat side outward, into

the grooves in both bearing blocks. Follow
by carefully placing the backup ring, flat
side outward, in the groove made by the
E-seal and the groove in the bearing
block.
(5) Place mounting flange, with shaft seal
side down, on a clean flat surface.
(6) Apply a light coating of petroleum jelly to
PUMP 18
the exposed face of the front bearing
block.
6-32
(7) Insert the drive end of the drive shaft
through the bearing block with the seal
side down, and the open side of the E-
seal pointing to the intake side of the
pump.
(8) Install the seal sleeve over the drive shaft
and carefully slide the drive shaft through
the shaft seal. Remove the seal sleeve
from shaft.
PUMP 19
(9) Install the idler gear shaft in the remaining

position in the bearing block. Apply a light
coat of clean oil to the face of the drive
and idler gears.
PUMP 20
(10) Pick up the rear bearing block, with seal

side up and with open end of the E-seal
facing the intake side of the pump, place
over the drive and idler gear shafts.
(11) Install two dowel pins in the holes in the
mounting flange or two long dowel pins
through gear housing if pump is a multiple
section pump.
PUMP 21
(12) To install the O-rings in the gear housing,

apply a light coating of petroleum jelly in
the grooves on both sides of the gear
housing.
Also coat the new O-ring and install them
in the grooves.
PUMP 22
6-33
(13) Gently slide the gear housing over the rear
bearing block assembly, slide housing
down until the housing engages the dowel
pins. Press firmly in place with hands, do
not force or use any tool.
Check to make sure the intake port in the
housing in on the same side as the open
end of the E-seal and that the marked
lines on the mounting flange and gear
housing are in alignment. PUMP 23
(14) The surface of the rear bearing block

should be slightly below the face of the
gear housing. If the bearing block sits
higher then the rear face of the gear
housing then the E-seal or O-ring have
shifted out of the groove. If this is the
case, remove the gear housing and check
for proper seal installation.
(15) Install the two remaining dowel pins in the

rear of the gear housing and place the
end cover over the back of the pump.
PUMP 24
(16) Install the four spacers and hexagon head

bolts through the bolt holes in the end
cover, hand tighten.
PUMP 25
6-34
(17) Place mounting flange of the pump back
in the protected jawed vise and alternately
torque the bolts.
·Tighten torque : 6~7kgf·m
(43.4~50.6lbf·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. If the
PUMP 26
drive shaft binds, disassemble the pump
and check for assembly problems, then
reassemble the pump.
6-35
2. MAIN CONTROL VALVE
1) ASSEMBLY
(1) General
① Ensure that the assembly area will be clean and free of contamination.
② Use a flat (within 0.2mm) work surface when bolting the valve sections together.
③ Use calibrated torque wrenches and instrumentation.
④ The formal Bills of Material, descriptions, and views are found in the attached documentation.
⑤ Additional auxiliary valve sections may be added to the main control valve in a similar manner as
indicated below, as approved by the Hyundai.
(2) Block subassembly
2.4~2.9kgf m
15L7HS31
① Attach all the o-rings to the appropriate grooves between the spool sections.
② Stack the valve sections such that all the work ports are facing up, the spool ends are all in the
same direction, and resting on a flat (within 0.2mm), uniform surface.
③ Insert all the tie rods through the drilled holes in each of the housings.
④ Press the sections together, being careful not to damage sealing surfaces or seals.
⑤ Install nuts to both ends of all tie rods and progressively torque in a circular pattern until reaching
a torque of 2.4~2.9 kgf·m (17.4~21.0 lbf·ft)on all tie rods. Periodically, make sure that the valve
remains flat while applying torque.
6-36
(3) Inlet section
LIFT LOAD CHECK V/V
SOLENOID V/V COIL

SPRING
LOAD CHECK
SOLENOID V/V CATRIDGE
(NORMALLY CLOSED)
SY PLUG
L AS
P OO
XS SY
AU L AS
POO Y NEEDLE VALVE
XS A SS
AU OL
O
T SP Y
TIL ASS
OL
PO
TS
LIF MAIN RELIEF VALVE
SEAL
SOLENOID V/V CATRIDGE DUST WIPER
(NORMALLY OPEN)
CAP
SOLENOID V/V COIL SECONDARY RELIEF VALVE
SEAL PLATE
15L7HS34
① Install the main relief valve assembly into the lower side cavity of the inlet section, as illustrated.
Torque to 4.5-5.0 kgf·m (32.5~36.2 lbf·ft).
② Install the normally open solenoid valve assembly in the side cavity of the inlet directly above the
main relief valve. Torque to 3.5-4.0 kgf·m (25.2~28.8 lbf·ft).
③ Install the plug assembly in the tank port of the inlet section.
④ Install the plug in the pressure gage port to the inlet. Torque to 4.5-5.0 kgf·m (32.5~36.2 lbf·ft).
6-37
(4) Lift section
LIFT LOAD CHECK V/V
SOLENOID V/V COIL

SPRING
LOAD CHECK
(NORMALLY CLOSED)
Y PLUG
A SS
OL
PO
XS SS
Y
AU A
OL
PO Y NEEDLE VALVE
XS A SS
AU OL
PO
TS SS
Y
TIL A
OL
PO
TS
SEAL
(NORMALLY OPEN)
CAP
SEAL PLATE
15L7HS34
① The spool assembly should already consist of the lift spool, the return spring, one spring seat on
either end of the spring, the seal plate, a spool seal, and a dust wiper. All of these are assembled
on the end of the spool opposite the clevis.
② Insert the clevis end of the spool into the right-hand side of the spool bore (the tallest end of the
housing). Place the spool cap over the spool and spring assembly and connect the cap to the
housing using two bolts. Torque both bolts alternatively until a torque of 1.0-1.5 kgf·m (7.2~10.8
lbf·ft) is reached on both bolts.
③ Install the second spool seal and dust wiper over the clevis end of the spool and retain with a seal
plate and two bolts. Torque both bolts alternatively until a torque of 1.0-1.5 kgf·m (7.2~10.8 lbf·ft)
is reached on both bolts.
④ The load check assembly is inserted into the top center cavity.
Torque to 3.5-4.0kgf·m (25.2~28.8 lbf·ft).
⑤ The normally closed solenoid is installed in the rightmost cavity on the top of the section.
⑥ Install the lift lock check valve assembly in the remaining open cavity in the top of the housing.
⑦ Install the needle valve subassembly in the cavity on the inlet-facing surface of the housing.
6-38
(5) Tilt section
LIFT LOAD CHECK V/V
SOLENOID V/V COIL

SPRING
LOAD CHECK
(NORMALLY CLOSED)
SY PLUG
L AS
P OO
XS SY
AU L AS
POO Y NEEDLE VALVE
XS A SS
AU OL
O
T SP Y
TIL ASS
OL
PO
TS
SEAL
(NORMALLY OPEN)
CAP
SEAL PLATE
15L7HS34
① The spool assembly should already consist of the tilt spool (with tilt plunger and spring inserted
into the bore on the spring end), the return spring, one spring seat on either end of the spring, the
seal plate, a spool seal, and a dust wiper. All of these are assembled on the end of the spool
opposite the clevis.
6-39
(6) Auxiliary sections
LIFT LOAD CHECK V/V
SOLENOID V/V COIL

SPRING
LOAD CHECK
(NORMALLY CLOSED)
Y PLUG
A SS
O OL
SP Y
AU
X
ASS
OL
PO Y NEEDLE VALVE
XS A SS
AU OL
PO
TS SS
Y
TIL A
OL
PO
TS
SEAL
(NORMALLY OPEN)
CAP
SEAL PLATE
15L7HS34
(Same procedure for all aux sections, but spool assembly components may vary)
① The spool assembly should already consist of the proper aux spool, the return spring, one spring
seat on either end of the spring, the seal plate, a spool seal, and a dust wiper. All of these are
assembled on the end of the spool opposite the clevis.
Torque to 3.5-4.0kgf·m (25.2~28.8 lbf·ft) .
(7) Outlet section

① Install the secondary relief valve into the cavity on the clevis end of the housing.
6-40
2) DISASSEMBLY INSTRUCTIONS
(1) General
① Subassemblies (such as relief valves, check valves, and spools) may be removed without having
to loosen the tie rods and disassembling the entire valve.
② Disassemble the valve sections on a flat working surface.
③ Ensure that the disassembly area will be clean and free of contamination.
④ Keep the disassembly area neat to avoid loss or damage of parts.
LIFT LOAD CHECK V/V
SOLENOID V/V COIL

SPRING
LOAD CHECK
(NORMALLY CLOSED)
Y PLUG
A SS
O OL
X SP SY
AU L AS
OO NEEDLE VALVE
X SP S SY
AU O LA
S PO
ILT SY
T L AS
POO
TS
SEAL
(NORMALLY OPEN)
CAP
SEAL PLATE
15L7HS34
(2) Procedure
① Loosen the tie rod nuts and remove the tie rods from the valve sections.
② Remove o-rings between valve sections and set aside to avoid damage.
③ Spools, relief valves, load check valves, lift lock poppets, solenoid valves, and plugs can all be
removed from the valve sections. Refer to the associated assembly procedures, above, for
specific torque and handling details. Inspect and repair or replace the assemblies as complete
units, as may be necessary.
④ Valve components are precision items, and care must be taken when handing them to avoid
damage or the introduction of contamination that could adversely affect performance.
6-41
3. LIFT CYLINDER
1) STRUCTURE
9
6
8 3
5
10
4
11
7
13
12
14
15
· I.D×O.D×Stroke : 45×55×1245mm
(1.7×2.2×49~108in)
· Rod O.D : 35mm (1.4 in)
D155HS16
1 Tube assy 6 Wear ring 11 O-ring

2 Rod assy 7 Retaining ring 12 Guide
3 Piston 8 Gland 13 DU bushing
4 Piston seal 9 Dust wiper 14 Spacer
5 Back up ring 10 Rod seal 15 O-ring
6-42
2) DISASSEMBLY
(1) Hold the cylinder tube in a vice, loosen the Guide
cylinder head and remove it.
Remove the spacer from the cylinder tube
and knock out the bushing. Hook a
wrench in the hole in the retainer at the
piston end and turn. Lever up the edge of
the guide, then turn the guide in again and
the guide can be removed. L15C3HS25

Check item Standard size Repair limit Remedy

cylinder rod & bushing (0.003~0.011) (0.020) bushing
piston ring & tube (0.002~0.012) (0.020) piston ring
4) ASSEMBLY
(1) Soak the piston ring in hydraulic oil at a
temperature of 40 to 50。 C, expand the
inside diameter and assemble on the
piston. Install a piston seal.
Bend the edge of the guide and rotate it to
install the guide completely.
L15C3HS26
6-43
4. TILT CYLINDER
1) STRUCTURE
·I.D×O.D×Stroke : 75×86×112mm
(2.9×3.3×4.4in)
·Rod O.D : 35mm(1.3in)
15DHS21
1 Tube assembly 9 DU bushing 17 Washer

2 Rod 10 U-packing 18 Eye
3 Piston 11 Back up ring 19 Bushing
4 Piston seal 12 Dust wiper 20 Hex bolt
5 Wear ring 13 Stop ring 21 Spring washer
6 O-ring 14 O-ring 22 Lock nut
7 Nylon nut 15 Back up ring 23 Grease nipple
8 Gland 16 O-ring
6-44
2) DISASSEMBLY
(1) 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.
When doing this, wind tape round the
threaded part of the rod and be careful not D255HS28
to damage the dust seal and rod seal

inside cylinder head.

Check item Standard size Repair limit Remedy
Clearance between 0.072~0.288 0.5

Replace bushing
cylinder rod & bushing (0.003~0.011) (0.020)
Clearance between rod 0.10~0.35 0.6
Replace bushing
head bushing & pin (0.004~0.014) (0.024)
6-45
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
Group 4 Connector Destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
15DEL01
1 Work lamp 9 Cluster 14 Glow controller

2 Horn assembly 10 Start switch 15 OPSS unit
3 Beacon lamp(opt) 11 Head lamp switch 16 Flasher unit
4 Combination lamp Illumination lamp 17 Hazard lamp switch(opt)
5 Rear work lamp(opt) Turn signal switch 18 Fuse box
6 Flasher lamp 12 Horn button 19 Battery
7 Back buzzer 13 Work lamp switch(opt) 20 Master switch
8 Forward-reverse lever
7-1
GROUP 2 ELECTRICAL CIRCUIT
CAB PART DASHBOARD PART
FRAME / ENGINE PART
20D7EEL02
7-2
MEMORANDUM
7-3
1. POWER CIRCUIT
The negative terminal of the battery is grounded to the machine chassis.
When the start switch is in the OFF position, the current flows from the positive battery terminal.
1) OPERATING FLOW
Battery(+) Start motor[CN-45(B+)] Fusible link[CN-95A(1→2)] Alternator[CN-74(B+)]
I/conn[CN-1(12,13,14) Start switch[CS-2(3)]
Start relay[CR-23(87)]
Fuse box[CN-36] (No.1) Cab[CN-7(1)]
OPSS buzzer[CN-113(2)]
Horn[CN-25(2)]
Brake switch[CD-4]
(No.2) Flasher unit[CR-11(2)]
(No.3) Opss unit[CN-55(12)]
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (Battery(+))
② - GND (Fusible link)
OFF OFF 10 ~ 13V
③ - GND (Fuse No.1, 2, 3)
④ - GND (Start key)
7-4
POWER CIRCUIT
3 4 CS-2 CL-16
CN-36 390 W
1 ST RW
200 RW HORN/BRAKE LAMP 10A 4
120 R
3 2 CL RB
H0 I
210 Gr TURN LAMP 10A
2
2
3 TN R
0,
212 Y OPSS UNIT 5A
1
I
START RELAY 5A 4 BR 4 BK LW
- ACC
4
1 R1
ILL/HEAD LAMP 15A B3 5
4 BR G1
5
TRAVEL 5A - ACC
4 BR 6 B GN
6
IG(STOP SOL/ALT) 5A - ACC
2 R2
R/COMBI RH
7
PREHEATING 5A - ST
8
CLUSTER 5A START KEY
9 10 11 12
WORK/BEACON LAMP
CN-17 10A CL-15
200 RW FOR CABIN 15A 390 W
1 1 ST RW
OPSS SYSTEM 5A
2 2 CL RB
3 CD-4 3 TN R
4 FUSE BOX 200 RW
Pa CN-4 4 BK LW
(FOR CABIN) 390 W
1 5
G1
BRAKE SW 2 6 B GN
3 R/COMBI LH
CN-113 4
1 5
200 RW
2 6
OPSS BUZZER 7
8
CR-11 9
L 1 10
G 210 Gr
B 2 11
E 3
12
FLASHER UNIT
CN-55
IGN 1
CN-1
SEAT S/W 2
1
REV S/W 3
CR-23 2
FWD S/W 4 120 R
86 30 87
TRAVEL CUT 5 3
RELAY2 6
30 4
GND 7 86
5
OPS-LAMP 8 85 87 85
6
BUZZER(-) 9 STARTER RELAY 7
BRAKE S/W 10
8
CN-74
RELAY3 11
212 Y 9 1 IG
BATT(+) 12 U
10 2 L
PARK'G S/W 13
14 11
~
120 120 R 120 R 120 R 3 G
OPSS UNIT SP1
12
SP4
B+
120 R 120 R
13 ALTERNATOR
120 R 120 R
14
15
CN-25 16 110 W
CN-95A 2
380 V 2
1 17 100 R
200 RW 1
2 18
F/LINK
HORN
CN-45
M
M
100 R
380 V
B+
G1 B
START MOTOR
CS-12
CS-11
2
3
5
6
7
8
9
4
5
1
1
3
4
2
38SQ(R)
4-FWD
2-TRH
1-TLH
5-REV
4-HO
8-Hi
6-ILL
7-Lo
OPTION
38SQ(B) 38SQ(B)
>
BATTERY
3-HO
3-C 9-C 12V MASTER SW

5-C 1
GEAR SELECTOR COMBI SWITCH
20D7EEL03
7-5
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-95A]
+
Alternator[CN-74(B )] I/conn[CN-1] Start switch[CS-2(3)]
Start relay[CR-23(87)]
Glow relay[CR-24(30)]
※T
The engine can be started only when the gearshift is in neutral position.
(1) When start key switch is in ON position
Start switch ON [CS-2(4)] Fuse box[No. 5→7] [CN-1(19)] Fuel stop solenoid[CN-87(1)]
Fuse box[No. 5→8] Glow relay[CR-24(85→87)] I/conn[CN-1]
Fusible link[CN-95B] Glow plug[CN-80]
(2) When start key switch is START position

Start switch START[CS-2(2)]
Fuse box[CN-36(4)] Glow controller[CN-62(3)]
Neutral relay[CR-5(4→2)]
Safety relay[CR-23(86→30)] I/conn[CN-1] Starter
2) CHECK POINT
① - GND (Battery B+)

② - GND (Fusible link)
Running ON ③ - GND (Fuse box) 10 ~ 14.5V
④ - GND (Start key)
⑤ - GND (Starter relay)
7-6
STARTING CIRCUIT
3 CS-2
CN-36 170 W
HORN/BRAKE LAMP 10A 4
120 R
3
H0 I
TURN LAMP 10A 180 WR
2
0,
CLUSTER 5A
CR-5 1
I
4 BR
220 Br 220 Br START RELAY 5A - ACC
3 4 4
4
1 R1
ILL/HEAD LAMP 15A B3
3 4 BR
5
320 YB TRAVEL 5A - ACC
2
4 4 BR
6
250 Or IG(STOP SOL/ALT) 5A - ACC
1 2 1 2 R2
7
PREHEATING - ST
RELAY NEUTRAL 260 V 5A
8
CLUSTER 5A START KEY
9 10 11 12
WORK/BEACON LAMP 10A
FOR CABIN 15A
OPSS SYSTEM 5A
FUSE BOX
5 CN-1
1
CR-23 2 CN-95B
86 30 120 R 160 Br
87 3 2
150 Y 170 W
30 4 1
320 YB
86 F/LINK
G1 B 5
85 87 85
6 CN-80
STARTER RELAY
7 170 W
8
CN-62 GLOW PLUG
9
CONTROLLER
GLOW
SENSOR 6
430 PG 10
COIL 5
G1 B 11 CN-87
EARTH 4
220 Y 120 120 R 120 R 150 Y
START 3 12 2
SP1 120 R 120 R SP4 250 Or
LAMP 2 13 1
260 V 120 R 120 R
ON 1 14
STOP SOL
15
CR-24 16
86 30 160 Br
87
120 R 17
30 CN-74
430 PG 18
86 250 Or 250 Or
85
260 V 19 1 IG
85 87 160 160 160 U
20 2 L
GLOW RELAY SP2 160
21
160 SP5 ~
160 160 120 R 3 G
22 B+
23
ALTERNATOR
24
CN-95A
25 110 W
2
2
26 100 R
150 150 Y 150 Y 150 1
27
SP3 150 Y 150 Y SP6 F/LINK
28
CN-45
150 Y
M
M
100 R
B+
START MOTOR
38SQ(R)
OPTION
38SQ(B) 38SQ(B)
BATTERY
12V MASTER SW
1
20D7EEL04
7-7
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 fusible link(CN-95A)
and the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator[CN-74(L)] I/conn[CN-2(18)] Cluster charging warning lamp ON[CN-56(14)]
(2) Charging flow
Alternator[CN-74(B+)] Fusible link[CN-95A] Starter motor[CN-45(B+)]
Battery (+)terminal Charging
2) CHECK POINT
① - GND (Alternator B+)

ON ON ② - GND (Start switch) 10 ~ 14.5V
③ - GND (Cluster)
※ GND : Ground
※ Cautions
1. When using an arc welder, always disconnect the ground lead from the battery to prevent alternator
or battery damage.
2. Attach the welding ground clamp as close to the weld area as possible to prevent welding current
from damaging the bearings of the alternator.
3. Do not disconnect the battery when the engine is running. The voltage surge can damage the
diode and resistors in the electrical system.
4. Do not disconnect an electric wire before the engine is stopped and the switches are OFF.
7-8
CHARGING CIRCUIT
CN-36 CS-2
170 W
HORN/BRAKE LAMP 10A 4
120 R
3
H0 I
TURN LAMP 10A 180 WR
2
0,
CLUSTER 5A
1
I
START RELAY 5A 4 BR
- ACC
2 CN-56
4
1 R1
ILL/HEAD LAMP 15A B3
4 BR 1 GLOW LAMP(-)
5
TRAVEL 5A - ACC
4 BR 2 GLOW LAMP(+)
6
250 Or IG(STOP SOL/ALT) 5A - ACC
2 R2 3 -
7
PREHEATING 5A - ST 4 OPSS LAMP
8
CLUSTER 5A START KEY 5 WATER SEPARATOR
9 10 11 12
WORK/BEACON LAMP 6 BRAKE OIL LEVEL

10A
7 PARKING BRAKE
FOR CABIN 15A
8 ENGINE CHECK
OPSS SYSTEM 5A 9 -
10 TURN SIGNAL RH
11 HEAD LAMP
FUSE BOX
12 TURN SIGNAL LH
448 Lg 13 AIR FILTER
14 CHARGE LAMP
15 -
16 T/M OIL TEMP
CN-1 17 ENG. OIL PS
1
3 18 FUEL EMPTY
19 ILLUMINATION
2 20 EARTH
3 CLUSTER
4
5
6
7
8
9
10
11 CN-87
120 120 R 120 R 150 Y
12 2
SP1 120 R 120 R SP4 250 Or
13 1
120 R 120 R
14
STOP SOL
15
16
17
CN-74
448 Lg 448 Lg 250 Or
18 1 IG
250 Or 250 Or 448 Lg U
19 2 L
20
~
120 R 3 G
21 B+
22
ALTERNATOR
23
24
1
25 CN-95A
110 W
2
26 100 R
1
27
28
F/LINK
CN-45
150 Y
M
M
100 R
B+
START MOTOR
38SQ(R)
OPTION
38SQ(B) 38SQ(B)
BATTERY
12V MASTER SW
20D7EEL05
7-9
GROUP 3 COMPONENT SPECIFICATION
No Part name Qty Specification Remark
1 Battery 1 12V-CMF100
RC : 190min
CCA : 850A
2 Working lamp 1 12V, 55W
3 License lamp 1 12V, 3.4W×12
4 Rear combination lamp 2 12V, 21W(T/S) 12V, 10W(Back)
12V, 5W (Tail)
12V, 21W(Stop)
5 Head lamp 2 12V, 55W
6 Flasher lamp 2 12V, 23/8W
7 Flasher unit 1 85±10C/M, (23W+23W)×2+3W×2
8 Backup alarm 1 12V, 90±5dB, 60±10C/M
9 Horn 1 12V, MAX 3.5A, 105~120dB
10 Fuel level sender 1 Reed switch - Magnet type
Float indicate E 1/2 F
Resistance[Ω] 105 32.5 5
Allowance[Ω] ±5% ±5% - 5%
11 Master switch 180A

12 Combination switch 1 12V, 16A
13 Hazard switch 1 12V, 16A
14 Start switch 1 12V/24V, 15~28A
15 OPSS unit 1 12V/24V, MAX 0.5A (at 12V)
16 Relay (4P) 2 12V, 20A
17 Relay (5P) 2 12V, 20A
7-10
GROUP 4 CONNECTOR DESTINATION
Connector No. of Connector part No.

number Type Destination
pin Female Male
CN-1 AMP 36 I/conn(Dashboard harness-frame harness) 1743059-2 1743062-2
CN-4 KET 12 I/conn(Head guard harness-dashboard harness) MG610346 MG640348
CN-5 KET 4 To support harness-RH S810-004201 -
CN-16 DEUTSCH 4 Heater for cabin - DT04-4P
CN-17 KET 4 Power output S810-004201 -
CN-25 MOLEX 2 Horn 35825-0211 -
CN-55 KET 14 OPSS unit S814-014100 -
CN-56 AMP 20 Cluster 368511-2 -
CN-62 YAZAKI 6 Glow unit 7123-2262 -
CN-65 KET 2 Back buzzer - MG640322
CN-74 KET 2 Alternator MG610043 -
CN-87 SUMITOMO 2 Fuel stop solenoid 6195-0003 -
CN-95A KET 2 Fusible link - S813-130201
CN-95B KET 2 Fusible link - S813-130201
CN-113 KET 2 OPSS buzzer S814-002100 -
CN-122 DEUTSCH 2 Forward solenoid DT06-2S -
CN-123 DEUTSCH 2 Reverse solenoid DT06-2S -
CN-131 PACKARD 2 Cut off solenoid (Tilt, lift) 1201-5792 -
CN-132 PACKARD 2 Cut off solenoid (Lift, down) 1201-5792 -
Switch
CS-2 KET 4 Start switch S810-004201 -
CS-6 DAEDONG 10 Heater switch 250-10PRG -
CS-11 AMP 5 Gear selector 172494-1 -
CS-12 AMP 9 Combination switch S811-009002 -
CS-17 KET 3 Parking switch S810-003201 -
CS-21 DAEDONG 10 Work lamp switch 250-10PRG -
CS-23 SWF 10 Beacon lamp switch 593757 -
CS-41 DAEDONG 10 Harzard switch 250-10PRG -
CS-73 KET 2 Seat switch S810-002201 -
Lamp
CL-3 KET 2 Head lamp S822-014000 S822-114000
CL-7 KET 2 Beacon lamp S822-014000 S822-114000
CL-15 DAEDONG 6 Combination lamp-LH 110-6PR -
CL-16 DAEDONG 6 Combination lamp-RH 110-6PR -
CL-21 KET 2 License lamp S822-014000 S822-114000
CL-23 KET 2 Working lamp S822-014000 S822-114000
Relay
CR-5 KET 4 Neutral relay S810-004201 -
CR-11 KET 3 Flasher unit relay S810-003702 -
7-11
Connector No. of Connector part No.
number Type Destination
pin Female Male
CR-13 KET 4 Head lamp relay S810-004201 -
CR-23 KET 4 Starter relay MG612017-5 -
CR-24 KET 4 Glow relay MG612017-5 -
CR-35 AMP 4 Warning relay S810-004202 -
Relay
CR-50 KET 5 Travel cut relay MG640927 -
CR-51 KET 5 Attach cut relay MG640927 -
Sensor and pressure switch
CD-2 KET 3 Fuel level sensor S810-003201 -
CD-4 DEUTSCH 2 Brake switch - DT04-2P-E005
CD-8 AMP 1 Temp sender (For cluster) S819-010122 -
CD-10 KET 1 Air cleaner switch ST730057-2 -
CD-18 AMP 1 Engine oil pressure sender S819-010122 -
CD-29 AMP 1 T/M temp switch S819-010122 -
CD-30 AMP 2 Temp sender (For glow) 85202-1 -
7-12
GROUP 5 TROUBLESHOOTING

Lamps dimming even at maxi- ·Faulty wiring. ·Check for loose terminal and discon-
mum engine speed. nected wire.
Lamps flicker during engine ·Improper belt tension. ·Adjust belt tension.
operation.
Charge lamp does not light d- ·Charge lamp defective. ·Replace.
uring normal engine operation. ·Faulty wiring. ·Check and repair.
Alternator makes abnormal ·Alternator defective. ·Replace
sounds.
Starting motor fails to run. ·Faulty wiring. ·Check and repair.
·Insufficient battery voltage. ·Recharge battery.
Starting motor pinion repeats ·Insufficient battery voltage. ·Recharge battery.
going in and out.
Excessively low starting motor ·Insufficient battery voltage. ·Recharge battery.
speed. ·Starting motor defective. ·Replace
Starting motor comes to a stop ·Faulty wiring. ·Check and repair.
before engine starts up. ·Insufficient battery voltage. ·Recharge battery.
Heater signal does not beco- ·Faulty wiring. ·Check and repair.
me red. ·Glow plug damaged. ·Replace
Engine oil pressure caution ·Caution lamp defective. ·Replace
lamp does not light when engi- ·Caution lamp switch defective. ·Replace
ne is stopped
(with starting switch left in"ON"
position).
7-13
SECTION 8 MAST
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1

Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7
Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10
SECTION 8 MAST
GROUP 1 STRUCTURE
1. 2 STAGE MAST(V MAST)
16
8 10
9 15
14
13
7
11
12
1
TILT CYLINDER
2
4
LIFT CYLINDER
CARRIAGE 6
5
16
3
15L7MS01
1 Outer mast 7 Chain sheave 13 Clamp

2 Inner mast 8 Chain 14 Back up liner
3 Roller 9 Anchor bolt 15 Shim(0.5, 1.0t)
4 Tilt cylinder pin 10 Roller 16 Shim(0.5, 1.0t)
5 Mast support cap 11 Retaining ring
6 Bushing 12 Chain guard
8-1
2. 3 STAGE MAST(TF MAST)
16
4
10
15
14
11 12
13
TILT CYLINDER
11 1
8
17
5
LIFT CYLINDER
2
3
7
6
FREE LIFT CYLINDER
10
CARRIAGE
15L7MS02
1 Outer mast 7 Bushing 13 Clamp

2 Middle mast 8 Chain sheave 14 Back up liner
3 Inner mast 9 Chain 15 Shim(0.5, 0.1Ton)
4 Roller 10 Anchor bolt 16 Shim(0.5, 0.1Ton)
5 Tilt cylinder pin 11 Retaining ring 17 Sheave bracket
6 Mast support cap 12 Chain guard
8-2
3. CARRIAGE, BACKREST AND FORK
15L7MS03
1 Backrest 3 Load roller 5 Fork assembly

2 Carriage 4 Side roller 6 Extension fork
8-3
1) FORKS
(1) Measure thickness of root of forks and
check that it is more than specified value.
EX : ℓ=900mm(35.4in)
mm(in)
STD Fork assy Applicable model Standard Limit
64FP-12030 15D/18D-7E 35(1.4) 32(1.3)
64FD-11010 20DA-7E 40(1.6) 36(1.4)
B153FK01
(2) Set forks in middle and measure

difference in height at top of forks.
Fork length Height
Model (mm) difference(mm)
15D/18D/ equal or below 1200 3
20DA-7E above 1200 6
Difference in height
at tip of forks
D255FK02
(3) Most force is concentrated at root of fork

and at hook, so use crack detection
method to check cracks.
2. MAST
1) Check for cracks at mast stay, tilt cylinder bracket, guide bar, fork carriage and roller shaft weld.
Check visually or use crack detection method. Repair any abnormality.
2) Set mast vertical, raise forks about 10cm from ground and check front-to-rear clearance and left-to-
right clearance between inner mast and fork carriage, and between outer mast and inner mast.
Use these figures to judge if there is any play at roller or rail.
·Front-to-rear clearance : Within 2.0mm(0.08in)
·Left-to-right clearance : Within 2.5mm (0.10in)
3) Check that there is an oil groove in bushing at mast support.
4) Set mast vertical, raise forks about 10cm from ground, and push center of lift chain with finger to
check for difference in tension.
If there is any difference in tension, adjust chain stopper bolt.
5) Check visually for abnormalities at thread of chain anchor bolt, and at contact surface between
chain wheel and chain.
Rotate chain wheel by hand and check for any play of bearing.
8-4
2. TROUBLESHOOTING
1) MAST
Forks fail to lower. ·Deformed mast or carriage. ·Disassemble, repair or replace.
Fork fails to elevate ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump
and cylinders in section 6, hydraulic
system.
·Deformed mast assembly. ·Disassemble mast and replace
damaged parts or replace complete
mast assembly.
Slow lifting speed and ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump
insufficient handling capacity. and cylinders in section 6, hydraulic
system.
·Deformed mast assembly. ·Disassemble mast and replace
damaged parts or replace complete
mast assembly.
Mast fails to lift smoothly. ·Deformed masts or carriage. ·Disassembly, repair or replace.
·Faulty hydraulic equipment. ·See Troubleshooting Hydraulic
Cylinders, pump and control valve in
section 6, hydraulic system.
·Damaged load and side rollers. ·Replace.
·Unequal chain tension between ·Adjust chains.
LH & RH sides.
·LH & RH mast inclination angles ·Adjust tilt cylinder rods.
are unequal. (Mast assembly is
twisted when tilted)
Abnormal noise is produced ·Broken load roller bearings. ·Replace.
when mast is lifted and lower- ·Broken side roller bearings. ·Replace.
ed. ·Deformed masts. ·Disassemble, repair or replace.
·Bent lift cylinder rod. ·Replace.
·Deformed carriage. ·Replace.
·Broken sheave bearing. ·Replace.
Abnormal noise is produced ·Insufficient lubrication of anchor ·Lubricate or replace.
during tilting operation. pin, or worn bushing and pin.
·Bent tilt cylinder rod. ·Replace.
8-5
2) FORKS

Abrasion Long-time operations causes the fork to If the measured value is below the wear
wear and reduces the thickness of the limit, replace fork.
fork.
Inspection for thickness is needed.
·Wear limit : Must be 90% of fork
thickness
Distortion Forks are bent out of shape by a If the measured value exceeds the
number of reasons such as allowance, replace fork.
overloading, glancing blows against
walls and objects, and picking up load
unevenly.
·Difference in fork tip height
Height
Fork length (mm) difference(mm)
equal or below 1200 3
above 1200 6
Fatigue Fatigue failure may result from the Repair fork by expert.
fatigue crack even though the stress to In case of excessive distortion, replace
fork is below the static strength of the fork.
fork. Therefore, a daily inspection
should be done.
·Crack on the fork heel.
·Crack on the fork weldments.
8-6
GROUP 3 ADJUSTMENT
1. MAST LOAD ROLLER(V MAST)
1) INNER/OUTER MAST ROLLER CLEAR-
ANCE ADJUSTMENT
(1) Measure the clearance with the mast
overlap at near 480mm.
(2) Shift the inner mast to one side to bring
the roller into contact with the outer mast,
and adjust the clearance between the
roller side face and mast at the closest
position on the opposite side to the 15L7MS04
following value by inserting the inner/outer

mast roller shim.
·Standard clearance A, B = 0.3 ~ 0.6mm
·Shim thickness 0.5, 1.0mm
(3) Distribute the shim thickness equally to
the left and right roller. Refer to Mast load
roller and back up liner, removal and
Installation.
(4) After the adjustment, check that the inner
mast moves smoothly in the outer mast.
15L7MS05
8-7
2. MAST LOAD ROLLER(TF MAST)
1) INNER AND MIDDLE MAST ROLLER
CLEARANCE ADJUSTMENT
the roller into contact with the outer mast
and the middle mast, and adjust the
clearance between the roller side face and
mast at the closest position on the 15L7MS06
opposite side to the following value by

inserting the inner and middle mast roller
shim, respectively.
·Standard clearance A = 0.3~0.6mm
the left and right roller. Refer to Mast load
roller and back up liner, removal and
Installation.
(4) After the adjustment, check that the inner
mast moves smoothly in the middle mast,
and the middle mast moves smoothly in
the outer mast.
2) OUTER AND MIDDLE MAST UPPER

ROLLER CLEARANCE ADJUSTMENT.
the roller into contact with the middle mast
and the inner mast, and adjust the
clearance between the roller side face and
mast at the closest position on the 15L7MS07
opposite side to the following value by

inserting the outer and middle mast roller
shim, respectively.
·Standard clearance B = 0.3~0.6mm
(3) Distribute the shim thickness equally to the left and right roller. Refer to Mast load roller and back
up liner, removal and lnstallation.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast, and the
middle mast moves smoothly in the outer mast.
8-8
3) CARRIAGE LOAD ROLLER
(1) Measure the clearance when the center of
the carriage upper roller is 100mm from
the top of the inner mast.
(2) Measure the clearance at upper, lower
rollers after loosen the adjust screws from
the side rollers. Shift the carriage to one
side to bring the roller into contact with the
inner mast, and measure the clearance
between the roller side face and mast at 15L7MS08
the closest position on the opposite side to

the following value by inserting the
carriage roller shim.
·Standard clearance C = 0.3~0.6mm
the left and right roller. Refer to Carriage
assembly.
(4) After the adjustment, the carriage should
move smoothly along the overall mast
length.
4) MAST BACK UP LINER

(1) Measure the clearance with the inner
mast at the bottom position.
(2) With the inner mast in contact with the
outer mast roller, adjust the clearance
between the mast back up liner and inner
mast to the following value by inserting the
back up liner shim.
·Standard clearance E = 0.2 ~ 0.6mm 15L7MS09

(3) After the adjustment, the mast should
move smoothly.
8-9
GROUP 4 REMOVAL AND INSTALLATION
1. FORKS
1) Lower the fork carriage until the forks are Pin
approximately 25mm(1inch) from the floor.
Knob
2) Turn the knob up and slide forks, one by
Spring
one, toward the center of the carriage
where a notch has been cut in the bottom
plate for easy fork removal.
3) Remove the fork one by one. On larger forks
it may be necessary to use a block of wood.
4) Reverse the above procedure to install load
forks. 15L7MS10
2. BACKREST
1) Remove bolts securing backrest to fork
carriage. Lift backrest straight up and
remove from carriage.
2) Position backrest on carriage and lower in
place. Install and tighten bolts.
15L7MS11
3. CARRIAGE ASSEMBLY
1) CARRIAGE
(1) With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is
done to create slack in the load chains when the carriage is lowered. Lower the carriage all the
way down to the floor. Make sure the carriage is level, this will prevent any binding when the mast
is raised.
(2) While supporting lift chains, remove the split pin and slide out chain anchor pins from the chain
anchors of stationary upright.
(3) Pull the chains out of the sheaves and drape them over the front of the carriage.
(4) Slowly raise elevating upright until mast clears top of fork carriage. Move carriage to work area
and lower mast.
Make sure carriage remains on floor and does not bind while mast is being raised.
(5) Inspect all parts for wear or damage. Replace all worn or damaged pars.
(6) Reverse the above steps to reinstall.
Replace the split pin of chain anchor with new one.
8-10
2) SIDE ROLLER
(1) Remove carriage as outlined in the carriage
assembly and removal paragraph.
(2) Loosen and remove nuts, adjust screws
and side rollers from carriage side pate.
(3) Thoroughly clean, inspect and replace all
worn or damaged parts.
(4) Reverse the above procedure to assembly.
※ Adjustment
· Once carriage is properly installed,
loosen nuts and adjust screws, (if not 15L7MS12
already done) allowing carriage to be

centered in the inner mast.
· Adjust side roller by tightening screw until
side roller just makes contact with mast.
Back off approximately 1/10 turn on
screw and tighten nut to lock screw in
place.
· Run carriage up and down for the inner
mast to be sure the carriage has free
movement and does not stick. Also,
make sure chains are properly adjusted.
Refer to chain adjustment paragraph.
Make adjustment when necessary and
recheck operation of carriage.
3) CARRIAGE LOAD ROLLER

(1) Remove carriage as outlined in the
carriage assembly removal paragraph.
(2) Loosen and remove flat head bolts and
plain washers from top load roller bracket.
(3) Using a pryer, remove load rollers from
load roller bracket.
(4) Reverse the above procedure to assemble.
Refer to MAST ROLLER ADJUSTMENT
paragraph.
15L7MS13
8-11
4) MAST LOAD ROLLER AND BACK UP
LINER
(1) 2 stage mast(V mast)
① Remove the carriage assembly and
move them to one side.
② Loosen and remove hexagon bolts and
washers securing lift cylinders to inner Inner
mast. mast
Stud
③ Loosen and remove hexagon bolts and bolt
nuts securing lift cylinders to inner mast.
④ Attach chains or sling to the inner mast
section at top crossmember. Using an
overhead hoist, slowly raise the inner
mast high enough to clear lift cylinder.
⑤ After lowering the lift cylinder rods, and
disconnecting lift cylinder hose, tilt the lift Clamp
cylinders LH and RH and them with
ropes to the outer mast.
Lift cylinder
⑥ Using the overhead hoist, lower inner
mast until top and bottom rollers and Outer
back up liners are exposed. mast
⑦ Using a pryer, remove load rollers from
load roller bracket. Remove back up
liners and shims.
⑧ Thoroughly clean, inspect and replace all
⑨ Reverse the above procedure to Bolt
assemble. Refer to MAST LOAD
ROLLER ADJUSTMENT paragraph.
15L7MS14
8-12
(2) 3 stage mast(TF mast)
① Remove the carriage assembly and
move it to one side.
② Loosen and remove hexagon bolt
securing bottom cylinder from outer mast.
③ Loosen and remove hexagon bolt and
special washers securing lift cylinders to
middle mast. Remove the spring pin.
④ Attach chains or sling to the inner and
middle mast section at top crossmember.
Using an overhead hoist, slowly raise the
uprights high enough to clear lift cylinder. Inner
⑤ After lowering the lift cylinder rods, and mast
disconnecting lift cylinder hose, tilt the lift
cylinders LH and RH and tie them with
ropes to the outer mast. Stud
⑥ Using the overhead hoist raise inner and bolt
middle masts. Place 4 inch block of
wood under the free lift cylinder bracket of
the inner mast then lower mast sections
(this will create slack in the chains).
⑦ Remove retaining rings securing chain
sheaves to sheave support brackets.
While support chains, remove chain Clamp
sheaves and let chains hang free. The
upper outer and lower middle mast rollers
and back up liners are now exposed.
⑧ Using a player, remove load rollers from Outer
load bracket. Remove back up liners and mast
shims.
⑨ Attach chains or sling to the middle mast
section at top crossmember. Using an
overhead hoist, slowly raise the middle
mast until top and bottom rollers are
exposed. Bolt
⑩ Using a pryer, remove load rollers from
load roller bracket.
⑪ Thoroughly clean, inspect and replace all
⑫ Reverse the above procedure to
assemble. Refer to MAST LOAD
ROLLER ADJUSTMENT paragraph.
15L7MS15
8-13
5) ELEVATING MAST
(1) Inner mast (V mast)
① After completing all necessary steps for load rollers and back up liner removal use an overhead
hoist and sling or chain around upper crossmember of the inner mast section.
② Lift inner mast upright straight up and out of outer mast section.
③ Replace and reverse above procedure to install. Make all necessary measurements and
adjustments.
(2) Inner and middle mast(TF mast)
① After completing all necessary steps for load rollers and back up liner removal. Remove rear
chains and sheave support if not already done.
② Disconnect free lift cylinder hose. Drain hose into a suitable pan or container and cap hose.
③ While supporting free lift cylinder assembly, remove bolts and washers securing cylinder to mast
crossmember.
④ Place a sling around free lift cylinder and attach to an overhead hoist. Slowly raise and move
cylinder to one side.
⑤ Attach chains or sling to the inner mast section at top crossmember. Using an overhead hoist
slowly raise the upright straight up and out of middle mast section.
⑥ Attach chains or sling to the middle mast section at top crossmember. Using an overhead hoist
slowly raise the upright straight up and out of outer mast section.
⑦ Replace upright and reverse above procedure to install. Make all necessary measurements and
adjustments.
8-14
6) CHAIN
(1) Chain sheave(V mast)
① Place a sling around carriage and attach
to an overhead hoist. Lift carriage high
enough so that the tension on the chain
over sheaves is relieved after the carriage
is blocked. Position wooden blocks under
the carriage and lower it.
② Remove the split pin securing the chain
anchor pins and discard.
While supporting the chains, remove the
chain anchor pins and drape the chains
over the carriage.
③ Remove retaining ring securing sheaves
to sheave support. Remove sheaves
with bearings.
④ Remove bearing retaining ring from
sheave and press bearings from
sheaves.
⑤ Thoroughly clean, inspect and replace all
⑥ Reverse the above to assemble and
install. Use new split pins in chain anchor
pins. 15L7MS16
(2) Rear chain sheave(TF mast)

① Raise and securely block carriage and Chain
Anchor Middle mast
inner mast section. bolt
② Remove the split pin securing the chain Sheave
anchor pins and discard. While
supporting the chains, remove the chain
anchor pins from outer mast section.
③ Remove chains.
④ Remove retaining ring securing chain
sheaves to sheave support. Pry off
sheaves with bearings.
⑤ Remove bearing retaining ring from
sheave and press bearings from
sheaves.
⑥ Thoroughly clean, inspect and replace all
Inner mast
⑦ Reverse the above procedure to
assemble and install. Use new split pins
Anchor
in chain anchor pins. bolt FREE LIFT CYLINDER
CARRIAGE
15L7MS17
8-15
(3) 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. Move assembly to work area.
③ Remove retaining ring securing chain wheel bearing to chain wheel bearing support.
④ Remove bearing retaining ring from chain wheel bearing and press bearings from chain wheel
bearings.
⑤ Thoroughly clean, inspect and replace all worn or damaged parts.
⑥ Reverse the above procedure to install.
(4) Rear chain(TF mast)
① Remove the carriage assembly and move to one side. Refer to carriage removal and installation.
② Raise and securely block truck approximately 6 inches from the floor.
③ Using a sling or chain around inner mast section attached to an overhead hoist, slowly raise inner
mast until there is enough slack in the chains to remove them. Block inner mast section.
④ Remove split pins and chain anchor pins securing chains to chain anchor(part of inner mast).
⑤ While supporting the chains, remove split and chain anchor pins securing chains to chain
anchors attached to outer mast section.
⑥ Remove chains.
⑦ Reverse the above to assemble and install. Use new split pins in chain anchor pins. Refer to this
section for Load chain lubrication and adjustment.
(5) Carriage chain
① Place a sling around carriage front plate and attach to an overhead hoist. Lift and secure
carriage high enough so that split and chain anchor pins on carriage can be easily be removed.
Remove chain anchor pins from carriage and drape chains out over carriage.
② Place a wooden block under the carriage and lower the carriage on the block.
③ While supporting the chains, remove split pins and chain anchor pins from chain anchors.
④ Remove chains and wash them with solvent. Refer to this section for Load chain inspection and
maintenance.
⑤ Reverse the above procedure to assemble and install. Use new split pins in chain anchor pins.
Refer to this section for Load chain lubrication and adjustment.
(6) Load chain inspection and maintenance
After every 200 hours of truck operation, lift chains should be inspected and lubricated inspect for
the following chain conditions :
① Wear
As the chain flexes on and off the chain wheel bearings, the joints very gradually wear. The
stretch a chain develops in service is due to material being worn off pin outer diameter and pitch
hole inner diameter on the inside plate.
Chain wear can be measured using a wear scale or steel tape. When chains have elongated
2%, they should be discarded. When checking chain wear, be sure to measure a segment of
chain that operates over a sheave. Do not repair chains by cutting our the worn section and
splicing in a new piece. If part of the chain is worn, replace all the chains on the truck.
8-16
② Rust and corrosion
Chains used on lift trucks are highly stressed precision components. It is very important that the
“as-manufactured” ultimate strength and fatigue strength be maintained throughout the chain
service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or
roller chain because corrosion causes side plate cracking.
③ Cracked plate
The most common cause of plate cracking is fatigue failure. Fatigue is a phenomenon that
affects most metals and many plastics. After many repeated heavy loads, the plates may crack
and the chains will eventually break. Fatigue cracks are almost always found through the pitch
holes perpendicular to the pitch line. Contrast this failure mode to the random failures caused by
stress-corrosion cracking. If cracks are present, replace all the chain on the truck. Noise in the
chain indicates that the plate is on the verge of cracking and will be failed before long.
④ Tight joints
All joints in lift chain should flex freely. Tight joints resist flexure, increase internal friction, thus
increasing chain tension required to lift a given load. Increased tension accelerates wear and
fatigue problems.
Tight joints in lift chains can be caused by :
·Bent pins or plates.
·Rusty joints.
·Peened plate edges.
Oil rusty chains and replace chains with bent or peened components.
⑤ Protruding or turned pins
Heavily loaded chains operating with lube generate tremendous friction between pins and plates.
In extreme cases, the frictional torque in the joint can actually turn pins in the press-fit outside
plates. If chain is allowed to operate in this condition, the pins slowly work out of the chain
causing chain failure. Turned pins can be quickly spotted because the flats on the V heads are
no longer in line. Chains with turned or protruding pins should be replaced immediately. Do not
attempt to repair the chain by driving pins back into the chain.
⑥ Chain side wear
A wear pattern on pin heads and outside plates indicates misalignment. This condition damages
chain and sheaves as well as increasing internal friction in the chain system.
⑦ Chain anchors and chain wheel bearings
An inspection of the chain system includes a close examination of chain anchors and chain
wheel bearings. Check chain anchors for wear, breakage and misalignment.
Anchors with worn or broken fingers should be replaced. Anchors should be adjusted to
eliminate twisting or other misalignment in the chain. When chain is misaligned, load is not
distributed uniformly between the plates. Prolonged operation will result in premature fatigue
failure. Chain wheel bearings with badly worn flanges and outside diameter should be replaced.
Heavy flange wear indicates chain misalignment.
8-17
⑧ Chain wear scale
The chain can be checked for wear or stretching with the use of a chain wear scale. Stretching of
a chain is due to the elongation of the pitch holes and wearing of the pin O.D. The greatest
amount of stretching occurs at the areas of the chain that flex over the sheaves most frequently.
Check the chain at this point with a scale. The wear scale has instructions printed on the sides
for use in determining chain stretch and are as follows :
·Determine pitch length of chain using 6 inch scale on one side of wear scale.
·If pitch is 1/2(12.7mm), 3/4(19.05mm), 1(25.4mm), 1-1/2(38.1mm), 2(50.8mm), use side A of scale.
·If pitch is 5/8(15.875mm), 1-1/4(31.75mm) or 2(50.8mm), use side B.
·Align point A or B to center of a pin and note position of the opposite A or B point.
·If other point also lines up with a pin, the chain is worn and should be replaced.
If any of the above conditions exists(cracked plates, turned pins, stretching etc), the chains should
be replaced in pairs as a complete assembly. Order chains by part number to insure the correct
chain length, pitch and material specifications.
(7) Load chain lubrication and adjustment
① Lubrication
The most important consideration in field maintenance of lift chains is lubrication. Hard working,
heavily loaded chains cannot be expected to give satisfactory wear life without scheduled
periodic re-lubrication. Like all bearing surfaces, the precision manufactured, hardened steel,
joint-wearing surfaces require a film of oil between mating parts to prevent rapid wear. Oil must
penetrate the chain joint to prevent wear. Applying oil to external surfaces will prevent rust, but oil
must flow into the live bearing surfaces for maximum wear life. Frequency of re-lube will vary with
operating conditions and environment, the best estimate of lube period is 200 hours. Trucks
parked outdoors or trucks in extremely severe service, may require more frequent re-lube to
maintain an oil film on all chain surface.
·Wipe off the old oil with a clean cloth and blow out the remaining dirt with compressed air.
Wear eye protection.
·With a clean brush, apply EP-140 extreme pressure lubricant or heavy motor oil(40W).
② Replacement
Replace chains as a pair. It will be virtually impossible to maintain uniform loading between the
strands if a new chain is put into service opposite an old chain. The joints in the old chain will be
greater than that on the new chain, greatly complicating the problem of maintaining equal chain
tension. The new chain will wear more slowly causing it to bear the major portion of the load
resulting in premature wear and fatigue failure. Don’t steam clean or decrease new chains.
The manufacturer’s grease is effective in reducing wear and corrosion. If the original factory lube
is dried out or wiped off, soak the new chain in heavy engine oil for at 1/2 hour prior to installing
on truck. After the old chains have been stripped from the mast, very carefully inspect chain
anchors and chain wheel bearing. Broken, cracked or worn anchor must be replaced using the
new anchor pin and split pin. Do not paint newly replaced chain after it has been installed.
8-18
③ Adjustment
Chain adjustments are important for the following reasons :
·Equal loading of chain.
·Proper sequencing of mast.
·Prevent over-stretching of chains.
·Prevent chains from jumping off sheaves if they are too loose.
④ Adjustment procedure
·With mast in its fully collapsed and vertical position, lower the fork to the floor.
·Adjust the chain length by loosening or tightening nut on the chain anchor.
After making adjustment on the mast, be sure to tighten the nut.
8-19

Service Manual: Forklift Diesel

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

Service Manual: Forklift Diesel

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual: Forklift Diesel

Uploaded by

Copyright:

Available Formats

SERVICE MANUAL

HYUNDAI FORKLIFT TRUCK

Kiều Văn Trung

Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Careless performing of the easy work may cause injuries.

· Wear well-fitting helmet, safety shoes and

· Flames should never be used instead of

· Exhaust gas is dangerous. Provide adequate

· When working on top of the machine, be

· Hand a caution sign in the operator's compartment

When inspecting the engine is running parts, or

· When working with others, choose a group

· Unless you have special instructions to the

· Always remember that the hydraulic oil circuit

1 Mast 7 Forks 13 Counterweight

Model Unit 15D-7E 18D-7E 20DA-7E

Item Unit Specification

Model - KUBOTA V2203-M-E3B

(2) MAIN PUMP

Item Unit Specification

(3) MAIN CONTROL VALVE

Item Unit Specification

Model KAPEC 280 27 613/G7

Brakes Travel Front wheel, wet disc brake

Steering Type Hydro static, power steering

No Item Size kgf·m lbf·ft

1 Engine mounting bolt, nut M12×1.25 12.3±2.4 89±17.4

(2) Fine thread

Thread size(PF) Width across flat(mm) kgf·m lbf·ft

3) PIPE AND HOSE(ORFS TYPE)

Thread size(UNF) Width across flat(mm) kgf·m lbf·ft

Thread size(PF) Width across flat(mm) kgf·m lbf·ft

Axle Gear oil 5 SAE 80W-90/API GL-5(DRY), MOBILFLUID 424(WET)

ASTM D975 No.1

Fitting NLGI No.1

No Description Period of replacement

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

1 Mast 9 Hydraulic pump 17 Counterweight

Remove and install following units as explained in the flow chart.

(2) Backrest(If necessary)

③ Pull the chains out of the sheaves and

④ Slowly raise inner mast upright until mast

(5) Lift cylinder

(7) Tilt cylinder pin

(3) Parking brake cable

(5) Inching linkage

(6) Transmission cooling piping

(8) Mounting bolts holding to flywheel

② Using a moving truck slowly pull out

(1) Overhead guard

(5) Mounting bolt

(5) Air cleaner hose

(4) Mounting bolt

Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

1 Engine 3 Drive shaft 5 Brake

Model KAPEC 280 27 613/G7

3) TORQUE CONVERTER HYDRAULIC CIRCUIT

Torque converter assy