CONTENTS

SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Group 3 Periodic Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-25

SECTION 4 BRAKE SYSTEM

Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10

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 6 HYDRAULIC SYSTEM

Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-26

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Group 4 Connector Destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
SECTION 8 MAST
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4
Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7
Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10
 FOREWORD

1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.

SECTION 1 GENERAL
This section gives the general information of the machine and explains the safety hints for
maintenance.
SECTION 2 REMOVAL & INSTALLATION OF UNIT
This section explains the procedures and techniques of removal and installation of each component.
SECTION 3 POWER TRAIN SYSTEM
This section explains the structure of the transmission as well as control valve and drive axle.
SECTION 4 BRAKE SYSTEM
This section explains the brake piping, each component and operation.
SECTION 5 STEERING SYSTEM
This section explains the structure of the steering unit, priority valve, trail axle as well as steering
circuit and operation.
SECTION 6 HYDRAULIC SYSTEM
This section explains the structure of the gear pump, main control valve as well as work equipment
circuit, each component and operation.
SECTION 7 ELECTRICAL SYSTEM
This section explains the electrical circuit and each component.
It serves not only to give an understanding electrical system, but also serves as reference material for
troubleshooting.
SECTION 8 MAST
This section explains the structure of mast, carriage, backrest and forks.

The specifications contained in this service manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.

0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(ΗΘΙÄ)
Any additions, amendments or other changes will When a manual is revised, an edition mark is
be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number(2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
the work because it is under
10 - 4 - 1
Added pages internal pressure.
10 - 4 - 2
Special technical precautions or
10 - 5
other precautions for preserving
ö Caution
standards are necessary when
performing the work.

0-2
 3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.

Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50in the vertical column at the left side, take this as ͽ, then draw a
horizontal line from ͽ.
(2) Locate the number 5in the row across the top, take this as ;, then draw a perpendicular line
down from ;.
(3) Take the point where the two lines cross as Ϳ. This point Ϳ gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.

2. Convert 550mm into inches.

(1) The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55mm.
(2) Carry out the same procedure as above to convert 55mm to 2.165 inches.
(3) The original value(550mm) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550mm = 21.65 inches.

Millimeters to inches ; 1mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
Ϳ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ͽ
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

0-3
Millimeters to inches 1mm = 0.03937in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1kg = 2.2046lb

0 1 2 3 4 5 6 7 8 9

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

0-4
Liter to U.S. Gallon 1˶ = 0.2642 U.S.Gal

0 1 2 3 4 5 6 7 8 9

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153

Liter to U.K. Gallon 1˶ = 0.21997 U.K.Gal

0 1 2 3 4 5 6 7 8 9

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

0-5
kgfÂm to lbfÂft 1kgfÂm = 7.233lbfÂft

0 1 2 3 4 5 6 7 8 9

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

0-6
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2

0 1 2 3 4 5 6 7 8 9

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice
verse is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table
of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

ÁC ÁF ÁC ÁF ÁC ÁF ÁC ÁF

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0

0-8
 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
Â 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
Â 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 40ÁC .
 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

20
19
18
17
1
16

15

14
2
3 13
4
21

7
12

8
11

10
9

15L7MOM57

1 Steering wheel 8 Forks 15 LPG tank

2 Mast 9 Tilt cylinder 16 Clamp
3 Lift chain 10 Front wheel 17 Overhead guard
4 Lift cylinder 11 Bonnet 18 Rear combination lamp
5 Cluster 12 Rear wheel 19 Turn signal lamp
6 Backrest 13 Counterweight 20 Head lamp
7 Carriage 14 Seat 21 Sub bonnet

1-5
 2. SPECIFICATIONS

C' C

D
M'

A
E
I

M
H
B

W
T
J

K L
G F
25L7SP01

Model Unit 15L(G)-7M 18L(G)-7M 20L(G)-7M

Capacity kg(lb) 1500(3000) 1800(3500) 2000(4000)

Load center R mm(in) 500(24") ← ←
Weight(Unloaded) kg(lb) 2788(6146) 2962(6530) 3109(6854)
Lifting height A mm(ft·in) 3325(10' 11") ← 3330(10' 11")
Free lift B mm(ft·in) 145(0' 6") ← 150(0' 6")
Lifting speed(Unload/Load) mm/sec 680/650 ← ←
Fork
Lowering speed(Unload/Load) mm/sec 450/500 ← ←
900×100×35 900×100×40
L×W×T L,W,T mm(inch) ←
(35.4×3.9×1.4) (35.4×3.9×1.4)
Tilt angle (Forward/Backward) C/C' degree 6/10 ← ←
Mast Max height D mm(ft·in) 4332(14' 3") ← ←
Min height E mm(ft·in) 2155(7' 1") ← ←
Travel speed(Unload) km/h 20.1 ← ←
Body Gradeability(Load) % 39.7 35.4 33.0
Min turning radius(Outside) F mm 1730(5' 8") 1746(5' 9") 1760(5' 9")
Hydraulic oil tank ℓ(usgal) 33(8.7) ← ←
ETC
Fuel tank(Gasoline) ℓ(usgal) 44(11.6) ← ←
Overall length G mm(ft·in) 2233(7' 4") 2263(7' 5") 2308(7' 7")
Overall width H mm(ft·in) 1070(3' 6") ← ←
Overhead guard height I mm(ft·in) 2110(6' 11") ← ←
Ground clearance(Load) J mm(ft·in) 120(0' 5") ← ←
Wheel base K mm(ft·in) 1410(4' 8") ← ←
Wheel tread front/rear M, M' mm(ft·in) 890/910(2' 11"/3' 0") ← ←

1-6
3. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE

Item Unit Specification

Model  HYUNDAI, L4KB [Theta]

Type  4-cycle, vertical
Cooling Method  Water cooled
Number of cylinders and arrangement  4 cylinders, In line
Firing order  1-3-4-2
Cylinder bore X stroke mm(in) 88Ý97(3.46Ý3.82)
Piston displacement cc(cu in) 2359(143.95)
Compression ratio  10.5
Rated gross horse power ps/rpm 50/2450
Maximum gross torque at rpm kgfÂm/rpm 16.3/1600
Engine oil quantity ˶(U.S.gal) 5.7(1.5)
Dry weight kg(lb) 160(352)
High idling speed rpm 2700
Low idling speed rpm 800
Rated fuel consumption g/ps.hr -
Starting motor V-kW 12 - 1.2
Alternator V-A 12 - 75
Battery V-AH 12 - 60
Fan belt deflection mm(in) 10~15(0.4~0.6)

2) MAIN PUMP

Item Unit Specification

Type  Gear
Capacity cc/rev 26
Maximum operating pressure bar 250
Rated speed (Max/Min) rpm 2700/500

3) MAIN CONTROL VALVE

Item Unit Specification

Type  Sectional
Operating method  Mechanical
Relief valve pressure(Main/Aux) bar 190/150
Flow capacity lpm 80

1-7
 4) STEERING UNIT

Item Unit Specification

Type  Load sensing/Non load reaction/Dynamic signal

Capacity cc/rev 120
Max. input pressure Mpa 22.7
Back pressure Mpa 2
Input torque N.m 1.5Ü0.2

5) POWER TRAIN DEVICES

Item Specification

Model KAPEC 280DB

Torque converter Type 3 Element, 1 stage, 2 phase
Stall ratio 2.9 : 1
Type Power shift
Gear shift(FR/RR) 1/1
Transmission Adjustment Electrical single lever type, kick down system
FR 1:1
Gear ratio
RR 1:1
Type Front-wheel drive type, fixed location
Axle Gear ratio 14.2 : 1
Gear Ring & pinion gear type
Q'ty(FR/RR) 2/2
Wheels Front 6.50-10-12PR
Rear 5.00-8-10PR
Travel Front wheel, wet disk brake
Brakes
Parking Ratchet, wet disk brake
Type Hydro static, power steering
Steering
Steering angle 81äto both right and left angle, respectively

1-8
4. TIGHTENING TORQUE OF MAJOR COMPONENTS

NO ITEMS SIZE kgfÂm lbfÂft

1 Engine mounting bolt, nut M12Ý1.25 12.5Ü2.5 90Ü18

2 Engine Radiator mounting bolt, nut M 8Ý1.25 2.5Ü0.5 18.1Ü3.6
3 Torque converter mounting bolt M10Ý1.25 6.9Ü1.4 50Ü10
4 Hydraulic MCV mounting bolt, nut M10Ý1.5 4.0Ü0.5 29Ü3.6
5 system Steering unit mounting bolt M10Ý1.5 4.0Ü0.5 29Ü3.6
6 Transmission mounting bolt, nut M16Ý2.0 7.5 54
7 Drive axle mounting bolt, nut M20Ý1.5 65Ü3 470Ü21.6
Power
8 train Steering axle mounting bolt, nut M20Ý2.5 58Ü8.5 420Ü61
system
9 Front wheel mounting nut M14Ý1.5 17.5Ü1.5 127Ü10.8
10 Rear wheel mounting nut M12Ý1.5 10Ü1 72Ü7.2
11 Counterweight mounting bolt M30Ý3.5 60Ü5 434Ü36
12 Others Operator's seat mounting nut M 8Ý1.25 2.5Ü0.5 18.1Ü3.6
13 Head guard mounting bolt M12Ý1.75 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
kgfÂm lbfÂft kgfÂm lbfÂft
M 6Ý1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8Ý1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10Ý1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12Ý1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14Ý2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16Ý2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18Ý2.0 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20Ý2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22Ý2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24Ý3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30Ý3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36Ý4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242

(2) Fine thread

8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 8Ý1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10Ý1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12Ý1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14Ý1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16Ý1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18Ý1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20Ý1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22Ý1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24Ý2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30Ý2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36Ý3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562

1-10
2) PIPE AND HOSE(FLARE TYPE)

Thread size(PF) Width across flat mm

kgfÂm lbfÂft

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

kgfÂm lbfÂft

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

kgfÂm lbfÂft

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.

Ambient temperature 。
C (。
F)
Service Kind of
point fluid Capacityℓ(U.S.gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)

Engine oil 5.7

pan Engine oil (1.5) SAE 10W-30(API SL class or better)

Torque
ATF 8.5
converter ATF DEXRON III
Engine oil (2.2)
transmission

5.6
Axle Gear oil (1.48) Mobil Fluid 424

ISO VG32
Hydraulic Hydraulic STD : 33(8.7)
tank oil ISO VG46
OPT : 40(10.6)
ISO VG68

LPG 15 LPG
Fuel tank
Gasoline 38.7(10.2) GASOLINE

NLGI No.1
Fitting Grease -
(Grease nipple) NLGI No.2

Brake
0.5
reservoir Brake oil Azolla ZS10(Hydraulic oil ISO VG10)
(0.13)
tank

Radiator Antifreeze:Water 10 Ethylene glycol base permanent type

50:50 (2.65)

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.

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).
ö 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

25 24 23 22

21
3
20
4
5
19

6 18

7 8 26 9 10 11 12 13 14 15 16 17

15L7MOM23

1 Mast 10 Transmission 19 Radiator

2 Lift cylinder 11 Torque converter 20 Muffler
3 Steering unit 12 Engine 21 LPG tank
4 Tilt cylinder 13 Air cleaner 22 Overhead guard
5 Main control valve 14 Exhaust pipe 23 Seat
6 Fork 15 Steering axle 24 Control lever
7 Front wheel 16 Steering cylinder 25 Steering wheel
8 Drive axle 17 Rear wheel 26 Drive shaft
9 Hydraulic pump 18 Tail pipe

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
Η Lower the fork carriage until the forks are Backrest
approximately 25mm(1in) from the floor.
Θ Turn knob up and slide one fork at a time Pin
toward the center of the carriage where a Knob
notch has been cut in the bottom plate for Spring
easy removal.
Carriage
Ι Remove only one fork at a time.
ö On larger forks it may be necessary to Fork
Center notch
use a block of wood.
15L7MRE02

(2) Backrest(If necessary)

Backrest
Η Remove bolts securing backrest to fork
carriage. Lift backrest straight up and
remove it from carriage.

Bolt
Carriage

15L7MRE03

(3) Carriage
Η With the mast vertical, raise the carriage Crane
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 Block
the mast is raised. 15L7MRE04

2-2
Θ While supporting lift chains, remove the
nuts and split pin from the chain anchors Lift chain
of stationary upright.
Outer mast

Nut
Split pin
20D7RE05

Ι Pull the chains out of the sheaves and

drape them over the front of the carriage.

15L7RE06

Κ 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.
ö Inspect all parts for wear or damage.
Replace all worn or damaged parts.

15L7RE07

2-3
(4) Piping
Η Remove the return hoses and clamps
attached to the cylinder.
Θ Remove the return hoses from the
connector. Band
clamp Hose
Ι Remove hose assembly, connector, clamp

down safety valve from the lift cylinder. Return

hose
Κ Disconnect hose assembly from the flow
regulator.
Lift
cylinder Return
hose

Flow
regulator

Down
safety valve
Hose assembly
Connector
15L7RE08

(5) Lift cylinder

Η Loosen hexagonal bolts and remove
washers securing the lift cylinders to Inner Stud
mast bolt
inner mast.
Θ 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.
Clamp
Ι Loosen and remove hexagon nuts and Lift cylinder
cylinder band securing cylinder to outer
Outer
mast. mast
Κ Using an overhead hoist, slowly raise the
inner mast high enough to clear lift
cylinder.
Λ Using an overhead hoist, draw out lift
cylinder carefully and put down on the Bolt
work floor. 15L7RE09

2-4
(6) Inner mast
Η Using an overhead hoist raise the inner
mast straight and carefully draw out of
outer mast section.
Inner
Be careful the mast not to swing or fall. mast

Outer
mast

15L7RE10

(7) Tilt cylinder pin

(8) Mast support cap
Η Attach a crane to the stay at the top of
the outer mast, and raise enough to
sustain jacked up machine.
ö This operation is carried out from under
the machine, so use a pit, or if there is no Outer
pit, jack up the machine and loosen with mast
on impact wrench.
Θ Remove the mounting bolts from the cap, Tilt cylinder
then slowly raise the outer mast.

Pin

Mounting bolt

Mast
support cap
Bushing
15L7RE11

2-5
2) INSTALLATION
After assembling mast components totally without piping connections, install mast assembly to the
equipment.
ö Installation procedure for each of mast component is the reverse of the removal procedure.
(1) Mast support cap
Η Check the mast support cap and spring pin for wear.
Θ Jack up the machine so that the front is raised and then using an overhead hoist assemble outer
mast to drive axle unit.
Ι Tighten mounting bolts to mast support cap.
ÂTightening torque : 19.9~26.9kgfÂm(144~195lbfÂft)
(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
Η 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.
Θ Assemble the cylinder rod to the inner
mast, and check the left-to-right play of
the mast at the maximum lifting height.
ö If play is to LEFT, install adjustment shim
to LEFT cylinder.
ö If play is to RIGHT, install adjustment
L15C3RE12
shim to RIGHT cylinder.
ÂShim 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. Brake valve
Brake pipe

Drive axle

15L7MRE12

(3) Parking brake cable

Disconnect parking brake cable from the
drive axle.

Parking brake
cable

Drive axle

15L7MRE13

2-8
(4) Drive axle
Η Attach a crane to the tilt cylinder notches Crane
on the dashboard and raise the machine.
Θ Loosen hexagonal bolts (1) connection
drive axle to the transmission.
Ι Put the block under the drive axle and
support under the drive axle with a truck. Tilt cylinder
Κ Remove drive axle mount bolts (2) from notch
the frame and then slowly pull out the
truck with drive axle to the front.
Drive axle
Λ Remove drive shaft assy from Bolt(2) Bolt(1)
transmission.

Frame

Drive shaft assy

Truck
15L7MRE14

(5) Inching linkage

Clevis pin
Remove the clevis pin from the
transmission control valve.
T/M control valve
Inching pedal

15L7MRE15

(6) Transmission cooling piping

Η Disconnect cooling oil hose from the
Radiator
transmission. assy

ö Make sure that the oil be drained from

the hose.
Transmission

Hose

Hose

15L7MRE16

2-9
(7) Torque converter
Η Remove the cover on top face of the
torque converter housing then remove
the 8 mounting bolts installed on the Cover
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.
Bolt
15L7MRE17

(8) Mounting bolts holding to flywheel

housing
Η Remove transmission assembly from the Mounting Bolt
engine flywheel housing by loosening the
8 mounting bolts.

15L7MRE18

Θ Using a moving truck slowly, pull out

transmission assembly to the front.
Crane

Frame

Truck
15L7MRE19

2-10
2) INSTALLATION
(1) Installation is the reverse order to removal, Bolt(1)
but be careful of the following points.
(2) Tightening torque Bolt(2)
ÂBolt (1) : 5.5~8.3kgfÂm (39.8~60lbfÂft)
ÂBolt (2) : 2.7~4.1kgfÂm (19.5~29.7lbfÂft)
ÂBolt (3) : 5.5~8.3kgfÂm (39.8~60lbfÂft)
Bolt(5)
ÂBolt (4) : 62~68kgfÂm (449~491lbfÂft)
ÂBolt (5) : 7.5kgfÂm (54.2lbfÂft)

Bolt(4) Bolt(3)

15L7MRE21

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.

15L7MRE22

2-12
(2) Remove the torque converter housing
cover, mounting bolts installed to flywheel
housing.
For details, see page 2-10.
Engine
(3) Engine accessory
Remove all wiring harnesses, cables and
hoses around the engine, dashboard and
frame.
Η Wiring harness to alternator and starter.
Θ Wiring harness for oil pressure and
engine water temperature gauges.
Ι Hoses to fuel tank and air cleaner.
Κ Exhaust pipe.
(4) Radiator hose
Open the drain valve of the radiator and
drain the cooling water, then remove the
15L7MRE23
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.
ö When sliding the engine, be careful of the
collision engine and radiator.

Engine
15L7MRE24

2-13
2) INSTALLATION
Installation is the reverse order of removal, 4
but be careful of the following points.
(1) Tighten the engine mounting bolts and 2
nuts.
(2) Tighten the engine mounting bracket bolts. 1
ö Do not remove the bolts unless necessary.
2
Loctite is coated over the threads of bolt.
So, once the bolts were removed, coat 3
them with loctite (#243) when installing. Engine
ö Before installing the bolts, loctite in the
holes should be removed by a tap. 15L7MRE25

(3) Tightening torque

ÂBolt(1) : 10~1.5kgfÂm (72~108.5lbfÂft)
(2) : 5.5~8.3kgfÂm (39.8~60lbfÂft)
(3) : 10~1.5kgfÂm (72~108.5lbfÂft)
(3) : 5.5~8.3kgfÂm (39.8~60lbfÂft)

(4) Radiator hoses

ÂDistance to insert hose : 40mm (1.57in) Muffler

(5) Air cleaner hose

Η Insert the air cleaner hose securely and
fit a clamp.
Θ Distance to insert hose
ÂAir cleaner hose : 35mm (1.4in)
ÂEngine end : 30mm (1.18in)

ENGINE

Air cleaner

15L7MRE26

2-14
4. STEERING AXLE
1) REMOVAL

Bar

Mounting bolt

15L7MRE27

(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.
ÂWeight of counterweight(standard)
15L(G)-7M : 700kg(1540lb)
18L(G)-7M : 870kg(1920lb)
20L(G)-7M : 1050kg(2310lb)

2-15
(2) Rear wheel
Remove mounting bolt and hub nut with
socket wrench and then carefully take out
the tire assembly.

20D7RE28

(3) Hose
Steering axle
Drain hydraulic oil in the hoses and
cylinder before removing them.
Loosen connector and then disconnect
the hoses.

Hose
15L7MRE29

(4) Mounting bolt

Steering axle
Put a block under the steering axle,
support on a truck, and raise the frame
with a crane. Remove the mounting bolts
installing to the frame, and pull out to the
rear.
Support
There are shims between the support and
steering axle to prevent play.

Mounting bolt
15L7MRE30

2-16
 SECTION 3 POWER TRAIN SYSTEM

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

Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-25
 SECTION 3 POWER TRAIN SYSTEM
GROUP 1 STRUCTURE AND OPERATION
1. POWER TRAIN DIAGRAM
1) STRUCTURE

4 5

15L7MPT26

1 Engine 3 Drive shaft 5 Brake

2 Transmission 4 Drive axle

3-1
2) SPECIFICATION

Item Specification

Model KAPEC 280DB

Torque converter Type 3 Element, 1 stage, 2 phase
Stall ratio 2.9 : 1
Type Power shift
Gear shift(FR/RR) 1/1
Transmission Adjustment Electrical single lever type, kick down system
FR 1:1
Gear ratio
RR 1:1
Type Front-wheel drive type, fixed location
Axle Gear ratio 14.2 : 1
Gear Ring & pinion gear type
Q'ty(FR/RR) 2/2
Wheels Front 6.50-10-12PR
Rear 5.00-8-10PR
Travel Front wheel, wet disk brake
Brakes
Parking Ratchet, wet disk brake
Type Hydro static, power steering
Steering
Steering angle 81äto both right and left angle, respectively

3-2
2. TORQUE CONVERTER
1) STRUCTURE

7
6

4 5

3
2
1

14
14
20
15
17 11 21
16
18
19
28
12
11
10

9
8
13

24 22

23
25

26
27
15L7APT03

1 Hexagon bolt 11 Plug 21 Air breather

2 Plain washer 12 O-ring 22 Magnetic plug
3 Flexible plate 13 Torque converter housing 23 Temperature sensor
4 Torque converter assembly 14 Hexagon bolt 24 Inner oil strainer
5 Shaft 15 Torque converter cover 25 Oil strainer spring
6 Snap ring 16 O-ring 26 O-ring
7 Gear 17 Plug 27 Oil strainer plug
8 Hexagon bolt 18 Spring 28 Gasket
9 Copper washer 19 Ball
10 Charging pump assembly 20 Plug

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 8 6 7 5 4 2

14

15

13

12

9
10
11

15L7APT28

1 Control valve 9 Output gear

2 Torque converter 10 Temperature sensor
3 Turbine wheel 11 Oil strainer
4 Impeller wheel 12 Idle gear
5 Stator wheel 13 Forward clutch pack
6 Forward clutch gear 14 Input shaft
7 Oil pump 15 Reverse clutch pack
8 Reverse clutch gear

3-5
2) INSTALLATION VIEW

1 3 5 6 4

2 7
15L7APT05

1 Torque converter 5 Air breather

2 Temperature sensor 6 Transmission oil filter
3 Control valve 7 Transmission output (Universal joint link part)
4 Oil level pipe and dipstick

3) OPERATION
The torque converter is an automatic fluid drive.
It transmits engine torque by means of hydraulic force.
The torque converter leads and the power which is delivered rotated the charging pump.
Oil is drawn from the transmission reservoir by the charging pump.
The pump delivers its entire output to a full-flow oil filter for cleaning.
From the oil filter, the oil supply is sent to the control valve.
The main pressure regulator valve provides pressure for clutch pack, directs oil to the solenoid
valve.
Moving the solenoid valve allows oil to charge the selected (forward or reverse) clutch line and to
engage that clutch.
The remaining oil appropriating clutch pressure flows into the torque converter.
A converter pressure regulator valve in the converter-in line limits the oil pressure there.
The oil pressure input to the torque converter is adjusted 4~7 kgf/cm2 (57~100 psi).
The oil pressure output from the torque converter is adjusted below 2~4.5 kgf/cm2 (28.4~64 psi).
The torque converter is continuously filled with oil during operation.
Rotation of the converter impeller imparts energy to the oil which, in turn, drives the turbines.
The oil then flows between the stator vanes which redirect it to the impeller.
At this time, torque is increased.
The oil from the torque converter enters the cooler.
The cooler is a heat exchanger in which the oil flows through air cooled passages.
After refrigerated, it is in charge of clutch lubrication through the lubrication oil path of the clutch
shaft. A lubrication valve between the cooler and lubrication system returns all excess oil to the
transmission reservoir.

3-6
 4) OPERATING MODES
(1) Forward

Input Ą Torque converter Ą Clutch shaft Ą

Forward clutch gear Ą Output gear Ą
Output

15L7APT29

(2) Reverse

Input Ą Torque converter Ą Clutch shaft Ą

Reverse clutch gear Ą Output gear Ą
Output

15L7APT30

3-7
5) TRANSMISSION CASE AND CONTROL VALVE
(1) Structure

20

18
17
22
13

10 19
21
9 25
23
11
12

24
26

4
14 5
15 6
7

28
29
30
31
2 32
1
3

16
15L7APT07

1 Transmission case 12 Socket bolt 22 Cylinder gear

2 Plug 13 Oil gauge 23 Idle gear
3 Oil seal 14 Clamp 24 Output gear
4 Ball 15 Socket bolt 25 Socket bolt
5 Spring 16 Flange bolt 26 Lock pin
6 O-ring 17 Control valve 28 O-ring
7 Plug 18 Solenoid valve 29 Adapter
9 Bolt 19 Gasket 30 O-ring
10 Transmission oil filter 20 Hexagon bolt 31 Plug
11 Pipe 21 O-ring 32 Socket bolt

3-8
(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.

3-9
6) CONTROL VALVE

(1) Operation

7 8 4

1 2 3 5 6

15L7APT08

1 Modulation 5 Inching valve pressure check port

2 Solenoid valve 6 Forward clutch pressure check port
3 Inching spool 7 Reverse clutch pressure check port
4 Main relief valve 8 Main pressure check port

The control valve consists of the main relief valve, solenoid valve, modulation valve and inching
valve.
The discharged oil from the gear pump enters main relief valve of the control valve and its
pressure is adjusted 10.8~14.9 kgf/cm2 (154~212 psi).
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 torque converter housing and transmission case.
The modulation valve provide a soft plugging when changing gears.
The modulation valve to absorb the small shocks of rapid pressure build up and quick release
during gear changes.
When full pressure builds up, the modulation valve shuts the modulation 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.

3-10
(2) Structure

Main relief valve

Modulation

8
2
7
26
4 5 10
6
25
Forward clutch pressure 9
check port 24
10
11 23
Inching valve pressure
check port
22
21

27

20 28 Main pressure
2 12 check port
19
1 18 29
Reverse clutch pressure
check port
17

16

15
14
13
Inching spool

Solenoid valve

15L7APT22

1 Plug 11 Spring 21 Stopper

2 O-ring 12 Solenoid valve 22 Spring
3 Spring 13 Seal 23 Spring
4 Plug 14 Snap ring 24 Valve
5 Plug 15 Plate 25 Piston
6 Spring 16 Spool 26 Plug
7 Piston 17 Valve 27 Screw
8 Plug 18 Spring 28 Body
9 Plug 19 Stopper 29 Gasket
10 O-ring 20 Nut

3-11
7) CLUTCH
(1) Operation

3 2 Reverse Forward

1
15L7APT31

1 Forward clutch plugging pressure delivery line ( )

2 Reverse clutch plugging pressure delivery line ( )
3 Clutch pack lubrication line ( )

When (forward/reverse) mode is selected through the solenoid valve of control valve, the flux
flowed by the oil pump flows into forward (reverse) clutch pack in 9~14.2 kgf/cm2 (128~202 psi) 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 clutch shaft is always revolving while connected with the turbine of torque
converter.
According to be plugging, the clutch gear is connected and revolved with drum.
This power is delivered with linking output gear in touch with clutch gear.

3-12
(2) Structure

7
8
9
8
9
21
20
19
18
17
15
14
13
12
10 6
11 5
11
22 16
1

29
28
4 27
3 26
25
26
25
2 24
21
20
19
18
17
15
14
13
12
23
11
11
16

15L7APT11

1 Shaft 11 Seal ring 21 Wire ring

2 Seal ring 12 Piston 22 Plate
3 Needle bearing 13 Quad ring 23 Clutch drum
4 Ring 14 Quad ring 24 Spacer
5 Seal ring 15 Plate 25 Snap ring
6 Bushing 16 Friction plate 26 Ball bearing
7 Reverse clutch gear 17 Plate 27 Forward clutch gear
8 Ball bearing 18 Snap ring 28 Spacer
9 Snap ring 19 Spring 29 Ball bearing
10 Clutch drum 20 Back plate

3-13
8) 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

15L7APT14

1 Output gear 4 Oil seal

2 Ball bearing 5 Seal ring
3 Cover

3-14
4. DRIVE AXLE
1) INSTALLATION VIEW

1 Carrier assembly 3 Traveling brake 5 Oil level gage

2 Drive axle housing 4 Hub

2) STRUCTURE

1 Pinion shaft 4 Axle shaft 7 Hub

2 Ring gear 5 Traveling brake
3 Differential device 6 Hub reduction

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 in
reduced at the hub reduction.

3-15
3) CARRIER ASSEMBLY

(1) Operation
Carrier sub assy includes differential device and parking brake.
The pinion shaft is supported by the taper roller bearing in the carrier case and the bolt at the end
of pinion shaft and transfers the power which is delivered from the drive shaft assy 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 spindle, the power transferred to
differential device is delivered to final drive through the axle shaft.
Parking brake, like as traveling brake system is consists of several friction plate functions braking
by sticking to each friction plate when pull parking hand lever.

15L7APT21

3-16
(2) Structure

10
5
6 2
7 4
9

15L7APT18

1 Parallel pin 5 Actuator 9 Eccentric shaft

2 Parking plate 6 Push pin 10 Lever
3 Friction plate-parking 7 Parking spline
4 Cone spring 8 Carrier case cover

3-17
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

10

4 7

6
2
5

10

15L7MPT19

1 Differential case (RH) 4 Differential gear 7 Differential spider

2 Differential case (LH) 5 Thrust washer 9 Socket bolt
3 Thrust washer 6 Differential gear 10 Taper roller bearing

3-18
GROUP 2 TROUBLESHOOTING

1. TRANSMISSION

Trouble symptom Probable cause Remedy

1. Output does not go up
1) Torque converter
- Torque converter oil ÂThe oil is in short supply. ÂReplenish oil.
ÂThe oil that is not regulated is used. ÂChange the oil to regular oil.
ÂThe air has mixed into oil. ÂTighten each joint coupling and the pipe
further.
ÂThe oil filter is clogging. ÂWash the oil filter or change it.

- Main body of torque ÂThe stator free wheel is broken. ÂChange the stall revolution then if the
converter revolution is extremely low, change the free
wheel inner race, free wheel cam and roller.
ÂThe stator free wheel is sticking. ÂCheck the rise of the temperature of oil at no
load.
Change the free wheel inner race, free wheel
cam and roller when the temperature of oil
rises abnormally.
ÂThe wheel with blades is broken or ÂCheck whether the aluminum powder and the
it is touching other components. like has mixed into torque converter oil.
Change the wheel with blades if the aluminum
powder and the like has mixed in.
2) Transmission
- Charging pump  The pump does not operates ÂChange the pump.
normally.
- Torque converter oil ÂThe oil is in short supply. ÂReplenish oil.
ÂThe oil that is not regulated is used. ÂChange the oil to regular oil.
ÂThe air bubble occurs because the ÂCheck and adjust the torque converter
torque converter pressure decrease. pressure.
ÂThe water has mixed into oil. ÂCheck the cooler, and change all oil.
- Valve assy ÂThe clutch oil pressure has de- ÂChange the spring.
creased, because the spring is
setting or break.
ÂThe valve does not move with the ÂRepair or change the valve.
valve opens.
ÂThe orifice is clogging. ÂWash the orifice.
- Clutch ÂThe seal ring of the clutch piston ÂChange the seal ring.
are damaged.
ÂThe clutch plate slips because the ÂMeasure the clutch pressure.
clutch oil pressure decrease.
ÂThe clutch plate is worn out or ÂChange the clutch plate.
damaged.
ÂThe clutch piston down not operate ÂRepair or change the clutch piston.
normally.

3-19
 Trouble symptom Probable cause Remedy
2. Power is not transmitted.
1) Torque converter ÂThe flexible plate is broken. ÂChange the flexible plate.
ÂThe oil is in short supply. ÂReplenish oil.
ÂThe shaft and spline are worn. ÂChange the shaft and the spline.
ÂThe gear is broken. ÂChange the gear.
 The charging pump does not ÂChange the charging pump.
operate normally.
2) Transmission
- Hydraulic converter oil ÂThe oil is in short supply. ÂReplenish oil.
- Clutch part ÂThe clutch plate is worn and broken. ÂChange the clutch plate.
ÂThe clutch plate is sticking. ÂChange the clutch plate.
ÂThe clutch shaft spline is worn. ÂChange clutch shaft.
ÂThe clutch pressure has decreased ÂChange the clutch.
because the seal of the clutch
piston do not operate normally.
- Output gear ÂThe gear is broken. ÂChange the gear.
- Solenoid valve ÂThe solenoid lines are broken. ÂChange the solenoid.
ÂSpool does not operate normally. ÂRepair or change the solenoid valve.
- Valve assy ÂThe clutch pressure has decreased ÂChange the spring.
because the spring is setting or
brake.
ÂThe valve does not move with the ÂRepair or change the valve.
valve opens.
ÂThe orifice is clogging. ÂWash the orifice.
3) Electric circuit ÂThe switches or the relays are brok- ÂRefer to the electric circuit figure and repair the
en. broken points.
ÂWiring has come off and they are ÂRefer to the electric circuit figure and repair the
broken. broken points.
3 . Oil temperature rise
abnormally
1) Torque converter
- Torque converter oil ÂAmount of oil is not appropriate. ÂCheck the oil level.
ÂThe oil that is not regulated is used. ÂChange the oil to regular oil.
ÂThe air has mixed into oil. ÂTighten each joint coupling and the pipe
further.
ÂThe water has mixed into oil. ÂCheck the cooler and change the all oil.
- Flows resistance ÂThe oil cooler is sticking. ÂWash the oil cooler or change them.
2) Transmission
- The clutch is dragging. ÂThe clutch plate is sticking. ÂChange the clutch plate.
ÂThe clutch piston does not operate ÂRepair the clutch piston or change them.
normally.
ÂThe pressure of clutch has decreas- ÂCheck the clutch pressure.
ed.

ÂThe bearing are worn or sticking. ÂChange the bearing.

3-20
 Trouble symptom Probable cause Remedy
4. Clutch or converter oil
pressure is too high
1) Torque converter ÂViscosity of oil is too high (at cold  Warm up the torque converter if the
time). temperature of torque converter oil is below
outside air temperature.
ÂThe oil that is not regulated is used. ÂChange the oil to regular oil.
2) Transmission  The value does not operate ÂRepair the valve assy and change them.
- Valve assy normally because the valve has
damage and the valve catch
rubbishy in valve.

5. Clutch or converter oil

pressure is too low
1) Torque converter ÂThe oil is in short supply. ÂReplenish oil.
ÂThe oil that isn't regulated is used. ÂChange the oil to regular oil.
ÂThe charging pump is worn and ÂChange the charging pump.
broken.
ÂThe oil seal ring or O-ring is worn. ÂChange the oil seal ring or the O-ring.
2) Transmission
- Valve assy ÂThe spring is setting and broken. ÂChange the spring.
ÂThe valve does not move with the ÂRepair the valves or change it.
valve opens.
ÂThe orifice is clogging. ÂWash the orifice.
- Clutch ÂThe seal ring of the clutch piston ÂChange the clutch piston.
are damaged.
6. Noises occurs
1) Transmission ÂThe clutch is sticking and dragging. ÂChange the clutch.
ÂThe bearings are sticking are worn. ÂChange the bearing.
ÂThe gear is broken. ÂChange the gear.
ÂThe spline is worn. ÂChange the spline.
ÂThe bolt is loosen or broken. ÂTighten the bolt or change it.

3-21
2. DRIVE AXLE

Trouble symptom Probable cause Remedy

1. Noise and vibration
1) Drive axle ÂLubricating oil shortage. ÂCheck oil level and refill lubricating oil.
ÂUsing different lubricating oil. ÂChange lubricating oil.
ÂMaladjustment or detect of wheel ÂChange wheel bearing.
bearing.
ÂIncorrect contact between ring gear ÂDisassemble, check or readjusting.
and pinion shaft.
ÂDamage or wear of ring gear and ÂChange the damaged gear.
pinion shaft.
ÂLoosened or worn bearing of pinion ÂDisassemble, check or change bearing.
shaft.
2) Differential
- In operation a ÂLoosened bolt of ring gear. ÂDisassemble, check or reassemble.
differential ÂBurned ring gear. ÂDisassemble, check or change.
ÂLoosened or worn differential ÂDisassemble, check, repair or change.
bearing.
ÂDamaged bevel gear bearing. ÂDisassemble, check or change.
- Occurrence for only ÂTightened excessively differential ÂChange pinion gear or spider.
revolution pinion gear on diff spider.
ÂTightened excessively side gear in ÂChange the side gear.
differential case
ÂDamaged diff pinion or side gear. ÂChange diff pinion or side gear.
ÂWorn or damaged thrust washer. ÂChange thrust washer.
ÂExcessive backlash between diff ÂChange diff pinion or side gear.
pinion and side gear.

3) Brake
- Brakes produst noise, ÂIncorrect axle fluid and/or friction ÂUse only MS precision specified or approved
chatter, vibration material used. materials.
ÂDrain and flush fluid from axle. Replace with
approved fluid.
ÂReplace all friction discs. Thoroughly clean or
replace stationary discs.

3-22
 Trouble symptom Probable cause Remedy
2. Oil leakage
1) External leakage ÂExcess of oil. ÂCheck oil level. Set of oil amount.
ÂUsing different oil. ÂChange oil.
ÂBlocking air breather. ÂWashing or change air breather.
ÂDamaged of hub oil seal. ÂDisassemble, check and change.
ÂLeakage at pinion shaft.
- Excess of oil. - Check oil level. Set of oil amount.
- Using different oil. - Change oil.
- Blocking air breather. - Washing or change air breather.
- Worn or maladjustment pinion - Change oil seal.
shaft oil seal.
ÂLoosened bleeder screw. ÂTighten bleeder screw to 150~200 kgfÂm.
ÂLoosened inlet fitting or plugs. ÂTighten inlet fitting to 380~420 kgfÂm.
ÂDamaged inlet fitting or plugs or ÂReplace inlet fitting or plug and O-ring if used.
damaged seats. Repair or resurface area; or replace as
necessary.
2) Internal brake
- Fluid bypasses seals ÂWorn or damaged piston seal. ÂReplace piston seals.
into and fills axle with ÂMelted or extruded piston seals. ÂCorrect cause of overheating and replace
fluid and blows out seals.
breather or emptied ÂCorrosion, pitting wear or other ÂClean, smooth, rework or replace affected
brake fluid reservoir. damage, marks, scratches to piston parts.
and/or brake housing bore in area
seal/sealing lips.
3. Axle does not revolution
1) Axle shaft ÂInjured axle shaft.
- Loosened and injured wheel bear- ÂDisassemble and change wheel bearing.
ing.
- A short shaft. ÂChange axle shaft
- Injured disc spline. ÂChange axle shaft
2) Hub ÂInjured axle shaft.
- Injured lock nut. - Change lock nut.
- Loosened and injured wheel - Reassemble or change wheel bearing.
bearing.
- Loosened and damaged bolt - Reassemble or change bolt.
between wheel shaft and hub
flange.
ÂLoosened or injured hub bolt and ÂReassemble or change hub bolt.
hub nut.

3) Differential ÂDamaged diff pinion and side gear. ÂChange the damaged part.
ÂDamaged diff spider. ÂChange the damaged part.
ÂDamaged differential case. ÂChange the damaged part.
ÂDamaged ring gear and pinion gear. ÂChange the damaged part.

3-23
 Trouble symptom Probable cause Remedy
4. Brake does not apply
1) Service brake. ÂEmpty fluid reservoir. ÂFill reservoir to correct level with specified
- Low or no pressure to fluid.
brake. ÂDamaged hydraulic system. ÂCheck hydraulic system.
ÂLeakage of brake actuation fluid. ÂRefer to "Brake leaks actuation fluid" in
trouble shooting.
2) Parking brake ÂParking brake not adjusted properly. ÂAdjust parking brake lever as described in
chapter 3.2) Assembly.
ÂCarrier case cover assemble.
(Chapter 3.2) Assembly)
5. Brake does not release
1) Hydraulic system ÂDamaged hydraulic system. ÂCheck hydraulic system.
- Vehicle does not move.
2) Service brake ÂDamaged piston return spring ÂCheck piston return spring assembly.
- Brakes dragging. assembly.
ÂPiston not returning. ÂCheck piston seals for swelling or damage
(Replace as necessary).
ÂWrong cooling and/or actuation fluid ÂCheck piston seals for swelling or damage.
used. Replace as necessary. Purge system and
use specified fluid.
3) Differential ÂDamaged diff pinion and side gear. ÂChange the damaged part.
ÂDamaged diff spider. ÂChange the damaged part.
ÂDamaged differential case. ÂChange the damaged part.
ÂDamaged ring gear and pinion gear. ÂChange the damaged part.

6. Braking performance
1) Service brake ÂInadequate actuation fluid supply to ÂReplenish fluid in brake system. Check for
- Noticeable change or brakes. leakage and correct cause.
decrease in stopping  Inadequate pressure to apply ÂCheck brake apply system. Check for leakage
performance. brakes. in brake system or brakes, and correct cause.
ÂWorn or damaged discs. ÂInspect and replace discs if necessary.
 As disc wear occurs, make sure brake
system can supply adequate fluid to fully
apply brakes.
ÂOverheated seals and/or discs. ÂInspect and replace discs and seals, if
necessary.

- Brake feel spongy/soft. ÂBrakes or brake system not proper- ÂBleed brakes and brake system.
ly bled.

3-24
GROUP 3 DISASSEMBLY AND ASSEMBLY

1. DISASSEMBLY OF TRANSMISSION
1) DISASSEMBLING OF TRANSMISSION ASSY
(1) Drain the transmission oil.
Remove the drain plug at T/C housing.
(2) Lay the wood plate (or plastic plate) on the
workshop's table (bottom).
And put the T/M assy on the wood plate (or plastic
plate) : For an (dis)assembly at the time of damage
prevent.
15L7ATM001
To avoid serious personal injury and possible
damage to components, be very careful when
using lifting devices during removal and
disassembly procedures.

(3) Removal torque converter part.

Η Remove the torque converter sub assy.
T/C sub assy

15L7ATM002

Θ Remove the hexagon bolt , washer, flexible plate.

15L7ATM003

(4) Remove the PTO shaft.

15L7ATM004

3-25
(5) Remove the socket gear.
Next remove the snap-ring at socket gear.

15L7ATM005

(6) Removal the oil pump sub assy.

Η Remove the hexagon bolt (M8Ý1.25PÝ38L), and
then remove the copper washer.

15L7ATM006

Θ Remove the plug. (PT 1/8)

15L7ATM007

Ι Remove the pump sub assy + gasket using the

plug hole for pulling out from the T/C housing.
(use M8Ý1.25PÝ38L hexagon bolt)

15L7ATM008

Κ Remove the O-ring at pump sub assy.

15L7ATM009

3-26
(7) Removal the control valve sub assy.
Η Remove the hexagon bolt (M8Ý1.25PÝ60L).

15L7ATM010

Θ Remove the part slowly with hit the end side softly.
ö Using a plastic hammer .
Do not hit steel parts with a steel hammer.
Pieces of a part can break off and cause serious
personal injury.

15L7ATM011

Ι Remove the control valve assy, and then remove

the gasket.

15L7ATM012

(8) Remove the oil filter, and then remove the filter
adapter.

15L7ATM013

(9) Remove the (T/C in relief, cooler relief) plug, and

then remove the spring, steel ball.
Next remove the O-ring at relief plug.

15L7ATM014

3-27
(10) Remove the cooler (in/out) plug.(PT 3/8)

15L7ATM015

(11) Remove the air breather.

15L7ATM016

(12) Remove the hexagon bolt, and then remove the T/C
cover.

15L7ATM017

(13) Remove the oil level gauge.

15L7ATM018

(14) Remove the socket bolt, and then remove the

clamp.

15L7ATM019

3-28
(15) Remove the socket bolt, and then remove the pipe.
Next remove the O-ring at the pipe.

15L7ATM020

(16) Remove the temperature sensor.

15L7ATM021

(17) Lay the T/M assy without damage to the T/C

housing.(engine mounting surface)

15L7ATM022

(18) Remove the plug, and then remove the spring, oil
strainer.
Next remove the O-ring at the plug.

15L7ATM023

3-29
(19) Remove the plug.(PT 1/8)

15L7ATM024

(20) Remove the socket bolt (T/M case + T/C housing

fastening bolt) 4 socket bolt exclusions.

15L7ATM025

15L7ATM026

(21) To turn over T/M assy without damage to the T/M

case.(main pump mounting surface)
Next remove the 4 socket bolt.

15L7ATM027

3-30
(22) Remove the part slowly with hit the end side softly.
ö Using a plastic hammer.

15L7ATM028

(23) Remove the T/C housing.

15L7ATM029

(24) Gear assemblies arrangements.

15L7ATM030

(25) Remove the O-ring.

15L7ATM031

(26) Remove the output gear assy.

15L7ATM032

3-31
(27) Remove the idle gear assy.

15L7ATM033

(28) Remove the clutch gear assy.

ö Store each gear assembly in separate box.

15L7ATM034

(29) Remove the oil seal.

15L7ATM035

3-32
2) DISASSEMBLING OF GEAR ASSEMBLIES
(1) Disassembling clutch gear assy.

15L7ATM036

Η Remove the seal ring.

15L7ATM037

Θ Pull out the bearing(#6207) and spacer from the

shaft.

15L7ATM038

Ι Pull out the forward clutch sub assy.

15L7ATM039

Κ Pull out the bearing(#6911) from the shaft.

15L7ATM040

3-33
Λ Pull out the reverse clutch sub assy.

15L7ATM041

Μ Forward clutch sub assy.

15L7ATM042

Ν Remove the forward clutch gear sub, and then

remove the spacer.

15L7ATM043

Ξ Remove the snap ring, and then remove the

bearing.

15L7ATM044

3-34
Ο Remove the snap ring, and then remove the back
plate, friction disk, and steel plate.

15L7ATM045

Π Remove the wire ring, and then remove the back

plate and spring.
When you remove the wire-ring, it might be shot
out by impact of spring. Certainly fixing the
spring, will have to remove.
Ρ Pull out the clutch piston, and then remove the seal
ring.
Next remove the quad ring at the clutch piston.

15L7ATM046

΢ Reverse clutch sub assy.

15L7ATM047

Σ Remove the reverse clutch gear sub.

15L7ATM048

3-35
Τ Remove the snap ring, and then remove the
bearing.

15L7ATM049

Υ Remove the snap ring, and then remove the back

plate, friction disk, and steel plate.

15L7ATM050

 Remove the wire ring, and then remove the back

plate and spring.
When you remove the wire-ring, it might be shot
out by impact of spring.
Certainly fixing the spring, will have to remove.
 Pull out the clutch piston, and then remove the seal
ring.
Next remove the quad ring at the clutch piston.

15L7ATM051

3-36
(2) Disassembling of Idle gear assy.

15L7ATM052

Η Pull out the bearing, and then remove the idle gear
upper(lower).

15L7ATM053

(3) Disassembling of output gear assy.

15L7ATM054

3-37
Η Remove the seal ring, oil seal and sealing cap.

15L7ATM055

Θ Pull out the bearing.

15L7ATM056

3-38
2. ASSEMBLY OF TRANSMISSION
1) ASSEMBLING OF GEAR ASSEMBLIES
ö Assemble the part with reverse the aforementioned disassemble procedure.

 Assembling of clutch gear assembly.

(1) Forward clutch drum sub assembly.
Η In drum internal groove tefron seal assembly.
ö Spread grease on seal ring.

15L7ATM057

Θ In piston groove quad ring assembly.

ö Spread grease on seal ring.

15L7ATM058

Ι Assemble piston at the drum.

15L7ATM059

Κ Assemble return spring, plate back and wire ring at

the drum sub.
ö When you assemble the wire ring, it might be shot
out by impact of spring.
Certainly fixing the spring, will have to assemble.

15L7ATM060

3-39
Λ First insert steel plate, and then insert friction disk
alternately.
Next insert the back plate, and then assemble the
snap ring.

15L7ATM061

Μ Assemble the bearing, and then assemble the

snap ring alternately.

15L7ATM062

Ν Arrange serration of the friction disk, and then

assemble the spacer, clutch gear sub.

15L7ATM063

Ξ Forward clutch drum sub assembly.

15L7ATM064

3-40
(2) Reverse clutch drum sub assembly.
Η Do work as the same way like forward clutch drum
sub assembly procedure 1) Η ~ Λ.
Θ Assemble the bearing, and then assemble the
snap ring alternately.

15L7ATM065

Ι Arrange serration of the friction disk, and then

assemble the clutch gear sub.

15L7ATM066

Κ Reverse clutch drum sub assembly.

15L7ATM067

(3) Clutch gear assembly

Η Assemble the reverse clutch drum sub assy at the
shaft sub assy.

15L7ATM068

Θ Assemble the bearing.

- Used method of heating bearing.
ö All bearings should never be heated above 120ÁC

15L7ATM069

3-41
Ι Assemble the forward clutch drum sub assy at the
shaft sub assy.

15L7ATM070

Κ Assemble the spacer and bearing.

- Used method of heating bearing.

15L7ATM071

Λ Assemble the seal ring.

ö Spread grease on seal ring

15L7ATM072

Μ Clutch gear assy.

15L7ATM073

3-42
Assembling of output gear assembly.
Η Assemble the bearing.
- Used method of heating bearing
ö All bearings should never be heated above 120ÁC

15L7ATM074

Θ Assemble the oil seal, seal ring and sealing cap.

ö Spread loctite #609 on the out wheel of oil seal,
spread grease on inside wheel of oil seal.
ö Spread grease on seal ring.
ö Spread loctite #592 on the out wheel of sealing
cap.

15L7ATM075

Ι Output gear assy.

15L7ATM076

3-43
 Assembling of idle gear assembly.
Η Press the idle gear upper and idle gear lower at the
idle gear shaft, and then assemble the bearing.
- Used method of heating bearing
ö All bearings should never be heated above 120ÁC

15L7ATM077

Θ Idle gear assy.

15L7ATM078

3-44
2) ASSEMBLING OF TRANSMISSION ASSY
(1) Press the oil seal.
ö Spread loctite #592 on the out wheel of oil seal,
spread grease on inside wheel of oil seal.

15L7ATM079

(2) Assemble the clutch gear assy.

ö When you insert the shaft after install the seal ring in
the shaft, please insert the shaft with turning it into
the shaft side and hole side of shaft for prevent the
damage of shaft.

15L7ATM080

(3) Assemble the idle gear assy.

15L7ATM081

(4) Assemble the output gear assy.

15L7ATM082

(5) Assemble the O-rings.

ö Spread grease on O-ring.

15L7ATM083

3-45
(6) Press the lock-pins.
ö After the assembling, please check whether you can
turn the input(output) gear lightly by your hand.

15L7ATM084

(7) Spread loctite #5127 on T/C housing space.

15L7ATM085

(8) Assemble the T/C housing.

15L7ATM086

(9) Assemble the part slowly with hit the end side softly.
ö Using a plastic hammer.

15L7ATM087

(10) Assemble the socket bolts.

(T/M case+ T/C housing softly fastening)

15L7ATM088

3-46
(11) Turn over T/M assy without damage to the T/C
housing.(engine mounting surface)
Next assemble the socket bolts.
ÂSocket bolt (M10Ý1.5pÝ40mm) Ý16EA
ÂTightening torque : 5.5~6.5 kgfÂm(40~47 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM089

(12) Assemble the socket bolts.

ÂSocket bolt (M10Ý1.5pÝ25mm) Ý2EA
ÂTightening torque : 5.5~6.5 kgfÂm(40~47 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM090

(13) Assemble the socket bolts.

ÂSocket bolt (M10Ý1.5pÝ30mm) Ý2EA
ÂTightening torque : 5.5~6.5 kgfÂm(40~47 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM091

(14) Assemble the plugs(PT 1/8) Ý8EA

ÂTightening torque : 1.0~1.5 kgfÂm(7.0~11 lbfÂft)
ö Spread loctite #577 on plug.

15L7ATM092

3-47
(15) Assemble the O-ring at the plug.
Insert the oil strainer, spring ,and then assemble O-
ring+plug assy.
ÂPlug tightening torque : 8~10 kgfÂm(58~72 lbfÂft)
ö Spread grease on O-ring.

15L7ATM093

(16) Assemble the temperature sensor.

ÂTightening torque : 3.0~4.0 kgfÂm(22~29 lbfÂft)
ö Spread loctite #577 on temperature sensor.

15L7ATM094

(17) Assemble the O-ring at the pipe, and then assemble

the pipe+O-ring assy.
Next assemble the socket bolts.
ÂSocket bolt (M8Ý1.5pÝ15mm) Ý2EA
ÂTightening torque : 3.0~3.3 kgfÂm(22~24 lbfÂft)
ö Spread grease on O-ring.
ö Spread loctite #277 on socket bolt.
15L7ATM095

(18) Assemble the clamp at the pipe,

and then assemble the socket bolt.
ÂSocket bolt (M10Ý1.5pÝ30mm)
ÂTightening torque : 5.5~6.5 kgfÂm(40~47 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM096

(19) Assemble the oil level gauge at the pipe.

15L7ATM097

3-48
(20) Assemble the T/C cover and hexagon bolts.
ÂHexagon bolt (M8Ý1.25pÝ16mm) Ý2EA
ÂTightening torque : 2.0~3.0 kgfÂm(14.5~21.7 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM098

(21) Assemble the air breather.

ÂTightening torque : 1.0~1.5 kgfÂm(7.0~11 lbfÂft)
ö Spread loctite #577 on air breather.

15L7ATM099

(22) Assemble the O-ring at the plug, and then insert

steel ball, spring.
Next assemble O-ring+plug assy.
- Plug(3/4-16 UNF)Ý2EA
ÂTightening torque : 3.5~4.5 kgfÂm(25~33 lbfÂft)
ö Spread loctite #577 on plug.
ö Spread grease on O-ring.
15L7ATM100

(23) Assemble the adapter filter, and then assemble the

oil filter.
- Adapter filter
ÂTightening torque : 3.5~4.5 kgfÂm(25~32 lbfÂft)
ö Spread loctite #277 on adapter filter.
- Oil filter
ÂTightening torque : 0.8~1.2 kgfÂm(5.8~8.7 lbfÂft)
15L7ATM101

(24) Install the gasket, and then install the control valve
assy.
ö Spread grease on gasket.

15L7ATM102

3-49
(25) Assemble the hex bolt.
ÂHexagon bolt (M8Ý1.25pÝ60mm) Ý10EA
ÂTightening torque : 3.0~3.3 kgfÂm(22~24 lbfÂft)

15L7ATM103

(26) Assemble the o-ring at the charging pump assy.

ö Spread grease on O-ring.

15L7ATM104

(27) Install the gasket at the T/C housing, and then install
the charging pump assy.
Next assemble the hexagon bolt and bronze
washer.
ö Spread grease on gasket.
ÂHexagon bolt (M8Ý1.25pÝ38L) Ý4EA
ÂTightening torque : 2.8~3.8 kgfÂm(20.2~27.5 lbfÂft)
15L7ATM105
ö Spread loctite #242 on hexagon bolt.

(28) Assemble the snap ring at the socket gear, and then
insert the socket gear sub assy at the cylinder gear
assy.

15L7ATM106

(29) Insert the PTO shaft.

15L7ATM107

3-50
(30) Install the flexible plate at the torque converter, and
then install the hexagon bolt and washer.
ÂHexagon bolt (3/8-24UNF-2B) Ý6EA
ÂTightening torque : 3.0~3.5 kgfÂm(21.6~25.3 lbfÂft)
ö Spread loctite #277 on hexagon bolt

15L7ATM108

(31) Insert the T/C sub assy at the T/M sub assy.

15L7ATM109

(32) Transmission assy.

15L7ATM110

ö Speed sensor plug(option)

In T/M CASE internal groove O-ring assembly, and
then insert the adapter at the T/M case.
Next assemble the O-ring+ plug at the adapter.
ÂSocket bolt (M6Ý1.0pÝ20mm)
ÂTightening torque : 0.5~0.8 kgfÂm (3.7~6 lbfÂft)
ö Spread loctite #242 on socket bolt.
15L7ATM111
ö Spread grease on O-ring.

15L7ATM112

3-51
3. DISASSEMBLY OF DRIVE AXLE
1) DISASSEMBLY
(1) Disassembling of drive axle assy.

15L7ADA001

(2) Remove bolts of hub sub assembly.

To avoid serious personal injury and possible
damage to components, be very careful when
using lifting devices during removal and
disassembly procedures.
- Inspect to make sure that neither lifting strap is
damaged.
15L7ADA002
- Do not subject lifting straps to any shock or drop
loading.

(3) After support hub sub assembly by lifting device,

make hub sub assembly separate at the same
intervals by tightening two jack screw.
Use care when you remove the hub assembly to
prevent the hub assembly from falling off of the
lifting device. Do not drop the hub assembly.
Damage to the hub assembly and serious
personal injury can result. 15L7ADA003

(4) Disassemble in order of separate plate Ą friction

plate Ą cone spring.

15L7ADA004

3-52
(5) Remove pins.

15L7ADA005

(6) Disassemble in order of special bolt Ą return spring.

15L7ADA006

(7) Detach brake piston.

15L7ADA007

(8) After remove retaining ring, pull out left axle shaft.
(Do work as the same way like right axle shaft)
Use a brass, leather or rubber mallet for
assembly and disassembly procedures.
Do not hit steel parts with a steel hammer.
Pieces of a part can break off and cause serious
personal injury.
15L7ADA008

(9) Disassembling of hub sub assy.

15L7ADA009

3-53
(10) Remove all snap rings.

15L7ADA010

(11) Remove all each parts in order of thrust washer Ą

planet gear Ą needle bearing Ą thrust washer.

15L7ADA011

(12) Loose lock nut by using jig.

15L7ADA012

(13) Extract planet carrier.

15L7ADA013

(14) Extract carrier housing with bearing.

15L7ADA014

3-54
(15) Remove bolts fixing flange hub and wheel shaft.

15L7ADA015

(16) Remove bolts fixing carrier assy.

15L7ADA016

(17) Extract the bracket.

15L7ADA017

(18) Extract carrier assembly.

15L7ADA018

(19) Fix carrier assembly to a jig.

15L7ADA019

3-55
(20) Remove carrier cap bolt.

15L7ADA020

(21) Extract the carrier cap (apply marking a match).

15L7ADA021

(22) Remove adjusting ring of both sides bearing cup.

15L7ADA022

(23) Extract differential assembly.

15L7ADA023

(24) After turn over carrier assy and fix it, remove nut.

15L7ADA024

3-56
(25) Remove U-joint flange.

15L7ADA025

(26) Remove carrier case cover bolts.

15L7ADA026

(27) Extract carrier case cover assembly.

15L7ADA027

(28) Extract push pins and actuator.

15L7ADA028

(29) Remove O-ring and spline parking.

15L7ADA029

3-57
(30) Remove parking friction plates and separate plates.

15L7ADA030

(31) Finish disassembling of carrier assembly.

15L7ADA031

3-58
2) ASSEMBLY
(1) Carrier sub assembly
Thrust washer
Differential device assembly
Differential gear
Η Prepare parts for assembly of differential. Spider
Differential
Differential case-RH
case-LH
Bearing
15L7MDA032

Θ Fix differential case RH and LH with bolt.

After paste loctite #277 on spiral of bolt.
Confirm torque : 350~380 kgfÂcm

15L7ADA033

Ι Assemble ring gear.

After paste loctite #277 on spiral of bolt.
Confirm torque : 710~760 kgfÂcm

15L7ADA034

Κ Assemble bearing.
Heating pressurize bearing cone.

15L7ADA035

3-59
 Adjusting shim and pinion shaft assembly
Η Fix carrier case to the jig.
ö Read the following information before installing new
gearset in the carrier. Always inspect the gearset
for correct marks to make sure the gears are a
matched set.

15L7ADA036

The locations of the gearset marks are shown in

right figure.
 Part number
a. Examples of gearset part numbers
- Conventional ring gear, XKCF-00513
- Conventional pinion shaft, XKCF-00514
ö Part No. : Refer to parts manual.
b. Location on pinion shaft : Shaft end 15L7ADA037

c. Location on ring gear : Front face or outer

diameter
 Tooth combination number
a. Example of a tooth combination number : 13-32
(An 13-32 gearset has an 13-tooth drive pinion
and a 32-tooth ring gear)
b. Location on pinion shaft : Shaft end
c. Location on ring gear : Front face or outer
diameter
 Pinion cone variation number
(The pinion cone variation number is not used
when checking for a matched gearset. The number
is used when you adjust the depth of the pinion in
the carrier.)
a. Examples - Pinion cone variation numbers
Â+2
Â+0.01mm
Â-1
Â-0.02mm
b. Location on gearset
End of pinion shaft head or outer diameter of ring
gear

3-60
Θ Decide thickness of shim by gauge and measuring
apparatus (Standard gap between bearing and
carrier case step : A)
(Mounting distance(MD) of pinion shaft : B)
ö Thickness of shim
ÂX = A - B + Carrier case bearing step depth
ex1) A= 0.35, B= -0.1, Bearing step depth= +0.1
ÂX = 0.35 + 0.1 + 0.1 = 0.55mm 15L7ADA038

ex2) A= 0.35, B= +0.1, Bearing step depth= -0.1

ÂX = 0.35 - 0.1 - 0.1 = 0.15mm

Ι Assemble shim.
ö Sort of shim : 0.1 , 0.15 , 0.25 , 0.5 (mm)

15L7ADA039

Κ Pressurize bearing cup.

15L7ADA040

Λ Put with heating bearing cone on pinion shaft.

15L7ADA041

Μ Put into pinion shaft.

15L7ADA042

3-61
Ν Set a ball.

15L7ADA043

Ξ Equip jig for fixing.

15L7ADA044

Ο Fasten the ball.

15L7ADA045

Π Revolve carrier case 180Á.

15L7ADA046

Ρ Put into spacer.

15L7ADA047

3-62
΢ Decide thickness of shim by gauge and measuring
apparatus (thickness : B)
ö Thickness of shim
ÂX = B - End play (0.03~0.06)
ex 1) B = 0.45,
ÂX = 0.45 - (0.03~0.06) = 0.42~0.39mm

15L7ADA048

Σ Remove pinion shaft.

15L7ADA049

Τ Pressurize bearing cup.

15L7ADA050

Υ Assemble again pinion shaft and the jig.

Assemble after paste grease on bearing cone
roller.

15L7ADA051

 Assemble shim.
ö Sort of shim : 0.1 , 0.15 , 0.2 (mm)

15L7ADA052

3-63
 Assemble bearing cone.
Assemble after paste grease on bearing cone
roller.

15L7ADA053

Assemble of parking sub assembly

Η Assemble pin into carrier case.

15L7ADA054

Θ Assemble in order of separate plate Ą cone spring

Ą friction plate.
But assemble separate plate lastly.
ÂSeparate plates : 4EA
ÂFriction plates : 3EA

15L7ADA055

Ι Assembles actuator in assembly direction.

15L7ADA056

Κ Assemble spline parking maching with friction plate

spline.

15L7ADA057

3-64
Λ Assemble push pin into actuator.

15L7ADA058

Μ Assemble O-ring on groove of pinion shaft.

Assemble after paste grease on O-ring grease.

15L7ADA059

Ν Assemble pin into the carrier case.

15L7ADA060

Assemble of carrier case cover assemble

Η Assemble oil seal into carrier case cover.
Paste #592 on outside of oil seal and grease on
inside of oil seal.

15L7ADA061

Θ Assemble eccentric shaft.

Put into longer shaft first.

15L7ADA062

3-65
Ι Assemble cover by first putting small O-ring on
eccentric shaft, and then put big O-ring on collor.

15L7ADA063

Κ Assemble set screw.

Assemble paste loctite #277.
Confirm torque : 200~250 kgfÂcm

15L7ADA064

Λ After complete assembling of axle when pull

parking lever. The stroke have to be keeped
11~21mm.

15L7ADA065

15L7ADA064-1

Μ Fix lever with snap ring.

15L7ADA066

3-66
Ν Assemble cap.
Assemble after paste loctite #609.

15L7ADA067

Ξ Assemble carrier cover assy.

Assemble after paste loctite #277.
Confirm torque : 304~405 kgfÂcm
Paste loctite #5127 on assembling side of carrier
case cover and carrier case.

15L7ADA068

ö Applying liquid gasket material.

ö Take care when you use liquid gasket materials to
avoid serious personal injury.
Follow the manufacturer's instructions to prevent
irritation to the eyes and skin.
 Remove all oil gasket material from both surfaces.
 Clean the surfaces where liquid gasket material
15L7ADA069
will be applied. Remove all oil, grease, dirt and
moisture without damaging the mating surfaces.
 Dry both surfaces.

ö The amount of liquid gasket material applied must not exceed 3mm diameter bead.
Too much gasket material can block lubrication passages and result in damage to the
components.
 Apply 3mm maximum diameter continuous bead of the liquid gasket material around one
surface. Keep bead far away from bolt holes to prevent sealant from getting in between mating
threads during bolt installation.
This could significantly reduce the effectiveness of the thread locking compound.
Figure DA071.
 Assemble the components immediately to permit the liquid gasket material to compress evenly
between the parts.
Tighten fasteners to the specified torque.
 Wait 20 minutes before filling the assembly with lubricant.

3-67
Ο Assemble flange U-joint.

15L7ADA070

Π Fasten nut.
Assemble paste loctite #242.
Confirm torque : 2600~2950 kgfÂcm
ö Preload : 10~19 kgfÂcm

15L7ADA071

Ρ Calking. (2 EA)

15L7ADA072

΢ Assemble differential sub in carrier case.

15L7ADA073

Σ Fit carrier cap with steel ball.

Bolt : paste loctite #277
Confirm torque : 1170~1130 kgfÂcm

15L7ADA075

15L7ADA074

3-68
 Adjusting the gearset backlash
Η Assemble bearing adjust ring.

15L7ADA076

Θ Adjust bearing adjust ring.

15L7ADA077

Ι Measure backlash.

15L7ADA078

Κ Fasten bearing adjust ring.

15L7ADA079

Λ Measure again backlash.

ö Backlash of pinion and ring gear : 0.15~0.20mm
ö If backlash is wrong, carry out adjusting work.
Adjust the left/right of ring bearing adjust by one
and one clip.

15L7ADA080

3-69
ö Backlash is increased by moving the ring gear
away from the pinion shaft. Backlash is decreased
by moving the ring gear toward the pinion shaft.
Refer to figure DA076 and DA077.
Μ Loosen one bearing adjusting ring one notch, then
tighten the opposite ring the same amount.
Refer to figure DA076 and DA077.
15L7ADA081

15L7ADA082

Adjusting tooth contact pattern of the gearset

ö After assembling, adjust pattern of the gear and
pinion shaft figure.
If pattern is not adjusted, take a measure as
measuring backlash again and then reassemble.
ö Always check tooth contact pattern on the drive
side of the gear teeth. Figure DA084.
15L7ADA083

15L7ADA084

Η Apply marking compound to approximately 6 teeth

of the ring gear. Figure DA085.

15L7ADA085

3-70
Θ Rotate ring gear forward and backward so that the
6 marked teeth go past the drive pinion six time to
get a good contact pattern.

Ι Compare the contact patterns to figure DA086,

DA087 and DA088.
ö In new gearsets, a good contact pattern is toward
the toe of the tooth, and centered between the top
and bottom of the tooth. Figure DA086.

15L7ADA086

15L7ADA087

15L7ADA088

ö In used gearsets, a good contact pattern fills

approximately the full length of the tooth.
The top of the pattern is near the top of the tooth.
The location should match the wear pattern on the
tooth. Figure DA089.

15L7ADA089

3-71
Κ If the contact patterns require adjustment along the
width of tooth (top/bottom), follow steps ͽ;
If the contact patterns require adjustment along the
length of tooth (toe/heel), follow steps Ϳ΀
ͽ High pattern : A high contact pattern indicates that
the pinion was installed too shallow into the
carrier. Figure DA087.
15L7ADA090
To correct, move the pinion toward the ring gear
by decreasing the shim pack between pinion
spigot and inner bearing cone.
Figure DA090.

; Low pattern : A high contact pattern indicates that

the pinion was installed too deep into that the
pinion was installed too deep into the carrier.
Figure DA088.
To correct, move the pinion away from the ring
gear by increasing the shim pack between pinion
spigot and inner bearing cone.
Figure DA091.
15L7ADA091

Ϳ Heel pattern : Decrease the gearset backlash

(within specified range) to move contact pattern
toward toe and away from heel. Refer to page 3-
69 "Adjusting the gearset backlash" figure DA092.

15L7ADA092

΀ Toe pattern : Increase the gearset backlash

(within specified range) to move contact pattern
toward heel and away from toe.
Refer to the pate 3-69 "Adjusting the gearset
backlash" figure DA093.

15L7ADA093

3-72
Λ Fix spring pin with ring bearing adjust.
And assemble them.

15L7ADA094

15L7ADA095

3-73
(2) Assemble of carrier assembly
Η Pressurize lock pin into axle housing.

15L7ADA096

Θ Paste sealant on axle housing.

(Loctite #5127)

15L7ADA097

Ι Assemble carrier assembly on axle housing.

15L7ADA098

Κ Fasten bolt.
Assemble bolt after spread loctite #277.
Confirm torque : 610~650 kgfÂcm

15L7ADA099

3-74
(3) Traveling brake system assembly
Axle shaft assembly
Η Insert snap ring on the axle shaft.

15L7ADA100

Θ After put the ball bearing, fix it with snap ring.

15L7ADA101

Ι After put axle shaft into axle housing fix with snap
ring.

15L7ADA102

Piston assembly
Η Assemble ring (large and small) at brake piston.
ö When assembling quad ring, pay attent to
chopping.
ö Before assemble quad ring, coating oil.

15L7ADA103

Θ Assemble shim.

15L7ADA104

3-75
ö When assembling the shim, you calculate the value
of the shim ad then assemble it.
 "L" : Piston assembling part axle housing stage
depth (standard : 56.9mm)
 "C":Carrier housing stage height (standard : 9mm)
 "F" : The total thickness of friction plate and
separate plate (standard : 20.5mm)
 "P":Piston thickness (standard : 27mm)
 "S":Brake stroke (basis stroke : 0.4mm)
 T":Shim

S = L-(C+F+P)
T = S-0.4 (basis stroke)
15L7ADA105
ex) if S = 0.5mm,
T = S-0.4 (basis stroke)
= 0.5-0.4 = 0.1mm
assemble for shim 0.1

Ι Assemble in order piston-brake Ą spring Ą

special bolt.
Bolt-special : Spread loctite
Confirm torque : 140~160 kgfÂcm

15L7ADA106

Κ Put pin into axle housing.

15L7ADA107

Λ Put in lock pin.

15L7ADA108

3-76
Μ Assemble in order of separate plate Ą friction plate
Ą cone spring. But Assemble separate plate lastly.
(Separate plate : 4EA , friction plate : 3EA)

15L7ADA109

(4) Hub assembly

Hub sub assembly
Η Pressurize hub bolt.

15L7ADA110

Θ Pressurize oil seal with loctite #592.

Spread grease inside of oil seal.

15L7ADA111

Ι Put with heating bearing cone on wheel shaft.

Assemble after paste axle oil on roll of bearing
cone.

15L7ADA112

Κ Assemble O-ring coated grease at wheel shaft.

15L7ADA113

3-77
Λ Assemble flange hub and wheel shaft.
ö Paste loctite #5127
Confirm torque : 600~700kgfÂcm
Bolt : Spread loctite #277

15L7ADA114

Μ Fix spacer.

15L7ADA115

Ν Assemble oil seal at carrier housing.

Oil seal with loctite #592.

15L7ADA116

Ξ Assemble bearing cup at carrier housing.

15L7ADA117

Ο Assemble bearing cup at upper side of carrier

housing.

15L7ADA118

3-78
Π Put carrier housing on assembled flange hub and
wheel shaft. Before assembling, spread grease
inside of flange hub.
ÂGrease : Shell retinax 0434 - 60~80% spread

15L7ADA119

Ρ Adjust preload for fix shim.

ÂPreload : 40~50kgfÂcm

15L7ADA120

΢ Put into shim.

ö Sort of shim : 0.1 , 0.15 , 0.25 , 0.5 (mm)

15L7ADA121

Σ Pressurize bearing cone.

Before assembling, paste axle oil on roller of
bearing cone.

15L7ADA122

Τ Assemble planet carrier.

15L7ADA123

3-79
Υ Fasten lock nut.
Confirm torque : 2800~3200kgfÂcm, calke after
assembling.
ÂPreload : 40~50kgfÂcm

15L7ADA124

 Assemble in order of washer Ą needle bearing Ą

planet gear Ą washer .
Before assembling washer, paste oil, spread
grease on needle bearing.

15L7ADA125

 Fix snap ring.

15L7ADA126

(5) Assemble of hub sub assembly

Η Paste loctite #5127 on axle housing.

15L7ADA127

Θ Assemble hub sub assembly.

Bolt : Assemble after spread loctite #277.
Confirm torque : 1170~1310kgfÂcm
ö Assemble hub sub assembly after support it by
lifting device as like the same way of
disassembling.

15L7ADA128

3-80
(6) The rest part assembly
Η Assemble O-ring and fitting bleeder for LH and RH.
Confirm torque : 380~420kgfÂcm

15L7ADA129

Θ Assemble bleeder and cap.

Screw : Assemble after spread loctite #577.
Confirm torque : 150~200kgfÂcm

15L7ADA130

Ι Assemble air breather.

15L7ADA131

Κ Assemble drain plug (magnetic).

Screw : Assemble after spread loctite #577.
Confirm torque : 700~900kgfÂcm

15L7ADA132

Λ Assemble drain plug (magnetic).

Screw : Assemble after spread loctite #577.
Confirm torque : 300~410kgfÂcm

15L7ADA133

3-81
Μ Put in dipstick.
ö Fill axle oil as much as standard.
Standard between the upper limit and the lowest
limit. Figure DA134.

15L7ADA134

15L7ADA135

Ν Assemble bracket.
Bolt : Paste loctite #277.
Confirm torque : 610~650kgfÂcm

15L7ADA136

Ξ Finish drive axle assembly.

15L7ADA137

3-82
(7) Functional test of hydraulic apply brake
ö The following procedure describes how to test the
hydraulic apply brake system only.
To perform this test, use a device that allows you to
observe possible leaks through oil seals and that
also allows you to verify that the piston return
system works correctly . For an accurate
evaluation, the device must allow piston
displacement of 0.4~0.6mm.
Η Brake bleeder valve while supplying hydraulic oil to
the pressure inlet. Pump oil through the brake until
oil coming out of the bleeder does not contain air
bubbles.
Close the brake bleeder valve.
Θ Actuate the piston at least five times with 60 bar.
Check for leaks and free movement of piston. Refer
to step 7).
Ι If you find a leak : Disassemble the hub sub
assembly. Determine the cause of the leak and
correct the problem. Check the seal surfaces for
sharp edges, nicks and burrs.
Κ Wait five minutes. Apply 60 bar to the piston and
lock pressure on. Pressure must not drop after one
minute.
Λ If pressure drops off : Disassemble the hub sub
assembly. Determine the cause of the leak and
correct the problem. Repeat step 1) - 5).
ö You must check that the brake completely releases
after you apply the brake.
Do not operate the brake system with the brake
partially released. Damage to brake components
can result.

3-83
 SECTION 4 BRAKE SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10
 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) 22.22mm (0.87in)
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

1
T/M control valve

Drive axle

15L7ABS01

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

Pedal height
160mm

Floor plate

Control valve
33mm(1.3in)

Inching spool

T/M

15L7MBS02

4-3
5. WET DISK BRAKE
1) STRUCTURE

1 2 3 4 6 7 9

5 8

15L7APT20

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.
ÂCylinder bore diameter : 22.22mm
ÂPiston stroke : 35mm
3) INSPECTION
(1) Clean and check these components.
ö 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
ö Prior to assembly make sure again of no contaminant of the components. Apply a thin coat
of brake oil to the components.
ÂAssembly 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
(1) Operating force of parking lever is 35~40
kgfÂm(253~290lbfÂft).
2 1
(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.
15L7ATA19

4-6
2. TROUBLESHOOTING
Problem cause Remedy
Insufficient braking force ÂHydraulic system leaks oil. ÂRepair and add oil.
ÂHydraulic system leaks air. ÂBleed air.
ÂDisk worn. ÂReplace.
ÂBrake valve malfunctioning. ÂRepair or replace.
ÂHydraulic system clogged. ÂClean.
Brake acting unevenly. ÂTires unequally inflated. ÂAdjust tire pressure.
(Machine is turned to one ÂBrake out of adjustment. ÂAdjust.
side during braking.) ÂDisk surface roughened. ÂRepair by polishing or replace.
ÂWheel bearing out of adjustment. ÂAdjust or replace.
ÂHydraulic system clogged. ÂClean.
Brake trailing. ÂPedal has no play. ÂAdjust.
ÂPiston cup faulty. ÂReplace.
ÂBrake valve return port clogged. ÂClean.
ÂHydraulic system clogged. ÂClean.
ÂWheel bearing out of adjustment. ÂAdjust or replace.
Brake chirps ÂBrake trailing. ÂSee above. Brake trailing.
ÂPiston fails to return. ÂReplace.
ÂDisk worn. ÂReplace.
ÂDisk surface roughened. ÂRepair by polishing or replace.
Brake squeaks ÂDisk surface roughened. ÂRepair by polishing or replace.
ÂDisk worn. ÂReplace.
ÂExcessively large friction between ÂClean and apply brake grease.
disk plate.
Large pedal stroke ÂBrake out of adjustment. ÂAdjust.
ÂHydraulic line sucking air. ÂBleed air.
ÂOil leaks from hydraulic line, or lack ÂCheck and repair or add oil.
of oil.
ÂDisk worn. ÂReplace.
Pedal dragging. ÂTwisted push rod caused by improp- ÂAdjust.
erly fitted brake valve.
ÂBrake valve seal faulty. ÂReplace.

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 Air vent plug
on the ground and removes cap from air
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 Vinyl tube
filled with hydraulic oil.
5) Loosen air vent plug by turning it 3/4 with a
wrench. Depress brake pedal to drain oil Vessel
mixed with air bubbles from plug hole.
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. 15L7ABS09

2. ADJUSTMENT OF PEDAL
1) BRAKE PEDAL
(1) Pedal height from floor plate
Adjust with stopper bolt.
ÂPedal height : 160mm (6.3in)
(2) Play Idle stroke : 1~3mm
Adjust with rod of master cylinder.
ÂPlay : 1~3mm (0.04~0.1in) Pedal height
160mm

Floor plate

15L7MBS10

4-8
 (3) Micro switch for parking brake (if equipped)
o
Η After assembling parking brake and Lever stroke 12.1
parking cable, put the parking brake lever
released.
Θ Loosen the nut for parking brake plate to
play up and down.
Ι Move up the plate so that the stopper can Micro switch
be contacted with the pin and then
Rachet
reassemble nut.
Nut
ÂMicro 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.
ÂPedal height : 160mm (6.3in) Inching stroke
1~3mm
(2) Adjust bolt so that brake pedal interconn-
ects with inching pedal at inching pedal
stroke 1~3mm. Pedal height
160mm

Floor plate

15L7MBS11

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
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE

Steering wheel

Steering cylinder

Steering unit

T
L
P
R
LS
Hydraulic tank

T4

Pump priority
valve "LS"
Pump priorty
valve "CF"

15L7MSS01

The steering system for this machine is composed of steering wheel assembly, 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

15L7MSS02

1 Hydraulic gear pump with priority valve 8 Suction strainer

4 Steering unit 12 Hydraulic tank
5 Steering cylinder

5-2
1) NEUTRAL

15L7MSS03

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(1) which is included in the pump
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

15L7MSS04

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 in the pump 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

15L7MSS05

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 in the pump 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

20
13
29 25
14
15
16 24 19
21 23
22
11 25
10 5
18 33
17 30
34
1 35
24 43
23 42
32

16
15
14
22 36
13 12
21
9 37
3
31 26 35
32 27 34 2
28 33
6
43 18 24
42 17 23
8
7

15L7MSS07

1 Steering axle center 14 Oil seal 27 Hex bolt

2 Hub sub assy 15 Collar 28 Pin
3 Hub cap 16 Retaining ring 29 Steering cylinder assy
4 Hub nut 17 Special bolt 30 Block-RR
5 Upper cover sub 18 Spring washer 31 Block-FR
6 Lower cover sub 19 Link sub assy 32 Shim
7 Hex bolt 20 Steer link pin 33 Shim
8 Spring washer 21 Steer link pin 34 Shim
9 Knuckle-LH 22 Grease nipple 35 Shim
10 Knuckle-RH 23 Split pin 36 Plain washer
11 King pin 24 Plain washer 37 Split pin
12 Slotted nut 25 Thrust washer 42 Hex bolt
13 Taper roller bearing 26 Lock plate 43 Spring washer

5-8
2) TIGHTENING TORQUE AND SPECIFICATION

80
.8
56

Stroke
86mm

Apply loctite #277

49.5~66.5 kgf m(358~481 lbf ft)

15L7SS08

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
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS
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 1Ü0.5ä; 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 withinÜ100mm (Ü4in)of specified value, adjust
turning angle stopper bolt.
Min turning radius(Outside)
15L(G)-7M 1985mm (78in)
18L(G)-7M 2013mm (79in)
20L(G)-7M 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.
ö Oil pressure :100~105kgf/cm2 (1420~1490psi)

2. TROUBLESHOOTING
Problem Cause Remedy
Steering wheel drags. ÂLow oil pressure. ÂCheck lockout. Repair.
ÂBearing faulty. ÂClean or replace.
ÂSpring spool faulty. ÂClean or replace.
ÂReaction plunger faulty. ÂReplace.
ÂBall-and-screw assembly faulty. ÂClean or replace.
ÂSector shaft adjusting screw excessi- ÂAdjust.
vely tight.
ÂGears poorly meshing. ÂCheck and correct meshing.
ÂFlow divider coil spring fatigued. ÂReplace.
Steering wheel fails to return ÂBearing faulty. ÂClean or replace.
smoothly. ÂReaction plunger faulty. ÂReplace.
ÂBall-and-screw assy faulty ÂClean or replace.
ÂGears poorly meshing. ÂCheck and correct meshing.

5-10
 Problem Cause Remedy
Steering wheel turns unstea- ÂLockout loosening. ÂRetighten.
dily. ÂMetal spring deteriorated. ÂReplace.
Steering system makes abn- ÂGear backlash out of adjustment. ÂAdjust.
ormal sound or vibration. ÂLockout loosening. ÂRetighten.
ÂAir in oil circuit. ÂBleed air.
Abnormal sound heard when Valve
steering wheel is turned fully ÂFaulty. (Valve fails to open.) ÂAdjust valve set pressure and check
for specified oil pressure.
Piping
ÂPipe(from pump to power steering ÂRepair or replace.
cylinder) dented or clogged.
Piping makes abnormal Oil pump
sounds. ÂLack of oil. ÂAdd oil.
ÂOil inlet pipe sucks air. ÂRepair.
ÂInsufficient air bleeding. ÂBleed air completely.
Valve or valve unit makes Oil pump
abnormal sounds. ÂOil inlet pipe sucks air. ÂRepair or replace.
Valve
ÂFaulty. (Unbalance oil pressure) ÂAdjust valve set pressure and check
specified oil pressure.
Piping
ÂPipe(from pump to power steering) ÂRepair or replace.
dented or clogged.
ÂInsufficient air bleeding. ÂBleed air completely.
Insufficient or variable oil flow. ÂFlow control valve orifice clogged. ÂClean
Insufficient or variable dischar- Piping
ge pressure. ÂPipe(from tank to pipe) dented or ÂRepair or replace.
clogged.
Steering cylinder head ÂPacking foreign material. ÂReplace
leakage (Piston rod) ÂPiston rod damage. ÂGrind surface with oil stone.
ÂRod seal damage and distortion. ÂReplace
ÂChrome gilding damage. ÂGrind
Steering cylinder head thread ÂO-ring damage. ÂReplace
(A little bit leak is no problem)
Welding leakage ÂCylinder tube damage. ÂTube replace.
Rod ÂTube inside damage. ÂGrind surface with oil store.
ÂPiston seal damage and distortion ÂReplace
Piston rod bushing inner ÂBushing wear. ÂReplace
diameter excessive gap

5-11
GROUP 3 DISASSEMBLY AND ASSEMBLY
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 0~7.1kgfÂm

(0~54.4lbfÂft)
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 [kgfÂm(lbfÂft)]

L 3/4 UNF - 16 9.5 (68.7)
R 3/4 UNF - 16 9.5 (68.7)
T 3/4 UNF - 16 9.5 (68.7)
P 3/4 UNF - 16 9.5 (68.7)
Mounting bolt M10Ý1.5 4Ü0.5 (28.9Ü3.6)

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)

ö 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.
ö 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.

ö 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)

ö 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.
ö 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 20ä
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 20ä 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.
ÂTightening torque : 4 Ü 0.5kgfÂm
(28.9 Ü 3.6lbfÂft)

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.
ö 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
ö 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 0.074~0.120 0.150 Replace
piston & cylinder tube (0.0029~0.0047) (0.0059) piston seal
Clearance between 0.025~0.16 0.210 Replace
cylinder rod & bushing (0.0010~0.0063) (0.0082) 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.
ö 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 45Ü4.5
kgfÂm(325Ü33lbfÂft).

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.
ö 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.
ö 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
ö Do not remove the stopper bolt unless necessary.

20
13
29 25
14
15
16 24 19
21 23
22
11 25
10 5
18 33
17 30
34
1 35
24 43
23 42
32

16
15
14
22 36
13 12
21
9 37
3
31 26 35
32 27 34 2
28 33
6
43 18 24
42 17 23
8
7

15L7MSS07

1 Steering axle center 14 Oil seal 27 Hex bolt

2 Hub sub assy 15 Collar 28 Pin
3 Hub cap 16 Retaining ring 29 Steering cylinder assy
4 Hub nut 17 Special bolt 30 Block-RR
5 Upper cover sub 18 Spring washer 31 Block-FR
6 Lower cover sub 19 Link sub assy 32 Shim
7 Hex bolt 20 Steer link pin 33 Shim
8 Spring washer 21 Steer link pin 34 Shim
9 Knuckle-LH 22 Grease nipple 35 Shim
10 Knuckle-RH 23 Split pin 36 Plain washer
11 King pin 24 Plain washer 37 Split pin
12 Slotted pin 25 Thrust washer 42 Hex bolt
13 Taper roller bearing 26 Lock plate 43 Spring washer

5-33
 2) CHECK AND INSPECTION

C A1,A2 B D1

D2

D3

15L7SS10

unit : mm(in)
Criteria
No. Check item Remarks
Standard size Repair limit
49.954~49.985 49.8
A1 OD of shaft (1.966~1.968) (1.960)
A Shaft
50.1~50.3 50.5
A2 ID of bushing (1.972~1.980) (1.988)
29.975~29.991 29.96
B OD of king pin Replace
(1.180~1.181) (1.179)
16.973~16.984 16.958
C OD of steering cylinder pin
(0.668~0.669) (0.667)
16.973~16.984 16.958
D1 OD of pin (0.668~0.669) (0.667)
D Knuckle D2 Vertical play - - Adjust with shims
16.992~17.0 17.012
D3 ID of bushing (0.6689~0.6692) (0.6697) Replace

ÂOD : Outer diameter

ÂID : Inner diameter

5-34
3) DISASSEMBLY
ö 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.

15L7MSE24

(2) Remove Hub cap.

(3) Pull out split pin and remove slotted nut.
Hub cap
(4) Using the puller, take off the hub together with Split pin
Slotted nut
the roller bearing.
Hub
ö 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.
Knuckle
ö Don't use same oil seal twice.
(7) Repeat the same procedure for the other side.
Moreover, when disassembling is completed, Washer
part the slotted nut in the knuckle to protect the
15L7MSS09
threaded portion.

(8) Loosen special bolt (17) and spring washer (18).

5
(9) Pry out the retaining ring (16) and remove oil 33
seal (14). 34
35
(10) Push out the king pin (11) without damaging the 13
14
knuckle (9). 15
16
(11) Remove spilt pin (23), plain washer (24) and link
pin (21). 11

19
22
21

18 9
17

24
23
15L7MSS12

5-35
4) ASSEMBLY
13
ö In reassembling, have all parts washed, grease 14
applied to lubricating parts, and all expendable 15
16
items such as oil seal and spring washers
replaced by new ones. 11

Perform the disassembly in reverse order.

22
(1) Tighten the special bolt (17) and washer (18) of 21
king pin (11). 9
18
(2) There is a notch in the middle of the king pin 17

(11), make sure that this notch is on the special 24

23
bolt side.
(3) Hub
Η Tighten nut (12) and lock with split pin (37). In
2
locking with split pin, locate the hole for the split
pin by turning the nut back 1/6 of a turn.
Adjust the preload of bearing.
4
Θ Mount the hub cap (3).
Bearing should be well greased before assem-
bling.
36
12
37
3
15L7MSS13

5-36
 SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-26
 SECTION 6 HYDRAULIC SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. HYDRAULIC CIRCUIT (NON OPSS / TRAVEL OPSS)

15L7MHS01

1 Hydraulic gear pump with priority valve 8 Suction strainer

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
7 Lift cylinder

6-1
HYDRAULIC CIRCUIT (TRAVEL WITH MAST OPSS)

15L7MHS02

1 Hydraulic gear pump with priority valve 8 Suction strainer

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
7 Lift cylinder

6-2
1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION

15L7MHS03

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(1)
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

15L7MHS04

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

15L7MHS05

When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward
position.
The oil from hydraulic gear pump(1) flows into main control valve(3) through the priority valve(1)
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

15L7MHS06

When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward
position.
The oil from hydraulic gear pump(1) flows into main control valve(3) through the priority valve(1)
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
4
21
22 7
20 6
19 9
25

5
28
29
7

1
12
26 11
18 27
17 24
2
16 23

10

3
13

14

9
15
8
15L7MHS06A

1 Housing 11 Back-up ring 21 Spring

2 Body 12 Side plate 22 Plug
3 Body-priority v/v 13 Oil seal 23 O-ring
4 Bushing 14 Snap ring 24 Adjust screw
5 O-ring 15 Bold 25 O-ring
6 Pin 16 Washer 26 Bolt
7 Drive gear 17 Plug 27 Poppet
8 Idle gear 18 O-ring 28 Spring relief
9 Side plate 19 Orifice plug 29 Plug
10 O-ring 20 Spool 30 O-ring

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. 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

6-8
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).

6-9
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.

6-10
(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.

6-11
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.

6-12
(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.

6-13
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

6-14
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.

6-15
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.

6-16
(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.

6-17
(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.

6-18
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).

6-19
4. 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

5. TILT CYLINDER

2
18 17 16 19,20,21 9 15 11,12 10 13,14 8 1 3 4 6 5
7

15L7HS14

1 Tube assembly 8 Gland 15 O-ring

2 Rod 9 Wiper dust 16 Rod eye
3 Piston 10 Du bushing 17 Spherical bearing
4 Piston seal 11 Rod seal 18 Grease nipple
5 Wear ring 12 Back up ring 19 Hex bolt
6 O-ring 13 O-ring 20 Spring washer
7 Nylon nut 14 Back up ring 21 Hex nut

6-20
6. 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

6-21
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
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).
ÂC Check condition 15L7AHS18
- Hydraulic oil : Normal operating temp
- Mast substantially vertical.
- Rated capacity load.
ÂHydraulic drift Within 5
- Down(Downward movement of forks) (after 10min)

: Within 100mm (3.9in)

- Forward(Extension of tilt cylinder)
: Within 5Á
(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
15L7AHS19
standard range.
mm (in)
Standard Under 0.6 (0.02)

2) HYDRAULIC OIL
(1) Using dipstick, measure oil level, and oil if
Oil dipstick
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 Drain plug
hours) 15L7MHS20

3) CONTROL VALVE
(1) Raise forks to maximum height and
measure oil relief pressure.
Check that oil relief pressure is 190kgf/cm2.
(2702psi)

6-22
2. TROUBLESHOOTING
1) SYSTEM
Problem Cause Remedy
Large fork lowering speed. ÂSeal inside control valve defective. ÂReplace spool or valve body.
ÂOil leaks from joint or hose. ÂReplace.
ÂSeal inside cylinder defective. ÂReplace packing.
Large spontaneous tilt of ÂTilting backward : Check valve defec- ÂClean or replace.
mast. tive.
ÂTilting forward : tilt lock valve defect- ÂClean or replace.
ive.
ÂOil leaks from joint or hose. ÂReplace.
ÂSeal inside cylinder defective. ÂReplace seal.
Slow fork lifting or slow mast ÂLack of hydraulic oil. ÂAdd oil.
tilting. ÂHydraulic oil mixed with air. ÂBleed air.
ÂOil leaks from joint or hose. ÂReplace.
ÂExcessive restriction of oil flow on ÂClean filter.
pump suction side.
ÂRelief valve fails to keep specified ÂAdjust relief valve.
pressure.
ÂPoor sealing inside cylinder. ÂReplace packing.
ÂHigh hydraulic oil viscosity. ÂChange to SAE10W, class CF engine
oil.
ÂMast fails to move smoothly. ÂAdjust roll to rail clearance.
ÂOil leaks from lift control valve spool. ÂReplace spool or valve body.
ÂOil leaks from tilt control valve spool. ÂReplace spool or valve body.
Hydraulic system makes ÂExcessive restriction of oil flow pump ÂClean filter.
abnormal sounds. suction side.
ÂGear or bearing in hydraulic pump ÂReplace gear or bearing.
defective.
Control valve lever is locked ÂForeign matter jammed between sp- ÂClean.
ool and valve body.
ÂValve body defective. ÂTighten body mounting bolts uniform-
ly.
High oil temperature. ÂLack of hydraulic oil. ÂAdd oil.
ÂHigh oil viscosity. ÂChange to SAE10W, class CF engine
oil.
ÂOil filter clogged. ÂClean filter.

6-23
 2) HYDRAULIC GEAR PUMP

Problem Cause Remedy

Pump does not develop full ÂSystem relief valve set too low or ÂCheck system relief valve for proper
pressure. leaking. setting.
ÂOil viscosity too low. ÂChange to proper viscosity oil.
ÂPump is worn out. ÂRepair or replace pump.
Pump will not pump oil. ÂReservoir low or empty. ÂFill reservoir to proper level.
ÂSuction strainer clogged. ÂClean suction strainer.
Noisy pump caused by ÂOil too thick. ÂChange to proper viscosity.
cavitation. ÂOil filter plugged. ÂClean filters.
ÂSuction line plugged or too small. ÂClean line and check for proper size.
Oil heating. ÂOil supply low. ÂFill reservoir to proper level.
ÂContaminated oil. ÂDrain reservoir and refill with clean oil.
ÂSetting of relief valve too high or too ÂSet to correct pressure.
low.
ÂOil viscosity too low. ÂDrain reservoir and fill with proper
viscosity.
Foaming oil. ÂLow oil level. ÂFill reservoir to proper level.
ÂAir leaking into suction line. ÂTighten fittings, check condition of
line.
ÂWrong kind of oil. ÂDrain reservoir, fill with non-foaming
oil.
Shaft seal leakage. ÂWorn shaft seal. ÂReplace shaft seal.
ÂWorn shaft in seal area. ÂReplace drive shaft and seal.

3) MAIN RELIEF VALVE

Problem Cause Remedy
Can’t get pressure ÂPoppet D, E or K stuck open or ÂCheck for foreign matter between
contamination under seat. poppets D, E or K and their mating
parts. Parts must slide freely.
Erratic pressure ÂPilot poppet seat damaged. ÂReplace the relief valve.
ÂClean and remove surface
marks for free movement.
Pressure setting not correct ÂNormal wear. Lock nut & adjust ÂSee øHow to set pressure on work
screw loose. main relief.
Leaks ÂDamaged seats. ÂReplace the relief valve.
ÂWorn O-rings. ÂInstall seal and spring kit.
ÂParts sticking due to contamination. ÂDisassemble and clean.
ø 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.

6-24
 4) LIFT CYLINDER

Problem Cause Remedy

Oil leaks out from gland ÂForeign matters on packing. ÂReplace packing.
through rod. ÂUnallowable score on rod. ÂSmooth rod surface with an oil stone.
ÂUnusual distortion of dust seal. ÂReplace dust seal.
ÂChrome plating is striped. ÂReplace rod.
Oil leaks out from cylinder ÂO-ring damaged. ÂReplace O-ring.
gland thread.
Rod spontaneously retract. ÂScores on inner surface of tube. ÂSmooth rod surface with an oil stone.
ÂUnallowable score on the inner ÂReplace cylinder tube.
surface of tube.
ÂForeign matters in piston seal. ÂReplace piston seal.
Wear(clearance between ÂExcessive clearance between ÂReplace wear ring.
cylinder tube and wear ring) cylinder tube and wear ring.
Abnormal noise is produced ÂInsufficient lubrication of anchor pin or ÂLubricate or replace.
during tilting operation. worn bushing and pin.
ÂBent tilt cylinder rod. ÂReplace.

6-25
GROUP 3 DISASSEMBLY AND ASSEMBLY

1. DISASSEMBLY
1) CLAMPING PUMP
(1) Clamping pump in a vice with pump shaft
facing up.
(Do not chuck the aluminum parts such as
body and housing.)
(2) Mark V by permanent marker pen.
This will assure proper reassembly.
PUMP101

2) HOUSING
(1) Loosen 8 bolts and remove housing.
(2) Pry off snap ring for hole and remove oil
seal from housing.
(3) Remove O-ring from housing.

PUMP102

3) GEAR
(1) Mark at the end of the idle gear by
permanent marker pen before removing
gear set. This will assure proper
reassembly.

PUMP103

(2) Dissemble gear set and side plate from

body.
(3) Dissemble E-type ring and backup ring
from side plate.

PUMP104

6-26
4) BODY AND REAR COVER
(1) Loosen the vice and remove body and
bronze side plate from rear cover.
(2) Remove O-ring from rear cover.
(3) Disassemble pin from body.

PUMP105

5) PRIORITY VALVE
(1) Loosen the plug at the side of drive gear,
be careful not to bounce out spring.
(2) Take out spring.
(3) Loosen plug opposite side and draw out
spool carefully.

PUMP106

6) RELIEF VALVE
ö Do not disassemble relief valve when
pressure setting and caulking is not
possible.
(1) Loosen adjust screw, be careful not to
bounce out spring.
(2) Take out spring and draw out poppet.
(3) Loosen plug for port of gage mounting.
(4) Remove O-ring from plug and adjust
screw.

6-27
2. ASSEMBLY
1) PREPARATION
(1) Clean all parts and dry them with
compressed air thoroughly.
(2) Check the permanent mark.
(3) Apply grease O-ring, oil seal, E-type ring
and side plate lightly.

2) PRIORITY VALVE
Suction Discharge
 Relief valve : if disassembled
(1) Fit O-ring on plug and adjust screw.
(2) Tighten plug for port of gage mounting.
(Tightening torque : 35 Nm)
(3) Assemble poppet, spring and adjust screw
into body in that order.
(4) Install relief valve to the machine after final
PUMP107
assembling and set the relief pressure and
caulk 3 places(equivalent), not to loosen.

 Priority valve
(1) Insert spool into spring groove from idle
gear side of body carefully and tighten
plug. (Tightening torque : 80 Nm)
(2) Put spring the other side and tighten plug.
(Tightening torque : 100 Nm)

6-28
3) REAR COVER AND BODY
(1) Assemble pin into body. Suction Discharge
(2) Assemble O-ring on the groove of rear
cover.
(3) Place the bronze face of side plate contact
with gear on rear cover.
Insert side plate into body and adjust pin
by pressing after adjusting pin hole of rear
PUMP108
cover and pin of body.
(4) Confirm the direction of rear cover, bronze
side plate and body same as drawing.

Suction Discharge

PUMP109

4) GEAR
(1) Place body up.
(2) Place peck center of idle gear up and
assemble drive gear and idle gear to body.
Suction Discharge
(3) Fit E-type ring and backup ring and
combine side plate with gear set.
(4) Confirm the direction of side plate same
as drawing. PUMP110

(5) Confirm the face of backup ring side

contact with housing.

PUMP111

6-29
5) HOUSING
(1) Press fit oil seal with same direction as
drawing carefully and fit snap ring.
(2) Fit O-ring into groove of housing.
(3) Insert drive gear into housing and
combine housing with body pressing
lightly after confirmed pin position.
(4) Tighten bolt with washer zigzag lightly, be
careful not to leave O-ring its place.
(5) Clamp rear cover in a vice.
(6) Tighten bolt zigzag with tightening torque
35~38 Nm.

6) INSPECTION
(1) Clamp drive gear shaft in a vice.
(2) Rotate the gear pump.
(3) Confirm rotation smoothly.

6-30
3. MAIN CONTROL VALVE
1) ASSEMBLY
(1) General
Η Ensure that the assembly area will be clean and free of contamination.
Θ Use a flat (within 0.2mm) work surface when bolting the valve sections together.
Ι Use calibrated torque wrenches and instrumentation.
Κ The formal Bills of Material, descriptions, and views are found in the attached documentation.
Λ 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

Η Attach all the o-rings to the appropriate grooves between the spool sections.
Θ 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.
Ι Insert all the tie rods through the drilled holes in each of the housings.
Κ Press the sections together, being careful not to damage sealing surfaces or seals.
Λ 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 kgfÂm (17.4~21.0 lbfÂft)on all tie rods. Periodically, make sure that the valve
remains flat while applying torque.

6-31
(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

Η Install the main relief valve assembly into the lower side cavity of the inlet section, as illustrated.
Torque to 4.5-5.0 kgfÂm (32.5~36.2 lbfÂft).
Θ 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 kgfÂm (25.2~28.8 lbfÂft).
Ι Install the plug assembly in the tank port of the inlet section.
Torque to 4.5-5.0 kgfÂm (32.5~36.2 lbfÂft).
Κ Install the plug in the pressure gage port to the inlet. Torque to 4.5-5.0 kgfÂm (32.5~36.2 lbfÂft).

6-32
(4) Lift section

LIFT LOAD CHECK V/V

SOLENOID V/V COIL

SPRING

LOAD CHECK
SOLENOID V/V CATRIDGE
(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
LIF MAIN RELIEF VALVE
SEAL
SOLENOID V/V CATRIDGE DUST WIPER
(NORMALLY OPEN)
CAP
SOLENOID V/V COIL SECONDARY RELIEF VALVE
SEAL PLATE

15L7HS34

Η 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.
Θ 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 kgfÂm (7.2~10.8
lbfÂft) is reached on both bolts.
Ι 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 kgfÂm (7.2~10.8 lbfÂft)
is reached on both bolts.
Κ The load check assembly is inserted into the top center cavity.
Torque to 3.5-4.0kgfÂm (25.2~28.8 lbfÂft).
Λ The normally closed solenoid is installed in the rightmost cavity on the top of the section.
Torque to 3.5-4.0 kgfÂm (25.2~28.8 lbfÂft).
Μ Install the lift lock check valve assembly in the remaining open cavity in the top of the housing.
Torque to 4.5-5.0 kgfÂm (32.5~36.2 lbfÂft).
Ν Install the needle valve subassembly in the cavity on the inlet-facing surface of the housing.
Torque to 1.0-1.5 kgfÂm (7.2~10.8 lbfÂft).

6-33
(5) Tilt 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

Η 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.
Θ 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 kgfÂm (7.2~10.8
lbfÂft) is reached on both bolts.
Ι 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 kgfÂm (7.2~10.8 lbfÂft)
is reached on both bolts.
Κ The load check assembly is inserted into the top center cavity.
Torque to 3.5-4.0 kgfÂm (25.2~28.8 lbfÂft).

6-34
(6) Auxiliary sections

LIFT LOAD CHECK V/V

SOLENOID V/V COIL

SPRING

LOAD CHECK
SOLENOID V/V CATRIDGE
(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
LIF MAIN RELIEF VALVE
SEAL
SOLENOID V/V CATRIDGE DUST WIPER
(NORMALLY OPEN)
CAP
SOLENOID V/V COIL SECONDARY RELIEF VALVE
SEAL PLATE

15L7HS34

(Same procedure for all aux sections, but spool assembly components may vary)
Η 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.
Θ 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 kgfÂm (7.2~10.8
lbfÂft) is reached on both bolts.
Ι 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 kgfÂm (7.2~10.8 lbfÂft)
is reached on both bolts.
Κ The load check assembly is inserted into the top center cavity.
Torque to 3.5-4.0kgfÂm (25.2~28.8 lbfÂft) .

(7) Outlet section

Η Install the secondary relief valve into the cavity on the clevis end of the housing.
Torque to 4.5-5.0 kgfÂm (32.5~36.2 lbfÂft).

6-35
2) DISASSEMBLY INSTRUCTIONS
(1) General
Η Subassemblies (such as relief valves, check valves, and spools) may be removed without having
to loosen the tie rods and disassembling the entire valve.
Θ Disassemble the valve sections on a flat working surface.
Ι Ensure that the disassembly area will be clean and free of contamination.
Κ Keep the disassembly area neat to avoid loss or damage of parts.

LIFT LOAD CHECK V/V

SOLENOID V/V COIL

SPRING

LOAD CHECK
SOLENOID V/V CATRIDGE
(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
LIF MAIN RELIEF VALVE
SEAL
SOLENOID V/V CATRIDGE DUST WIPER
(NORMALLY OPEN)
CAP
SOLENOID V/V COIL SECONDARY RELIEF VALVE
SEAL PLATE

15L7HS34

(2) Procedure
Η Loosen the tie rod nuts and remove the tie rods from the valve sections.
Θ Remove o-rings between valve sections and set aside to avoid damage.
Ι 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.
Κ 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.

6-36
4. LIFT CYLINDER
1) STRUCTURE

9
6
8 3

5
10
4
11
7
13

12

14

15

 I.DÝO.DÝStroke : 45Ý55Ý1245mm
(1.7Ý2.2Ý49~108in)
 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

6-37
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

3) CHECK AND INSPECTION mm(in)

Check item Standard size Repair limit Remedy

Clearance between 0.072~0.288 0.5 Replace

cylinder rod & bushing (0.003~0.011) (0.020) bushing
Clearance between 0.05~0.030 0.5 Replace
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 50Á 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

6-38
5. TILT CYLINDER
1) STRUCTURE

15
8

21

20
18 19

16
17

1
7
6
5
4
3
14
13
11 . I.D O.D Stroke : 75 86 112mm
12 (2.9 3.3 4.4in)
. Rod O.D : 35mm(1.3in)
10

15L7HS21

1 Tube assy 9 Dust wiper 16 Rod eye

2 Rod 10 Du bushing 17 Spherical bearing
3 Piston 11 Rod seal 18 Grease nipple
4 Piston seal 12 Back up ring 19 Hex bolt
5 Wear ring 13 O-ring 20 Spring washer
6 O-ring 14 Back up ring 21 Hex nut
7 Nylon nut 15 O-ring
8 Gland

6-39
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.

3) CHECK AND INSPECTION mm(in)

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)

6-40
 SECTION 7 ELECTRICAL SYSTEM

Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Group 4 Connector Destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
 SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION

10

1
9

8
7

2
3

6
5

11 12 13 14 15 16

17 18 19

15L7AEL01

1 Battery 8 Rear lamp 15 Switch assembly

2 Flasher lamp 9 Combination lamp 16 Fuse box
3 Work lamp 10 Beacon lamp 17 Flasher unit
4 Combination switch 11 Forward-reverse lever 18 OPSS unit
5 Horn assembly 12 Operating panel 19 Buzzer
6 Back buzzer 13 Start switch
7 License lamp 14 Horn button

7-1
GROUP 2 ELECTRICAL CIRCUIT
CABIN PART
CN-27
290
DASHBOARD PART FRAME/ENGINE PART
ACC 1
G1
ILL- 2
G1
GND 3
562 CN-17 F/COMBI H/LAMP
SPK FRT RH- 4 200-R RH RH
566 1
RADIO/USB PLAYER
290-W 290

FUEL SENDER(LPG)
SPK FRT LH- 5
2

120

180
170
TEL MUTE 6 340-L 340 CLUSTER
3

TM TEMP S/W
C
L T

E
ANT 12V 7 G1-B

LICENSE LAMP
W

W
GRAMMAR SEAT

B
4

WATER SEPARATOR

OPTION
200

A/CLEANER
BACK UP+ 8

WG

CD-29
FOR CABIN

BRAKE OIL LEVEL

E/G TEMP GAUGE

Pa
1 2 3 4 5 6 7 8 9 10 11 12

TURN SIGNAL LH
TURN SIGNAL RH

B
340 CN-72

PARKING BRAKE

SWITCH
EARTH(GAUGE)
ENGINE CHECK
ILL+ 9

10A

10A

15A

10A

10A

15A
GLOW LAMP(+)

5A

5A

5A

5A

5A

5A
CHARGE LAMP

ANTI-RESTART
GLOW LAMP(-)

ILLUMINATION
CN-71 1

T/M OIL TEMP

CD-10
FUEL GAUGE
FUEL EMPTY

CL-21
ENG. OIL PS
G5

CD-2
NC 10

OPSS LAMP

HEAD LAMP

AIR FILTER
CR-11 1 6

WORK/BEACON LAMP

2
1
560

SEAT SWITCH
SPK FRT RH+ 11 310-R 310 250 G5-B
L 1

HORN/STOP LAMP
2 5 3

BI-FUEL SELECT/HEAT
EARTH

SPEED CONTROL
REMOCON+ 12
G 210-G 210 250-R

ILL/HEAD LAMP
4

OPSS SYSTEM
B 2 4

START RELAY
G1-B G1

IG
REMOCON GND G3-B

450-W
13

FUSE BOX
TURN LAMP

446-R

458-V
FOR CABIN
-

-
3

340-L
E CS-73

G3-B

G3-B
3

G3-B
OPS-UNIT
564

CLUSTER
SPK FRT LH+ 14 460

TRAVEL
FLASHER UNIT 1 2

CN-57

CN-36
CN-56
CN-5
NC 15 G3 460-Gr

10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
CR-5

2
4

1
3
G1 2 1
GND 16 87a 5
86 87 87a 220-L 220
ANTENA

87
320-Y

334-Gr
320

448-Br

230-Br
450-W

212-W

240-W

290-W
234-R
HANILEH SEAT

330-G

330-G

456-G

392-G

210-G
430-R

312-R
446-R

200-R

250-R

205-R
270-P

270-P
395-L
314-L
340-L

328-L

314-L

452-L

220-L

280-L
340-L
30

G1-B

G2-B

G2-B
350-Gr 350
CN-24 86 CS-73
562 85 30 G1-B
CS-73
2 85 460
560 1
1 NEUTRAL RELAY G3
CS-2 START KEY 2
170-W
RH SPEAKER CR-13 4 *BI-FUEL EXT. SWITCH SEAT
120-R
3

H0 I
87a CD-2 CN-7
CN-23 86 87 87a 330-G 330 180-Gr B G3-B G3-B
87 2 3 2 1 1 1
566

0,
2 230-Br 230 Y 394-WL 394-Y
30 1 2 2 2 CN-131
564

I
4 BR
1 360-G 360 L 398-Gr 398-Gr 336 336-P
86
- ACC
1 3 3 3 2 CUTOFF SOL1
1 R1
85 30 G1-B B3 G3-B (TILT/LIFT)
LH SPEAKER 85 4 BR
FUEL SENDER 4 4 1
- ACC
HEADLAMP RELAY (GASOLINE) 336-P

234
4 BR

395
G1

G2
334

328
430

314
330
312
446
448

450
452

456

392

200
210
212
220
230
240
250

280
290
205

120

170
340
CL-1 - ACC 2
200 2 R2 G3-B
2 - ST 1
G1
CR-50 CN-2
420 420-Y 420 DO-2
1 87a 1 CN-1
86 87 87a
CN-132
ROOM LAMP 322-W 322 394 336-P
87 2 1 1 2 CUTOFF SOL2
326 205 205-R 205 250-R 398 G3-B (LIFT DOWN)
30 3 2 SEAT HEAT 2 1
CN-22 326-R 446-R 250
86 4 CN-1 3 CLUSTER 3 336-P

392
395
250
G1
G2
290
210
220

200

230
330
280

312
314
212
340
205
328

240
334
234
446
456
452
450
170
448
120
430
458
G1 85 30 458-V 446 2
M 1 1 1
85 4 CLUSTER 4 G3-B
510 322 1 250-R 458 1
2 TRAVEL CUT RELAY 2 2 SEAT HEAT 5 5
WASHER PUMP 2 446-R 450-W DO-3
3 3 S/W A/CLEANER 6 CLUSTER 6
*TIER3:EXT. 3 458-V 460-Gr 450
4 4 FUEL SENDER 7 OPSS UNIT 7 CN-122
DO-4 CAP 4 G2 460 352 352-G
5 5 8 8 1
G1 N/C : EXT. G1 450-W 336-P 420 420-Y
1 CAP 6 6 S/W T/M TEMP 9 RY CUTOFF 9 2
510 250 460-Gr 352-G 336
2 CR-51 7 7 SEAT SWITCH 10 GEAR SELECTOR 10 F/SOL
DIODE 336-P 336 446 420-Y 340
87a 8 8 11 RY TRAVEL CUT 11
86 87 87a 456 336-P 120-R 120
87 9 9 CUTOFF SOL1 12 RY POWER 12 DO-1
205-R 452 352-G 120-R SP2 352 420-Y
CS-3 30 10 10 F-SOL 13 RY POWER 13 2
G1 205-R 450 420-Y 120-R 420 422-G
9 10 10 86 11 11 TRAVEL SOL 14 RY POWER 14 1
340 85 30 324-Y 324 170 120-R 120
9 85 12 12 ALT B+ 15 15
530 290 448 SP1 120-R 456-G 354
3 8 ATTACH CUT RELAY 13 13 ALT B+ 16 CLUSTER 16
120 120-R
CN-123
7 210 452-L 354 354-P
14 14 ALT B+ 17 CLUSTER 17 1
8 520 430
6 6 CN-113 220 448-Br 422-G
15 15 18 CLUSTER 18 2
1 458 456-G
5 332-Br 332 170-W
1 16 16 F/KIT INTERFACE 19 KEY START 19 R/SOL
452-L
I

4 200-R 200 430-R

2 17 17 F/KIT INTERFACE 20 CLUSTER 20
0,

510 340 448-Br 320-Y

3 18 18 F/KIT INTERFACE 21 RY NEUTRAL 21
OPSS BUZZER CN-65
0 I

200 170-W 170 G3 G3-B

2 19 19 F/KIT INTERFACE 22 22 1
290 320
430-R 340-L 456 354-P
1 CS-5 20 20 F/KIT INTERFACE 23 SWITCH COMBI 23 2
420
G1-B 230 320-Y 354-P 452
WIPER SWITCH 21 21 F/KIT INTERFACE 24 GEAR SELECTOR 24 BACK-UP BUZZER
336
380-V 380 330 G2-B 448
22 22 25 CLUSTER 25
280 340-L
CN-21 23 23 ILLUMINATION 26 26 CN-74
530 HORN SWITCH 352
354-P
E 2 1 372-Br 430 TO: BP
460 24 24 R-SOL/BZ/LAMP 27 S/W CUTOFF 27 1 L
Pf 1 G1 312 G2-B 374-Y 320 U
2 CS-17 25 25 MAIN EARTH 28 S/W CUTOFF 28 2 DUMMY
372
B 3
3
290
NO NC NC
Br
3
328-L 328 314
374 26 26 29 29
232 ~
520 W 326-R 372-Br 232-Gr 372 3
4 27 27 F/KIT INTERFACE G
NO 2 232
374-Y
30 S/W SPEED CONTROL 30 B+
B G1-B 340
28 28
374
COM 1 F/KIT INTERFACE 31 31
- +
COM
205 391 391-W 391 ALTERNATOR
M PARKING SWITCH 29 29 32 FUEL- SELECT 32
Lo 4 328 394 232-Gr 394-Y
30 30 F/KIT INTERFACE 33 S/W BI-FUEL 33 CN-45
370 398 398-Gr G2 TO: BP
WIPER MOTOR CS-21 31 31 34 RY F/LAMP 34 M
9 10 10
G1-B G1 458 391-W
32 32 FUEL SELECT 35 35
G1 M
370-P 394-Y G1-B
CL-15 9 33 33 FUEL SENDER (G) 36 EARTH 36
390 320 354 398-Gr 120-R
RW ST 1
340 8 34 34 FUEL SENDER (G) B+
RB CL 2 8 420
6 7 35 35 START MOTOR
R
312 2 336 391 G1-B
TN 3 36 36 MAIN EARTH
354 6
LW BK 7 280-L 280 394 OPTION
4 5
5
398
CN-6
5 1 310 170-W 38SQ(R)
G1 4 VSW (IG ON) 1
350 458 456-G 38SQ(B) 38SQ(B)
B GN 6 ENGINE TEMP GAUGE 2
3
R/COMBI LH 360 452-L
2 ENGINE OIL PRESS S/W 3

FUEL SYSTEM INTERFACE

370-P 370 322 448-Br
1 CR-36 CHARGE INDICATION 4 BATTERY
CL-16 324 232-Gr MASTER SW
REAR WORK SWITCH 87a SPEED SELECT(HIGH/LOW) 5 12V
390 332 30 86
430-R
RW ST 1 391-W
340 250 85 ENGINE CHECK(MIL) 6
RB CL 2 380 395 395-L FUEL LAMP 320-Y
314 CS-41 392 87 STARTER COMMAND 7
R TN 3 G1-B 250-Or RELAY 391-W
354 9 10 10 395 86 FUEL SELECT 8
340-L 398 87a 87 85 372-Br
LW BK 4 398-Gr LPG CUTOFF SW1
9 G1 30 9
5 374-Y
G1 8 LPG CUTOFF SW2 10
B GN 6 8 345-B
6 7 5V RTN 11
R/COMBI RH 2 310-WB 344-G
6 CS-6 FPP1 12
7 310-WB 540 342-Or
H/LAMP 5 5 1 5V EXT 13 CN-15 CD-11
RH 1 540 346-B G4 G3

I 0
4 2 IVS 14 3 3 SHIELD
W 330 238-L 238-L 238-L
3 3 VEHICLE SPEED(-) 15 2 2 VRS(-)
B G1 314-RB 314 290 236-W 236-W 236-W
2 4 BI-FUEL : EXT VEHICLE SPEED(+) 16 1 1 VRS(+)
2
312-R 312 550
B G1 1 5 6
CN-3 CS-66 SPEED-SENSOR
E 550 8 G1 G1-B G1-B G1
340
HAZARD SWITCH 6
1 1
W 1
C 7 394 394-Y 394-YB 394 CN-124
L 314 4 5 2 2
T 391 391-W 391-WB G3-B
CL-15 CN-4 8 7
3 3 6 2 3 G 6
F/COMBI 390-W 390-W 390-W 340 392 392-G 392-G
RW ST 1 1 9 5 - 5
9 4 4
RH G1 10 P.D 1

SENSOR
340-L 340-L 340-L 250 250-Or 250-Or 391 1 346-W
RB CL 2 2 10
5 5 5 4 AMP IVS 4
312-R 312-R 312-R 458 458-V 458-WR 392 7 SW 342-Or
BEACON R TN 3 3 HEATER SWITCH 6 6 3 PS Vdc 3

G1-B
G2-B
G3-B
LAMP CL-7 354-L 354-L 354-L 777 2 344-G
LW BK 4 4 7 6 2 SIG 2
G1 200-R 6 4 345-B
5 5 1 458 8 1 G(sig) 1
M 280 8
G1-B G1-B G1-B * HEATER OPTION 2 777
B GN 6 6 9 ACCEL PEDAL
314-L 314-L 3 391
R/COMBI LH CN-16 10 9
G1

CN-46
280
330
340
312
354
314
390

200
290

7 10 TIER3 : ELECTRIC PEDAL

330-G 330-G G1 4
8 1 1
370-P 370-P 550 BI-FUEL SWITCH
5
CN-18

CL-16 9 2 2 0.7?

390-W 280-L 280-L 540

10
11
12
1
2
3
4
5
6
7
8
9

RW ST 1 10 3 3 6 DIODE
340-L 290-W M 777-Y
2
MAIN EARTH
RB CL 2 11 4 4
314-L 250-Or
R TN HEATER 1
G1
280
330
340
312
354
314
390

200
290

3 12
G1
310
350
360
322
324
332
380

200
390
230

312
314
212
340
205
328
354

240
334
234
352
460
372
374
232

354-L
LW BK 4
5
CN-4 G1-B
390
B GN 6
1 R/COMBI RH
340
2
312
3
354 CL-3
4 B G1-B
200 330-GW
5 W
G1
CL-3 6 H/LAMP LH
B G1 314
350-Gr

316-Gr

7
230-Br
240-W
352-G

360-G
360-G
312-R

310-R
380-V
354-L

314-L

G1-B

W 330 330

316-Gr
230-Br
460-Gr

334-Gr

376-Gr

376-Gr

232-Gr
8
332-Br

372-Br

340-L
205-W

322-W

212-W

390-W
352-G

G1-B
200-R

200-R

205-R

234-R
324-Y

380-V

374-Y

CL-17
354-L

328-L
G1-B

G1-B

370

G-B
H/LAMP LH 9 B G1-B
E
CS-12
CS-11

280 340-L
10 C W
1
2
3
4
5

1
2
3
4
5
6
7
8
9

HORN

CS-42
CN-55

CN-25
BRAKE S/W
CD-4

CS-68
OPSS UNIT

290

CR-15
CL-17 11 L 312-R
10

10
10
11
12
13
14

2
1

5
4

5
4

1
6

2
1
2
3
4
5
6
7
8
9

3
T

30

85
86
87
87a
B G1
E 12 T/LAMP LH
2-TRH

4-HO
1-TLH
4-FWD
5-REV

340
8-Hi

Pa

10

10
7-Lo

87 87a
W
6-ILL

30
1-N

L 312
GEAR SELECTOR

T
REAR WORK
COMBI.SWITCH

GND
IGN

RELAY2

RELAY3

T/LAMP LH
OPS-LAMP
FWD S/W

86

85
REV S/W

BRAKE S/W
TRAVEL CUT
SEAT S/W

LAMP CL-23
BATT(+)
PARK'G S/W
BUZZER(-)

>

G1-B
9

9
7

7
8

8
2

1
370-P
REAR WORK LPG CUTOFF SWITCH SPEED CONTROL SWITCH ILLUM RELAY
3-HO

LAMP CL-23 3-C 9-C

G1 5-C

370 BEACON
LAMP CL-7 STEERING COLUMN SWITCH
G1-B
M 280-WL 15L7MEL01

7-2
·CERTI

HDGCP90

15L7AEL07-1

7-3
·NON CERTI

HDGCP90

15L7AEL07-2

7-3-1
MEMORANDUM

7-4
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+)] I/conn[CN-1(12,13,14)]
Start switch[CS-2(3)]
Fuse box[CN-36] (No.1) Cab[CN-17(1)]
OPSS buzzer[CN-113(2)]
Horn[CN-25(2)]
Brake switch[CD-4]
I/conn[CN-4(5)] I/conn[CN-18(9)] Room lamp[CL-1(2)]
Radio/USB player[CN-27(8)]

2) CHECK POINT

Engine Key switch Check point Voltage

Η - GND (Battery(+))
OFF OFF Θ - GND (Fuse No.1) 10 ~ 13V
Ι - GND (Start key)

7-5
 POWER CIRCUIT

2 3 CS-2 CL-16
CN-17 CN-36 390
1 ST RW
120 4
200 200 HORN/STOP LAMP 10A
1 3 2 CL RB

H0 I
TURN LAMP 10A
2 2

2
3 TN R

0,
212 OPS-UNIT 5A
1

3
3

I
4 BR 4 BK LW
START RELAY 5A - ACC

4
4 ILL/HEAD LAMP 15A B3
1 R1
5
4 BR
G1

5
- ACC
(CABIN) TRAVEL 5A
4 BR 6 GN B

6
BI-FUEL SELECT/HEAT 10A - ACC
2 R2
R/COMBI RH

7
- ST
SPEED CONTROL 5A

8
CLUSTER 5A START KEY

9 10 11 12
WORK/BEACON LAMP 10A CL-15
FOR CABIN 15A 390
1 ST RW
OPSS SYSTEM 5A
2 CL RB
CD-4 3 TN R
CN-113 FUSE BOX 200
Pa CN-4 4 BK LW
332 390 390 390 5
1 1
G1
200 2 6 GN B
2 BRAKE SW
3 R/COMBI LH
OPSS BUZZER
4 CN-18
200 200
CS-5 5 1
G1 G1 G1
6 2
380
7 3
8 8
HORN SWITCH 200 200
9 9
10 10
G1 G1
11 11
12 12

CN-55
IGN 1
SEAT S/W 2 CN-1 CN-74
REV S/W 3 1 TO : BP
1 L
FWD S/W 4 2 U
2 DUMMY
TRAVEL CUT
RELAY2
5
6
3 ~
4 3 G
GND 7 B+
5
OPS-LAMP 8
6 ALTERNATOR
BUZZER(-) 9
BRAKE S/W 10 7
RELAY3 11 8 CN-45
TO : BP
BATT(+) 12 9 M
PARK'G S/W 13 10 M
14
11
OPSS UNIT 120 120 120 120
12 B+
SP1 120 120 SP2
13 START MOTOR
120 120
14
15
16
17
CN-25 OPTION
380 18
1
200 19
2 38SQ(R) 38SQ(B) 38SQ(B)
20
HORN
21
22 BATTERY
23 12V MASTER SW
24 1
25
26
27
28
29
200

200
380

G1

G1
G1

G1
G1

ROOM LAMP
CS-11

30
CL-1

CN-27
CS-12

31
1

10
11
12
13
14
15
16
5

2
3

2
5
6
7
8
9
4
1

1
3
4
2

1
2
3
4
5
6
7

9
8

32
REMOCON+
GND

GND
REMOCON GND
NC

NC
ACC

33
4-FWD

2-TRH
1-TLH
5-REV

4-HO

BACK UP+
TEL MUTE
ANT 12V

ILL+
8-Hi
6-ILL

ILL-
7-Lo

SPK FRT RH+

SPK FRT LH+

SPK FRT RH-
SPK FRT LH-

34
1-N

35
G1 G1
36
>

RADIO/USB PLAYER
3-HO

3-C 5-C 9-C ANTENA

GEAR SELECTOR COMBI SWITCH

15L7MEL02

7-6
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Start motor[CN-45(B+)] I/conn[CN-1(12,13,14)] Start switch[CS-2(3)]
öT
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] ILLUM relay[CR-15(30)]
Combi switch[CS-12(5)]
Headlamp relay[CR-13(30)]

(2) When start key switch is START position

Start switch START[CS-2(2)] Fuse box[CN-36(4)] Neutral relay[CR-5(87)]

2) CHECK POINT

Engine Key switch Check point Voltage

Η - GND (Battery B+)

Θ - GND (Fuse box No.5)
Running ON 10 ~ 14.5V
Ι - GND (Start key)
Κ - GND (Neutral relay)

7-7
 STARTING CIRCUIT

2
CN-36 CS-2
170
HORN/STOP LAMP 10A
4
120
3

H0 I
CR-5 TURN LAMP 10A 180
2

0,
OPS-UNIT 5A
1

I
4 BR
220 220 START RELAY 5A - ACC

4
1 R1
ILL/HEAD LAMP 15A B3
4 BR

5
TRAVEL 5A - ACC

3 4 BR

6
BI-FUEL SELECT/HEAT 15A - ACC
2 R2

7
- ST
SPEED CONTROL 5A

8
NEUTRAL RELAY CLUSTER 5A START KEY
4

9 10 11 12
WORK/BEACON LAMP 10A
FOR CABIN 15A
OPSS SYSTEM 5A

FUSE BOX

CR-13 CN-1
1
230 2
3
4
5
HEAD LAMP RELAY 6
7
8
CR-15 9
10
11
230 120 120 120
12
SP1 120 120 SP2
13
120 120
14
ILLUM RELAY 15
16
17
18
19
20
21
22
23
24
25
26
27
28
230

CN-45
CS-11

CS-12

TO : BP
M
M
5

2
3

5
6
7
8
9
4
1

1
3
4
2

4-FWD

2-TRH
1-TLH
5-REV

4-HO
8-Hi
6-ILL

7-Lo

120
B+
1-N

START MOTOR
>

38SQ(R)
3-HO

3-C 9-C OPTION

5-C

GEAR SELECTOR 38SQ(B) 38SQ(B)

COMBI SWITCH

BATTERY
12V MASTER SW
1

15L7MEL03

7-8
GROUP 3 COMPONENT SPECIFICATION

No Part name Qty Specification Remark

1 Battery 1 CCA : 550

20HR : 60AH CMF 60(223Ý168Ý220)
2 Working lamp 1 12V, 55W
3 License lamp 1 12V, 10W
4 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 12V, (23W23W)Ý23WÝ2
8 Back horn 1 12V, 90Ü5dB, 60Ü10C/M
9 Horn 1 12V, MAX 3.5A, 113Ü5dB(at 2m distance)
10 Master switch 1 180A
11 Combination switch 1 12V, 16A
12 Hazard switch 1 12V, 16A
13 Start switch 1 12V/24V, 15~28A
14 OPSS unit 1 12V/24V, MAX 0.5A(at 12V)
15 Relay(4P) 2 12V, 20A
16 Relay(5P) 2 12V, 20A

7-9
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-2 KET 4 I/conn (Dashboard harness-travel ext harness) MG610331 MG640329
CN-3 KET 6 To : Ext bi-fuel switch MG610335 -
CN-4 KET 12 I/conn (Dashboard harness-head guard harness) MG610346 MG640348
CN-5 KET 4 Support harness-RH S810-004201 -
CN-6 AMP 16 Fuel system interface connection - 368050-1
CN-7 KET 4 To : Ext bi-fuel MG610331 MG640333
CN-15 DEUTSCH 3 Speed sensor DT06-3S DT04-3P
CN-16 DEUTSCH 4 Heater DT06-4S DT04-4P
CN-17 KET 4 Power output for cabin S810-004201 MG620046
CN-18 KET 4 Power output for cabin S810-004201 -
CN-25 AMP 1 Horn 17809-2 -
CN-36 - - Fuse box 21HF-10500 -
CN-45 RING TERM - Start motor - -
CN-48 KET 2 Hour meter S822-014000 S822-114000
CN-55 KET 14 OPSS unit S814-014100 MG640352
CN-56 AMP 20 Cluster 368511-2 -
CN-57 AMP 8 Cluster 368540-2 -
CN-65 KET 2 Back buzzer - MG640322
CN-71 KET 2 Seat heat(Grammer seat) MG610043 MG620042
CN-113 KET 2 OPSS buzzer S814-002100 MG640322
CN-122 DEUTSCH 2 Forward solenoid DT06-2S -
CN-123 DEUTSCH 2 Reverse solenoid DT06-2S -
CN-124 AMP 6 Accel pedal 174262-2 -
CN-131 PACKARD 2 Cut off solenoid 1(Tilt/lift) 12015792 12047670
CN-132 PACKARD 2 Cut off solenoid 2(Lift/down) 12015792 12047670
Switch -
CS-2 KET 4 Start switch S810-004201 -
CS-5 RING TERM - Horn switch S820-105000 -
CS-6 DAEDONG 10 Heater switch 250-10PRG -
CS-11 AMP 5 Gear selector switch 172494-1 -
CS-12 AMP 9 Combination switch S811-009002 -
CS-17 KET 3 Parking switch S810-003201 -
CS-21 DAEDONG 10 Rear work switch 250-10PRG -
CS-41 DAEDONG 10 Hazard switch 250-10PRG -
CS-42 DAEDONG 10 Speed control switch 250-10PRG
CS-68 DAEDONG 10 Cut off switch 250-10PRG -
CS-73 KET 2 Seat switch MG610043 MG620042

7-10
Connector No. of Connector part No.
Type Destination
number pin Female Male
Lamp
CL-3 KET 1 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-17 KET 1 Flasher lamp S822-014000 S822-114000
CL-21 KET 1 License lamp ST750018-3 ST750036-3
CL-23 KET 1 Rear working lamp S822-014000 S822-114000
Relay
CR-5 KET 5 Neutral relay MG640927 -
CR-11 KET 3 Flasher unit S810-003702 -
CR-13 KET 5 Head lamp relay MG640927 -
CR-15 KET 5 Illumination relay MG640927 -
CR-35 AMP 4 Warning relay S810-004202 -
CR-36 KET 5 Fuel lamp relay MG640927 -
CR-51 KET 5 Attach cut relay MG640927 -
Sensor and pressure switch
CD-2 KET 2 To : Frame harness-Fuel tank S810-002201 S810-102201
CD-4 AMP 2 Brake switch 171809-2 -
CD-10 KET 1 Air cleaner switch ST730057-2 -
CD-29 AMP 1 T/M temp switch 172320-2 -
DO-1 - 2 Diode 174352-2 21EA-50550
DO-2 - 2 Diode 174352-2 21EA-50550
DO-3 - 2 Diode 174352-2 21EA-50550

7-11
GROUP 5 TROUBLESHOOTING

Trouble symptom Probable cause Remedy

Lamps dimming even at maxi- ÂFaulty wiring. ÂCheck for loose terminal and discon-
mum engine speed. nected wire.
Lamps flicker during engine ÂImproper belt tension. ÂAdjust belt tension.
operation.
Charge lamp does not light ÂCharge lamp defective. ÂReplace.
during normal engine operation. ÂFaulty wiring. ÂCheck and repair.
Alternator makes abnormal ÂAlternator defective. ÂReplace
sounds.
Starting motor fails to run. ÂFaulty wiring. ÂCheck and repair.
ÂInsufficient battery voltage. ÂRecharge battery.
Starting motor pinion repeats ÂInsufficient battery voltage. ÂRecharge battery.
going in and out.
Excessively low starting motor ÂInsufficient battery voltage. ÂRecharge battery.
speed. ÂStarting motor defective. ÂReplace
Starting motor comes to a stop ÂFaulty wiring. ÂCheck and repair.
before engine starts up. ÂInsufficient battery voltage. ÂRecharge battery.
Heater signal does not beco- ÂFaulty wiring. ÂCheck and repair.
me red. ÂGlow plug damaged. ÂReplace
Engine oil pressure caution ÂCaution lamp defective. ÂReplace
lamp does not light when engi- ÂCaution lamp switch defective. ÂReplace
ne is stopped
(with starting switch left in"ON"
position).

7-12
 SECTION 8 MAST

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4
Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7
Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10
 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
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
1) FORKS
(1) Measure thickness of root of forks and
check that it is more than specified value.
EX : ˶=900mm(35.4in)
mm(in)
STD Fork assy Applicable model Standard Limit
64FP-12030 15L(G)/18L(G)-7M 35(1.4) 32(1.3)
64FD-11010 20L(G)-7M 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)
15L/18L/20L-7M equal or below 1200 3
15G/18G/20G-7M 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.
ÂFront-to-rear clearance : Within 2.0mm(0.08in)
ÂLeft-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
Problem Cause Remedy
Forks fail to lower. ÂDeformed mast or carriage. ÂDisassemble, repair or replace.
Fork fails to elevate ÂFaulty hydraulic equipment. ÂSee troubleshooting hydraulic pump
and cylinders in section 6, hydraulic
system.
ÂDeformed mast assembly. ÂDisassemble mast and replace
damaged parts or replace complete
mast assembly.
Slow lifting speed and ÂFaulty hydraulic equipment. ÂSee troubleshooting hydraulic pump
insufficient handling capacity. and cylinders in section 6, hydraulic
system.
ÂDeformed mast assembly. ÂDisassemble mast and replace
damaged parts or replace complete
mast assembly.
Mast fails to lift smoothly. ÂDeformed masts or carriage. ÂDisassembly, repair or replace.
ÂFaulty hydraulic equipment. ÂSee Troubleshooting Hydraulic
Cylinders, pump and control valve in
section 6, hydraulic system.
ÂDamaged load and side rollers. ÂReplace.
ÂUnequal chain tension between ÂAdjust chains.
LH & RH sides.
ÂLH & RH mast inclination angles ÂAdjust tilt cylinder rods.
are unequal. (Mast assembly is
twisted when tilted)
Abnormal noise is produced ÂBroken load roller bearings. ÂReplace.
when mast is lifted and lower- ÂBroken side roller bearings. ÂReplace.
ed. ÂDeformed masts. ÂDisassemble, repair or replace.
ÂBent lift cylinder rod. ÂReplace.
ÂDeformed carriage. ÂReplace.
ÂBroken sheave bearing. ÂReplace.
Abnormal noise is produced ÂInsufficient lubrication of anchor ÂLubricate or replace.
during tilting operation. pin, or worn bushing and pin.
ÂBent tilt cylinder rod. ÂReplace.

8-5
 2) FORKS

Problem Cause Remedy

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.
ÂWear 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.
ÂDifference 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.
ÂCrack on the fork heel.
ÂCrack 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.
ÂStandard clearance A, B = 0.3 ~ 0.6mm
ÂShim 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
(1) Measure the clearance with the mast
overlap at near 480mm.
(2) Shift the inner mast to one side to bring
the roller into contact with the outer mast
and the middle mast, and adjust the
clearance between the roller side face and
mast at the closest position on the 15L7MS06

opposite side to the following value by

inserting the inner and middle mast roller
shim, respectively.
ÂStandard clearance A = 0.3~0.6mm
ÂShim 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 middle mast,
and the middle mast moves smoothly in
the outer mast.

2) OUTER AND MIDDLE MAST UPPER

ROLLER CLEARANCE ADJUSTMENT.
(1) Measure the clearance with the mast
overlap at near 480mm.
(2) Shift the inner mast to one side to bring
the roller into contact with the 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.
ÂStandard clearance B = 0.3~0.6mm
ÂShim 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 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
15L7MS08
between the roller side face and mast at the
closest position on the opposite side to the
following value by inserting the carriage
roller shim.
ÂStandard clearance C = 0.3~0.6mm
ÂShim thickness 0.5, 1.0mm
(3) Distribute the shim thickness equally to 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.
15L7MS09
ÂStandard clearance E = 0.2 ~ 0.6mm
ÂShim thickness 0.5, 1.0mm
(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.
ö 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)
Η Remove the carriage assembly and
move them to one side.
Θ Loosen and remove hexagon bolts and
washers securing lift cylinders to inner Inner
mast. mast
Stud
Ι Loosen and remove hexagon bolts and bolt
nuts securing lift cylinders to inner mast.
Κ 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.
Λ 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
Μ Using the overhead hoist, lower inner
mast until top and bottom rollers and Outer
back up liners are exposed. mast
Ν Using a pryer, remove load rollers from
load roller bracket. Remove back up
liners and shims.
Ξ Thoroughly clean, inspect and replace all
worn or damaged parts.
Ο Reverse the above procedure to Bolt
assemble. Refer to MAST LOAD
ROLLER ADJUSTMENT paragraph.

15L7MS14

8-12
(2) 3 stage mast(TF mast)
Η Remove the carriage assembly and
move it to one side.
Θ Loosen and remove hexagon bolt
securing bottom cylinder from outer mast.
Ι Loosen and remove hexagon bolt and
special washers securing lift cylinders to
middle mast. Remove the spring pin.
Κ 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
Λ 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
Μ 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).
Ν 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.
Ξ Using a player, remove load rollers from Outer
load bracket. Remove back up liners and mast

shims.
Ο 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
Π Using a pryer, remove load rollers from
load roller bracket.
Ρ Thoroughly clean, inspect and replace all
worn or damaged parts.
΢ Reverse the above procedure to
assemble. Refer to MAST LOAD
ROLLER ADJUSTMENT paragraph.
15L7MS15

8-13
5) ELEVATING MAST
(1) Inner mast (V mast)
Η 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.
Θ Lift inner mast upright straight up and out of outer mast section.
Ι Replace and reverse above procedure to install. Make all necessary measurements and
adjustments.
(2) Inner and middle mast(TF mast)
Η After completing all necessary steps for load rollers and back up liner removal. Remove rear
chains and sheave support if not already done.
Θ Disconnect free lift cylinder hose. Drain hose into a suitable pan or container and cap hose.
Ι While supporting free lift cylinder assembly, remove bolts and washers securing cylinder to mast
crossmember.
Κ Place a sling around free lift cylinder and attach to an overhead hoist. Slowly raise and move
cylinder to one side.
Λ 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.
Μ 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.
Ν Replace upright and reverse above procedure to install. Make all necessary measurements and
adjustments.

8-14
6) CHAIN
(1) Chain sheave(V mast)
Η 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.
Θ 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.
Ι Remove retaining ring securing sheaves
to sheave support. Remove sheaves
with bearings.
Κ Remove bearing retaining ring from
sheave and press bearings from
sheaves.
Λ Thoroughly clean, inspect and replace all
worn or damaged parts.
Μ Reverse the above to assemble and
install. Use new split pins in chain anchor
pins. 15L7MS16

(2) Rear chain sheave(TF mast)

Η Raise and securely block carriage and Chain
Anchor Middle mast
inner mast section. bolt
Θ 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.
Ι Remove chains.
Κ Remove retaining ring securing chain
sheaves to sheave support. Pry off
sheaves with bearings.
Λ Remove bearing retaining ring from
sheave and press bearings from
sheaves.
Μ Thoroughly clean, inspect and replace all
Inner mast
worn or damaged parts.
Ν 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)
Η Remove the carriage assembly and move to one side.
Θ 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.
Ι Remove retaining ring securing chain wheel bearing to chain wheel bearing support.
Κ Remove bearing retaining ring from chain wheel bearing and press bearings from chain wheel
bearings.
Λ Thoroughly clean, inspect and replace all worn or damaged parts.
Μ Reverse the above procedure to install.
(4) Rear chain(TF mast)
Η Remove the carriage assembly and move to one side. Refer to carriage removal and installation.
Θ Raise and securely block truck approximately 6 inches from the floor.
Ι 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.
Κ Remove split pins and chain anchor pins securing chains to chain anchor(part of inner mast).
Λ While supporting the chains, remove split and chain anchor pins securing chains to chain
anchors attached to outer mast section.
Μ Remove chains.
Ν 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
Η 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.
Θ Place a wooden block under the carriage and lower the carriage on the block.
Ι While supporting the chains, remove split pins and chain anchor pins from chain anchors.
Κ Remove chains and wash them with solvent. Refer to this section for Load chain inspection and
maintenance.
Λ 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 :
Η 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
Θ 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.
Ι 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.
Κ 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 :
ÂBent pins or plates.
ÂRusty joints.
ÂPeened plate edges.
Oil rusty chains and replace chains with bent or peened components.
Λ 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.
Μ 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.
Ν 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
 Ξ 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 :
ÂDetermine pitch length of chain using 6 inch scale on one side of wear scale.
ÂIf 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.
ÂIf pitch is 5/8(15.875mm), 1-1/4(31.75mm) or 2(50.8mm), use side B.
ÂAlign point A or B to center of a pin and note position of the opposite A or B point.
ÂIf 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
Η 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.
ÂWipe off the old oil with a clean cloth and blow out the remaining dirt with compressed air.
Wear eye protection.
ÂWith a clean brush, apply EP-140 extreme pressure lubricant or heavy motor oil(40W).
Θ 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
Ι Adjustment
Chain adjustments are important for the following reasons :
ÂEqual loading of chain.
ÂProper sequencing of mast.
ÂPrevent over-stretching of chains.
ÂPrevent chains from jumping off sheaves if they are too loose.
Κ Adjustment procedure
ÂWith mast in its fully collapsed and vertical position, lower the fork to the floor.
ÂAdjust 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