CONTENTS

FOREWORD ....................................................................................................................................... 2
SECTION 1 GENERAL ................................................................................................................. 11
GROUP1 SAFETY HINTS ...................................................................................................... 12
GROUP2 SPECIFICATIONS ................................................................................................... 16
GROUP3 PERIODIC REPLACEMENT .................................................................................... 24
SECTION2 REMOVAL AND INSTALLATION OF UNIT .................................................................. 25
GROUP1 STRUCTURE ......................................................................................................... 26
GROUP2 REMOVAL AND INSTALLATION OF UNIT .............................................................. 27
SECTION3 POWER TRAIN SYSTEM ............................................................................................ 42
GROUP1 STRUCTURE AND OPERATION ............................................................................. 43
GROUP2 DISASSEMBLY AND ASSEMBLY AND TROUBLESHOOTING ................................... 46
SECTION4 BRAKE SYSTEM ........................................................................................................ 68
GROUP1 STRUCTURE AND FUNCTION ............................................................................... 69
GROUP2 OPERATIONAL CHECKS AND TROUBLESHOOTING ............................................... 79
GROUP3 TESTS AND ADJUSTMENTS .................................................................................. 81
SECTION5 STEERING SYSTEM ................................................................................................... 83
GROUP1 STRUCTURE AND FUNCTION ............................................................................... 84
GROUP2 OPERATIONAL CHECKS AND TROUBLESHOOTING ............................................... 93
GROUP3 DISASSEMBLY AND ASSEMBLY ............................................................................. 96
SECTION6 HYDRAULIC SYSTEM .............................................................................................. 121
GROUP1 STRUCTURE AND FUNCTION ............................................................................. 122
GROUP2 OPERATIONAL CHECKS AND TROUBLESHOOTING ..................................... 134
GROUP3 DISASSEMBLY AND ASSEMBLY ........................................................................... 138
SECTION7 ELECTRICAL SYSTEM .............................................................................................. 152
GROUP1 COMPONENT LOCATION ................................................................................... 153
GROUP2 ELECTRICAL CIRCUIT .......................................................................................... 154
GROUP3 COMPONENT SPECIFICATION ............................................................................ 159
GROUP4 CONNECTOR DESTINATION ............................................................................... 160
GROUP5 TROUBLESHOOTING .......................................................................................... 163
SECTION8 LPG SYSTEM ........................................................................................................... 164
GROUP1 OPEN LOOP LPG FORKLIFT TRUCK SYSTEM COMPONENTS PRINCIPLE ............. 165
GROUP2 GAS FILLING AND OPERATION ........................................................................... 176
GROUP3 HANDLING OF ACCIDENTS AND EMERGENCIES ................................................ 179
GROUP4 TROUBLESHOOTING .......................................................................................... 180
SECTION9 MAST ..................................................................................................................... 187
GROUP1 STRUCTURE ....................................................................................................... 188
GROUP2 OPERATIONALCHECKS ANDTROUBLESHOOTING............................................... 192
GROUP3 ADJUSTMENT .................................................................................................... 195
GROUP4 REMOVAL AND INSTALLATION........................................................................... 198

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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 LPG SYSTEM
This section explains principle, component, operation and troubleshooting.
SECTION 9 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.

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2 HOW TO READ THE SERVICE MANUAL
Distribution and updating
Any additions, amendments or other changes will be sent to HYUNDAI distributors.
Get the most up-to-date information before you start any work.

1) Filing method
See the page number on the bottom of the page.

2) Revised edition mark(①②③…)

When a manual is revised, an edition mark is recorded on the bottom outside

corner of the pages.

Revisions
Revised pages are shown at the list of revised pages on the between the
contents page and section 1 page.

Symbols
So that the shop manual can be of ample practical use, important places for
safety and quality are marked with the following symbols.

Symbol Item Remarks

Special safety precautions are necessary when performing

the work.
Safety
Extra special safety precautions are necessary when
performing the work because it is under internal pressure.

Special technical precautions or other precautions for

※
preserving standards are necessary when performing the
Caution
work.

3 / 210
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 ○a,
then draw a horizontal line from ○ a.
② Locate the number 5in the row across the top, take this as ○ b , then draw a
perpendicular line down from ○ b.
③ Take the point where the two lines cross as ○c . This point ○ c 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 ○
b 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

50 1.969 2.008 2.047 2.087 2.126 2.165○

c 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

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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 15.43 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 37.48 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 59.5. 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 81.57 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 103.62 108.03

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

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Liter to U.S. Gallon 1ℓ = 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 1ℓ = 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

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kgf•m to lbf•ft 1kgf•m = 7.233lbf•ft
0 1 2 3 4 5 6 7 8 9
0 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

7 / 210
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2
0 1 2 3 4 5 6 7 8 9

0 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

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TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a Fahrenheit temperature reading into a centigrade
temperature reading 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.

9 / 210
 ℃ ℃/℉ ℉ ℃ ℃/℉ ℉ ℃ ℃/℉ ℉ ℃ ℃/℉ ℉

-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

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SECTION 1 GENERAL

Group 1 Safety Hints----------------------------------------------------------------12-15

Group 2 Specifications-------------------------------------------------------------16-23
Group 3 Periodic replacement -------------------------------------------------------24

11 / 210
GROUP1 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
equipment.

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.

• Flames should never be used instead

of lamps. Never use a naked flame to
check leaks or the level of oil or
electrolyte.

• Exhaust gas is dangerous. Provide

adequate ventilation when working a
closed space.

12 / 210
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, move the control levers to each
position two or three times.

• When working on top of the machine,

be careful not to lose your balance and
fall.

• 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.

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 the brake lock.

13 / 210
• 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.

• When working with others, choose a

group leader and work according to his
instructions.
Do not perform any maintenance
beyond the agreed work.

• 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.

• 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.

14 / 210
• 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 oil specified for the ambient temperature.
• Always use pure oil or grease, and be sure to use clean containers.
• When checking or changing the oil, do it in a place free of dust, and prevent any dirt
from getting into the oil.

• Before draining the oil, warm it up to a temperature of 30 to 40℃.

• 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.

15 / 210
GROUP2 SPECIFICATIONS

1 GENERAL LOCATIONS

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

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 2 SPECIFICATIONS

Model Unit 25LE-7 30LE-7 35LE-7

Capacity kg 2500 3000 3500

Load center R mm 500 500 500
Weight (Unloaded) kg 3732 4139 4512
Lifting height A mm 3005 3005 3005
Free lift B mm 155 155 155
Fork Lifting speed (Unload/Load) mm/sec 550/660 450/550 450/550
Lowering speed (Unload/Load) mm/sec 580/460 480/350 480/350

L×W×T LWT mm 1050×100×45 1050×125×45 1050×125×45

Tilt angle(forward/backward) C/C' degree 6/10 6/10 6/10

Mast Max height D mm 3465 3465 3465
Min height E mm 2040 2040 2040
Travel speed km/h 18.5/17.4 18.5/17.4 18.5/17.4
Body Gradeability ％（°） 20 20 19
Min turning radius (Outside) F % 2310 2395 2430
Hydraulic oil tank ℓ 30 (60 MAX.) 30 (60 MAX.) 30 (60 MAX.)
ETC
Fuel tank (Gasoline) ℓ 30 (60 MAX.) 30 (60 MAX.) 30 (60 MAX.)

Overall length G mm 3685 3740 3815

Overall width H mm 1102 1102 1102
Overhead guard height I mm 2170 2170 2170
Ground clearance (Load) J mm 145 145 145
Wheelbase K mm 1650 1700 1700
Wheel tread front/rear M/M' mm 1005/980 1005/980 1005/980

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 3 SPECIFICATION FOR MAJOR COMPONENTS

1) Engine
Item Unit Specification
Model - GCT/GK25
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 89X100
Piston displacement cc 2488
Compression ratio - 8.7
Rated gross horse power KW/rpm 35/2550
Maximum gross torque at rpm N•m/rpm 1765/1600
Engine oil quantity L 4.4
Dry weight kg 245
High idling speed rpm 2550±20
Low idling speed rpm 850±20
Rated fuel consumption g/kWh 265
Starting motor V-kW 12 - 2.2
Alternator V-A 12 - 50
Battery V-AH 12 - 60

2) Main pump
Item Unit Specification
Type - Gear
Capacity mL/r 28.4
Maximum operating pressure bar 245
Rated speed (Max/Min) rpm 3000/400

3) Main control valve

Item Unit Specification
Type - Sectional
Operating method - Mechanical
Relief valve pressure (Main/Aux) bar 210/165
Flow capacity lpm 76

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 4) Steering unit
Item Unit Specification

Type - Load sensing/Non load reaction/Dynamic signal

Capacity mL/r 125
Back pressure Bar 25
Input torque N•m 1.4±0.2

5) Power train devices

Item Specification

Model YJH265
Torque converter Type -
Stall ratio 3.05
Type Power shift
Gear shift (FR/RR) 1/1
Transmission Adjustment Electrical single lever type
FR 17.4972
Gear ratio
RR 17.4972
Type Dry
Axle Gear ratio 1:1
Gear integrated structure type
Q'ty (FR/RR) Single: 2/2 Double: 4/2
Single: 28×9-15-14PR
2.5 TON
Double: 28×9-15-14PR
Wheels Front
Single: 28×9-15-14PR
3.0~3.3 TON
Double: 28×9-15-14PR
2.5 TON 6.0-9-10PR
Rear
3.0~3.3 TON 6.5-10-10PR
Travel Front wheel, dry drum brake
Brakes Parking Ratchet, dry drum brake
Type Hydrostatic, power steering
Steering Steering angle 79°to both right and left angle, respectively

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 4 TIGHTENING TORQUE OF MAJOR COMPONENTS

NO Item Size kgf·m lbf·ft

1 Engine mounting bolt, nut M12×1.25 12.5±2.5 90±18

2 Engine Radiator mounting bolt, nut M 8×1.25 2.5±0.5 18.1±3.6
3 Torque converter mounting M10×1.25 6.9±1.4 50±10
4 MCV mounting bolt, nut M10×1.5 4.0±0.5 29±3.6
5 Hydraulic Steering unit mounting bolt M10×1.5 4.0±0.5 29±3.6
6 t Transmission mounting bolt, M16×2.0 7.5 54
7 Power train Drive axle mounting bolt, nut M20×1.5 65±3 470±21.7
8 system Steering axle mounting bolt, M20×2.5 58±8.5 420±61
9 Front wheel mounting nut M20×1.5 40±10 289±72
10 Rear wheel mounting nut M14×1.5 18±2 130±14
11 Counterweight mounting bolt M30×3.5 215±33 1555±239
12 Others Operator's seat mounting nut M8×1.25 2.5±0.5 18.1±3.6
13 Head guard mounting bolt M12×1.75 6.2 44.8

5 TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
① Coarse thread
8T 10T
Bolt size kgf·m lbf·ft kgf·m lbf·ft
M 6 × 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6

M 8 × 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8

M10 × 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60

M12 × 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114

M14 × 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167

M16 × 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247

M18 × 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343

M20 × 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482

M22 × 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709

M24 × 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832

M30 × 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655

M36 × 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242

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② Fine thread
8T 10T
Bolt size kgf·m lbf·ft kgf·m lbf·ft
M 8 × 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0

M10 × 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6

M12 × 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115

M14 × 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174

M16 × 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260

M18 × 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376

M20 × 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522

M22 × 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692

M24 × 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890

M30 × 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795

M36 × 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561

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 2) PIPE AND HOSE (FLARE TYPE)
Thread size Width across flat(mm) kgf·m lbf·ft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253

3) PIPE AND HOSE (ORFS TYPE)

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

9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253

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

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253

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 6 RECOMMENDED LUBRICANTS

Service Kind of fluid Capacity Ambient temperature℃ (℉)

point -20 -10 0 10 20 30 40

(-4) (14) (32) (50) (68) (86) (104)

Engine oil Engine oil 6.5L

pan 15W/40

Torque transmission 9L
converter oil 8#
transmission
Drive Axle Gear oil 6.5L
85/90 GL-5

Hydraulic Hydraulic oil STD:35L

tank OPT:40L L-HM32

Fuel tank LPG 50L LPG

Gasoline
（ Dual fuel 20L 92#
system）
Fitting Grease
(Grease NLGI No.1
nipple)

NLGI No.2

Brake Brake oil 0.25L

reservoir Caltex DOT3
tank
Radiator Antifreeze: 11.1L
Water=50:50 Ethylene glycol base permanent type

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 engine
start up is below 0℃ , even if the ambient temperature in daytime is expected to rise to 10℃ or
more.

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GROUP3 PERIODIC REPLACEMENT

For operation safety, never fail to perform periodic maintenance or make periodic
replacement of the consumable parts listed in the following.
These parts may deteriorate in time and are susceptible to wear. It is difficult to
estimate the degree of wear at time of periodic maintenance; 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).
Note that periodic replacement has nothing to do with guarantee service.

No. Periodical replacement of safety parts Interval

1 Fuel hose Every 2 to 4 years

2 Hydraulic pump hose Every 2 years
3 Power steering hose Every 2 years
4 Packing, seal, and O-ring for steering cylinder Every 2 to 4 years
5 Lift chain Every 2 to 4 years
6 Lift cylinder hose Every 1 to 2 years
7 Tilt cylinder hose Every 1 to 2 years
8 Side shift cylinder hose Every 1 to 2 years
9 Dust seals for master cylinder Every 1 years
10 Brake hose or tube Every 1 to 2 years
11 Brake reservoir tank tube Every 2 to 4 years
12 Intake air line Every 2 years
13 Coolant Every 2 years
14 Radiator hoses and clamps Every 2 years

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SECTION2 REMOVAL AND INSTALLATION OF
UNIT

Group 1 Structure --------------------------------------------------------------------- 26

Group 2 Removal and Installation of Unit ----------------------------------- 27-41

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GROUP1 STRUCTURE

1 Mast 8 Torque converter 15 Counterweight

2 Lift cylinder 9 Engine 16 Steering wheel
3 Tilt cylinder 10 Fan 17 Overhead guard
4 Fork 11 Rear wheel 18 Seat
5 Front wheel 12 Steering cylinder 19 Air cleaner
6 Drive axle 13 Steering axle（Rear） 20 LPG tank
7 Transmission 14 Muffler

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GROUP2 REMOVAL AND INSTALLATION OF UNIT

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

1 MAST
1) REMOVAL

Fork Carriage Piping Mast

A. Forks
a) Lower the fork carriage until the forks
are approximately 25mm (1in) from the
floor.
b) Turn knob up and slide one fork at a
time toward the center of the carriage
where a notch has been cut in the
bottom plate for easy removal.
c) Remove only one fork at a time.
※ On larger forks it may be necessary to
use a block of wood.

B. Backrest (If necessary)

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

C. Carriage
a) 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.

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 b) While supporting lift chains, remove
nuts and split pin from the anchor
bolt.

c) Pull the chains out of the sheaves

and drape them over the front of the
carriage

d)Slowly raise inner mast upright until

mast clears top of fork carriage. Move
carriage to work area and lower the
mast.
Make sure that carriage remains on
floor and does not bind while mast is
being raised.
※ Inspect all parts for wear or damage.
Replace all worn or damaged parts.

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 D. Piping
a) Remove the return hoses and
clamps attached to the cylinder.
b) Remove hose assembly, valve
and tee from the lift cylinder.
※ Put blind plugs in the piping
immediately after removing hoses.
This prevents the hydraulic oil from
flowing out and also prevents dust and
dirt from getting in.

E. Lift cylinder
a) Loosen hexagonal bolts and remove
washers securing the lift cylinders to
inner mast.
b) 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.
c) Loosen and remove hexagon nuts
and clamp securing cylinder to outer
mast.
d) Using an overhead hoist, slowly
raise the inner mast high enough to
clear lift cylinder.
e) Using an overhead hoist, draw out lift
cylinder carefully and put down on
the work floor.

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F. Inner mast
a) Using an overhead hoist, raise the
inner mast straight and carefully
draw out of outer mast section.
Be careful the mast not to swing or
fall.

G. Tilt cylinder pin

Hold the mast with a crane, remove the
bolt of the pin, then remove the pin.
H. Mast support cap
a) Attach a crane to the stay at the top
of the outer mast, and raise enough
to sustain jacked up machine.
※ This operation is carried out from
under the machine, so use a pit, or if
there is no pit, jack up the machine and
loosen with impact wrench.
b) Remove the mounting bolts from the
cap, then slowly raise the outer mast.

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 2) INSTALLATION
After assembling mast components totally without piping connections, install mast
assembly to the equipment.
※ Installation procedure for each of mast component is the reverse of the removal
procedure.

A. Mast support cap

a) Check the mast support cap and spring pin for wear.
b) Jack up the machine so that the front is raised and then using an overhead
hoist assemble outer mast to drive axle unit.
c) Tighten mounting bolts to mast support cap. Apply loctite#277.
Tightening torque: 23.4±3.5kgf•m (169±25.3 lbf•ft)

B. Tilt cylinder pin

Hold the mast with a crane, operate the tilt control lever and align the holes,
then knock the pin.

C. Lift cylinder installation and

adjustment
a) 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.
b) Assemble the cylinder rod
to the inner mast, and check
the left-to-right play of the
mast at the maximum lifting
height.
※ If play is to LEFT, install
adjustment shim to LEFT
cylinder.
※ If play is to RIGHT, install
Adjustment shim to RIGHT
cylinder.
Shim thickness: 1.0mm(0.04in)

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2 POWER TRAIN ASSEMBLY

1) REMOVAL

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A. Mast
Refer to the chapter MAST.

B. Brake piping
Disconnect the brake piping
from the brake housing of drive
axle.

C. Parking brake cable

Disconnect parking brake cable
from hand brake.

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D. Drive axle
a) Attach a crane to the tilt
cylinder notches on the
dashboard and raise the
machine.
b) Loosen hexagonal bolts (1)
connection rive axle to the
transmission.
c) Put the block under the drive
axle and support under the
drive axle with a truck.
d) Remove drive axle mount bolts
(2) from the frame and then
slowly pull out the truck with
drive axle to the front.

E. Inching linkage
Remove the clevis pin from the
transmission control valve.

F. Transmission cooling piping

a) Disconnect cooling hose from
the transmission.
※ Make sure that the coolant be
drained from the hose.

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G. Transmission
a) Remove the cover on top face
of the Transmission housing
then remove the 8mounting
bolts installed on the engine
flywheel. To rotate the flywheel,
remove 1 mounting bolt, then
insert a turning tool in the
mounting hole. One man
must turn the engine fan by
hand while the other turns the
flywheel.

b) Remove Transmission from the

engine flywheel housing by
loosening the 8 mounting bolts.

c) Using a moving truck slowly,

pull out transmission assembly
to the front.

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2) INSTALLATION
A. Installation is the reverse order
to removal, but be careful of the
following points.
B. Tightening torque
Bolt (1) : 5.9~8.9kgf•m
Bolt (2) : 2.7~4.1kgf•m
Bolt (3) : 7.8~11.6kgf•m
Bolt (4) : 18.9~25.2±3 kgf•m

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3 ENGINE
Lever the torque converter, transmission and front axle inside the frame, then
remove the engine assembly.

1) REMOVAL

A. 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.

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 Remove the torque converter
housing cover, mounting bolts
installed to flywheel housing.
For details, see section 2.

B. Engine accessory
Remove all wiring harnesses,
cables and hoses around the
engine, dashboard and frame.
a) Wiring harness to alternator
and starter.
b) Wiring harness for oil pressure
and engine water temperature
gauges.
c) Cables for meters, buttons and
accelerator pedal.
d) Hoses to fuel tank and air
cleaner.
e) Exhaust pipe.

C. Radiator hose
Open the drain valve of the
radiator and drain the cooling
water, then remove the radiator
hose.

D. Mounting bolt
Attach a crane to the engine
hook and raise, then remove
mounting bolts. Raise the
engine slightly, slide towards the
radiator, then lift up.
※ When sliding the engine, be
careful of the collision engine and
radiator.

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2) INSTALLATION
Installation is the reverse order of
removal, but be careful of the
following points.
① Tighten the engine mounting
bolts and nuts.
② Tighten the engine mounting
bracket bolts.
※ Do not remove the bolts unless
necessary.
Loctite is coated over the threads of
bolt. So, once the bolts were
removed, coat them with Loctite
(#243) when installing.
※ Before installing the bolts,
Loctite in the holes should be
removed by a tap.
③ Tightening torque
Bolt (1):
5.5~8.3kgf•m(39.8~60.0lbf•ft)
Bolt (2):
10~15kgf•m(72.3~108lbf•ft)
Bolt (3):
10~15kgf•m(72.3~108lbf•ft)
④ Tightening torque of mounting
bolt installing to torque
converter housing.5.5~8.3kgf•m
(40~60lbf•ft)
⑤ Radiator hoses
Distance to insert hose: 40mm
(1.57in)
⑤ Air cleaner hose
a) Insert the air cleaner hose
securely and fit a clamp.
b) Distance to insert hose
Air cleaner hose: 35mm (1.4in)
Engine end: 35mm (1.4in)

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 4 STEERING AXLE
1) REMOVAL
Counterweight→Rear wheel→Hose→Mounting bolt

① Counterweight
Hold the counterweight with hoist bars, and raise it with a crane.
Remove the mounting bolts, raise slightly and move it slowly to rear side.
•Weight of counterweight(standard)
25LE-7 1390kg (3064lb) 30LE-7 1656kg (3651lb)
35LE-7 2031kg (4478lb)

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

③ Hose
After draining out oil in the
hoses, disconnect the hoses
from the steering axle.

④ Mounting bolt
Put a block under the steering
axle, support on a truck, a raise
the frame with a crane.
Remove the mounting bolts
installing to the frame, and pull
out to the rear.
There are shims between the
support and steering axle to
prevent play.

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SECTION3 POWER TRAIN SYSTEM

Group 1 Structure and Operation ----------------------------------------------- 43-45

Group 2 Disassembly and assembly and troubleshooting---------------- 46-67

42 / 210
GROUP1 STRUCTURE AND OPERATION

1 POWER TRAIN DIAGRAM

STRUCTURE

1 Engine 3 Drive axle

2 Transmission 4 Brake

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2 TORQUE CONVERTER
1) STRUCTURE

1 Bolt 9 Bolt
2 Plate 10 Torque converter housing cover
3 Flexible plate 11 Temperature sensor
4 Torque converter assembly 12 Inner oil strainer
5 Bolt 13 Oil strainer spring
6 O-ring 14 O-ring
7 Oil level gauge 15 Oil strainer plug
8 Oil level gauge guide 16 Torque converter housing

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2) OPERATION
A. The torque converter is connected with a flywheel by a flexible plate, engine
output is delivered from the flywheel to the flexible plate.
B. The exterior of the torque converter is protected by the torque converter
housing.
C. 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.

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GROUP2 DISASSEMBLY AND ASSEMBLY AND
TROUBLESHOOTING

1 Parameters

Table 1 Main technical parameters of gearbox

Items JHTY30
Matching engine rated power KW 35.3
Matching engine rated speed r/min 2250
Transmission Forward gear 17.4972
ratio Back gear 17.4972
Main oil pressure MPa 1.1―1.5
Torque converter inlet pressure MPa 0.3―0.7
Electrical device (voltage/power) 12V•DC/26W
Model YJH265
Effective diameter mm 265
Torque converter
≥3.05
coefficient at zero speed
Highest efficiency ＞0.79
Torque Nominal torque of pump
converter impeller under zero speed 33±1.65
condition N•m
Nominal torque of pump
impeller in the highest
31±1
efficiency working
condition N•m
Rotation direction (facing the input end) Clockwise
No. 6 and No. 8 hydraulic
Working fluid
transmission oil

Working oil temperature ℃ 80―100

Maximum working oil temperature ℃ 120 (no more than 5min)

Dimensions (L×W×H) mm x mm x mm 885x470x500

Net mass kg 183

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1) Maintenance and adjustment
① Oil level check
Fill in the oil and drive in neutral for 5 minutes. After turning off the engine, check
the oil level of the oil dipstick. The oil should be within the specified range of the
dipstick.
② Change the oil, check and clean the filter
a) Start the engine, run for about ten minutes, and then stop.
b) Remove the oil drain plug to drain the oil. Tighten the drain plug after
draining the oil.
c) Remove the fixing bolts, remove the oil filter seat assembly, remove the
coarse filter and clean the coarse filter with kerosene. (Note: If the paper pad
is damaged during disassembly, clean up the remaining paper pad on the
bonding surface and replace with a new one).

d) After cleaning, blow dry compressed air from the inner side of the coarse
filter to the outer side, and install it when it is completely dry. Note: If any
damage is found on the strainer, it needs to be replaced with a new strainer.
e) Remove and replace the fine filter.

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 f) Refill oil (perform the above 1).
g) After the new machine is used for 100 hours, the fine filter should be
replaced and the coarse filter should be cleaned; the fine filter should be
replaced and the coarse filter should be cleaned every 500 hours after use;
the coarse filter should be replaced every 2000 hours of use.
2) Internal structure and working principle
① Working principle
a) Transmission principle
The transmission diagram of the hydraulic transmission gearbox is shown in
Figure 1. The hydraulic torque converter is driven by the engine through the
elastic coupling plate 1 to drive the pump wheel 4 to rotate, so that the liquid
flow flows into the turbine 2 at a high speed along the direction of its blades
and pushes the turbine to rotate. The guide wheel 3 causes the torque
converter to generate a pitch change function, and transmits the torque to the
hydraulic transmission gearbox input shaft assembly 11 through the turbine
shaft. When the forward gear is engaged, the reverse clutch is idling, and the
transmission sequence is piece 11 → piece 7 → piece 20 → piece 19 →
piece 17 → piece 12 → piece 13 to drive the differential 15 to output. When
the reverse gear is engaged, the forward clutch is idling, and the
transmission sequence is piece 11 → piece 10 → piece 18 → piece 21 →
piece 20 → piece 19 → piece 17 → piece 12 → piece 13 to drive the
differential 15 to output. The forward and reverse clutches are controlled by
the shift control valve. The oil pump 6 is an internal gear pump, which is
driven by the engine through the diameter of the pump wheel. The oil pump
provides pressure oil to the system. After the hydraulic torque converter
works, the oil enters the radiator on the vehicle, and then enters the gearbox
to lubricate the friction plates, bearings and gear.

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Figure 1 The schematic diagram of JHTY30B hydraulic transmission gearbox

1 Elastic coupling plate 8 friction plate 15 differential assembly

2 Turbine 9 separator 16 planet gear
3 Guide wheel 10 reverse gear 17 helical bevel gear
4 Pump wheel 11 input shaft assembly 18 idler shaft
5 Turbine shaft 12 tooth shaft 19 output shaft
6 Oil pump 13 gear ring 20 output gear
7 forward gear 14 half shaft gear 21 idler

b) Principle of oil circuit

The schematic diagram of the oil circuit of the hydraulic transmission gearbox
is shown in Figure 2. In the figure, F represents the forward gear and R
represents the reverse gear.

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Figure 2 Schematic diagram of oil circuit of JHTY30B hydraulic transmission gearbox

1 Oil filter 4 Micro valve 7 Safety valve

2 Oil pump 5 Buffer valve 8 Oil filter
3 Main pressure regulating valve 6 Electromagnetic shift valve 9 Car cooler
② Structure introduction
a) Introduction to the structure
The structure diagram of the hydraulic transmission gearbox is shown in
Figure 3, and its working principle is as described above. The hydraulic
transmission gearbox is composed of four parts: a hydraulic torque converter,
a gearbox and a reducer. The power of the engine is input to the clutch
assembly 6 of the gearbox by the torque converter turbine shaft through the
spline connection through the pitch changing action of the torque converter.
The gearbox includes clutch assembly 6, idler gear 11, output gear 12, idler
shaft 9, cover and solenoid control valve assembly 5, micro valve assembly
14, oil supply pump assembly 4 and other major parts and components. The
reducer is mainly composed of output shaft 10, spiral bevel gear 16, gear
shaft 1, etc. The two ends of the gear shaft are supported by tapered roller
bearings 2, and both ends are equipped with adjusting shims to adjust the
color impression and backlash of the spiral bevel gear. And bearing
clearance. The power transmitted from the gearbox is decelerated by the
reducer and is generated by the differential assembly 15 to drive the half
shaft gears and the half shafts to the wheels. Piece 8 is a gearbox housing,
in which gears, shift clutches, reduction gears, differentials, etc. are installed,
and it also functions as an oil tank.

50 / 210
51 / 210
b) hydraulic torque converter
The structure diagram of YJH265 hydraulic torque converter is shown in
Figure 4. It is mainly composed of turbine shaft 8, pump wheel 10, guide
wheel 4, turbine 3, elastic coupling plate 2 and other components.

1
2
3
4
5
6

8
9
10

Figure 4 YJH265 torque converter structure diagram

1 Oil drain plug 5 Thrust bearing 9 one-way clutch
2 Elastic plate 6 Ball bearing 10 pump wheel
3 Turbine 7 retaining ring
4 Guide wheel 8 turbo shaft

The pump wheel 10 is connected with the engine flywheel through the
elastic connecting plate 2. The pump wheel converts the engine model
energy into the kinetic energy of the working fluid, and causes the lead
blades of the liquid flow to flow into the turbine 3 at a high speed, which
drives the turbine to rotate, which is output by the turbine shaft 8 and
transmits torque and speed to the gearbox. After the liquid flows out of the
turbine, it enters the guide wheel 4. When the torque converter is in a
torque-changing stage with a large load and a low turbine speed, the guide
wheel is wedged by the one-way clutch and cannot rotate. The torque
acting on the guide wheel by the liquid flow is counteracted on the turbine,
causing the torque on the turbine to be equal to that of the pump. Between
the torque of the wheel and the guide wheel, the output torque is greater

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 than the input torque, and an automatic torque conversion is generated.
When the ratio of the turbine speed to the pump wheel speed is greater
than a certain value, the guide wheel disengages and rotates freely, and
the torque conversion ends. This state is Coupling state.
YJH265 is a press-welding hydraulic torque converter, which cannot be
disassembled.
c) Fuel supply pump assembly
The structure diagram of the YQX30-3000 oil supply pump assembly is
shown in Figure 5. The oil supply pump assembly is mainly composed of
driving gear 1, guide wheel seat 2, passive gear 3, pump casing 4 and other
parts. The fuel supply pump assembly is installed on the torque converter
housing. The guide wheel seat 2 is connected with the torque converter
guide wheel through splines. The pump housing 4 is a casting with a
high-pressure cavity and a low-pressure cavity. The driving gear 1 and the
torque converter pump. The wheels are connected and driven by the engine
to drive the driven gear 3 to rotate, forming an internal gear pump to supply
oil to the system.

Figure 5 YQX30-3000 oil supply pump assembly structure diagram

1 Drive gear 3 Passive gear

2 Guide wheel seat 4 Pump housing

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d) Micro valve assembly
The structure diagram of YQX30-5000 micro valve assembly is shown in
Figure 6. The micro valve assembly is mainly composed of micro slide valve
13, micro valve body 12, spring 8, micro valve stem 7, and other parts. The
micro valve assembly is installed on the outside of the gearbox. The
micro-motion valve stem is connected to the micro-motion pedal connecting
rod. When the micro-motion pedal is depressed, the micro-motion valve
stem moves outwards. When the micro-motion valve stem moves outwards
by 2mm, the clutch begins to depressurize, and the clutch pressure drops to
a certain value. When a pressure is applied, the friction plate slips and the
vehicle achieves a fretting effect; when the fretting valve stem moves
12.5mm outward, the clutch pressure drops to 0, the clutch friction plate and
the spacer cannot be combined, and the vehicle stops moving; when the
fretting valve stems When the rod moves 29mm outwards, the stroke of the
micro-moving valve rod ends.

Figure 6 YQX30-5000 micro valve assembly structure diagram

1 Screw plug 6 O-ring 11 cushion

2 Screw plug 7 Micro valve stem 12 micro-motion valve body
3 Retaining ring for hole 8 spring 13 micro-motion spool valve
4 Spring 9 retaining ring for hole
5 Blocking 10 oil seal

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 e) Clutch
The YQX38-1000 clutch assembly structure diagram is shown in Figure 7. It
is used for JHTY30B hydraulic transmission gearbox. The clutch assembly
consists of input shaft 9, forward gear 4, piston 2, clutch housing 22, friction
plate 19, spacer 18, Return spring 5, reverse gear 6, sealing ring 8 and other
parts and components. The left and right clutches are wet multi-plate
hydraulic clutches, each equipped with 4 spacers and friction plates that are
assembled alternately. The clutch shell is welded to the input shaft as a
whole, and the pressure oil is distributed through the control valve into the
forward or reverse clutch to achieve forward movement. Reverse gear shift.
There is a sealing ring 6 on the outer circle of the piston, and a 0-shaped
sealing ring 3 is installed on the input shaft to ensure that the clutch is sealed.
When in neutral, no pressure oil enters the clutch, and the piston recalls the
smell under the spring force of the return spring, so that the diaphragm and
the friction plate are in a separated state. When shifting gears, oil pressure
acts on the piston to combine the diaphragm and the friction plate, and the
power from the torque converter is transmitted to the forward gear or the
reverse gear by friction.

Figure 7 YQX38-1000 Clutch assembly structure diagram

1 end plate 8 seal ring (A) 15 Steel ball

2 piston 9 input shaft 16 Plug
3 O-ring 10 thrust ring (A) 17 Seal ring(B)
4 forward gear 11 needle roller bearing 18 Spacer
5 return spring 12 thrust ring (B) 19 Friction plate
6 reverse gear 13 Retaining ring for shaft 20 Snap ring
7 bearing 14 Spring seat 21 Input shaft assembly

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f) Differential assembly
The structure diagram of the YQX30-2000 differential assembly is shown in
Figure 9. It is used in the JHTY30B hydraulic transmission gearbox and is
supported on the gearbox housing by ball bearings 8 at both ends. The
differential assembly is equipped with two side gears 9 and four planetary
gears 10. The planetary gears are supported by a cross gear shaft 2,
wherein the gear shaft 2 is fixed on the left and right differential housings 3
and 7. The thrust washer 1 and the washer 11 are installed between the
differential housing, the planetary gears and the side gears. The differential
housing is made into a left and right split type, the left differential housing 7
and the right differential housing 3 are connected by bolts 4, and the ring
gear 5 is fixed to the right differential housing 3 with bolts 4.

Figure 8 YQX30-2000 differential assembly structure diagram

1 Thrust washer 5 Gear ring 9 half shaft gear
2 Cross gear shaft 6 Bolt 10 planet gear
3 Right differential case 7 Left differential case 11 washer
4 Bolt 8 bearing

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g) Cover and control valve assembly
The structure diagram of YQXD30-4000 covers and control valve assembly
is shown in Figure 10 and 11. It is composed of solenoid valve 1 and housing
cover 2 and control valve assembly 3. The control valve assembly is
installed on the inner side of the housing cover. The housing cover is
equipped with solenoid valve 1 and torque converter oil inlet overflow valve 4
to keep the torque converter oil inlet pressure at 0.5MPa-0.7 MPa.

Figure 9 YQXD30-4000 cover and control valve structure diagram

1 Solenoid valve 3 Control valve assembly

2 Housing cover 4 Relief valve

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The general structure diagram of YQXD30-4100 control valve is shown in
Figure 11. It is composed of main pressure valve 1, reverse buffer valve 2,
forward buffer valve 3 and so on. The main pressure valve controls the
clutch oil pressure in the range of 1.1MPa-1.4 MPa, part of the oil enters the
control valve through the micro valve to realize gear shifting; part of the oil
enters the overflow valve to adjust the oil pressure within the range of
0.5MPa-0.7 MPa, and then enter the torque converter to work. The cushion
valve is used to reduce the impact when the clutch is engaged and
disengaged.

Figure 10 YQXD30-4100 control valve assembly structure diagram

1 Main pressure valve 3 Forward gear cushion valve

2 Reverse gear cushion valve

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 3) Disassembly and assembly
① Gearbox disassembly and assembly

Before disassembling the

gearbox, drain the residual oil in
the box and replace the gasket at
the oil drain plug. After draining
the residual oil, screw the drain
plug back to the gearbox.

Parts description Characteristic requirements Tooling, tools

a. Tightening torque 80-100N.m
1- Oil drain plug b. Replace the gasket after 27mm outer hexagon socket
disassembly

Turn off the lock plate 2, remove

the bolt 1 and the bearing seat 3,
2
remove the differential assembly
4, and reinstall the bearing seat in
the original position after
removing the differential to
prevent the bearing seat from
being misplaced; installation
Attention should be paid to the
position of the bearing seat. The
left and right sides must not be
interchanged. The bolt tightening
torque is required to be
132-165N.m. The lock plate must
be locked after installation.
Parts description Characteristic requirements Tooling, tools
1-bolt Tightening torque 132-165N.m 21mm outer hexagon socket
2- lock piece Replace after disassembly
Left and right are not
3-Bearing frame
interchangeable
4-Differential assembly

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 3

Remove the torque

converter assembly 5.

Parts description Characteristic requirements Tooling, tools

Rotate and push in while
5- Torque converter assembly
installing

Remove the fixing bolt 6

4 and remove the oil supply
pump assembly 8. If the
paper pad is damaged
during installation, clean
the remaining paper pad
on the joint surface and
replace it with a new one.
After disassembly, replace
the gasket 7 at the bolt.
The tightening torque of
the bolt is required to be
22-30N.m.
Parts description Characteristic requirements Tooling, tools
12mm outer hexagon
6-bolt Tightening torque 22-30N.m
socket
7-seal Wearing parts
The O-ring on the outer circle
needs to be replaced after
8-Oil pump assembly
disassembling the assembly
(Wearing parts)
9-Paper pad Wearing parts

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 5
Remove the fixing bolts, and
remove the torque converter
housing assembly 12. When
disassembling, pay attention to
the large and two small three
O-rings on the joint surface; if the
paper pad is damaged during
installation, clean the remaining
paper pad on the joint surface.
Replace with a new paper pad.

Parts description Characteristic requirements Tooling, tools

10-bolt Tightening torque 45-59N.m 16mm outer hexagon socket
11-Spring cushion
12-Torque converter housing
assembly
13-O ring Wearing parts
14-Paper pad Wearing parts

Remove the fixing bolts and

remove the control valve
assembly 17; pay attention to the
two O-rings on the joint surface
when disassembling; if the paper
pad is damaged during
installation, clean the remaining
paper pad on the joint surface
and replace it with a new one.

Parts description Characteristic requirements Tooling, tools

15-bolt Tightening torque 45-59N.m 16mm outer hexagon socket
16-Spring cushion
17-Control valve assembly
18-O ring Wearing parts
19-Paper pad Wearing parts

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 7 Remove the fixing bolts and
remove the micro valve assembly
22; pay attention to the two
O-rings on the joint surface when
disassembling; if the paper pad is
damaged during installation,
clean the remaining paper pad on
the joint surface and replace it
with a new one. When installing
the bolts, the tightening torque of
the bolts requires 22-30N.m.

Parts description Characteristic requirements Tooling, tools

20-bolt Tightening torque 22-30N.m 13mm outer hexagon socket
21-Spring cushion
22-Micro valve assembly
23-Paper pad Wearing parts

8
Remove the fixing bolts and
remove the oil filter seat
assembly 26; if the paper pad is
damaged during installation,
clean the remaining paper pad on
the bonding surface. Replace the
paper pad with a new one, clean
and check the coarse filter, and
replace the coarse filter if
necessary.

Parts description Characteristic requirements Tooling, tools

24-bolt Tightening torque 45-59N.m 8mm hex socket
25-Spring cushion
26-oil filter seat
27-Paper pad Wearing parts
500 hours cleaning, 2000 hours
28-Filter assembly
replacement
29-Dipstick assembly

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 9

Use a crowbar to gently remove

the clutch assembly and idler
shaft.

Parts description Characteristic requirements Tooling, tools

30-Idler
31-Clutch assembly

10
Remove the bearing caps 33 (42)
at both ends, and remove the
pinion 38 and the driven spiral
bevel gear 45. When installing,
note that the adjustment pads 34
and 39 at both ends should be
installed back to the original place
according to the quantity and
position at the time of
disassembly.

Parts description Characteristic requirements Tooling, tools

32(45)-bolt Tightening torque 45-59N.m 16mm outer hexagon socket
33(44)-Spring cushion
33(43)-end cap
35(42)-O-ring
37(40)-bearing
Adjust the thickness of the pad
36(41)-Adjustment pad and the left and right sequence
cannot be changed at will
38-bush
39-pinion
46-driven spiral bevel gear

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 11

Remove the fixing bolts and

remove the output shaft assembly
51. When installing, pay attention
to the adjustment pads 52 and 49
should be installed back to the
original place according to the
amount of disassembly.

Parts description Characteristic requirements Tooling, tools

47-bolt Tightening torque 22-30N.m 13mm outer hexagon socket
48-Spring cushion
49-support sheet
The thickness of the adjustment
50-Adjustment pad
pad cannot be changed at will
51-collar
52-active spiral bevel gear
assembly
The thickness of the adjustment
53-Adjustment pad
pad cannot be changed randomly

12

Use a crowbar to remove the

output gear 1 and the idler gear 2;
pay attention to the installation
positions of the 2 gears during
installation, and do not install
them backwards.

Parts description Characteristic requirements Tooling, tools

1- output gear The installation position of the two
2- idler gears cannot be changed

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 Remove the ring gear 3, open the
differential, take out the internal
planetary gear 9 and the side
gear 7; pay attention to check the
wear of gaskets 6 and 8 during
installation, and replace new
gaskets if necessary. All bolts
here need to be used the torque
wrench is tightened, and the
tightening torque is 70-80N.m.

Parts description Characteristic requirements Tooling, tools

1-bearing
2-bolt
3-gear ring
4-nut Tightening torque 70-80N.m 15mm outer hexagon socket
When installing, it needs to be
aligned with the right half of the
5-Differential left half shell
differential according to the
processing mark
6-washer
After the installation is complete,
7-Axle shaft gear the half shaft gear needs to be
able to rotate flexibly
8-Planetary gear
9-bowl washer
10- cross shaft
When installing, it needs to be
aligned with the left half of the
11-Differential right half shell
differential according to the
processing mark
When installing, it needs to be
aligned with the right half of the
12-bolt
differential according to the
processing mark

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14 Remove the bearing and clutch
gear 3 at both ends, remove the
retaining ring 7 and remove the
friction plates 8, 9, and then
remove the retaining ring 11 to
take out the return spring 13 and
the piston assembly 14; check the
wear of each friction plate before
installation, if necessary, replace
the friction plate, and replace the
sealing ring 16 (4 pieces) after
disassembly.

Parts description Characteristic requirements Tooling, tools

1- Sealing ring A Wearing parts
2-bearing
3-Thrust ring B
4-forward clutch gear
5-Needle bearing
6-Thrust ring A
7-shaft retaining ring
8-spring seat
9-Return spring
10-Circlip After installation, the gap between
the circlip and the end plate
should be ensured to be Feeler gauge
11-end plate
1.1-1.3mm

12-Internal friction plate 2000 hours replacement

13- spacer Wearing parts
14-piston
15-seal ring B Wearing parts
16-O ring Wearing parts
17-plug
18-steel ball
19-Input shaft assembly
20-plug
21-Reverse gear clutch gear

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② Matters needing attention
a) The sequence of disassembly and assembly of the gearbox is basically the
opposite.
b) When disassembling and assembling the gearbox, handle it with care to
prevent parts from bumping and damage. After disassembly, the parts must
be placed in an orderly manner. The parts that need to be reassembled must
be cleaned with kerosene and dried with dry high-pressure air before
assembly.
c) The adjustment gaskets in the gearbox are required to be installed back to
the original place according to the disassembled quantity, and shall not be
added, reduced or replaced at will.
d) The disassembly and assembly process must be operated in strict
accordance with the above-mentioned instructions, and blind disassembly
and brutal operation are strictly prohibited.

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SECTION4 BRAKE SYSTEM

Group 1 Structure and function ------------------------------------------------- 69-78

Group 2 Operational checks and troubleshooting -------------------------- 79-80
Group 3 Tests and adjustments ------------------------------------------------- 81-82

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GROUP1 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 140kgf/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) DRUM BRAKE

Item Specification
Type Dry drum brake
Master cylinder full stroke (Non boosted) 28mm
Pedal adjustment Pedal height 160mm
Play 1~3mm
Brake oil Caltex DOT3

2) PARKING BRAKE

Item Specification
Type Ratchet, internal expanding mechanical
type
Parking lever stroke / Cable stroke 48.3°/ 11.7mm

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3 BRAKE PEDAL AND PIPING
1) STRUCTURE

Drive axle

1 Brake pedal 3 Reservoir tank assembly

2 Parking lever assembly 4 Brake master cylinder

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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.

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 5 DRY DISK BRAKE

Two Types Front wheel Brake，Internal expanding and Hydraulic

Pedal lever ratio 7.52

Master cylinder
19.05mm
bore

Wheel Brake 2-3.5t

Type Two Servo mechanism with Parking Brake

Slave cylinder bore 28.58

Size of friction plate

（length×width× 348×76×8mm
depth）

Area of Friction Plat 264 cm2×4

Brake drum bore 314mm

Parking Brake Front wheel Brake，Internal expanding and Hydraulic

5.1Summary
Brake System is front wheel brake，which made up by brake master cylinder, Brake
and Brake pedal.
5.2 Brake master cylinder
It’s including one valve seat, one return spring, and cup, piston, subsidiary cup.
Fastening ends with tab washer and tab wire, preventing dust and dirt from getting
in with dust cover, pushing Brake pedal will push rod then moving brake master
cylinder. When push Brake pedal, push rod push piston, brake fluid return to oil
tank by oil return port until master cup block the oil return port. After master cup
blocking the oil return port, brake fluid in front piston part will be compressed and
return spring open, then flow in slave cylinder by brake pipeline. Brake fluid push
every slave cylinder and every piston extend outward, friction plat and brake drum
will be touched, finally achieving slow down or brake. At the same time, the behind
part in piston will be filled with brake fluid, which flowed by oil return port and
intake port. Releasing brake pedal, the piston will be pushed by return spring,
brake fluid in every brake slave cylinder also will be pushed by brake shoe return
spring, the brake fluid flow in brake master cylinder (the front part in position),

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piston come back to the position, brake fluid in brake master cylinder flow back to
oil tank by oil return port. The pressure will be adjusted to a certain proportion with
the pressure in brake slave cylinder, putting the cup in slave cylinder in the right
piston to prevent oil from spilling, and removing air-resistor which might arise in
emergent brake.

Brake master cylinder

1 Lug 5 Tab wire 9 Master cup 13 Body
2 Lock nut 6 Tab washer 10 Spring
3 Push rod 7 Subsidiary cup 11 Return spring
4 Dust cover 8 Piston 12 Valve seat

5.3 Wheel Brake

Wheel Brake is Internal expanding and Hydraulic, constitute by brake shoe, spring,
slave cylinder, adjustment and base plate, two brakes are set up in both ends of front
axle. One end of brake shoe is connected to support pin, another end is connected to
gap adjustment and pushed to base plate by spring and compression spring pull rod.
Master brake shoe is equipped with manual pull rod, slave brake shoe is equipped
with adjust rod which is a part of automatic gap adjustment.

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1 Brake slave cylinder assembly
2 Spring
3 Cup
4 Piston
5 Slave cylinder cover
6 Piston carrier rod
7 Brake shoe return spring
8 Friction plate
9 Spring
10 Manual push-rod
11 Spring stay device
12 Brake shoe
13 Compression spring seat
14 Compression spring pull rod
15 Compression spring
16 Spring
17 Pawl
18 Spring
19 Gap adjustment assembly
20 Pin
21 Base plate
22 Brake shoe return spring 3t,3.5t Wheel Brake
23 Manual pull-rod
24 Brake cable assembly

Brake of forward as follows, by operating brake slave cylinder, master brake shoe and
slave brake shoe each acted upon by two forces which are equal but opposite in
direction, friction plate and brake drum are touched, master brake shoe will be pushed
to adjustment by the friction which create between in friction plate and brake drum.
Then, a force is created in gap adjustment, which is bigger than the force used in
operating brake slave cylinder, and it will push slave brake shoe, the top of slave
brake shoe will be pushed to supporting pin powerful, so then a quite big brake force
creates. On the other hand, the operation of brake is opposite in backward, but the
brake force is the same direction with forward.

Forward Backward
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5.4 Automatic gap adjustment
(The following is 2t brake theory, 2-3.5t are same as 2t)
Automatic gap adjustment can keep distance of friction plate and brake drum in
0.4-0.45mm（3-3.5t, 0.25-0.4mm） automatically. But it only works in backward brake.
In backward, brake shoe will disconnect when push brake pedal, so then, master
brake shoe and slave brake shoe touch brake drum and turn together until the top of
master brake shoe start touching supporting pin.
At the same time, when slave brake shoe is away from supporting pin, part A which is
a part of adjust rod is pulled comparatively, so adjust rod will revolves around part B,
part C descend and part D turn left, finally achieving adjust automatically. When
pushing brake pedal harder, the pressure on both ends of adjustment will be bigger,
the resistance in screw thread also will be bigger, which result in part D cannot turn
anymore.

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6 BRAKE VALVE
1) STRUCTURE

1 Front housing 11 Seal 20 O-ring

2 Rear housing 12 Seal 21 Check ball
3 Push rod 13 Seal 22 O-ring
4 Bellows 14 Seal 23 Check spring
5 Master piston 15 Relief piston 24 Cage
6 Lock washer 16 Shim 25 Air bent
7 Piston ball 17 Relief spring 26 Check plug
8 Piston ring 18 Relief plug 27 O-ring
9 Servo piston 19 O-ring 28 Bolt
10 Servo spring

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2) DISASSEMBLY
① Remove push rod (3), bellows
(4), air vent (25) and bolt (28).

② Remove front housing (1), rear

housing (2), servo spring (10),
servo piston (9) and master
piston (5).

③ Remove relief plug (18) with

O-ring (19), relief spring (17),
shim (16) and relief piston (15).

④ Remove O-ring (20), check plug

(26) with O-ring (27), cage (24),
check spring (23), check ball (21)
and O-ring (22).

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3) INSPECTION AND ASSEMBLY

① Clean all parts thoroughly and lubricate the parts either with mineral or with
hydraulic oil, according to their use destination.
② All single parts are to be checked for damage and replaced, if required.
③ Assembly is in opposite order to disassembly.
④ Seal kit: XKAU-00176

Use only brake fluid (Caltex DOT3) into the compensation reservoirs.

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GROUP2 OPERATIONAL CHECKS & 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 kgf•m (253 - 290lbf•ft).
② Check that parking brake can hold machine in position when loaded on 20%
slope. If there is no slope available, travel at low speed and check braking
effect of parking brake.

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 2 TROUBLESHOOTING

Problem cause Remedy

Insufficient •Hydraulic system leaks oil. •Repair and add oil.
braking force •Hydraulic system leaks air. •Bleed air.
•Disk worn. •Replace.
•Brake valve malfunctioning. •Repair or replace.
•Hydraulic system clogged. •Clean.
Brake acting •Tires unequally inflated. •Adjust tire pressure.
unevenly. •Brake out of adjustment. •Adjust.
(Machine is •Disk surface roughened. •Repair by polishing or
turned to one replace.
side during •Wheel bearing out of adjustment. •Adjust or replace.
braking.) •Hydraulic system clogged. •Clean.
Brake •Pedal has no play. •Adjust.
trailing. •Piston cup faulty. •Replace.
•Brake valve return port clogged. •Clean.
•Hydraulic system clogged. •Clean.
•Wheel bearing out of adjustment. •Adjust or replace.
Brake chirps •Brake trailing. •See above. Brake trailing.
•Piston fails to return. •Replace.
•Disk worn. •Replace.
•Disk surface roughened. •Repair by polishing or
replace.
Brake •Disk surface roughened. •Repair by polishing or
squeaks replace.
•Disk worn. •Replace.
•Excessively large friction between •Clean and apply brake
disk plate. grease.
Large pedal •Brake out of adjustment. •Adjust.
stroke •Hydraulic line sucking air. •Bleed air.
•Oil leaks from hydraulic line, or lack of •Check and repair or add
oil. oil.
•Disk worn. •Replace.
Pedal •Twisted push rod caused by •Adjust.
dragging. improperly fitted brake valve.
•Brake valve seal faulty. •Replace.

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GROUP3 TESTS AND ADJUSTMENTS

1 AIR BLEEDING OF
BRAKESYSTEM
1) Air bleeding should be performed
by two persons:
One rides on truck for depressing
and releasing brake pedal: the
other person is on the ground
and removes cap from air vent
plug on wheel cylinder.
2) Block the front wheel securely
and apply parking brake.
3) Start the engine.
4) Attach a vinyl tube to air vent plug
and immerse other end of tube
into a vessel filled with hydraulic
oil.
5) Loosen air vent plug by turning it
3/4 with a wrench. Depress brake
pedal to drain oil mixed with air
bubbles from plug hole.
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.

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

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3 MICRO SWITCH FOR PARKING
BRAKE (IF EQUIPPDE)
1) After assembling parking brake
and parking cable, put the
parking brake lever released.
Loosen the nut for parking brake
plate to play up and down.
Move up the plate so that the
stopper can be contacted with
the pin and then reassemble
nut.
•Micro switch stroke when
parking brake is applied: 2~3mm
(0.08 ~ 0.1in)

4 INCHING PEDAL
1) Pedal height from floor plate
Adjust with stopper bolt.
•Pedal height: 160mm (6.3in)
2) Adjust bolt so that brake pedal
interconnects with inching pedal
at inching pedal stroke 0mm.

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SECTION 5 STEERING SYSTEM

Group 1 Structure and Function ------------------------------------------------ 84-91

Group 2 Operational Checks and Troubleshooting ------------------------92-95
Group 3 Disassembly and Assembly ----------------------------------------96-120

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GROUP 1 STRUCTURE AND FUNCTION

1 OUTLINE

The steering system for this machine is composed of steering wheel assembly,
steering unit, steering cylinder, steering axle and piping. 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.

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2 HYDRAULIC CIRCUIT

1 Gear pump 4 Steering cylinder

2 Hydraulic tank 5 Return filter
3 Steering unit 6 Suction strainer

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1) NEUTRAL

The steering wheel is not being operated so control spool (G) does not move.
The oil from hydraulic gear pump (1) enters priority valve and the inlet pressure
oil moves the spool
(D) to the left.
Oil flow into LS port to the hydraulic tank (5).
So, the pump flow is routed to the main control valve.

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2) LEFT TURN

When the steering wheel is turned to the left, the spool (G) within the steering unit
(2) 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 (2)
through the spool (D) of priority valve 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 (5).
When the above operation is completed, the machine turns to the left.

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3) RIGHT TURN

When the steering wheel is turned to the right, the spool (G) within the steering
unit (2) connected with steering column turns in right hand direction.
At this time, the oil discharged from the pump flows into the spool (G) where it is
directed out of the right work port (R).
Oil returned from cylinder returns to hydraulic tank (5).
When the above operation is completed, the machine turns to the right.

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3 STEERING UNIT
1) STRUCTURE

1 Dust seal 11 O-ring 21 Housing

2 Retaining ring 12 Rolled screw 22 Spool
3 Cap seal 13 Gear Oil Pump 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

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2) OPERATION

① 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.

② 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.

③ 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.

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4 STEERING AXLE
1) STRUCTURE

1 Steering axle 17 Hub 33 Thrust washer

2 Knuckle-RH 18 Hub bolt 34 Pin
3 Knuckle-LH 18 Hub nut 35 Spring washer
4 Special bolt 20 Hub cap 36 Hardened washer
5 King pin 21 Steering link 37 Upper cover
6 Taper roller bearing 22 Steering cylinder 38 Lower cover
7 Oil seal 23 SPH plain bearing 39 Hex bolt
8 Retaining ring 24 Steer link pin 40 Spring washer
9 Collar 25 Plain washer 41 Shim (0.1t)
10 Grease nipple 26 Grease nipple 42 Shim (0.15t)
11 Oil seal 27 Lock plate 43 Shim (0.3t)
12 Taper roller bearing 28 Bolt 44 Spacer
13 Split pin 29 Hex nut 45 Hex bolt
14 Nut 30 Hex bolt 46 Taper roller bearing
15 Washer 31 Trunnion block 47 Plate
16 Plate 32 Bushing 48 Split pin

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 2) TIGHTENING TORQUE AND SPECIFICATION

Type Unit Center pin support single shaft

Structure of knuckle - Elliott type
Toe-in degree 0
Camber degree 0
Caster degree 0
King pin angle degree 0
Max steering angle of wheels degree 79/ 56
(Inside/Outside)
Tread mm 970

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GROUP2 OPERATIONAL CHECKS & TROUBLESHOOTING

1 OPERATIONAL CHECKS
Check item Checking procedure
Steering wheel • Set rear wheels facing straight forward, then turn steering wheel
30-60mm to left and right.
(1.2-2.4 in) Measure range of steering wheel movement before rear wheel
starts to move. 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 0±0.5°; rear axle is bent.
• Ask assistant to drive machine at minimum turning radius.
• Fit bar and a piece of chalk at outside edge of counterweight to
mark line of turning radius.
• If minimum turning radius is not within±100mm (±4in) of specified
value, adjust turning angle stopper bolt.
Min turning radius (Outside)
25LE-7 2076mm(82in)
30LE-7 2136mm(84in)
35LE-7 2136mm(84in)
Steering axle Remove plug from outlet port of flow divider and install oil pressure
Hydraulic pressure of gauge.
power steering Turn steering wheel fully and check oil pressure.
※ Oil pressure : 90kgf/cm2 (1280psi)

2 TROUBLESHOOTING
Problem Cause Remedy
Steering •Low oil pressure. •Check lockout. Repair.
wheel drags. •Bearing faulty. •Clean or replace.
•Spring spool faulty. •Clean or replace.
•Reaction plunger faulty. •Replace.
•Ball-and-screw assembly faulty. •Clean or replace.
•Sector shaft adjusting screw •Adjust.
excessively tight.
•Gears poorly meshing. •Check and correct meshing.
•Flow divider coil spring fatigued. •Replace.
Steering •Bearing faulty. •Clean or replace.
wheel fails to •Reaction plunger faulty. •Replace.
return •Ball-and-screw assembly errors •Clean or replace.
smoothly. •Gears poorly meshing. •Check and correct meshing.

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Problem Cause Remedy
Steering wheel turns •Lockout loosening. •Retighten.
unsteadily. •Metal spring deteriorated. •Replace.
Steering system makes •Gear backlash out of •Adjust.
abnormal sound or adjustment. •Retighten.
vibration. •Lockout loosening. •Bleed air.
•Air in oil circuit.
Abnormal sound heard Valve
when steering wheel is •Faulty. (Valve fails to open.) •Adjust valve set pressure
turned fully and check for specified oil
Piping pressure.
•Pipe (from pump to power •Repair or replace.
steering cylinder) dented or
clogged.
Piping makes abnormal Oil pump
sounds. •Lack of oil. •Add oil.
•Oil inlet pipe sucks air. •Repair.
•Insufficient air bleeding. •Bleed air completely.
Valve or valve unit makes Oil pump
abnormal sounds. •Oil inlet pipe sucks air. •Repair or replace.
Valve
•Faulty. (Unbalance oil •Adjust valve set pressure
pressure) and check specified oil
pressure.
Piping
•Pipe (from pump to power •Repair or replace.
steering)
dented or clogged. •Bleed air completely.
•Insufficient air bleeding.
Insufficient or variable oil •Flow control valve orifice •Clean
flow. clogged.
Insufficient or variable Piping
discharge pressure. •Pipe (from tank to pipe) dented •Repair or replace.
or clogged.
Steering cylinder head •Packing foreign material. •Replace
leakage (Piston rod) •Piston rod damage. •Grind surface with oil
•Rod seal damage and stone.
distortion. •Replace
•Chrome gilding damage. •Grind
Steering cylinder head •O-ring damage. •Replace
thread
(A little bit leak is no
problem)
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Welding leakage •Cylinder tube damage. •Replace.
Rod •Tube inside damage. •Grind surface with oil
•Piston seal damage and store.
distortion •Replace
Piston rod bushing inner •Bushing wear. •Replace
diameter excessive gap

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GROUP3 DISASSEMBLY AND ASSEMBLY

1 STEERING UNIT
1) STRUCTURE

1 Bolt-socket 12 Needle Roller Thrust Bearing 23 Rotor

2 Washer-Spring 13 Washer 24 O-Ring 29×2
3 Cap-Front 14 Spool 25 Ring
4 O-Ring 15 Washer 26 Limited Post
5 X-Type Seal Ring 16 Pin 27 Cap-Rear
6 Screw-Bore 17 Spring-Plate 28 Nameplate
7 O-Ring 18 Sleeve 29 Washer
8 Housing 19 Drive 30 Rivet
9 O-Ring 82×1.9 20 Plate 31 Screw-Rolled
10 Ball 21 Stator 32 Bolt-Hex
11 Baffle Ring 22 O-Ring 82×1.9

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2) TOOLS
① Holding tool

② Assembly tool for O-ring and kin-ring.

③ Assembly tool for lip seal.

④ Assembly tool for cardan shaft.

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⑤ Assembly tool for dust seal.

⑥ Torque wrench 0~7.1kgf•m (0~54.4lbf•ft) 13mm socket spanner6, 8mm and

12 mm hexagon sockets 12mm screwdriver 2mm screwdriver 13mm ring
spanner 6, 8 and 12mm hexagon socket spanners Plastic hammer Tweezers

3) TIGHTENING TORQUE
L: Left port
R: Right port
T: Tank
P: Pump

Port Size Torque [kgf•m(lbf•ft)]

L 3/4 UNF - 16 13 (94)
R 3/4 UNF - 16 13 (94)
T 3/4 UNF - 16 13 (94)
P 3/4 UNF - 16 13 (94)
Mounting bolt M10×1.5 4.0 ±0.5 (29±3.6)

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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).

② Remove the end cover,

sideways.

③ Lift the gearwheel set (With

spacer if fitted) off the unit.
Takeout the two O-rings.

④ Remove cardan shaft.

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⑤ Remove distributor plate

⑥ Screw out the threaded bush

over the check valve.

⑦ Remove O-ring.

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.

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 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.

⑩ Press out the cross pin.

Use the special screw from
the end cap.

※ 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.

⑪ Carefully press the spool out of

the sleeve.

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⑫ Press the neutral position
springs out of their slots in
the spool.

⑬ Remove dust seal and O-ring.

⑭ Disassembling the pressure relief valve

Screw out the plug using an 8mm hexagon socket spanner.
Remove seal washers.

⑮ Unscrew the setting screw using an 8mmhexagon socket spanner.

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16 Shake out spring and piston. The valve seat is bonded into the housing and
cannot be removed.

17 The pressure relief valve is now disassembled.

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5) ASSEMBLY
A. Assemble spool and sleeve.
※ When assembling spool and
Sleeve only one of two possible
ways of positioning the spring slots
is correct.
There are three slots in the spool
And three holes in the sleeve in
the end of the spool / sleeve
opposite to the end with spring
slots.
Place the slots and holes opposite each other so that parts of the holes
in the sleeve are visible

B. 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).

C. Line up the spring set.

D. Guide the spool into the sleeve.

Make sure that spool and sleeve
are placed correctly in relation
to each other.

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E. Press the springs together and
push the neutral position springs
into place in the sleeve.

F. Line up the springs and center

them.

G. Guide the ring down over the sleeve.

※ The ring should be able to
rotate free of the springs.

H. Fit the cross pin into the

spool / sleeve.

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I. Fit bearing races and needle
bearing as shown on below
drawing.

※ Assembly pattern for standard bearings

a) Outer bearing race
b) Thrust bearing
c) Inner bearing race
d) Spool
e) Sleeve

J. Installation instruction for O-ring

Turn the steering until the
bore is horizontal. Guide the
outer part of the assembly tool
into the bore for the
spool / sleeve.

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K. Grease O-ring with hydraulic
oil and place them on the tool.

L. 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.

M. Press and turn the O-ring into

position in the housing.

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N. 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.

O. Installation instructions for lip seal

Lubricate the lip seal with
hydraulic oil and place it on the
assembly tool.

P. Guide the assembly tool right to the bottom.

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Q. Press and turn the lip seal into
place in the housing.

R. With a light turning movement,

guide the spool and sleeve into
the bore.
※ Fit the spool set holding the
cross pin horizontal.

S. The spool set will push out the

Assembly tool guide. The O-ring
are now in position.

T. Turn the steering unit until the

Bore is vertical again.
Put the check valve ball into
the hole indicated by the arrow.

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U. Screw the threaded bush lightly
Into the check valve bore.
The top of the bush must lie just
below the surface of the housing.

V. Grease the O-ring with mineral

oil approx. viscosity 500 cst at

20℃.

W. Place the distributor plate so

that the channel holes match
the holes in the housing.

X. Guide the cardan shaft down

into the bore so that the slot is
parallel with the connection
flange.

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Y. Place the cardan shaft as shown
so that it is held in position by
the mounting fork.

Z. Grease the two O-rings with

mineral oil approx. viscosity
500 cst at 20°C and place them
in the two grooves in the gear rim.
Fit the gearwheel and rim on the
cardan shaft.

AA. 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.

BB. Fit the spacer, if any.

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CC. Place the end cover in position.

DD. Fit the special screw with

washer and place it in the
hole shown.

EE. Fit the six screws with washers

and insert them.
Cross-tighten all the screws
and the rolled pin.
•Tightening torque:
3.0 ± 0.6kgf•m (21.7 ± 4.3lbf•ft)

FF. Place the dust seal ring in the housing.

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GG.Fit the dust seal ring in the housing.

HH.Press the plastic plugs into the connection ports.

※ Do not use a hammer!

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2 STEERING CYLINDER
1) STRUCTURE

1 Tube assembly 6 Bushing

2 Rod assembly 7 U-packing
3 Piston seal 8 Dust wiper
4 Wear ring 9 O-ring
5 Gland

2) DISASSEMBLY
※ Before disassembling steering cylinder, release oil in the cylinder first.
① Put wooden blocks against the cylinder tube, then hold in a vice.
② Remove the gland by hook a wrench in the notch of cylinder head and turn
counter-clockwise. (3) Remove the cylinder rod and piston from the tube.
③ Check wear condition of the sealing parts. If there are some damages,
replace with new parts.

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 3) CHECK AND INSPECTION
mm(in)
Criteria
Check item Remedy
Standard size Repair limit
Clearance between
0.064~0.137
piston & cylinder 0.180 (0.0070) Replace piston seal
(0.0025~0.0054)
tube
Clearance between
0.024~0.112
cylinder rod & 0.120 (0.0049) Replace bushing
(0.0009~0.0044)
bushing
Seals, O-ring Damage Replace
Cylinder rod Dents Replace
Cylinder tube Biting Replace

4) ASSEMBLY
A. Install a new piston seal the groove on the piston.
※ Be careful not to scratch the seal too much during installation or it will not
seat properly.

B. Install the rod seal to the position in the gland applying a slight coat with
grease prior to install.

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C. Install the dust wiper to the gland
using a special installing tool.
Coat the dust wiper with grease
slightly before installing.
D. Set a special tool the cylinder,
gland assembly into the cylinder
tube.

E. Using a hook spanner, install the

gland assembly, and tighten it with
torque 45±4.5kgf•m (325±32.5lbf•ft).

F. After the gland assembly was

Installed to the cylinder tube, calk
at the tube end into the groove on
the gland to prevent screw
loosening.
※If it need calking again, never
using previous calking position.

G. 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.
H. Install cylinder into steering axle.
I. While idling the engine with the rear wheels off the ground, operate the
steering wheel left and right alternately.
※ Then, repeat the above operation at gradually increasing engine rpm. This
releases air from the system and completes preparation for operation.
J. Stop the engine, lower the floating rear wheels, and check pump joints for oil
leaks and looseness and retighten, them as required.

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3 STEERING AXLE
1) STRUCTURE

1 Steering axle 17 Hub 33 Thrust washer

2 Knuckle-RH 18 Hub bolt 34 Pin
3 Knuckle-LH 19 Hub nut 35 Spring washer
4 Special bolt 20 Hub cap 36 Hardened washer
5 King pin 21 Steering link 37 Upper cover
6 Taper roller bearing 22 Steering cylinder 38 Lower cover
7 Oil seal 23 SPH plain bearing 39 Hex bolt
8 Retaining ring 24 Steer link pin 40 Spring washer
9 Collar 25 Plain washer 41 Shim (0.1t)
10 Grease nipple 26 Grease nipple 42 Shim (0.15t)
11 Oil seal 27 Lock plate 43 Shim (0.3t)
12 Taper roller bearing 28 Bolt 44 Spacer
13 Split pin 29 Hex nut 45 Hex bolt
14 Nut 30 Hex bolt 46 Taper roller bearing
15 Washer 31 Trunnion block 47 Plate
16 Plate 32 Bushing 48 Split pin

117 / 210
 2) CHECK AND INSPECTION

unit: mm(in)
No. Check item Criteria Remarks
Standard
Repair limit
size
A A1 OD of shaft 55(2.2) 54.5(2.1)
Shaft
A2 ID of bushing 55(2.2) 55.5(2.2)
B OD of king pin 35(1.4) 34.5(1.4) Replace
C OD of steering cylinder pin 20(0.8) 19.5(0.8)
D D1 OD of pin 20(0.8) 19.5(0.8)
Knuckle D2 Vertical play - - Adjust with shims
D3 ID of bushing 20(0.8) 20.5(0.8) Replace
•OD: Outer diameter
•ID: Inner diameter

3) DISASSEMBLY
※Servicing work on the knuckle part can be carried out without removing the rear
axle shaft from chassis. The work can be done by jacking up the counter weight
part of the truck.
A. Loosen the hub nut and take off the steering wheel tire.

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B. Remove Hub cap.
C. Pull out split pin and remove slotted nut.
D. Using the puller, take off the hub together with the roller bearing.
※Be very careful because just before the hub comes off, tapered roller bearing
will fall out.
E. After hub is removed, take off the inner race of roller bearing.
F. Pull out oil seal.
※Don't use same oil seal twice.
G. Repeat the same procedure for the other side.
Moreover, when disassembling is completed, part the slotted nut in the
knuckle to protect the threaded portion.

H. Loosen special bolt (4) and spring washer (35).

I. Remove hexagon bolt (39) and upper cover (37).
J. Push out the king pin (5) without damaging the knuckle arm (3).
K. If defect is observed in bearing (6), pull it out by using extractor.
L. Remove spilt pin (13), plain washer (25) and link pin (24).

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4) ASSEMBLY
※ In reassembling, have all parts washed, grease applied to lubricating parts,
and all expendable items such as oil seal and spring washers replaced by new
ones.
Perform the disassembly in reverse order.
A. Tighten the special bolt (4) and washer (35) of king pin (5).
B. There is a notch in the middle of the king pin (5), make sure that this notch is
on the special bolt side.
C. Do not hammer to drive in bearing (6) because it will break.
Always use drive-in tool.
Be sure that the fixed ring of the bearing is placed in position facing the
knuckle (3).
D. Hub
- Mount oil seal (11) and inner race of tapered roller bearing (12) on the
knuckle. The bearing should be well greased before assembling.
- Install the outer race of the bearing (46) in the wheel center and assemble
to the knuckle.
- Tighten nut (14) and lock with split pin (48). In 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.
- Mount the hub cap (20).
Bearing should be well greased before assembling.

120 / 210
SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and Function ---------------------------------------------122-133

Group 2 Operational Checks and Troubleshooting ---------------------134-137
Group 3 Disassembly and Assembly ---------------------------------------138-151

121 / 210
GROUP1 STRUCTURE AND FUNCTION

1 HYDRAULIC CIRCUIT

1 Hydraulic tank 7 Side shift cylinder

2 Suction strainer 8 Fork positioner cylinder
3 Hydraulic gear pump 9 Steering unit
4 Main control valve 10 Steering cylinder
5 Lift cylinder 11 Return filter
6 Tilt cylinder 12 Down safety valve

122 / 210
2 HYDRAULIC GEAR PUMP
1) STRUCTURE

1 GEAR PUMP ASSY 3 CONNECTOR 5 ELBOW-90

2 BOLT-W/WASHER HEX 4 O-RING

123 / 210
3 MAIN CONTROL VALVE
1) STRUCTURE (4- Spool)

1 T cover 6 Lift block assy

2 Aux2 block assy 7 Main Relief valve
3 Aux Relief valve 8 PF port fitting
4 Aux1 block assy 9 inlet block assy
5 Tilt block assy 10 Aux Relief valve

124 / 210
2) INLET SECTION OPERATION
① Structure and description

1 plug 5 Relief valve

2 Body 6 Steering relief valve
3 PF port fitting 7 LS port fitting
4 priority valve

125 / 210
 ② Operation

The P port is the pump oil inlet, the PF port is connected to the steering unit inlet, the
EF port is connected to the working valve, the LS port is connected to the steering unit
control port, and the T port is the safety valve return port. When the oil is in the P port,
the hydraulic oil is preferentially supplied to the PF port through the priority valve.

126 / 210
3) LIFT SECTION OPERATION
① Lift position

1A

When the lift control lever is pulled back, the spool moves to the right and the
neutral passage is closed.
The oil supplied from the pump flow into lift cylinder port(1A). The pump pressure
reaches proportionally the load of cylinder.
The return oil from cylinder flows into the tank.

127 / 210
② Lower position

1A

When the lift control lever is pushed forward, the spool moves to the left and the
neutral passage is closed.
The spool moves to the lift lower position, opening up the neutral passage to tank
and (1A) → T.
In lift lower position the fork drops due to its own weight.

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4) TILT SECTION OPERATION
① Tilt forward position

2A 2B

When the tilt control lever is pushed forward, the spool moves to the left and the
neutral passage is closed.
The oil supplied from the pump flow into tilt cylinder port(2B). The pump pressure
reaches proportionally the load of cylinders.
The return oil from cylinder port(2A) flows into the tank through the hole of the tilt
lock spool.

129 / 210
 ② Tilt backward position

2A 2B

When the tilt control lever is pulled back, the spool moves to the right and the neutral
passage is closed.
The oil supplied from the pump flows into tilt cylinder port(2A). The pump pressure
reaches proportionally the load of cylinder.
The return oil from cylinder port(2B) flows into the tank via the low-pressure passage.

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5) MAIN RELIEF VALVE
① Pressure setting
A good pressure gauge must be installed in the line which is in
communication with the work por t relief. A load must be applied in a
manner to reach the set pressure of the relief unit.
Procedure
 Loosen lock nut.
 Set adjusting bar to desired
pressure setting.
 Tighten lock nut.
 Retest in similar manner as above.

② Operation
Pressurized oil over the relief pressure pushes pilot poppet and flows to tank
passage, therefore the system pressure keeps under the adjusted relief
pressure.

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4 LIFT CYLINDER

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

1 Tube assembly 9 Bushing 17 Washer

2 Rod 10 U-packing 18 Eye
3 Piston 11 Back up ring 19 Bushing
4 Seal ring 12 Dust wiper 20 Hexagon bolt
5 Wear ring 13 Stop ring 21 Spring washer
6 O-ring 14 O-ring 22 Lock nut
7 Hexagon nut 15 Back up ring 23 Grease nipple
8 Gland 16 O-ring

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6 FREE LIFT CYLINDER

1 Tube assembly 6 Check valve 11 Dust wiper

2 Rod 7 Retaining ring 12 Retaining ring
3 Piston 8 Set screw 13 O-ring
4 Piston seal 9 Gland 14 Back up ring
5 Wear ring 10 U-packing

133 / 210
GROUP2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1 OPERATIONAL CHECKS
1) CHECK ITEM
① Check visually for deformation, cracks or
damage of rod.
② Set mast vertical and raise 1m from ground.
Wait for 10 minutes and measure hydraulic
drift (amount forks move down and amount
mast tilts forward).
•Check condition
- Hydraulic oil: Normal operating temp
- Mast substantially vertical.
- Rated capacity load.
•Hydraulic drift
- Down (Downward movement of forks)
: Within 100mm (3.9in)
- Forward (Extension of tilt cylinder)
: Within 5。
③ If the hydraulic drift is more than the
specified value, replace the control valve or
cylinder packing.
Check that clearance between tilt cylinder
bushing and mounting pin is with in
standard range.
mm (in)
Standard Under 0.6 (0.02)

2) HYDRAULIC OIL
① Using dipstick, measure oil level, and oil if
necessary.
② When changing hydraulic oil, clean
suction strainer (screwed into outlet
port pipe) and line filter (screwed into inlet
pipe). Line filter uses paper element, so
replace periodically (every 6 months or Drain plug Oil dipstick
1000 hours)
③ Raise forks to maximum height and
measure oil pressure.
④ Check that oil pressure is 220 kgf/cm2.
(3130 psi)

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2 TROUBLESHOOTING
1) SYSTEM
Problem Cause Remedy
Large fork •Seal inside control valve defective. •Replace spool or valve body.
lowering •Oil leaks from joint or hose. •Replace.
speed. •Seal inside cylinder defective. •Replace packing.
Large •Tilting backward: Check valve Clean or replace.
spontaneou defective.
s tilt of mast. •Tilting forward: tilt lock valve •Clean or replace.
defective.
•Oil leaks from joint or hose. •Replace.
•Seal inside cylinder defective. •Replace seal.
Slow fork •Lack of hydraulic oil. •Add oil.
lifting or •Hydraulic oil mixed with air. •Bleed air.
slow mast •Oil leaks from joint or hose. •Replace.
tilting. •Excessive restriction of oil flow on •Clean filter.
pump suction side.
•Relief valve fails to keep specified •Adjust relief valve.
pressure.
•Poor sealing inside cylinder. •Replace packing.
•High hydraulic oil viscosity. •Change to SAE10W, class
CF engine oil.
•Mast fails to move smoothly. •Adjust roll to rail clearance.
•Oil leaks from lift control valve •Replace spool or valve body.
spool.
•Oil leaks from tilt control valve •Replace spool or valve body.
spool.
Hydraulic •Excessive restriction of oil flow •Clean filter.
system pump suction side.
makes •Gear or bearing in hydraulic pump •Replace gear or bearing.
abnormal defective.
sounds.
Control •Foreign matter jammed between •Clean.
valve lever spool and valve body.
is locked •Valve body defective. •Tighten body mounting bolts
uniformly.
High oil •Lack of hydraulic oil. •Add oil.
temperature. •High oil viscosity. •Change to SAE10W, class
CF engine oil.
•Oil filter clogged. •Clean filter.

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 2) HYDRAULIC GEAR PUMP
Problem Cause Remedy
Pump does not •System relief valve set too low •Check system relief valve for
develop full or leaking. proper setting.
pressure. •Oil viscosity too low. •Change to proper viscosity oil.
•Pump is worn out. •Repair or replace pump.
Pump will not •Reservoir low or empty. •Fill reservoir to proper level.
pump oil. •Suction strainer clogged. •Clean suction strainer.
Noisy pump •Oil too thick. •Change to proper viscosity.
caused by •Oil filter plugged. •Clean filters.
cavitation. •Suction line plugged or too •Clean line and check for proper
small. size.
Oil heating. •Oil supply low. •Fill reservoir to proper level.
•Contaminated oil. •Drain reservoir and refill with
•Setting of relief valve too high clean oil.
or too low. •Set to correct pressure.
•Oil viscosity too low. •Drain reservoir and fill with
proper viscosity.
Foaming oil. •Low oil level. •Fill reservoir to proper level.
•Air leaking into suction line. •Tighten fittings, check condition
of line.
•Wrong kind of oil. •Drain reservoir, fill with
non-foaming oil.
Shaft seal •Worn shaft seal. •Replace shaft seal.
leakage. •Worn shaft in seal area. •Replace drive shaft and seal.

3) MAIN RELIEF VALVE

Problem Cause Remedy
Can get •Poppet D, E or K stuck open •Check for foreign matter
pressure or contamination under seat. between poppets D, E or K and
their mating parts. Parts must
slide freely.
Erratic pressure •Pilot poppet seat damaged. •Replace the relief valve.
•Clean and remove surface
marks for free movement.
Pressure •Normal wear. Lock nut & •See section 6 for how to set
setting not adjust screw loose. pressure on work main relief.
correct
Leaks •Damaged seats. •Replace the relief valve.
•Worn O-rings. •Install seal and spring kit.
•Parts sticking due to •Disassemble and clean.
contamination.

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 4) LIFT CYLINDER
Problem Cause Remedy
Oil leaks out from •Foreign matters on •Replace packing.
gland through rod. packing. •Smooth rod surface with an oil
•Unallowable score on stone.
rod.
•Unusual distortion of dust •Replace dust seal.
seal.
•Chrome plating is striped. •Replace rod.
Oil leaks out from •O-ring damaged. •Replace O-ring.
cylinder gland
thread.
Rod spontaneously •Scores on inner surface •Smooth rod surface with an oil
retracts. of tube. stone.
•Unallowable score on the •Replace cylinder tube.
inner surface of tube.
•Foreign matters in piston •Replace piston seal.
seal.
Wear (clearance •Excessive clearance •Replace wear ring.
between cylinder between cylinder tube and
tube and wear ring) wear ring.
Abnormal noise is •Insufficient lubrication of •Lubricate or replace.
produced during anchor pin or worn
tilting operation. bushing and pin.
•Bent tilt cylinder rod. •Replace.

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GROUP3 DISASSEMBLY AND ASSEMBLY

1 HYDRAULIC GEAR PUMP

※ Tools required
•Metric socket set
•Internal snap ring pliers
•Shaft seal sleeve
•Torque wrench

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1) It is very important to work in a
clean work area when repairing
hydraulic products. Plug ports and
wash exterior of pump with a
proper cleaning solvent before
continuing.
2) Remove port plugs and drain oil
From pump.
3) Use a permanent marker pen to
mark a line across the mounting flange, gear housing and end cover.
This will assure proper reassembly and rotation of pump.
4) Remove key from drive shaft if applicable.

5) Clamp mounting flange in a

protected jaw vise with pump
shaft facing down.
6) Loosen the four metric hexagon
head bolts.
7) Remove pump from vise and
place on clean work bench,
remove the four hexagonal head
bolts and spacers applicable.

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8) Lift and remove end cover.

9) Carefully remove gear housing and place on work bench.

Make sure the rear bearing block remains on the drive and idler shafts.

10) Remove rear bearing block from drive and idler shafts.

11) Remove idler shaft from bearing block.

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12) Remove drive shaft from
mounting flange.
There is no need to protect the
shaft seal as it will be replaced as
a new item.

13) Remove the front bearing block.

14) Turn mounting flange over, with

shaft seal up, and remove the
retaining ring with proper snap
ring pliers.

15) Remove the oil seal from

Mounting flange, be careful not to
mar or scratch the seal bore.
16) Remove the dowel pins from the
gear housing. Do not lose pins.

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 17) Remove seals from both bearing
blocks and discard.

2 INSPECT PARTS FOR WEAR

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

4) Inspect gear face for scoring or excessive wear. If the face edge of gear teeth is
sharp, they will mill into the bearing
blocks.
If wear has occurred, the parts are
unusable.

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5) Inspect bearing blocks for excessive
wear or scoring on the surfaces
which are in contact with the gears.
Also inspect the bearings for
excessive wear or scoring.
6) Inspect the area inside the gear
housing.
It is normal for the surface inside the
gear housing to show a clean "wipe"
on the inside surface on the intake
side.
There should not be excessive wear or deep scratches and gouges.

※ General information

It is important that the relationship of the mounting flange, bearing blocks and gear
housing is correct. Failure to properly assemble this pump will result with little or
no flow at rated pressure.

※ This pump is not bi-rotational.

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 3 ASSEMBLY
※New seals should be installed
upon reassembly of pump.
1) Install new shaft seal in mounting
flange with part number side facing
outboard. Press the seal into the seal
bore until the seal reaches the bottom
of the bore. Uniform pressure must be
used to prevent misalignment or
damage to the seal.

2) Install retaining ring in groove in seal

bore of mounting flange.

3) Place front and back bearing blocks

on a clean surface with the E-seal
grooves facing up.
Apply a light coating of petroleum jelly
in the grooves.
Also coat the E-seal and backup with
the petroleum jelly, this will help keep
the seals in place during assembly.

4) Place the E-seals, flat side outward,

into the grooves in both bearing
blocks.
Follow by carefully placing the backup
ring, flat side outward, in the groove
made by the E-seal and the groove.
5) Place mounting flange, with shaft seal
side down, on a clean flat surface.
6) Apply a light coating of petroleum jelly
to the exposed face of the front
bearing block.

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7) Insert the drive end of the drive shaft
through the bearing block with the
seal side down, and the open side of
the E-seal pointing to the intake side
of the pump.

8) Install the seal sleeve over the drive

shaft and carefully slide the drive
shaft through the shaft seal.
Remove the seal sleeve from shaft.

9) Install the idler gear shaft in the

remaining position in the bearing
block.
Apply a light coat of clean oil to the
face of the drive and idler gears.

10) Pick up the rear bearing block, with

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

12) To install the O-rings in the gear

housing, apply a light coating of
petroleum jelly in the grooves on
both sides of the gear housing.
Also coat the new O-ring and install
them in the grooves.

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13) Gently slide the gear housing over the
rear bearing block assembly, slide
housing down until the housing
engages the dowel pins.
Press firmly in place with hands, do
not force or use any tool.
Check to make sure the intake port in
the housing in on the same side as
the open end of the E-seal and that
the marked lines on the mounting flange and gear housing are in alignment.
14) The surface of the rear bearing block should be slightly below the face of the gear
housing.
If the bearing block sits higher, then the rear face of the gear housing then the
E-seal or O-ring have shifted out of the groove. If this is the case, remove the
gear housing and check for proper seal installation.

15) Install the two remaining dowel pins in the rear of the gear housing and place the
end cover over the back of the pump.

16) Install the four spacers and hexagon head bolts through the bolt holes in the end
cover, hand tighten.

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17) Place mounting flange of the pump back in the protected jawed vise and
alternately torque the bolts.
•Tighten torque: 3.0~4.0kgf•m
(22~29lbf•ft)

18) Remove pump from vise.

19) Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft
away from the inlet one revolution. If the drive shaft binds, disassemble the pump
and check for assembly problems, then reassemble the pump.

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4 LIFT CYLINDER
1) STRUCTURE

1 Tube assembly 6 Wear ring 11 O-ring

2 Rod assembly 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

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2) DISASSEMBLY
① Hold the cylinder tube in a vice,
loosen the cylinder head and remove it.
Remove the spacer from the cylinder
tube and knock out the bushing.
Hook a wrench in the hole in the retainer
at the piston end and turn. Lever up the
edge of the guide, then turn the guide again and the guide can be removed.

② CHECK AND INSPECTION mm(in)

Check item Standard size Repair limit Remedy
Clearance between 0.072~0.288 0.5 (0.020) Replace bushing
cylinder rod & bushing (0.003~0.011)
Clearance between 0.05~0.030 0.5 (0.020) Replace piston ring
piston ring & tube (0.002~0.012)

③ ASSEMBLY
Soak the piston ring in hydraulic oil at a temperature of 40 to 50℃, 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.

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5 TILT CYLINDER
1) STRUCTURE

1 Tube assembly 9 Bushing 17 Washer

2 Rod 10 U-packing 18 Eye
3 Piston 11 Back up ring 19 Bushing
4 Seal ring 12 Dust wiper 20 Hexagon bolt
5 Wear ring 13 Stop ring 21 Spring washer
6 O-ring 14 O-ring 22 Lock nut
7 Nylon nut 15 Back up ring 23 Grease nipple
8 Rod cover 16 O-ring

150 / 210
 2) DISASSEMBLY
Hold the parallel parts of the cylinder tube bottom in a vice and mark the rod
head end to show how much it is screwed in, then remove the rod head. Next,
hook a wrench into the notch at the cylinder head and remove the cylinder
head from cylinder tube.
When doing this, wind tape round the threaded part of the rod and be careful
not 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 (0.020) Replace bushing
cylinder rod & bushing (0.003~0.011)
Clearance between rod 0.10~0.35 0.6 (0.024) Replace bushing
head bushing & pin (0.004~0.014)

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SECTION7 ELECTRICAL SYSTEM

Group 1 Component Location ------------------------------------------------------153

Group 2 Electrical Circuit ------------------------------------------------------154-158
Group 3 Component Specification ------------------------------------------------159
Group 4 Connector Destination ---------------------------------------------- 160-162
Group 5 Troubleshooting ------------------------------------------------------------163

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GROUP1 COMPONENT LOCATION

1 Flasher lamp 7 Forward-reverse lever 13 OPSS unit

2 Work lamp 8 Operating panel 14 Flasher unit
3 Combination switch 9 Start switch 15 Battery
4 Horn assembly 10 Light switch 16 Beacon lamp
5 Combination lamp 11 Switch board
6 Back buzzer 12 Fuse box

153 / 210
GROUP2 ELECTRICAL CIRCUIT

154 / 210
MEMORANDUM
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

Start switch[CS-2(3)] Cab [CN-17(1),18(1)]

Fuse box [CN-36] (No.1) OPSS buzzer[CN-113(2)]

Horn [CN-25(2)]

Brake switch [CD-4]

(No.2) Flasher unit [CR-11(2)]

(No.3) OPPS unit [CN-55(12)]

2) CHECK POINT
Engine Key switch Check point Voltage
OFF OFF 10 ~ 13V
①GND (Battery(+))

②GND (Fuse No.1)

③GND (Start key)

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POWER CIRCUIT

156 / 210
 2 STARTING CIRCUIT
1) OPERATING FLOW

Battery (+) terminal Start motor [CN-45(B+)] I/conn [CN-1(12,13,14)] Start switch

※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]
I/conn [CN-1(19)]
Fuel system interface [CN-6(1)]
② When start key switch is START position
Start switch START[CS-2(2)] Fuse box[CN-36(4)] Neutral
relay[CR-5(4→2)] I/conn[CN-1(21)] → Fuel system interface[CN-6(7)]

2) CHECK POINT
Engine Key switch Check point Voltage
Running ON 10 ~ 14.5V
①GND (Battery B+)

②GND (Fuse box No.5)

③GND (Start key)

④GND (Neutral relay)

157 / 210
158 / 210
GROUP3 COMPONENT SPECIFICATION

No Part name Qty Specification Remark

1 Battery 1 CCA: 750A
20HR: 93AH
6-QW-93(300×170×225)
2 Working lamp 1 9-36V, 12W（3W×4）
3 License lamp 1 12V, 3.4W×2
4 Combination lamp 2 12V, 0.5W×4(T/S) 12V, 0.5W×4(Back)
12V, 0.5W×4 (Tail)
12V, 0.5W×4(Stop)
5 Head lamp 2 9-36V, 12W（3W×4）
6 Flasher lamp 2 12-24V, 0.8W
7 Flasher & Relay 1 12V, 40A (Relay)
12V, (21W+21W) ×2+(5W+5W) ×2
12V,80A(Relay-Power)
8 Back horn 1 12V, 105±5dB, 75±5C/M
9 Horn 1 12V, MAX 4A, 105~118dB
10 Combination switch 1 60W+60W+60W+60W+60W+60W+50
W
11 Start switch 1 12V/24V, 15~28A
12 OPSS unit 1 12V/24V, MAX 0.5A(at 12V)
13 Relay (4P) 2 12V, 40A
14 Relay (5P) 2 12V, 40A

159 / 210
 GROUP4 CONNECTOR DESTINATION

Connector Type No. of Destination Connector part No.

number pin Female Male

CN-1 AMP 16 I/conn (Dashboard harness-frame harness) 368047-1 368050-1

CN-2 KET 4 I/conn (Dashboard harness-travel harness) MG610331 MG640333

CN-3 KET 3 I/conn (Dashboard harness-frame harness) MG642292-5 MG652290-5

CN-4 KET 12 I/conn (Dashboard harness-head guard harness) MG610346 MG640348

CN-5 KET 4 Support harness-RH MG610047 MG620046

CN-6 AMP 2 I/conn (Dashboard harness-frame harness) 174352-2 174354-2

CN-7 KET 2 I/conn (Dashboard harness-frame harness) MG642928-5 MG652934-5

CN-17 KET 4 Power output for cabin MG610047 MG620046

CN-25 AMP 2 Horn 171809-2 -

CN-36 - - Fuse box 21HF-10500 -

CN-45 YAZAKI - Start motor 7123-6214-40 、 -

S820-208000

CN-55 KET 14 OPSS unit MG610350 MG640352

CN-56 AMP 20 Cluster 368511-1 -

CN-57 AMP 8 Cluster 368540-1 -

CN-65 AMP 2 Back buzzer 174352-2 -

CN-70 4 I/conn (Dashboard harness-frame harness) MG610047 MG620046

CN-71 KET 2 Seat heat MG610043 MG620042

CN-74 RING TERM 1 Alternator B+ S820-105000 -

CN-74 YAZAKI 2 Alternator 7223-6224-40 -

CN-80 1 Brake switch DJ7021-6.3-21 -

CN-81 2 LPG Gasoline solenoid valve DJ3021Y-2.5-11

CN-82 2 solenoid valve DJ3021Y-2.5-11

CN-87 SUMITOMO 2 Injection pump 6098-0131 -

CN-95A KET 2 Backup Plugin 21N4-01310 MG620558

CN-95B KET 2 Backup Plugin 21N4-01310 MG620558

CN-113 AMP 2 OPSS buzzer 174352-2 174354-2

CN-122 AMP 3 T/M SOL 282087-1 -

CN-132 AMP 2 Attach cut sol 174352-2 174354-2

CN-132A AMP 2 Attach cut sol 174352-2 174354-2

Switch

CS-2 KET 4 Start switch MG610047 -

CS-5 RING TERM - Horn switch DJ431-6 -

CS-11 RING TERM 5 Gear selector switch DJ7061-6.3-21 -

CS-12 RING TERM 9 Combination switch - DJ7061-6.3-11

CS-17 KET 3 Parking switch MG610045 -

CS-21 SWF 8 Rear work switch DJ7086-6.3-21 -

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 2 DJ7021A-2.8-21 -

CS-73 AMP 2 Seat switch 174352-2 174354-2

CS-74 AMP 2 Load sensor 174352-2 174354-2

CS-77 AMP 2 Rear grip horn switch 174352-2 174354-2

Connector Type No. of Destination Connector part No.

number pin Female Male

Lamp

CL-3 KET 1 Head lamp-LH ST730018-3 ST750036-3

CL-4 KET 1 Head lamp-RH ST730018-3 ST750036-3

CL-7 KET 1 Beacon lamp ST730018-3 ST750036-3

CL-15 KET 1 Combination lamp-LH ST730018-3 ST750036-3

CL-16 KET 1 Flasher lamp-RH ST730018-3 ST750036-3

CL-16 KET 1 Combination lamp-RH ST730018-3 ST750036-3

CL-17 KET 1 Flasher lamp-LH ST730018-3 ST750036-3

CL-23 KET 1 Rear working lamp ST730018-3 ST750036-3

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 Tail lamp relay MG640927 -

CR-23 KET 4 Starter relay MG612017-5

CR-51 KET 5 Attach cut relay MG640927

Sensor and pressure switch

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CD-2 KET 3 Fuel level sensor MG610045 -

CD-4 RING TERM 2 Brake switch DJ7021-6.3-21 -

CD-8 MHI 1 E/G water temp sensor ST730018-3

CD-10 KET 1 Air cleaner switch ST730057-2 -

CD-18 KET 1 E/G Oil Pressure Sensor switch ST730057-2

CD-29 AMP 1 T/M temp switch 171809-2 -

DO-1 AMP 2 Diode 174352-2 21EA-50550

RS-1 KET 2 Resistor MG610043 21HA-40110

162 / 210
GROUP5 TROUBLESHOOTING

Trouble symptom Probable cause Remedy

Lamps dimming even at •Faulty wiring. •Check for loose
maxi- mum engine speed. terminal and
disconnected wire.
Lamps flicker during engine •Improper belt tension. •Adjust belt tension.
operation.
Charge lamp does not light •Charge lamp defective. •Replace.
during normal engine •Faulty wiring. •Check and repair.
operation.
Alternator makes abnormal •Alternator defective. •Replace
sounds.
Starting motor fails to run. •Faulty wiring. •Check and repair.
•Insufficient battery voltage. •Recharge battery.
Starting motor pinion repeats •Insufficient battery voltage. •Recharge battery.
going in and out.
Excessively low starting •Insufficient battery voltage. •Recharge battery.
motor speed. •Starting motor defective. •Replace
Starting motor comes to a •Faulty wiring. •Check and repair.
stop before engine starts up. •Insufficient battery voltage. •Recharge battery.
Heater signal does not •Faulty wiring. •Check and repair.
become red. •Electric plug damaged. •Replace
Engine oil pressure caution •Caution lamp defective. •Replace
lamp does not light when •Caution lamp switch •Replace
engine is stopped (with defective.
starting switch left in "ON"
position).

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SECTION8 LPG SYSTEM

Group 1 Loop LPG forklift truck system components principle -----165-175

Group 2 Gas filling and operation -------------------------------------------176-179
Group 3 Handling of accidents and emergencies -----------------------------180
Group 4 Troubleshooting ------------------------------------------------------181-186

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GROUP1 OPEN LOOP LPG FORKLIFT TRUCK SYSTEM
COMPONENTS PRINCIPLE

1. SYSTEM SPECIFICATIONS

The LPG forklift is a conversion device mounted on the original gasoline engine to
allow it to accept LPG as fuel. There are basically two kinds of modification:
a. Dual fuel system: After the forklift is refitted, the original gasoline engine system
remains, so the forklift can use both fuels. The converter has a toggle switch that
allows the operator to choose which one to use for fuel.
b. Single fuel system: After the forklift is refitted, the pressure relief valve and the
gasoline pump of the original gasoline system have been removed, and the liquefied
gas mixer has been replaced. At this time, the forklift can only use liquefied gas as fuel

2. PRINCIPLE OF CONVERSION SYSTEM

The principle of dual fuel and single fuel LPG conversion system is generally similar
with minor differences. Please refer to the attached diagrams.

1) Dual fuel system will still use gasoline as fuel, so the original gasoline engine
parameters (Idling and ignition timing, etc.) have not changed. But the basic
165 / 210
characteristics of LPG fuel are different from gasoline (air-fuel ratio, combustion rate,
heat content, etc.). As a result, the output power of the internal combustion engine at
the highest speed will be slightly worse than that of the original gasoline engine (about
90-95%). But a well-tuned dual fuel forklift will not be able to tell the difference under
normal operation.
2) Single fuel system, because gasoline is no longer used, the ignition timing can be
slightly increased within the limits allowed by the original gasoline engine by several
degrees, and the appropriate Angle can be selected within the range of 2~6 degrees
to give full play to the maximum efficiency of liquefied gas.

166 / 210
LPG forklifts are divided into single and dual fuel systems, which are slightly
different in system structure. Dual fuel forklifts retain the gasoline carburetor and
add the fuel switch.
The structural system of LPG forklift truck is illustrated by the structure diagram of
dual fuel system (See above). The working principle is as follows: LPG is stored in
the cylinder. Before the forklift starts, open the manual switch at the outlet of the
cylinder. Liquid LPG will pass through the filter/vacuum cut-off valve, on the one
hand, the impurities in the liquid LPG will be removed, on the other hand, when the
internal combustion engine stops running for some reason, the vacuum signal from
the carburetor will disappear, and the internal vacuum valve will immediately close
(the first safety lock), cutting off the flow of LPG. LPG flow to voltage regulator/
relief valve, the LPG in the heated vaporization into gas, and two depressions are
required to reach the pressure condition of the internal combustion engine.
However, the internal valve is still in the normally closed state, only when the
internal combustion engine operation caused by vacuum suction began to flow
(second safety lock), its vaporization process needs to absorb a lot of heat, in
order to prevent the device from freezing, the engine hot water must be directed to
the voltage regulator/ relief valve.
At this time, the gaseous LPG enters the LPG mixer and only starts to flow out
when the vacuum suction is caused during the operation of the internal
combustion engine (the third safety lock). During this time, THE LPG will mix with

167 / 210
 the clean air in a certain proportion and become combustible gas into the
combustion chamber of the engine, so that the engine can run normally and
produce power.
Dual fuel system in the choice of burning gasoline, just open the fuel switch, the
system will automatically close the LPG supply system through the solenoid valve,
the gasoline supply system can work normally.

3. PIPELINE PRESSURE RELIEF VALVE

Based on safety considerations, if there is residual liquid gas in the gas pipeline
system, in order to prevent its expansion due to heat and lead to pipeline burst, it is
necessary to install this device. When the internal pressure reaches 2.64MPa, it
will automatically start and vent.

4. FILTER/ VACUUM CUT-OFF VALVE

It has two functions:
A. Filter screen to remove impurities in the gas, so as not to enter the
downstream vaporization equipment to cause obstruction
B. When the internal combustion engine stops running for some reason, the
vacuum signal from the carburetor disappears and the internal valve
immediately closes, cutting off the gas flow to the gasoline engine.
Refer to the attached Section (FIG.1)

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Principle：The fuel filter valve is under spring or electromagnetic pressure, usually
closed, and requires an electromagnetic or vacuum signal from the running engine to
open. This is the first "lock" in the IMPCO vehicle system safety device. Once the
engine stops running, the fuel flow stops automatically. The filter valve opens when it
receives a normal electromagnetic or vacuum signal, allowing 150PSI gas to flow to
the voltage regulator/ relief valve.
Above the device is a filter chamber, with a filter screen, the function is to prevent
foreign matter from entering the fuel system, if the accumulation of foreign matter too
much will affect the air, so it must be periodically inspected, cleaned or replaced.
When the engine is stationary, the valve inside the device is closed by the spring
sheet above it, so that the LPG liquid cannot flow.
Vacuum signal must reach 490Pa to open valve. When the engine flameout and stops
running, the vacuum signal disappears, the device will automatically shut down and
cut off LPG, so it is a safety equipment.

5. VOLTAGE REGULATOR/ RELIEF VALVE

It has two functions：
① Liquid gas is heated here and transformed into gas, so it is also called
"evaporator".
② The gas reaches the pressure required by gasoline internal combustion engine
through two-stage decompression process, but the internal valve is normally
closed. Only when vacuum suction (negative pressure) from internal combustion
engine operation reaches 372.4Pa it starts to flow out. In the process of gas
vaporization, a large amount of external heat is absorbed, so the hot water pipe of
the internal combustion engine needs to be introduced into the shell to heat up,
so as to prevent ice from causing internal failure.

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 Refer to the attached Section (FIG. 2)

The principle: IMPCO's LPG pressure regulating valves are secondary valves
because they lower the pressure in two steps from medium to low and measure the
gas output by referring to a negative pressure signal from the air/fuel mixer.
Normally, the regulating valve is closed and a signal from the mixer is required to open
the valve in the second chamber for fuel to flow in. If the engine stops running at this
point, the fuel flow will stop automatically, which is the second safety "lock" in the
IMPCO vehicle system safety device. The amount of fuel sent by the pressure
regulating valve is proportional to the strength of the vacuum signal. Upon receiving
the vacuum signal from the mixer, the pressure regulating valve opens and gas flows
into the mixer. As the gas flows through the regulating valve, the pressure drops in two
steps from bottle pressure to just below atmospheric pressure.
The device has two functions:
① Convert liquid LPG to vapor state
② Adjust the outlet pressure of steam LPG to the required starting pressure
The structure of the device is mainly divided into two parts:
a) First chamber: the first stage of step-down to 10KPa
a) Second chamber: the second stage step-down to 372.4Pa

• First stage antihypertensive effect:

① When there is no LPG under the primary chamber diaphragm (1), the pressure
of the spring (2) above it presses the diaphragm downward, resulting in the
primary chamber valve (3) being in the "normally open state" through the action
of the ejector rod.
② When liquid LPG is introduced into the device and passes through the valve (3),
it rapidly expands and naturally vaporizes into vapor state, filling the primary
chamber. At this time, its gaseous pressure resists the pressure of spring (2) in

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 the opposite direction and pushes the primary diaphragm (1) upward, resulting
in the closure of the primary chamber valve (3).
③ The above two actions continuously alternate operation, so that the indoor
vapor gas pressure is maintained at about 10KPa.
④ Liquid gas absorbs a lot of "latent heat" around in the process of vaporization,
which will lead to the phenomenon of ice inside the device. In order to prevent
the phenomenon of gas loss, the cooling water must be imported into the
engine to indirectly heat up in the "warm water chamber" to prevent freezing.
• Second-stage antihypertensive effect:
① When the pressure of the diaphragm (4) and its spring (5) of the secondary
chamber is in equilibrium, the valve (6) of the secondary chamber is in "normally
closed state".
② When the engine is started, the vacuum suction is passed into the lower part of
the diaphragm (4) of the secondary chamber of the device through the LPG mixer,
causing the diaphragm to move down, and the valve (6) of the secondary
chamber is "open" through the action of the ejector rod (7).
③ The vapor gas piled up below the secondary valve (6) flows rapidly into the
secondary room at this time, and the vapor pressure pushes the diaphragm (4) up
in the opposite direction, making the secondary valve (6) close again.
④ The above two actions continuously alternate operation, so that the secondary
indoor pressure is maintained at 372.4Pa.
⑤ The opening time of the secondary valve (4) is proportional to the strength of the
vacuum suction of the engine. Therefore, according to the requirements of the
engine, the accurate flow of vapor gas can be introduced into the LPG mixer and
properly mixed with the intake air volume to achieve the best air-fuel ratio.
The function of manual valve is to press down the diaphragm of the secondary
chamber (4) and open the valve (6) of the secondary chamber when necessary, so
that the gaseous gas flows into the secondary chamber.

6. THERMOSTAT
Its function is to keep the temperature of the hot water within a certain range, in hot
conditions, not due to overheating and cause propane cracking in the valve, but in
cold conditions can continue to allow gas vaporization. At the same time to protect
the diaphragm, prolong its life.

7. GAS PRESSURE REDUCING VALVE (MIXER)

The combustion air and gas fuel enter the internal combustion engine at the right
mixture ratio here, so it is also called the mixer.
After modification, the air-fuel ratio must be adjusted on the pressure reducing valve.

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The principle: IMPCO's LPG mixer restrictor nozzles are usually closed and require a
vacuum signal from the running engine to draw fuel out of the nozzle. This is the third
installment of the IMPCO vehicle system safety device.
Once the engine stops rotating, the restrictor nozzle will close and automatically
disconnect the fuel flow. When the mixer receives a vacuum signal from the engine,
the air valve opens (the size of the opening is proportional to the amount of air
entering the engine) so that the fuel from the regulator enters and mixes with the air in
the appropriate proportion. The mixture enters the engine cylinder through the intake
manifold, where it is compressed, ignited, and burned.
① Refer to the attached section (FIG. 3)
② Under normal conditions, the gas metering valve of the device is closed, and
there is no gas inflow.
③ When the engine starts, the air flows through the central "floating air valve",
causing the spring to compress and the air valve to move down, causing the "LPG
metering valve" to open, allowing the LPG inflow to mix with the air.
④ The greater the engine suction, the greater the opening of the "LPG metering
valve", the more LPG inflow.

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⑤ The gas flow rate can be adjusted by "power adjustment button". Turn its index to
R (thick), the flow increases, turn to L (light) will reduce.
⑥ "Idle speed control button" is to bypass the appropriate amount of inlet air below
the mixer, so when this button is turned in, the fuel mixture ratio becomes thicker
and when it is spun out, it becomes lighter.

8. SOLENOID VALVE
The switch device for using two fuels according to the driver's intention is the gasoline
solenoid valve and the LIQUEFIED petroleum gas solenoid valve, both of which are
normally closed.

9. PRECAUTIONS FOR USE:

① LPG contains non-volatile substances, which can easily damage the diaphragm
and seals. If the quality is not good, the sewage outlet should be opened every 2
months to remove LPG deposits.
a) If the filter screen is not too dirty, you can use compressed air in the opposite
direction to blow off the accumulated impurities, if it is too dirty, you must
replace the new parts: the filter screen cannot be cleaned with any solvent, if
the old screen is used, pay attention to the normal installation direction is the
dirty side toward the liquefied gas inlet.
b) If the internal accumulation of impurities and tar, must be cleaned, preferably
with warm soapy water or neutral soap for cleaning (do not use any solvent).
After cleaning, check the inside carefully for any damage or abnormal
phenomena, and illuminate the diaphragm with strong light to check for small
holes or cracks. Is it still resilient? Has it aged or hardened? Liquefied
petroleum gas vehicles have a special phenomenon in the tar dissolved in
liquid fuel is liquefied petroleum gas, can penetrate filter, but in the
downstream of the pressure reducing valve (or pressure regulating valve), in
the process of evaporation and decomposition, accumulated inside the relief
valve caused heavy tar precipitation, the diaphragm doesn't work, and caused
the vehicle failure. In general, the entire gas system will be replaced only if
there is serious damage to the installation. Otherwise, replacement parts or
renovations can be carried out using repair kits.
② For dual-fuel forklifts, at least 15 to 20 minutes of work with gasoline every day, in
order to maintain the good working state of the gasoline engine, otherwise, the
life of the valve seat will be reduced due to long-term lubrication.
③ For dual-fuel forklift trucks, when starting the engine with gasoline, as long as the
switch is placed in the "gasoline" position, but when starting with LPG, the
gasoline in the carburetor should be burned out first. To do this, the switch must
be placed in the middle position (i.e., no gas or oil) and then switched to the
"LPG" position after the gasoline in the carburetor has burned out.
④ If LPG is not to be used for a long time, it is necessary to burn or exhaust the LPG
in the pipe and evaporator, and open the evaporator drain hole, release the dirty
liquid, and then clean the evaporator. Otherwise, non-volatile substances in THE

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 LPG can deposit on the seals and diaphragm, corroding the seals and
diaphragm.
⑤ Forklift should clean the mixer once a year, check and adjust the engine
emissions, but also after removing the pipeline filter with compression blowing dirt
in the pipeline filter, to prevent airway blockage.

10. TAR DISCHARGE METHOD

A workplace ready for maintenance should consider:
① The surrounding environment should be well ventilated and assisted by fans
when necessary to diffuse possible liquefied gas leakage.
② Fireworks, heat sources or equipment that may produce sparks are strictly
prohibited around, such as grinder, grinder, etc.
③ There should be no low-lying areas in the vicinity, such as repair ditches, where
there may be liquefied air flow.
④ Prepare necessary fire extinguishing equipment, fire extinguishers or water
sources.
Methods:
a) At the user site, it is necessary to wait for the forklift to work for several hours (1 ~
2 hours in summer, 2 ~ 3 hours in winter). When the engine is shut down, the tar
can be released according to the following steps. At this time, the tar has basically
dissolved into liquid for outflow.
b) Stop the forklift, lower the fork frame to the lowest level, fix and turn off the front
and rear wheels, remove the cathode of the battery.
c) Close the outlet of the LPG cylinder or remove the high-pressure hose of the
quick joint.
d) After determining to cut off the air source, turn the switch to LPG position (dual
fuel forklift) and press the accelerator pedal in neutral state to burn off the
remaining LPG gas, which approximately needs to last 3 to 5 minutes until the
engine completely stops.
e) Pad the bottom of the angle joint of the air outlet of "pressure regulating valve (or
pressure reducer)" with gauze, sponge paper and other oil-absorbing objects.
f) Remove the clamp of the intake hose (here is the low-pressure pipe) from the
LPG pressure reducing valve to the mixer, loosen the half circle of the angle
coupling of the Inch 5/8 taper thread counterclockwise, so that its outlet is vertical
to the ground (6 o 'clock direction).
g) If there are lots of tar, there will be hot black oily liquid out of the water, dripping
onto the gauze, tissue and other oil-absorbing objects, need to be placed for
about 15 minutes.
h) After the tar is exhausted, tighten the taper thread right Angle joint, cover the air
pipe, tighten the clamp.
i) Apply soapy water or similar solution to each joint and start the engine to detect
possible leaks and retighten.
j) Remove the external tar and dust adhesive that flows out of the shell. Pay special
attention to whether there is a vent hole of φ1.0 on one side of the primary

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 chamber of the pressure reducing valve. If so, open it with a needle.
k) According to the quality of LPG gas, tar should be released regularly.
It should be at least once every two months if the LPG quality is not good

Figure 1 below shows that the LPG gas used by the user's forklift truck contains too
much tar. The photo obviously shows that the tar leaking out of the casing of the
pressure reducing valve blocks the breathing hole on one side of the primary chamber
of the pressure reducing valve.

FIG. 1
Views 2 and 3 show that opening the outlet pipe at the interface between the pressure
relief valve and the mixer, a large amount of black tar like coffee immediately flows out of
the nozzle, which takes more than 10 minutes to basically clean up.

FIG. 2 FIG. 3

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GROUP2 GAS FILLING AND OPERATION

1. GAS FILLING
LPG forklift if fuel used up and not let the engine off, when the cylinder liquefied
petroleum gas used up, the driver would feel power decreases, but still running at the
remnants of liquefied gas bottle a distance, the driver not to step on the gas and the
car drove to safe location, prepare inflatable (dual fuel system, at this time you can
switch to petrol to continue running for a period of time.
① There are two ways for LPG forklifts to refuel:
a) According to the design of the forklift, the cylinder can be removed and replaced
with a new cylinder filled with liquefied gas.
b) Direct inflation to the cylinder, this method refers to the factory has its own gas
equipment, when the forklift needs to be inflated, the forklift will drive to the gas
station, directly inflated, do not have to unload the cylinder.
② No matter what kind of gas filling method is adopted, matters needing attention
should be noted:
a) Filling or replacing must be carried out in a place with good ventilation and
safety and in accordance with local fire protection standards.
b) The forklift must stop and turn off, and the operator must leave the driver's seat
c) No fireworks or close to heat source, fire source and low depression around (to
avoid the accumulation of liquefied gas)
d) Handle cylinders with care. Do not bump, throw or roll them on the ground after
they are unloaded from the forklift.
e) Filling must be carried out by trained and experienced personnel
f) During the filling process, the filling personnel must monitor the whole process
and shall not leave the site.
③ Filling. steps
a) Before decanting, tighten the manual switch at the outlet and let the engine
continue to run at idle speed until the fuel in the tube is burned out
b) There is a quick joint at the outlet of the liquid outlet valve of the cylinder, which
is unscrewed and separated (because the male and female joints have reverse
installation inside, so both ends will not be deflated, and a little leakage is
normal). The female joint is fixed at the male joint on the support to prevent
accidents caused by the unscrewing of the liquefied gas hose.
c) Carefully remove the cylinder, place the cylinder in an upright position, and
connect the charging connector to the charging valve of the cylinder (spare with
the vehicle).
d) When charging, tighten the filling valve on the bottle.
e) Open the "80% liquid level hole" on the bottle by hand, pull the spanner on the
inflatable gun, and start to add air.
f) When the liquid level in the cylinder reaches 80%, white fog will emerge from
the "80% liquid level hole". At this time, stop refueling immediately, tighten the
80% liquid level hole to close, and remove the air gun. At this time, a little
leakage occurs, which is normal
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(Warning: because liquefied gas will expand when heated in the bottle, the gas
must not exceed 80%!)
g) Check the liquid level gauge and observe whether the indicator is correct.
h) If the filling valve on the cylinder is still constantly leaking liquefied gas, it means
that there may be foreign matter in the internal one-way check valve and it
cannot be switched on normally. At this time, the air gun can be re-set and a
small amount of liquefied gas can be added to blow away the foreign matter. If
the situation does not improve, the cylinder can no longer be used and should
be repaired.
i) Carefully handle the aerated cylinder, place it back on the forklift support and
secure it.
j) Combine the quick connector back again to ensure tightening.
k) Open the manual switch on the cylinder to let the liquefied gas out and check
whether the quick connector is deflated.
④ It is recommended that the operator develop the habit of checking cylinders each
time the cylinder is decanted or gassed as follows:
a) Whether there is serious dent, scratch or rust on the cylinder body
b) Whether the appearance of all accessories on the cylinder is obviously
damaged, whether there is any air leakage phenomenon
c) Whether the safety relief valve on the cylinder is blocked by foreign matter and
whether the blue plastic cap is broken or missing
Note: In the event of any of the above, the cylinder shall not be used or filled and
should be replaced and repaired
⑤ Especially, to emphasize here is the purity of liquefied gas use has direct impact
to the operation of the forklift truck, if the liquefied gas contains impurities, foreign
bodies, the tar composition, water, or too much, will be within the liquefied gas
system on the pipes and fittings cause congestion, and malfunction, light engine
operation, power output, or even cause the engine flameout, start is not easy to
wait for a phenomenon
Recommendation:
a) LPG fuel with high purity and low content of impurities, moisture and tar should
be used as far as possible
b) If the user's local gas source is not good, it is necessary to implement regular
maintenance, in order to remove the foreign body and tar accumulated in the
liquefied gas system, replace the filter screen, etc., to ensure the smooth
operation of the engine; The poorer the fuel quality, the shorter the repair cycle
c) When the temperature drops below zero, the natural evaporation rate of LPG
slows down, so it is advisable to add more propane in LPG to facilitate
evaporation.
⑥ After being used for a period of time, there will be residual liquid in the cylinder.
You can erect the cylinder in an open space without fire, open the "80% liquid
level hole", let the residual liquid drain out, and then drain water upside down

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2. PRE-STARTUP CHECK
a. According to the inspection items of ordinary gasoline or diesel forklift truck.
b. Check whether the cylinder is firm and whether the LPG system is abnormal
c. Open the manual switch on the cylinder to check whether the system leaks
d. Start the engine and check whether the operation is normal

3. ENGINE STARTING METHOD

a. Verify that the manual valve on the cylinder is fully open
b. The starting mode is exactly the same as the general gasoline engine, the only
difference is that there is no need to step on the accelerator
c. For dual fuel systems, the switch valve must be turned to the "LPG" position
d. In a cold day， it is best to warm the car for two or three minutes and let the cooling
water system of the engine heat up before running, so as to ensure that warm water
flows to the "pressure relief valve", accelerate its vaporization, and do not frost caused
by improper air supply or flout.

4. OPERATION OF THE LPG FORKLIFT

The operation of the LPG forklift is exactly the same as that of the general gasoline
engine.

5. SPECIAL NOTES FOR DUAL FUEL SYSTEM

1. Dual-fuel system switching method
a. The switch should be implemented after the forklift stops, never in the running
operation state
b. When switching from gasoline to liquefied GAS, the engine continues to run at a
rapid speed. At this time, switch the switch from "GAS" (gasoline) position to the
central position, continue to burn out the accumulated gasoline in the carburetor until
the engine is turned off. At this time, switch the valve to "LPG" (liquefied GAS) position
and restart
c. When switching from liquefied GAS to gasoline, you can directly turn the switch
valve from "LPG" position to "GAS" position (do not need to stay in the central "OFF"
position).

2. Although the dual fuel system mainly burns liquefied gas, its gasoline system still
needs to pay attention to the following matters:
a. Keep the petrol tank at least 1/4 full in case of emergency
b. Occasionally change to gasoline, to ensure that the gasoline system is not idle for
too long and failure, it is recommended to burn 10 kilograms of gasoline per month

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GROUP3 HANDLING OF ACCIDENTS AND EMERGENCIES

1. ODOR
Generally, liquefied gas is filled with odorous agent, so it is easy to detect the leakage
situation, if you smell the odor:
a. Immediately move the forklift to a well-ventilated place, turn off the engine and
make sure there are no fireworks nearby
b. Tighten and close the manual switch on the cylinder
c. Carefully and step by step check each pipeline, joint and LPG conversion device,
find out the leakage parts
d. Maintenance by qualified or experienced technicians

2. ACCIDENT
a. Stop immediately and turn off the engine
b. Tighten and close the manual switch on the cylinder
c. Make sure there are no fireworks near the forklift truck. If necessary, use fan to
disperse air leakage
d. Check and repair by qualified or experienced technicians

3. FIRE
a. Tighten the manual switch on the cylinder to close if possible
b. If a water source is nearby, pour water over the cylinder to keep it cool
c. Notify the fire department immediately
d. If cylinders also catch fire, evacuate the area immediately

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GROUP4 TROUBLESHOOTING

1. ENGINE CANNOT BE STARTED WITH LIQUEFIED GAS

a. Check whether the manual switch on the cylinder is fully on
b. Check the level gauge on the cylinder to observe the amount of liquid in the cylinder
c. The overflow valve may be accidentally closed. In this case, tighten the manual
switch and close it first, stay for five seconds and then slowly unscrew it again to make
the overflow valve automatically reset and open
d. (Dual fuel system) checks whether the switch is at "LPG"
e. (Dual fuel system) start engine with gasoline
f. Inform our designated repair shop, send it to the factory for repair.

2. CONDITIONS SHOULD NOT BE REPAIRED

When the driver encounters the following conditions, considering the attribution of
guarantee liability, the driver should not carry out repairs by himself:
a. Unable to start with liquefied gas
b. Difficulty or poor startup
c. Device can start but cannot work smoothly.
d. Flameout by accident
e. Unstable at idle speed
f. Idle speed is too high
g. Tempering
h. Accelerating rocky
i. Performance is poor at high speed.

3. FACTORY MAINTENANCE
When the LPG forklift truck breaks down and is sent to the factory for maintenance,
the owner (or driver) should first describe the symptoms of the problem Often the
so-called failure of the driver, may be caused by the lack of understanding of the
liquefied gas system or incorrect operation, at this point, experienced personnel are
required to do the correct demonstration and guidance. If necessary, the forklift should
be operated by a professional to determine the crux of the problem

4. CHECK GASOLINE ENGINE

The problem of LPG forklift is not necessarily caused by the LPG conversion device,
but often caused by the ignition system, intake system or cooling system of the
gasoline engine. Therefore, before the diagnosis of LPG, it is necessary to confirm
that the equipment and performance of the original gasoline engine are normal.
(If the dual fuel system fails when using liquefied gas, you can first change the fuel
back to gasoline and run the forklift to see if the problem still exists, so that you can
judge whether the problem is the original gasoline engine.)

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5. PRELIMINARY INSPECTION PROCEDURE
Preliminary inspection procedure before diagnosing the LPG system is as follows:
a. Whether the storage of liquefied gas in the cylinder is sufficient?
b. Is the manual switch on the "overflow valve" on the cylinder fully open?
c. Is there freezing or frosting in the LPG pipeline or any LPG conversion device?
d. Whether the high-pressure and low-pressure liquefied gas pipelines are deformed,
twisted, loosed or leaking?
e. Does "vacuum signal tube" have the above phenomenon?
f. Does the cooling water pipe connected to the "pressure reducing valve/voltage
regulator" have the above phenomenon?
g. Is the ignition system normal (remove a spark plug and check the spark condition of
its ignition)?
h. Is there any passive tampering in the LPG conversion device?

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6. TROUBLESHOOTING FLOWCHART
The motor spins, but the engine won't start

Check and repair No Check that the spark plug

ignition system ignites properly

Yes

Make sure there is liquefied gas in the cylinder and

open manual valve

No Carefully remove the high pressure liquefied gas pipe at the Yes

filter inlet and check fuel leakage

Connect the high-pressure liquefied gas

pipe, tighten and close the manual

switch at the outlet of the steel pipe, and Connect the high-pressure LPG tube and

then slowly open it for the return of the test the leak with soapy water

internal overflow valve

Under the condition of starting the motor,

remove the high pressure liquefied gas
check the vacuum suction at the engine inlet
pipe at the filter inlet again and check
branch pipe (throttle closed state), it should
fuel leakage
be about 330 mm H2O

No
Insufficient normal

suction

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 Carefully unscrew the 1 Engine intake system leaks Check whether the

"quick change connector" 2 Slow start motor speed: vacuum suction at

and press the internal insufficient battery voltage, poor the "mixer" is

reverse fixture near the end start motor, poor wiring, too between 100-150

of the manual switch with a much lubricating oil or too high mm H2O?

tool to see if there is fuel viscosity

leakage？ 3 Insufficient cylinder pressure

No Yes

Lower

Manual switch High pressure Normal

internal failure, liquefied gas pipeline

cannot normally blockage, eliminate it

Check whether the
vent air, replace
vacuum signal at
the switch or 1.Check for leaks between
"filter/vacuum cut-off
throttle and mixer.
valve" is between
cylinder 2.Check the mixer for
100-150 mm H2O
abnormalities or blockages
inside

The vacuum signal tube between the Lower

mixer and the vacuum cut-off valve is
Normal
squeezed, deformed or damaged. The
joints at both ends are not locked

Check the closing

function of the vacuum Abnormal Repair
shut-off valve

Normal

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Check Higher Test whether the Normal Is the test
diaphragm primary chamber
and hole pressure of "pressure secondary
of reducing chamber pressure
chamber valve/regulator" is
seat once between 1.5-2.5？ around -1.5?

Lower Higher Lower

1. The air tightness between the mixer

Poor fuel flow; Check chamber and the pressure reducing valve/regulator
seat once, filter dirty, blocked is poor and there is leakage；
line between filter and 2. The valve lever in the secondary
vaporizer/regulator, insufficient chamber is deformed and cannot be
cylinder stock opened normally；
3. "Pressure relief valve/regulator" air
outlet or low-pressure hose is blocked or
squeezed out of shape by tar or foreign
matter.

Disassemble the
mixer, disassemble
Check whether the
and clean it, and
tube inside the mixer
inspect it. Replace No can float freely
parts with repair kits if
necessary

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7. TROUBLE SHOOTING CHECKLIST
troubleshooting

Item Introduction
Close the manual "overflow valve" at the upper outlet of the cylinder
completely and leave it for about 5 seconds to hear a slight "click" inside,
then slowly open the manual valve.
Introduction：There is a "super flow valve" in the "overflow valve", which
could not see on the outside of the cylinder. This is a safety device, its role
is to when the liquefied gas hose or other components within the system
1 caused by accidentally broken when a large number of leaks, can
automatically and quickly close the overflow valve, prevent further liquefied
gas leaked out, and when the leakage situation stops, the " super flow
valve" will automatically replace, return to the on state. Because the internal
spring of this " super flow valve " is very sensitive, sometimes the manual
valve will open too fast, resulting in its accidental closure, so the above
measures must be taken to re-open it.
Reasons for the blockage：
a. foreign body accumulation in the pipeline (especially in newly modified
vehicles).
b. The pipe is excessively concave or deformed.

The way in which the foreign body in the tube is discharged:

2 a. Refer to "LPG system correct disassembly steps", pay attention to safety,

no fireworks!

b. Close the cylinder air outlet manual valve

c. Remove the connector at the LPG inlet of "filter/vacuum cut-off valve"
d. Open the cylinder manual valve, make the liquefied gas briefly ejected
two or three times, blow out the foreign matter
e. If there is still blockage, replace the pipe
Remove the "filter/vacuum cut-off valve", decompose it step by step for
maintenance, and replace the parts if necessary.
Introduction：The filter heart in the filter is too dirty, will cause the pressure
3 difference to the liquid gas in circulation, and lead to the local vaporization
of liquid fuel here. If this phenomenon occurs, the outside of the filter will
feel cold, and even frost phenomenon, seriously affect the gas, resulting in
the internal combustion engine horsepower weakened or even flout

4 Test "primary chamber" and "secondary chamber" exhaust pressure

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 Check and repair the following:
a. The engine cooling water level is too low.
b. fan belt is loose or broken.
5
c. Cooling system leakage.
d. Cooling pump failure
e. The temperature controller is faulty
Remove the "pressure reducing valve/regulator", and then step by step to
examine the inside.
a. Clean internal parts including diaphragm with warm soapy water
6 b. After the diaphragm is dried, check whether there is crack hole or other
damage under strong light, whether there is still elasticity, no aging or
hardening?
c. Check the air tightness of the "secondary chamber" valve.

7 Check if there is tar accumulation inside? Wash it with warm soapy water
Firstly, before disassembling the mixer, check that the internal floating
Venturi tube is operating properly as follows:
a. Remove the hose connecting the front end of the mixer and the air filter.
b. Start the engine and run at idle speed.
c. Check the floating vente tube inside the "mixer", a little movement
should be visible at the initial engine start, more obvious when press the
accelerator hard.
d. If there is no obvious movement when press the accelerator hard, it
8 means that the suction at the "mixer" is insufficient, and there is air leakage
between the "mixer" and the engine (Vacuum suction at the "mixer" should
be at least 100-150 mmH2O).
e. If there is no air leakage, further disassemble the mixer to decompose
and inspect the inside.
Secondly, clean the inside of the "mixer" with warm soapy water and air dry.
Check whether foreign matter is removed. Are there any visible scratches or
burning caused by the engine backfiring? Check valve seat for damage and
deformation? Replace the parts if necessary.
A small amount of gasoline is discharged into the engine, which has no
obvious effect in high-speed operation, but when the engine returns to idle
speed, there will be instability, or even flameout:
10
a. Carefully remove the gasoline solenoid valve, close to one end of the
pressure reducing valve, start the engine to check for leakage.
b. Check whether the solenoid valve line is correct and firm.

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SECTION9 MAST

Group 1 Structure ----------------------------------------------------188-191

Group 2 Operational Checks and Troubleshooting ----------192-194
Group 3 Adjustment -------------------------------------------------195-197
Group 4 Removal and Installation -------------------------------198-210

187 / 210
GROUP1 STRUCTURE

1 2 STAGE MAST (V MAST)

1 Outer mast 6 Anchor bolt 10 Trunnion cap

2 Inner mast 7 Chain wheel bearing 11 Bushing
3 Roller 8 Retaining ring 12 Roller
4 Shim (0.5, 1.0t) 9 Tilt cylinder pin 13 Shim (0.5, 1.0t)
5 Chain

188 / 210
2 2 STAGE MAST (VF MAST)

1 Outer mast 6 Shim (0.5, 1.0t) 11 Bushing

2 Inner mast 7 Roller 12 Sheave
3 Chain 8 Shim (0.5, 1.0t) 13 Sheave bracket
4 Anchor bolt 9 Tilt cylinder pin 14 Clamp
5 Back up liner 10 Support cap

189 / 210
3 3 STAGE MAST (TF MAST)

1 Outer mast 6 Roller 11 Sheave

2 Middle mast 7 Shim (0.5, 1.0t) 12 Tilt cylinder pin
3 Inner mast 8 Back up liner 13 Support cap
4 Chain 9 Shim (0.5, 1.0t) 14 Bushing
5 Anchor bolt 10 Sheave bracket 15 Clamp

190 / 210
4 CARRIAGE, BACKREST AND FORK

1 Backrest 3 Load roller 5 Fork assembly

2 Carriage 4 Side roller 6 Extension fork

191 / 210
GROUP2 OPERATIONALCHECKS ANDTROUBLESHOOTING

1 OPERATIONAL CHECKS
1) FORKS
① Measure thickness of root of forks and
check that it is more than specified value.
EX: ℓ=1050mm(41.3in)
mm(in)
STD Fork assembly Applicable mode Standard Limit

64HN-21030 25LE-7 45(1.8) 40(1.6)

64HN-31020 30LE-7 45(1.8) 40(1.6)

64HN-31020 35LE-7 45(1.8) 40(1.6)

② Set forks in middle and measure difference in height at top of forks.

Model Fork length Height difference(mm)
(mm)

25LE-7, 900~1800 3

30LE-7, 900~1150 3

35LE-7, 1150~1800 6

③ Most force is concentrated at root of fork and at hook, so use crack

detection method to check cracks.
2) MAST
① Check for cracks at mast stay, tilt cylinder bracket, guide bar, fork
carriage and roller shaft weld.
Check visually or use crack detection method. Repair any
abnormality.
② Set mast vertical, raise forks about 10cm from ground and check
front-to-rear clearance and left-to- right clearance between inner
mast and fork carriage, and between outer mast and inner mast. Use
these figures to judge if there is any play at roller or rail.
•Front-to-rear clearance: Within 2.0mm(0.08in)
•Left-to-right clearance: Within 2.5mm (0.10in)
③ Check that there is an oil groove in bushing at mast support.
④ Set mast vertical, raise forks about 10cm from ground, and push
center of lift chain with finger to check for difference in tension.
If there is any difference in tension, adjust chain stopper bolt.
⑤ Check visually for abnormalities at thread of chain anchor bolt, and
at contact surface between chain wheel and chain.
Rotate chain wheel by hand and check for any play of bearing.

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2 TROUBLESHOOTING
1) MAST
Problem Cause Remedy
Forks fail to lower. •Deformed mast or carriage. •Disassemble, repair or
replace.
Fork fails to •Faulty hydraulic equipment. •See troubleshooting hydraulic
elevate pump and cylinders in section
6, hydraulic system.
•Deformed mast assembly. •Disassemble mast and replace
damaged parts or replace
complete mast assembly.
Slow lifting speed •Faulty hydraulic equipment. •See troubleshooting hydraulic
and insufficient pump and cylinders in section
handling capacity. 6, hydraulic system.
•Deformed mast assembly. •Disassemble mast and replace
damaged parts or replace
complete mast assembly.
Mast fails to lift •Deformed masts or carriage. •Disassembly, repair or replace.
smoothly. •Faulty hydraulic equipment. •See Troubleshooting Hydraulic
Cylinders, pump and control
valve in section 6, hydraulic
system.
•Damaged load and side •Replace.
rollers.
•Unequal chain tension •Adjust chains.
between
LH & RH sides.
•LH & RH mast inclination •Adjust tilt cylinder rods.
angles are unequal. (Mast
assembly is twisted when
tilted)
Abnormal noise is •Broken load roller bearings. •Replace.
produced when •Broken side roller bearings. •Replace.
mast is lifted and •Deformed masts. •Disassemble, repair or
lowered. replace.
•Bent lift cylinder rod. •Replace.
•Deformed carriage. •Replace.
•Broken sheave bearing. •Replace.
Abnormal noise is •Insufficient lubrication of •Lubricate or replace.
produced during anchor pin, or worn bushing
tilting operation. and pin.
•Bent tilt cylinder rod. •Replace.

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2) FORKS
Problem Cause Remedy
Abrasion Long-time operations cause the fork to If the measured value is
wear and reduces the thickness of the below the wear limit,
fork. replace fork.
Inspection for thickness is needed.
•Wear limit: Must be 90% of fork
thickness
Distortion Forks are bent out of shape by a If the measured value
number of reasons such as exceeds the allowance,
overloading, glancing blows against replace fork.
walls and objects, and picking up load
unevenly.
•Difference in fork tip height: 15mm
•Difference in fork tip width: 35mm
Fatigue Fatigue failure may result from the Repair fork by expert.
fatigue crack even though the stress In case of excessive
to fork is below the static strength of distortion, replace fork.
the fork. Therefore, a daily inspection
should be done.
•Crack on the fork heel.
•Crack on the fork weldments.

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GROUP3 ADJUSTMENT

1 MAST LOAD ROLLER (V, VF MAST)

1) INNER/OUTERMASTROLLER 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 following
value by inserting the inner/outer mast roller shim.
•Standard clearance A, B = 0~0.6mm
•Shim thickness 0.5, 1.0mm
③ Distribute the shim thickness equally to the left and right roller. Refer
to Mast load roller and back up liner, removal and Installation.
④ After the adjustment, check that the inner mast moves smoothly in
the outer mast.

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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 and middle masts, and
adjust the clearance between the roller
side face and mast at the closest position
on the opposite side to the following value
by inserting the inner and middle mast roller
shim, respectively.
•Standard clearance A = 0~0.6mm
•Shim thickness 0.5, 1.0mm
③ Distribute the shim thickness equally to the left and right roller. Refer
to Mast load roller and back up liner, removal and Installation.
④ After the adjustment, check if 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
outer-mast and the middle-mast, and
adjust the clearance between the roller
side face and mast at the closest
position on the opposite side to the
following value
by inserting the outer and middle mast roller
shim, respectively.
•Standard clearance B = 0~0.6mm
•Shim thickness 0.5, 1.0mm
③ Distribute the shim thickness equally to the left and right roller. Refer
to Mast load roller and back up liner, removal and installation.
④ After the adjustment, check that the inner mast moves smoothly in
the middle-mast, and the middle mast moves smoothly in the
outer-mast.

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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,

middle and lower rollers after loosen
the adjust screws from the side rollers.
Shift the carriage to one side to bring
the roller into contact with the inner
mast, and measure the clearance between the
roller side face and mast at the closest
position on the opposite side to the following
value by inserting the carriage roller shim.
•Standard clearance C = 0~0.6mm
•Shim 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

4) MAST BACK UP LINER

① Measure the clearance with the
middle mast at the bottom position.

② With the middle-mast in contact with

the outer-mast roller, adjust the
clearance between the mast back
up liner and middle mast to the
following value by inserting the
back up liner shim.
•Standard clearance E = 0.2 ~ 0.6mm
•Shim thickness 0.5, 1.0mm

③ After the adjustment, the mast should move smoothly.

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GROUP4 REMOVAL AND INSTALLATION

1 FORKS
1) Lower the fork carriage until the forks
are approximately 25mm(1inch) from the floor.
2) Turn knob up and slide forks, one by
one, toward the center of the carriage
where a notch has been cut in the
bottom plate for easy removal.
3) Remove the fork one by one. On larger
Fork sit may be necessary to use a block of wood.
4) Reverse the above procedure to install load forks.

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.

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.

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2) SIDE ROLLER
① Remove carriage as outlined in
the carriage assembly and removal
paragraph.
② Loosen and remove nuts, adjust screws
and side rollers from carriage side pate.
③ Thoroughly clean, inspect and replace
all worn or damaged parts.
④ Reverse the above procedure to
assembly.

※ Adjustment

• Once carriage is properly installed,

loosen nuts and adjust screws, (if not
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 Remove load rollers from load roller bracket.
④ Reverse the above procedure to assemble.
Refer to MAST ROLLER ADJUSTMENT
paragraph.

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4) MAST LOAD ROLLERANDBACK UP
LINER
① 2 stage mast (V mast)
a) Remove the carriage assembly
and move them to one side.
b) Loosen and remove hexagon bolts
and washers securing lift cylinders
to inner mast.
c) Loosen and remove hexagon bolts
and nuts securing lift cylinders to
inner mast.
d) 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.
e) After lowering the lift cylinder rods,
and disconnecting lift cylinder hose,
tilt the lift cylinders LH and RH and
them with ropes to the outer mast.
f) Using the overhead hoist, lower
inner mast until top and bottom
rollers and back up liners are
exposed.
g) Remove load rollers from load roller bracket. Remove back up liners and
shims.
h) Thoroughly clean, inspect and replace all worn or damaged parts.
i) Reverse the above procedure to assemble. Refer to MAST LOAD
ROLLERADJUSTMENT paragraph.

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② 2 stage mast (VF mast)
a) Remove free lift chain connected
between carriage and free lift
cylinder.
b) Remove the carriage assembly and
move them to one side.
c) Loosen and remove hexagon bolts
and washers securing lift cylinders
to inner mast.
d) Loosen and remove hexagon bolts
and nuts securing lift cylinders to
inner mast.
e) 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.
f) After lowering the lift cylinder rods,
and disconnecting lift cylinder hose,
tilt the lift cylinders LH and RH and
them with ropes to the outer mast.
g) Using the overhead hoist, lower
inner mast until top and bottom
rollers and back up liners are
exposed.
h) Remove load rollers from load roller bracket. Remove backup liners and
shims.
i) Thoroughly clean, inspect and replace all worn or damaged parts.
j) Reverse the above procedure to assemble. Refer to MAST
LOADROLLERADJUSTMENT paragraph.

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③ 3 stage mast (TF mast)
a) Remove the carriage assembly
and move to one side.
b) Loosen and remove hexagon bolt
securing bottom cylinder from
outer mast.
c) Loosen and remove bolts and
special washers securing lift
cylinders to middle-mast.
d) 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.
e) After lowering the lift cylinder rods,
and disconnecting lift cylinder hose,
tilt the lift cylinders LH and RH and
tie them with ropes to the outer
mast.
f) Using the overhead hoist raise
inner and middle masts. Place 4
inches block of wood under the
free lift cylinder bracket of the inner
mast then lower mast sections (this
will create slack in the chains).
g) Remove retaining rings securing
chain sheaves to sheave support
brackets. While support chains,
remove chain sheaves and let
chains hang free. The upper
outer and lower middle mast rollers
and back up liners are now
exposed.
h) Remove load rollers from load
bracket. Remove back up liners
and shims.
i) 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.
j) Using a player, remove load rollers from load roller bracket.
k) Thoroughly clean, inspect and replace all worn or damaged parts.
l) Reverse the above procedure to assemble. Refer to MASTLOAD
ROLLER ADJUSTMENT paragraph.

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5) ELEVATING MAST
① Inner mast (V, VF mast)
a) 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.
b) Lift inner mast upright straight up and out of outer mast section.
c) Replace and reverse above procedure to install. Make all
necessary measurements and adjustments.

② Inner and middle mast (TF mast)

a) After completing all necessary steps for load rollers and back up
liner removal. Remove rear chains and sheave support if not
already done.
b) Disconnect free lift cylinder hose. Drain hose into a suitable pan or
container and cap hose.
c) While supporting free lift cylinder assembly, remove bolts and
washers securing cylinder to mast crossmember.
d) Place a sling around free lift cylinder and attach to an overhead
hoist. Slowly raise and move cylinder to one side.
e) 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.
f) 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.
g) Replace upright and reverse above procedure to install. Make all
necessary measurements and adjustments.

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6) CHAIN
① Chain sheave (V, VF mast)
a) 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.
b) 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.
c) Remove retaining ring securing
sheaves to sheave support.
Remove sheaves with
bearings.
d) Remove bearing retaining ring
from sheave and press
bearings from sheaves.
e) Thoroughly clean, inspect and
replace all worn or damaged
parts.
f) Reverse the above to
assemble and install. Use new
split pins in chain anchor pins.

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② Rear chain sheave (TF mast)
a) Raise and securely block
carriage and inner mast
section.
b) Remove the split pin securing
the chain anchor pins and
discard. While supporting
the chains, remove the chain
anchor pins from outer mast
section.
c) Remove chains.
d) Remove retaining ring securing
chain sheaves to sheave
support.
Pry off sheaves with bearings.
e) Remove bearing retaining ring
from sheave and press
bearings from sheaves.
f) Thoroughly clean, inspect and
replace all worn or damaged
parts.
g) Reverse the above procedure
to assemble and install. Use
new split pins in chain anchor
pins.

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③ Chain wheel bearing support (TF mast)
a) Remove the carriage assembly and move to one side.
b) 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.
c) Remove retaining ring securing chain wheel bearing to chain wheel
bearing support.
d) Remove bearing retaining ring from chain wheel bearing and press
bearings from chain wheel bearings.
e) Thoroughly clean, inspect and replace all worn or damaged parts.
f) Reverse the above procedure to install.

④ Rear chain (TF mast)

a) Remove the carriage assembly and move to one side. Refer to
carriage removal and installation.
b) Raise and securely block truck approximately 6 inches from the
floor.
c) 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.
d) Remove split pins and chain anchor pins securing chains to chain
anchor (part of inner mast).
e) While supporting the chains, remove split and chain anchor pins
securing chains to chain anchors attached to outer mast section.
f) Remove chains.
g) 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
a) 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.
b) Place a wooden block under the carriage and lower the carriage on
the block.
c) While supporting the chains, remove split pins and chain anchor
pins from chain anchors.
d) Remove chains and wash them with solvent. Refer to this section
for Load chain inspection and maintenance.
e) Reverse the above procedure to assemble and install. Use new
split pins in chain anchor pins.

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 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:
a) 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 the worn
section and splicing in a new piece. If part of the chain is worn,
replace all the chains on the truck.
b) 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.
c) 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.
d) Tight joints
e) All joints in lift chain should flex freely. Tight joints resist flexure,
increase internal friction, thus increasing chain tension required to
lift a given load. Increased tension accelerates wear and fatigue
problems.
Tight joints in lift chains can be caused by:
•Bent pins or plates.
•Rusty joints.
•Peened plate edges.
Oil rusty chains and replace chains with bent or peened
components.

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f) 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.
g) 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.
h) 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.
i) Chain wear scale
The chain can be checked for wear or stretching with the use of a
chain wear scale. Stretching of a chain is due to the elongation of
the pitch holes and wearing of the pin O.D. The greatest amount
of stretching occurs at the areas of the chain that flex over the
sheaves most frequently. Check the chain at this point with a scale.
The wear scale has instructions printed on the sides for use in
determining chain stretch and are as follows:
•Determine pitch length of chain using 6 inches scale on one side of
wear scale.
•If pitch is 1/2(12.7mm), 3/4(19.05mm), 1(25.4mm), 1-1/2(38.1mm),
2(50.8mm), use side A of scale.
•If pitch is 5/8(15.875mm), 1-1/4(31.75mm) or 2(50.8mm), use side
B.
•Align point A or B to center of a pin and note position of the
opposite A or B point.
•If other point also lines up with a pin, the chain is worn and should
be replaced.
If any of the above conditions exists (cracked plates, turned pins,

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 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
a) 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 environments changing, the best estimate of lube period is 200
hours. Trucks parked outdoors or trucks in extremely severe
service, may require more frequent re-lube to maintain an oil film on
all chain surface.
•Wipe off the old oil with a clean cloth and blow out the remaining
dirt with compressed air.
Wear eye protection.
•With a clean brush, apply EP-140 extreme pressure lubricant or
heavy motor oil(40W).
b) 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 joint 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.
c) Adjustment
Chain adjustments are important for the following reasons:
•Equal loading of chain.
•Proper sequencing of mast.

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 •Prevent over-stretching of chains.
•Prevent chains from jumping off sheaves if they are too loose.
d) Adjustment procedure
•With mast in its fully collapsed and vertical position, lower the fork
to the floor.
•Adjust the chain length by loosening or tightening nut on the chain
anchor.
After making adjustment on the mast, be sure to tighten the nut.

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