FOREWORD

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

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

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

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

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

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

2. Convert 550mm into inches.

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

Millimeters to inches ; 1mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

0-3
Millimeters to inches 1mm = 0.03937in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

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

Kilogram to Pound 1kg = 2.2046lb

0 1 2 3 4 5 6 7 8 9

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

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

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

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

0 1 2 3 4 5 6 7 8 9

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

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

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

0 1 2 3 4 5 6 7 8 9

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

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

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

0-5
kgfÂm to lbfÂft 1kgfÂm = 7.233lbfÂft

0 1 2 3 4 5 6 7 8 9

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

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

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

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

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

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

0 1 2 3 4 5 6 7 8 9

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

Á
C Á
F Á
C Á
F Á
C Á
F Á
C Á
F

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

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

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

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

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

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

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

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

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

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

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

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

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

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

0-8
 CONTENTS

SECTION 1 GENERAL
Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Inspection and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19

SECTION 4 BRAKE SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-11

SECTION 5 STEERING SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-17
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
SECTION 8 MAST
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5
Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8
Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11
 SECTION 1 GENERAL

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

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
 GROUP 1 SAFETY HINTS

Careless performing of the easy work may

cause injuries.
Take care to always perform work safely, at least
observing the following.
 Oil is a dangerous substance. Never handle
oil, grease or oily clothes in places where
there is any fire of flame.
As preparation in case of fire, always know the
location and directions for use of fire extinguishers
D50ASF01
and other fire fighting 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.

D50ASF02

 Flames should never be used instead of

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

D50ASF03

 Exhaust gas is dangerous. Provide adequate

ventilation when working a closed space.

D50ASF04

1-1
 Be particularly careful when removing the
radiator cap and the hydraulic oil tank filler
cap, if this is done immediately after using the
machine, there is a danger that boiled oil may
spurt out.
 The procedure for releasing the hydraulic
pressure is as follows : lower the fork to the ground,
and stop the engine(Motor), move the control
levers to each position two or three times.
D50ASF05

 When working on top of the machine, be

careful not to lose your balance and fall.

D50ASF06

 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 he engine is running.

D50ASF07

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
D50ASF08
the brake lock.

1-2
Â Immediately remove any oil or grease on the
floor of the operator's compartment, or on the
handrail. It is very dangerous if someone
slips while on the machine.

OIL

D50ASF09

 When working with others, choose a group

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

D50ASF10

 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.

D50ASF11

 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.

1-3
Â Thoroughly clean the machine. In particular, be careful to clean the filler caps, grease fittings and the
area around the dipsticks. Be careful not to let any dirt or dust into the system.
 Always use HYUNDAI Forklift genuine parts for replacement.
 Always use the grades of grease and oil recommended by HYUNDAI Forklift.
Choose the viscosity specified for the ambient temperature.
 Always use pure oil or grease, and be sure to use clean containers.
 When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into
the oil.
 Before draining the oil, warm it up to a temperature of 30 to 40Á C.
 After replacing oil, filter element or strainer, bleed the air from circuit.
 When the strainer is located in the oil filler, the strainer must not be removed while adding oil.
 When changing the oil filter, check the drained oil and filter for any signs of excessive metal particles
or other foreign materials.
 When removing parts containing O-ring, gaskets or seals, clean the mounting surface and replace
with new sealing parts.
 After injecting grease, always wipe off the oil grease that was forced out.
 Do not handle electrical equipment while wearing wet places, as this can cause electric shock.
 During maintenance do not allow any unauthorized person to stand near the machine.
 Be sure you fully understand the contents of the operation. It is important to prepare necessary tools
and parts and to keep the operating area clean.
 When checking an open gear case there is a risk of dropping things in. Before removing the covers to
inspect such cases, empty everything from your pockets. Be particularly careful to remove wrenches
and nuts.
 Way to use dipstick
Push the dipstick fully into the guide, and then pull out.
Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you
consider the maintenance is too difficult, always request the HYUNDAI Forklift distributor to carry out
it.

1-4
GROUP 2 SPECIFICATIONS

1. MAJOR COMPONENTS

20

19

17
1
18
16

15
2
3 14
4
13
5
21
6

7
8

12

11

10
9
35L7OM57

1 Steering wheel 8 Forks 15 LPG tank

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

1-5
 2. SPECIFICATIONS

C C'
D

R
A
E

M
M'

H
B

F
J

L K
G
35L7ASP01

Model Unit 35L-7A 40L-7A 45L-7A 50L-7A

Capacity kg 3500 4000 4500 5000
Load center R mm 600 ą ą ą
Weight(Unloaded) kg 5593 6163 6579 7043
Lifting height A mm 3020 ą ą 2930
Free lift B mm 120 ą ą ą
Fork Lifting speed(Unload/Load) mm/sec 530/510 ą ą 460/410
Lowering speed(Unload/Load) mm/sec 450/500 ą ą ą
LÝWÝT L,W,T mm 1070Ý122Ý50 1070Ý150Ý50 1220Ý150Ý50 ą
Tilt angle(Forward/Backward) C/C’ degree 8/10 ą ą ą
Mast Max height D mm 4224 ą 4245 4147
Min height E mm 2235 2200 2220 ą
Travel speed(Unload) km/h 23.8 22.9 22.9 22.8
Body Gradeability(Load) % 40.4 36.2 31.7 28.6
Min turning radius(Outside) F mm 2770 2830 2890 2950
Max hydraulic pressure kgf/cm2 210 ą ą ą
ETC Hydraulic oil tank ˶ 68 ą ą ą
Fuel tank(Gasoline) ˶ - - - -
Overall length G mm 3070 3125 3185 3245
Overall width H mm 1370 1746 ą ą
Overhead guard height I mm 2240 ą ą ą
Ground clearance J mm 170 155 ą ą
Wheel base K mm 2000 ą ą ą
Wheel tread front/rear M, M' mm 1132/1140 1282/1140 ą ą

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

Item Unit Specification

Model  GM, 4.3L V6

Type  4-cycle, in-line, Vertical OHV
Cooling Method  Water cooling
Number of cylinders and arrangement  6 cylinders, V6
Valve configuration  Push rod actuated overhead valve
Cylinder bore X stroke mm(in) 101.6Ý88.39(4Ý3.48)
Piston displacement cc(cu in) 4294(262)
Compression ratio  9.4
Rated gross horse power ps/rpm 95/2300
Maximum gross torque at rpm kgfÂm/rpm 34/1400
Engine oil quantity ˶(U.S.gal) 6(1.6)
Dry weight kg(lb) 220(485)
High idling speed rpm 2400
Low idling speed rpm 750
Rated fuel consumption g/ps.hr -
Starting motor V-kW 12-1.7
Alternator V-A 12-70A
Battery V-AH 12-80
Fan belt deflection mm(in) 10~15(0.4~0.6)

(2) MAIN PUMP

Item Unit Specification

Type  Fixed displacement gear pump

Capacity cc/rev 46.6 7.6
Maximum operating pressure bar 250
Rated speed (Max/Min) rpm 3000/600

(3) MAIN CONTROL VALVE

Item Unit Specification

Type  Sectional
Operating method  Mechanical
Main relief valve pressure bar 210/150
Flow capacity lpm 110

1-7
 (4) POWER TRAIN DEVICES

Item Specification

Model DE 280 (KAPEC)

Torque converter Type 3 Element, 1 stage, 2 phase
Stall ratio 2.25 : 1
Type Power shift
Gear shift(FR/RR) 2/2
Transmission Control Electrical single lever type
FR 1 : 2.550 2 : 1.29
Overhaul ratio
RR 1 : 2.550 2 : 1.29
Type Front-wheel drive type, fixed location
Axle
Gear ratio 11.692
Q'ty(FR/RR) Single : 2/2 Double : 4/2
Wheels Single 3.5 ton : 8.25-15-14 PR 4.0/4.5 ton : 300-15-18 PR
Front(drive)
Double 7.5-16-12 PR
Rear(steer) 7.0-12-12 PR
Travel Front wheel, wet disc brake
Brakes
Parking Toggle, internal expanding mechanical type
Type Full hydraulic, power steering
Steering
Steering angle 74.8äto both right and left angle, respectively

1-8
4. TIGHTENING TORQUE FOR MAJOR COMPONENTS

NO Item Size kgfÂm lbfÂft

1 Engine mounting bolt, nut M16Ý2.0 7.5 54

2 Engine Radiator mounting bolt, nut M 8Ý1.25 2.5Ü0.5 18Ü3.6
3 Torque converter mounting bolt M10Ý1.5 3.85Ü0.35 28Ü2.5
4 Hydraulic MCV mounting bolt, nut M14Ý2.0 19.6Ü2.9 142Ü21
5 system Steering unit mounting bolt M10Ý1.5 4Ü0.5 29Ü3.6
6 Drive axle mounting bolt, nut M24Ý2.0 100Ü10 723Ü72
7 Steering axle mounting bolt, nut M14Ý2.0 19.6Ü2.9 142Ü21
Power
8 train Front wheel mounting nut M22Ý1.5 62Ü9.3 448Ü67
system Rear wheel mounting nut M20Ý1.5 60.0Ü5.0 434Ü36
9
10 Counterweight mounting bolt M30Ý3.5 120Ü15 1555Ü239
11 Others Operator's seat mounting nut M 8Ý1.25 2.5Ü0.5 18.1Ü3.6
12 Head guard mounting bolt M12Ý1.75 6.2 44.8

1-9
5. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT

(1) Coarse thread

8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 6 Ý 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 Ý 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 Ý 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 Ý 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 Ý 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 Ý 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 Ý 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 Ý 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 Ý 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 Ý 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 Ý 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 Ý 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242

(2) Fine thread

8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 8 Ý 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 Ý 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 Ý 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 Ý 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 Ý 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 Ý 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 Ý 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 Ý 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 Ý 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 Ý 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 Ý 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561

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

Thread size Width across flat mm kgfÂm lbfÂft

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

3) PIPE AND HOSE(ORFS TYPE)

Thread size Width across flat mm kgfÂm lbfÂft

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

4) FITTING

Thread size Width across flat mm kgfÂm lbfÂft

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

1-11
6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.

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

Engine oil 4.3

pan Engine oil (1.1) SAE 10W-30(API SL class or better)

Torque
ATF 12˶
converter ATF DEXRON III
Engine oil (3.2)
transmission

10.5˶
Axle Gear oil Mobil Fluid 424
(2.8)

ISO VG32
Hydraulic Hydraulic 63.5
tank oil (16.8) ISO VG46

ISO VG68

Fuel tank LPG 20 LPG

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

Brake
0.25
reservoir Brake oil (0.06) Azola ZS10(Hydraulic oil SAE 10W)
tank

Radiator Antifreeze:Water 21.5 Ethylene glycol base permanent type

50:50 (5.7)

NOTES :
Η SAE numbers given to engine oil should be selected according to ambient temperature.
Θ For engine oil used in engine oil pan, use SAE 10W oil when the temperature at the time of
engine start up is below 0ÁC , even if the ambient temperature in daytime is expected to rise
ÁC or more.
to 10Á

1-12
GROUP 3 PERIODIC REPLACEMENT
For operation safety, never fail to perform periodic maintenance or make periodic replacement of the
consumable parts listed in the following.
These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the 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. Description Period of replacement

1 Master cylinder and wheel cylinder caps, dust seals Every 1 year
2 Brake hose or tube Every 1 or 2 years
3 Brake reservoir tank and tube Every 2 to 4 years
4 Power steering hose Every 2 years
5 Stop lamp switch(Oil pressure type) Every 2 years
6 Fuel hose Every 2 to 4 years
7 Rubber parts of power steering Every 2 to 4 years
8 Lift chain Every 2 to 4 years
9 Hose of load handling Every 1 or 2 years

1-13
 SECTION 2 REMOVAL & INSTALLATION OF UNIT

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

Group 2 Removal and installation of unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
GROUP 1 STRUCTURE

25 24 23 22

2
21
3

4 19
5 20

6 18

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

35L7AOM23

1 Mast 10 Transmission 19 Radiator

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

2-1
 GROUP 2 REMOVAL AND INSTALLATION OF UNIT

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

1. MAST
1) REMOVAL

(1) Forks
Backrest
① Lower the fork carriage until the forks are
approximately 25mm(1in) from the floor.
② Release fork anchor pins and slide one Pin
fork at a time toward the center of the
Knob
carriage where a notch has been cut in Spring
the bottom plate for easy fork removal.
③ Remove only one fork at a time. Carriage
※ On larger forks it may be necessary to Fork
use a block of wood. Center notch 35DS7RE04

(2) Backrest(If necessary)

① Remove bolts securing backrest to fork
carriage, lift backrest straight up and
remove it from carriage. Backrest

Carriage Bolt

35DS7RE05

(3) Carriage
① With the mast vertical, raise the carriage
high enough to place blocks under the
load forks. This is done to create slack in
the load chains when the carriage is
lowered. Lower the carriage all the way
down to the floor. Make sure the carriage
is level, this will prevent any binding when
the mast is raised. 35L7RE53

2-2
② While supporting lift chains, remove the
Chain
split pin and nuts from the anchor bolt.
Outer
mast
Anchor
bolt

Nut Split pin

35DS7RE06-1

③ Pull the chains out of the sheaves and

drape them over the front of the carriage.

Mast

Carriage

Lift chain

Block
35DS7RE07

④ Slowly raise inner mast upright until mast

clears top of fork carriage. Move carriage
to work area and lower the mast.
Inner 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.

Carriage

Lift chain 35DS7RE08

2-3
(4) Piping
① Remove the return hoses and clamps
attached to the cylinder.
② Remove the return hose from the tee. Return
③ Remove hose assembly, tee and down hose

safety valve(1).
※ Put blind plugs in the piping immediately Hose
clamp
after removing hoses.
This prevents the hydraulic oil from Lift
flowing out and also prevents dust and cylinder
dirt from getting in.

35DS7RE09

(5) Lift cylinder

Hex bolt
① Loosen and remove hexagon bolts and Washer
washers securing lift cylinders to inner
mast.
② Bind the lift cylinder with overhead hoist
rope and pull up so that the rope has no Clamp
Inner
slack or binding. mast

Make sure the lift cylinder be tightened

firmly for safety.
③ Loosen and remove hexagon bolts, nuts
Lift Outer
and clamp securing lift cylinders to outer cylinder mast
mast.
④ Using an overhead hoist, slowly raise the
inner mast high enough to clear lift
cylinder.
⑤ Using an overhead hoist, draw out lift Hex bolt

cylinder carefully and put down on the Clamp

work floor.

35DS7RE10

2-4
(6) Inner mast
① Using an overhead hoist raise the inner
mast straight and carefully draw out of
outer mast section.
Be careful the mast not to swing or fall. Inner
mast

Outer
mast

35DS7RE11

(7) Tilt cylinder pin

(8) Mast mounting pin
① Attach a crane to the stay at the top of the
outer mast, and raise enough to sustain
jacked up machine. Outer mast
※ This operation is carried out under the Tilt cylinder
machine, so use a pit, or if there is no pit,
jack up the machine and loosen with an
impact wrench.
② Loosen the mounting socket bolts and Tilt cylinder pin
remove the mast mounting pins.
Then slowly raise the outer mast.

Socket bolt
Frame

Mast
mounting pin

35DS7RE12

2-5
2) INSTALLATION
After assembling mast components totally without piping connections, install mast assembly to the
equipment.
※ Installation procedure for each of mast component is the reverse of the removal procedure.
(1) Mast mounting pin
① Check the mast mounting pins for wear, then install pins into the mast support bracket.
② Jack up the machine so that the front is raised and then using an overhead hoist assemble outer
mast to frame.
③ Tighten mounting socket bolts to frame.
·Tightening torque : 35.1~47.5kgf·m(254~344lbf·ft)
(2) Tilt cylinder pin
Hold the mast with a crane, operate the tilt control lever and align the holes, then knock the pin.
(3) Lift cylinder installation and adjustment
① Assemble the lift cylinder inside the outer
mast, then tighten the stopper bolt. If the
cylinder assembly has been replaced,
adjust as follows so that the left and right
cylinders are synchronized at the maxi-
mum lifting height.
② Assemble the cylinder rod to the inner
mast, and check the left-to-right play of
the mast at the maximum lifting height.
※ If play is to LEFT, install adjustment shim
to LEFT cylinder.
※ If play is to RIGHT, install adjustment
D503RE03
shim to RIGHT cylinder.
·Shim thickness : 1.0mm(0.04in)

2-6
2. POWER TRAIN ASSEMBLY
1) REMOVAL

D503RE04

(1) Mast
Refer to section on mast(Page 2-2)

2-7
(2) Brake piping Brake valve
Disconnect the brake piping from the
brake housing of drive axle unit.
Brake pipe

Drive axle

35D7ERE13

(3) Parking brake cable

Disconnect parking brake cable from the
brake housing of drive axle unit. Parking
brake
Parking lever
brake cable

Drive axle

35D7ERE16-1

(4) Drive axle

※ Before removing the drive axle unit, drain
all of the oil from the axle.
① Loosen hexagonal bolts connecting drive 4 Trunnion bolt
axle to the transmission.
※ If there is a pit, use the pit for safety.

② Jack up the machine and then put the

block under the frame.

③ Prepare the truck under the drive axle 3 Truck

2 Block
unit to support it.

④ Remove trunnion fixing the axle to the

frame and then carefully draw the truck
out of the vehicle with the drive axle unit. 1 Drive axle
mounting bolt
35D7ERE15

2-8
(5) Inching linkage
Inching pedal
Remove the bolt fixing the linkage
assembly to T/M control valve.

Bolt

T/M control valve 35DS7RE16

(6) Transmission cooling piping

① Disconnect cooling hose and connector Radiator
assy
from the transmission.
※ Make sure that the coolant be drained
Hose
from the hose.

Hose

Transmission assy

35L7ARE17

(7) Torque converter

Cover
① Remove the cover on top face of the
torque converter housing then remove Bolt
the 4 mounting bolts installed on the
engine flywheel. To rotate the flywheel, Transmission

remove 1 mounting bolt, then insert a

turning tool in the mounting hole. One Torque
converter
man must turn the engine fan by hand
while the other turns the flywheel.

35L7ARE18

2-9
 (8) Mounting bolts holding to flywheel
housing
① Remove the transmission assembly from Mounting bolt
the engine flywheel by loosening the
mounting bolts.

35L7ARE19

② Using a moving truck slowly, pull out

transmission assembly to the front.

Frame

Block

Truck 35DS7RE20

2) INSTALLATION
(1) Installation is the reverse order to removal,
but be careful of the following points.
(2) Tightening torque
① Bolt(1) Bolt(1)
·6-bolts for upper side of flywheel housing : Bolt(2)
3.5~4.2kgf·m(25.3~30.3lbf·ft)
·4-bolts for lower side of flywheel housing :
1.5kgf·m(10.8lbf·ft)
② Bolt(2) : 3.5~4.2kgf·m(25.3~30.3lbf·ft)

35L7ARE21

2-10
3. ENGINE
Lever the torque converter, transmission and front axle inside the frame, then remove the engine
assembly.
1) REMOVAL

D503RE25

(1) Overhead guard

Remove the wiring for rear combination
lamp, working lamp, head lamp and
flasher lamp on the stay of the overhead
guard and then raise it together with the
bonnet.

35L7RE22

2-11
 (2) Remove the torque converter housing
cover, mounting bolts installed to flywheel
housing.
For details, see page 2-9. Engine

(3) Engine accessory

Remove all wiring harnesses, cables and
hoses around the engine, dashboard and
frame.
① Wiring harness to alternator and starter.
② Wiring harness for oil pressure and
engine water temperature gauges.
③ Cables for meters, buttons and accelerator
pedal.
④ Hoses to fuel tank and air cleaner.
⑤ Exhaust pipe.
(4) Radiator hose
Open the drain valve of the radiator and
drain the cooling water, then remove the 35L7RE23

radiator hose.

(5) Mounting bolt

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

35L7ARE24

2) INSTALLATION
Installation is the reverse order of removal,
but be careful of the following points. 7.5kgf.m
(54.2lbf.ft)
(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. 5.5~8.3kgf. m
※ Before installing the bolts, loctite in the (39.7~60.0lbf. ft)

holes should be removed by a tap. 35L7ARE25

2-12
(3) Radiator hoses
·Distance to insert hose : 45mm(1.77in)
Engine
(4) Air cleaner hose
① Insert the air cleaner hose securely and
fit a clamp.
② Distance to insert hose

·Air cleaner hose : 45mm(1.77in) Air cleaner

·Engine end : 60mm(2.36in)
Muffler Tail pipe

Loctite #243

Engine
Exhaust pipe

Engine

Exhaust pipe
35L7ARE26

2-13
5. STEERING AXLE
1) REMOVAL

Drawbar

Mounting bolt

35L7RE27

(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)
35L-7A 1820kg (4010lb)
40L-7A 2200kg (4850lb)
45L-7A 2550kg (5620lb)
50L-7A 2900kg (6390lb)

·Tightening torque : 199±29.9 kgf·m (1440±216lbf·ft)

2-14
(2) Rear wheel
Remove mounting bolt and hub nut with
socket wrench and then carefully take out
the tire assembly.

35DS7RE28

(3) Hose
Drain hydraulic oil in the hoses and
cylinders before removing them.
Steering axle
Remove the fitting and then disconnect
the hoses.

Hose
35DS7RE29

(4) Mounting bolt

Put a block under the steering axle, Steering axle
support on a truck, an raise the frame with
a crane. Remove the mounting bolts
installing to the frame, and pull out to the
rear. Support
There are shims between the support and
steering axle to prevent play.
Mounting bolt
35DS7RE30

2-15
 SECTION 3 POWER TRAIN SYSTEM

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

Group 2 Inspection and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19
GROUP 1 STRUCTURE AND OPERATION
1. POWER TRAIN COMPONENT OVERVIEW
1) STRUCTURE

8
1 2 3 4 7

10

Engine 11

5 9

35D7ETA01

1 Torque converter 5 T/M control valve 9 Disk brake

2 T/M oil level gauge 6 Differential 10 Drive axle oil level gauge
3 Transmission 7 Drive shaft 11 Drive axle
4 T/M oil pump 8 Drive wheel

2) OPERATION
Power train system consists of engine , torque converter(1) , transmission(3) , drive shaft(7) , drive
axle(11) and drive wheel(8).
Engine power is transmitted to the transmission(3) through the torque converter(1).
Transmission(3) which operates as a type of regularly and continuously engaged counter shaft
shifting by 2 stage both forward and reverse consists of 4 hydraulic clutch packs.
Clutch piston is released by tension of spring.
The power is transmitted to spiral gear and bevel gear set of differential through the output gear and
then goes to the drive wheel via drive axle.

3-1
2. SPECIFICATION
Item Unit Specification

Type - 3 elements 2 phase 1 stage

Torque converter
Power transmit - Torque flow
Type/Number of speed - Power shift / Two speed(F2 / R2)
FR/RR 1 stage - 2.55
Transmission Gear ratio
FR/RR 2 stage - 1.29
P.T.O system - Included
T/M valve Shift system - Electric
Charging pump Discharged flow rate cc/rev 20.6
Differential - 2.923
Drive axle Gear ratio Planetary - 4
Total - 11.692
Service brake - Oil disc brake
Brake
Parking brake - Separated drum brake
Gear type - Spiral bevel gear
Differential
Differential type - 4 pinions

3-2
2. TORQUE CONVERTER
1) STRUCTURE

Input plate Turbine

Impeller Torque converter
Stator
1 2

Pump gear

A D C B

Engine side Transmission side

35D7ETA02

No Item Specification
1 Torque converter input plate 4.5Ü0.3kgÂm (32.5Ü2.2lbfÂft)
2 Torque converter pump gear 2.0Ü0.3kgÂm (14.5Ü2.2lbfÂft)
A Pilot boss outer diameter 19.959 - 19.980mm(0.786 - 0.787in)
B Oil seal outer diameter 134.9 - 135.0mm(5.311 - 5.315in)
C Needle bearing outer diameter 68.000 - 68.019mm(2.677 - 2.678in)
D Seal ring inner diameter 60.333 - 60.363mm(2.375 - 2.376in)

2) OPERATION
(1) Turbine. (2) Stator. (3) Impeller. (4) Housing. (5) Stator support. (6) Flexible plate. (7) Stator
clutch.
The torque converter hydraulically connects the engine to the transmission. There is no direct
mechanical connection between the engine and the transmission. When the machine works against
a load, the torque converter can multiply the torque from the engine and send a higher torque to the
transmission. The oil for the operation of the torque converter comes from the transmission oil
pump. The oil flows through a small passage in stator support (5) around the shaft of the stator
support and into the converter. Outlet oil from the converter flows through the transmission oil cooler
and into the lubrication system.
The torque converter has four main parts : housing (4), impeller(pump) (3), turbine (1) and stator
(2). The housing is connected to the engine flywheel through flexible plate (6). Impeller (3) and
housing (4) are connected and turn with the engine flywheel at the same engine speed. Turbine (1)
turns the transmission input shaft. Stator (2) is installed stationary on stator support (5).

3-3
Impeller (3), which turns with housing (4) at engine speed, directs the oil toward the outside of the
impeller and against the blades of turbine (1). When the oil hits the turbine blades, it causes turbine
(1) and the input shaft to turn. This sends torque to the transmission. Oil returns through the stator
vanes to the impeller. The stator vanes direct the oil back to the impeller that causes a torque
increase.
When the speed of turbine (1) is the same as the speed of impeller (3) stator clutch (7) permits the
stator to turn freely with engine rotation but it locks(holds), to prevent opposite rotation to engine
rotation. The free rotation of the stator helps also to decrease the sudden or fast movement of the
oil which can cause cavitation(air bubbles) in the hydraulic system. When the turbine speed is less
than the speed of impeller (3), stator (2) holds in place. Torque is multiplied only when the stator is
held in place.

3-4
3. TRANSMISSION
1) STRUCTURE

1 2 3 4 5 6 7 8 9

10

11

12

13

20 14

19 15

18 16
17

35D7ETA03

1 Torque converter 8 Clutch piston 15 Output shaft

2 Input shaft 9 Valve assembly 16 Clutch drum (FR)
3 3 P.T.O gears 10 Clutch (RR, 1 stage) 17 Clutch (FR, 2 stage)
4 Pump assembly 11 Gear (RR, 1 stage) 18 Gear (Output, 2 stage)
5 Gear (RR, 2 stage) 12 Gear (FR, 1 stage) 19 Gear (FR, 2 stage)
6 Clutch (RR, 2 stage) 13 Clutch (FR, 1 stage) 20 Counter shaft
7 Clutch drum(RR) 14 Gear (Output, 1 stage)

2) OPERATION

Transmission enables to a power transmission and a gearshift by the operation of hydraulic friction
clutch pack which is controlled through the torque converter.
In accordance with the drive speed of vehicle, transmission shifts the gear to the optimal stage for a
stable drive.
T/M transmits the power to drive axle by 2 stage each of forward and reverse gear selections.
T/M consists of 4 hydraulic clutches and it is released by spring tension.
Direction and gear stage are electrically changed. The power from the transmission is transmitted to
all of the powertrain components.

3-5
3) TRANSMISSION GEAR ARRAY

T/C input

T/C input 1
relief
2

3
T/C output
(to cooler)
From cooler

INPUT
T/C output
relief

COUNTER F R

8
OUTPUT

7 4

6 5

35D7ETA04

1 Cylinder clutch (RR) 4 Gear(Output, 1st stage) 7 Gear(FR, 2nd stage)

2 Gear(RR, 2nd stage) 5 Gear(Output, 2nd stage) 8 Gear clutch(FR)
3 Gear(RR, 1st stage) 6 Gear(FR, 1st stage)

ö Selection of either forward or reverse gear makes all of the parts inside the T/M operate.

3-6
 4) TRANSMISSION INPUT PORT

1 2

7 6 5 4 3

35D7ETA05

1 T/C input port pressure 5 RR 1st stage pressure

2 Main line pressure 6 RR 2nd stage pressure
3 FR 2nd stage pressure 7 T/C output port pressure
4 FR 1st stage pressure

ÂTransmission pressure
Engine Unit Main line T/C input port T/C output port FR 1,2 stage RR 1,2 stage
rpm (Neutral) (Neutral) (Neutral) clutch clutch
kgf/cm2 6.5~13.2 0.7~4.2 0.2~1.2 6.5~13.2 6.5~13.2
Idle
(psi) (92.5~187.7) (9.9~59.6) (2.8~17.1) (92.5~187.7) (92.5~187.7)
kgf/cm2 7.5~14.5 1.5~9.1 0.7~2.5 7.5~14.5 7.5~14.5
1300
(psi) (106.7~206.2) (21.3~129.4) (10.0~35.6) (106.7~206.2) (106.7~206.2)
kgf/cm2 7.5~15.0 2.6~11.1 1.0~4.2 7.5~15.0 7.5~15.0
2200
(psi) (106.7~213.4) (37.0~157.9) (14.2~59.7) (106.7~213.4) (106.7~213.4)

3-7
 5) TRANSMISSION INPUT PORT

R2 R1 F1 F2

T P

S Directional
Modulation valve
valve (Solenoid shift valve)
Torque converter 1.8 1.6
outlet relief valve T/C in
0.2~4.2 kgf/cm 2
Main relief valve Pedal
7.0~15.0 kgf/cm2
Inching valve
P
T/C out
Oil filter
Oil
cooler
20.6 cc/rev
TRANSMISSION
TRANSMISSION Torque converter PUMP
LUBRICATING inlet relief valve
0.8~7.2 kgf/cm 2

Oil sump
D357TA06

(1) Specification

Item Unit Specification

Rated flow ˶/rpm 37.4 / 2200
Main relief pressure kgf/cm²(psi) 7.0 ~ 15.0(99.6~213.4)
T/C relief pressure kgf/cm²(psi) 0.8 ~ 7.2(11.4~102.4)
Clutch pressure kgf/cm²(psi) 7.0 ~ 15.0(99.6~213.4)
Residual pressure kgf/cm²(psi) Max. 0.3(4.3)
( Clutch release condition )

(2) Electric input data

Item Unit Specification

Initial coil current at 20Á
C A / VDC 0.7/24
Resistance at 20Á
C ̫ 39.3
Shifting time sec 1.0 ~ 1.6
Connector - DR/D Models With Diode

3-8
4. DIFFERENTIAL CARRIER ASSEMBLY
1) STRUCTURE

1 2 3 4

35D7ETA07

No Item Unit Specification

1 Differential pinion gear inner diameter mm(in) 20.000 - 20.021(0.787~0.788)
2 Spider outer diameter mm(in) 19.959 - 19.980(0.786~0.787)
3 Pinion gear washer mm(in) 1.92 - 2.08(0.076~0.082)
4 Side gear washer mm(in) 1.95 - 2.05(0.077~0.081)
5 Side gear - -

2) OPERATION
Differential transmits the power from the transmission to drive wheel.
When the vehicle is running one side wheel rotates slower than the other side wheel.
Differential is composed of 4 pinions(1), 2 side gears(5) and 1 spider(2).
The spider is meshed vertically between 4 pinions(1) and 2 side gear(5), so the engagement
become a right angle.

3-9
5. DRIVE AXLE
1) STRUCTURE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

35D7ETA08

1 Sun gear 6 Hub assy 11 Pinion shaft

2 Planetary gear 7 Disk brake 12 Spider
3 Inner gear 8 Drive shaft 13 Differential pinion gear
4 Inner gear carrier 9 Differential carrier assy 14 Differential side gear
5 Tapered bearing 10 Ring gear

2) OPERATION
Drive axle which consists of differential carrier assembly(9), drive shaft(8) and hub assembly(6)
transmits the drive force from transmission to drive wheel.
Pinion shaft(11) is connected to transmission output shaft and spline.
The power of transmission is transmitted to differential which consists of pinion shaft(11) and ring
gear(10) and the differential rotates the drive shaft.
The differential transmits the drive force from transmission to wheels and one wheel's rotation
speed is differ from the other.
The differential consists of 4 pinions(13) , 2 side gears(14) and spider and the engagement
between 4 pinions(13) and side gear(14) makes a right angle.
Side gear(14) and drive shaft(8) are connected with spline and the drive shaft(8) consists of
planetary gear(2), inner gear(3), wheel hub(6) and drive wheels.

3-10
3) DRIVE AXLE TIGHTENING TORQUE

1 2 3 4 5 6

10

7 9

35D7ETA09

No Item Specification

1 Inner carrier 2.2Ü0.3kgfÂm (15.9Ü2.2lbfÂft)

2 Spindle 12Ü0.5kgfÂm (86.8Ü3.6lbfÂft)
3 Adjust bolt for service piston 1.5Ü0.1kgfÂm (10.8Ü0.7lbfÂft)
4 Adjuster nut 1.0Ü0.2kgfÂm (7.2Ü1.4lbfÂft)
5 Differential cap 16Ü0.5kgfÂm (115.7Ü3.6lbfÂft)
6 Differential case 6Ü0.5kgfÂm (43.4Ü3.6lbfÂft)
7 Wheel hub 3.0Ü0.3kgfÂm (21.7Ü2.2lbfÂft)
8 Ring gear 13.5Ü0.5kgfÂm (97.6Ü3.6lbfÂft)
9 Differential carrier assembly 11.5Ü0.5kgfÂm (83.2Ü3.6lbfÂft)
10 Connection between differential carrier and drive axle LOCTITE #5127

3-11
 4) DISK BRAKE

1 2 3 4 5 6 7

35D7ETA10

1 Spindle 4 Service piston 7 Drive shaft

2 Steel plate 5 Service piston adjust bolt 8 Parking brake
3 Disk plate 6 Spline collar

Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the
high humid or dusty area.
Because it is possible to use the brake semi-permanently, there is no need to replace or change the
lining as drum type brake do. Also with self-adjust of friction plate clearance, it's easy to prevent the
break performance drop due to friction material wear.
Major components are 3 disk plates (3), 4 steel plates (2), service piston (4) and 4 piston adjust bolts (5).
Braking take places when the discs and plates are pressed each other which make rotation resistance to
the collar (6) and the drive shaft (7).

3-12
GROUP 2 INSPECTION AND TROUBLESHOOTING
1. INSPECTION
To check the problems of transmission, operate the machine and test its performance.
Check and record the abnormal noise and if the machine doesn't operate perfectly, refer to problem
and possible cause in the troubleshooting table.
1) VISUAL CHECK
(1) Start engine and check T/M oil level at the neutral gear shift.
(2) Check any kind of damage or leakage on the oil piping, hose, connection, etc.
(3) Operate the Forward/Reverse lever to both of directions.
(4) Check the contamination in the strainer and filter inside the transmission.
Η If rubbed paper particles detected, check clutch defects.
Θ If metal particles detected inside the filter, check metallic friction inside the T/M or mechanical faults.
Ι If rubber particles detected, check seal or hose defects.
Κ If Aluminum particles detected, check converter or control valve damage.
(5) If metal or rubber particles found, clean all of the T/M hydraulic parts.
(6) Replace damaged parts with the new one.
2) DRIVE CHECK
Fill T/M oil to the proper level before starting the machine.
Improper oil level can cause the damages on the components.
(1) After starting engine, step on the brake pedal and then operate the Forward/Reverse lever to both
of directions.
(2) If the machine moves to each of directions, it will operates normally but check noise and cause
and then note them.
In case of abnormal operation, refer to troubleshooting table.

3-13
2. TROUBLESHOOTING
1) CHECK LIST DURING OPERATION

No Condition Possible causes Correction

1 Transmission does not (1) Low oil pressure or no oil (1) Check oil level.
operate in any speed or pressure caused by :
does not engage(slips) in a. Low oil, no oil, or thick oil. a. Check mix another oil.
all speeds b. Inching control valve linkage b. Check tightening bolt or replace
loose, broken or adjustment is a control valve assy.
not correct.
c. Inching valve spool stuck(held) c. Replace a spool of the control
open. valve assy or check it.
d. Failure of the oil pump or a d. Replace the oil pump or have to
defect in the oil pump. check.
e. Converter drive tangs worn off e. Check tightening torque of bolt
or not engaged into pump from torque converter gear.
or broken bolt.
f. Main regulator valve stuck f. Check control valve assy.
open.
g. Restriction in the oil flow circuit g. Check suction filter due to a
such as dirty oil screen. clogged from a mixed foreign
material.

2 Transmission does not (1) Low oil pressure. (1) Check oil level.
shift (2) Main regulator valve will not (2) Check control valve assy.
move(stuck).
(3) Solenoids or related electric (3) Check solenoids valve or related
components are out of order. electric components.

3 Transmission gets hot. (1) Restriction in cooling circuit. (1) Check restriction in cooling
(2) Oil level too high or too low. (2) circuit of transmission.
(3) Low pump pressure -worn or (3) Check oil level or replacement.
damaged pump.
(4) Converter one way clutch worn
and slipping.
(5) Air mixed in the oil. Air leaks on (5) Check transmission inside cover.
the intake side of the pump.
(6) Low oil flow through converter. (6) A plugged(restriction) oil flow
passage.
(7) Wrong application for vehicle (7) Check reliable work place under
(loads are too heavy for the lift circumstance.
truck).
(8) Too much inching operation (8) Check control valve assy.
(slipping the clutch plates and
discs).
(9) Too much stalling of torque (9) Check torque converter assy or
converter. replacement.

(10) Cooler bypass valve stuck(held) (10)Replace cooler bypass valve.

open, full oil flow does not go
through oil cooler.

3-14
2) CHECK LIST FROM OPERATION NOISES

No Condition Possible causes Correction

1 Noise in neutral only. (1) Worn bushing in pump (1) Replace related with other
assembly. component of charging.
(2) Worn one-way clutch in torque (2) Replace torque converter assy.
converter.
(3) Oil level low. (3) Check oil level.
(4) Converter housing or converter (4) Should be alignment with engine
tangs not in alignment with or transmission pump.
engine or transmission pump.

2 Pump noise not normal. (1) A loud sound at short time (1) Replace the oil pump.
periods gives an indication that
foreign material is in the
transmission hydraulic system.
(2) A constant loud noise is an (2) Replace the oil pump.
indication of pump failure.

3 Noise in the transmission (1) Converter housing or converter (1) Should be alignment with engine
that is not normal. tangs not in alignment with or transmission pump.
engine or transmission pump.
(2) Transmission components have (2) Transmission components have
wear or damage. wear or damage.
a. Damaged gears. a. Replace gear.
b. Worn teeth or clutch plates b. Replace plate and disc.
and/or clutch discs and slipping
clutch plates and discs noise.
c. Failure of the thrust washers. c. Replace to thrust washer.
e. Other component parts have e. Replace to other component.
wear or damage.

4 Noise in the control valve. (1) Air in the hydraulic system. (1) Replace to control valve assy.
a. Air leakage on suction side of
the pump or Low oil level that
causes aeration.
(2) Restrictions in oil passage. (2) Replace to control valve assy.
(3) Valve spools movement has (3) Replace to control valve assy.
restriction.

3-15
3) CHECK LIST FROM PRESSURE TEST

No Condition Possible causes Correction

1 Low pressure to forward (1) Inching valve linkage adjustment (1) Adjust inching valve.
and reverse clutches. is not correct.
(2) Inching valve spool held(stuck) (2) Replace inching spool.
open.
(3) Clutch piston seals cause (3) Replace clutch and piston seal.
leakages.
(4) A defective regulator valve (4) Replace the spring of the
spring. regulator.
(5) Low oil pressure, see Probable (5) Check oil flow circuit of the
Cause for Low oil pressure. transmission.
(6) Cooler external lines are not (6) Check the cooler external lines.
connected correctly.

2 Clutch pressure and main (1) Pressure regulator valve is not (1) Check adjusting pressure valve.
pressure are high. free to move(stuck).
(2) A restriction in the hydraulic (2) Check the hydraulic circuit.
circuit.

3 Pressure to one clutch is (1) Clutch piston seal alignment is (1) Replace clutch piston seal.
low. not correct, oil leaks through.
(2) Seal rings on shaft or clutch (2) Replace shaft sealing and clutch
piston seals are broken or worn. piston seal.
(3) Control valve surface not flat or (3) Replace the control valve gasket.
gasket has damage.

4 Low main line pressure. (1) Low oil level.

(2) Main regulator valve movement
is restricted.
(3) Transmission pump is worn.
(4) Inner oil leakage.
(5) Low oil pressure.
5 High converter pressure. (1) Main regulator valve stuck open (1) Check adjusting main valve.
so most of the flow goes to the
converter.
(2) A restriction inside the converter (2) Replace torque converter assy.
assembly.
(3) A plugged(restriction) oil flow (3) Check the oil flow hole of the
passage. transmission.

6 Low converter pressure. (1) Main regulator valve movement (1) Check main regulator valve or
is restricted (plugged). change.

7 Converter outlet pressure (1) Low oil pressure. (1) Check the oil level.
or cooler inlet pressure is Cooler bypass valve stuck open. Cooler bypass valve stuck open.
low.

8 Converter outlet pressure (1) Restriction(plugging) in oil cooler (1) Check the oil cooler lines
or cooler inlet pressure lines or a plugged oil cooler.
too high.

3-16
4) DRIVE AXLE

No Condition Possible causes Correction

1 Constant noise in (1) Oil is not enough(Replace (1) Refueling lubricating oil.
differential. interval : 50 hrs first, then every
500hrs ).
(2) Wrong kind of oil. (2) Change lubricating oil.
(3) Wheel bearings out of (3) Replace bearing.
adjustment or have a defect.
(4) Drive gear and pinion not in (4) Re-assemble.
adjustment for correct tooth
contact.
(5) Teeth of drive gear and pinion (5) Replace damaged gear.
have been damage or worn.
(6) Gear backlash is too much or (6) Replace differential gear set.
too little.
(7) Loose or worn on pinion (7) Replace bearing.
bearings.
(8) Loose or worn on side bearing. (8) Replace bearing.
2 Noise at different intervals. (1) Ring gear does not run even.
a. Bolts on drive gear are not a. Tighten bolts.
tightened correctly.
b. Drive gear has a defect b. Replace damaged drive gear
(warped). set.
(2) Loose or broken differential (2) Replace bearing.
bearings.

3 Noise on turns only. (1) Differential pinion gears are tight (1) Replace differential pinion gear
on the spider. or spider.
(2) Side gears are tight in differential (2) Replace differential side gear.
case.
(3) Differential pinion or side gears (3) Replace differential gear set.
have a defect.
(4) Thrust washers worn or have a (4) Replace differential washer.
damage.
(5) Too much clearance(backlash) (5) Replace differential gear set.
between side gears and pinions.

4 Leakage of the oil. (1) Leakage through axle hub

carrier
a. Too much oil. a. Adjust oil level.
b. Wrong kind of oil. b. Change lubricating oil.
c. Much restriction on air eather. c. Replace air breather.
(2) Leakage around pinion shaft.
a. Too much oil. a. Adjust oil level.
b. Wrong kind of oil. b. Change lubricating oil.
c. Much restriction on air eather. c. Replace air breather.
d. Oil seal worn or not installed d. Replace oil seal.
correctly.

3-17
No Condition Possible causes Correction

5 Drive wheels do not rotate (1) Broken axle shaft.

a. Loose wheel bearings. a. Re-assemble wheel bearings.
b. Axle shaft too short. b. Replace drive shaft
c. Loose flange studs or nuts. c. Tighten studs or nuts
(2) Drive gear teeth have been (2) Replace damaged drive gear set
damaged.
(3) Side gear on differential damaged. (3) Replace damaged gear
(4) Differential pinion shaft or spider (4) Replace damaged gear
broken

3-18
GROUP 3 DISASSEMBLY AND ASSEMBLY

1. DISASSEMBLY OF DRIVE AXLE

1) DISASSEMBLE WHEEL HUB SUB ASSEMBLY

(1) Loosen oil drain plug using torque

wrench(1) in axle housing and drain oil.

35DSEDA01

(2) Loosen oil drain plug in planetary housing

and drain oil.

35DSEDA02

(3) Loosen 4 socket head bolts and remove

the planetary carrier.

35DSEDA03

3-19
(4) Remove O-ring(2) and snap ring(3) from
the housing of planetary. 


35DSEDA04

(5) Remove 3 pins(6) with a plastic hammer.



35DSEDA05

(6) Remove needle bearings(6), planet

gears(5) and thrust washers(7). 
  


35DSEDA06

(7) Remove sun gear(8) and drive shaft(9).


35DSEDA07

3-20
(8) Remove snap ring(10) and then remove
sun gear from the shaft(9).




35DSEDA08

(9) After removing bolt(11), remove ring

gear(13) and torque plate assembly(12)  
from the spindle.
ö Must measure the rolling resistance of
tapered roller bearing.


35DSEDA09

(10)Remove C-ring(14) from the ring gear and

pull the spindle(15) out of the ring gear. 


35DSEDA10

(11)Pull out bearing inner race on flange using

2 X M8 bolts.

35DSEDA11

3-21
(12)Remove wheel hub from the axle housing
after loosen 14 bolts and 2 nuts.

35DSEDA12

(13)Disassemble drive shaft and disc & plate

assembly.

35DSEDA13










35DSEDA14

(14)After loosing 4 bolt-self adjust (18),

disassemble spring-self adjust (20) from 
 
bushing-self adjust (19).
Then disassemble piston (17) from axle
housing (16).

After removing 3 pins(23), then finally
remove square ring (21),(22). 
ö Do not reuse damaged square ring.




35DSEDA15

3-22
(15)Remove bearing cup from the wheel hub
by using jig and hammer. Shaft seal may
be damaged.

35DSEDA16

2) DISASSEMBLY OF THE DIFFERENTIAL

CARRIER ASSEMBLY

(1) Loosen 12 bolts(1) and then remove
carrier from the housing by using a lifting
machine.

35DSEDA17

(2) For the reassembly, check rolling

resistance and record it.
After loosen 2 bolt(2), washer(3) and then
remove backing plate(4).
 

35DSEDA18

(3) Before removing differential assembly from 

carrier(5), check the location of cap(6) and 
mark it for reassembly.
(4) Remove 4 hexagon bolts(7) and cap(6).


35DSEDA19

3-23
(5) Remove differential assembly(8) from the
carrier.  

(6) Disassemble bearing(9) from the

differential housing and remove 12
bolts(10).

35DSEDA20

(7) After removing 12 mounting bolts(11) from

the housing and then disassemble the ring 
gear.

35DSEDA21

(8) Check the mark on the housing and

separate the housing from the differential.
If there is no mark, be sure to mark on the
housing.
When reassembling, it must be placed at
the same position as before.

35DSEDA22

(9) Remove thrust washers, side gears, pinion

gears and spider and then place them on
the clean place.

35DSEDA23

3-24
(10)Loosen 4 bolts (12) and then remove drum
from the parking brake. 

35DSEDA24

(11)After removing lock nut(13) and then 


remove the yoke(14). 
(12)Loosen 4 bolts(15) and then remove 

parking brake(16) from the carrier
housing.
(13)Remove the drive bevel pinion shaft (17)
carefully by using a plastic hammer.
ö Be careful not to damage bevel pinion
35DSEDA25
shaft.

(14)Remove shim(18) and spacer(19) from

pinion shaft.  
Using a bearing puller, disassemble inner
race of taper roller bearing from the pinion
shaft.

35DSEDA26

(15)Remove outer race of taper roller bearing

and shim from the housing by using a jig
and hammer.
ö Do not reuse damaged shims.

35DSEDA27

3-25
(16)Remove outer race of taper roller bearing
on the opposite side.

35DSEDA28

3-26
2. REDISASSEMBLY OF DRIVE AXLE
Clean every parts with cleanser and then remove remained loctite.
Be careful not to spill cleanser on your body.
Avoid drinking cleanser or breathing its fumes.
Wear protective clothing, glasses and gloves.
If spilled on the skin, flush your skin with water immediately.
If swallowed, get medical attention immediately.
 Check wear, damage or crack for all the parts and replace if needed.
 If the teeth of gear are damaged, replace it as a set.
 Replace damaged tapered roller bearing.
 Do not reuse deformed shims or worn thrust washers.
 Polish the surface on which seal contacted if needed.

1) ADJUSTMENT OF BEVEL PINION SHAFT

Adjusting shim of bevel pinion shaft.
(1) Adjust shim thickness and bevel pinion
shaft with following method.
Η Measure "E" at the housing.
Θ By the equation " X = E - B - T Ü C ",
define the the shim thickness(1).
B : Mounting dimension of bevel pinion
shaft , 131.20mm (5.2 in)
T : Height of bearing. 35L7ADA01

C: Dimension of carved seal on the

pinion. If there's no mark C=0.

EX) : From the housing

"E" = 162.85mm
B is factory dimension
EE

"B" = 131.20mm
From the bearing
"T" = 31.5mm
T

Mark on the pinion

X

"C"= 0.05mm
Shim thickness :
"X" = 162.85 -131.20 - 31.5 - 0.05
= 0.10mm 35L7ADA02

ö If teeth are damaged, replace it as a set

(Bevel gear and shaft). Do not reuse
damaged shims and bearing.

3-27
(2) Using different kinds of shims, adjust shim
thickness as measured by previous
equation.
Place shims at the bearing place.
Using a jig, assemble drive bearing so that
the outer race contact with the bearing
place.

35L7ADA03

(3) Heat the inner race of bearing to max

100äC and then assemble it to the pinion
shaft.
Also inner race should contact with
bearing place.

35L7ADA04

3-28
2) ADJUSTMENT OF PINION SHAFT

(1) Assemble bearing cup.

Assemble spacer to the pinion shaft and
then install measured shims onto the
spacer.

35DSEDA28

35DSEDA26

(2) Insert pinion shaft into the carrier.

After assemble bearing cone and lock nut.
Apply grease on the outer bearing.
Apply loctite #271 or #277 on the thread of
pinion and then tighten lock nut.
ÂTightening torque : 45~51kgfÂm
Measure rolling resistance of pinion shaft.
ÂRolling resistance : 0.2~0.41kgfÂm
35DSEDA33

Coke lock nut into the pinion shaft slot.

3-29
3) ASSEMBLY OF DIFFERENTIAL ASSEMBLY
(1) Assemble thrust washer, side gear and
spider with gears and then install them to
the differential housing.
Apply grease on the bevel gear and thrust
washer.

35L7ADA05

(2) Assemble differential housing.

ö Check marks on the housing.
Match two marks at the same position.

D357DA32

(3) Tighten 12 bolts(1) to the differential

housing.
1
Apply loctite #271 or #277 on the thread of
bolt.
ÂTightening torque : 5~7.5kgfÂm

D357DA331

(4) Assemble ring gear by tightening 12

bolts(2).
2
Apply loctite #271 or #277 on the thread of
bolt.
ÂTightening torque : 12.5~14.5kgfÂm

D357DA341

3-30
(5) Install differential assembly into the carrier.
Place the bearing cup and screw into the
housing.
At that moment, using a screw adjust
rotation backlash.
Install the dial gauge on the gear tooth and
measure the backlash while rotating bevel
gear.
ö Rotation backlash : 0.18~0.23mm
(6) Assemble bearing cap. 35L7ADA06

ö Fix bearing cap with hexagon bolt.

ÂTightening torque : 15~17 kgfÂm
Unit : kgfÂm
Measure rolling resistance of tapered roller
P Z
bearing.
The following table shows the relation 0.20 0.44~0.47
between preload (P) of bevel pinion shaft 0.25 0.49~0.52
and rolling resistance (Z). 0.30 0.55~0.58
(Calculated at adjustment of pinion shaft 0.35 0.59~0.62
Θ)

(7) Confirm that the screw contacts with bearing.

(8) After complete assembly of bearing, measure rotation backlash once more and readjust with a
screw if needed.
(9) Apply loctite #271 to the thread of bearing cap bolt and then assemble it with tightening torque of
15~17kgfÂm
(10)Assemble plate with hexagon bolts. Apply loctite #271 or #277 to the tapped side of bolt and then
assemble at the tightening torque of 0.8~1.2 kgfÂm.
ö Assemble opposite side with the same methods.
(11)Apply marking liquid on 3~4 teeth of the ring gear and then rotate pinion gear to check gear
contact.
Check out the contacted shape.

3-31
4) ASSEMBLY OF CARRIER
(1) Assemble carrier assembly into the axle
housing.
(2) Fix the carrier assembly with hexagon
bolt(1).
Apply loctite #271 or #277 to thread of bolt
and then assemble it with tightening
torque of 11~13kgfÂm.
1 35L7ADA07

(3) Assemble brake drum to yoke with tighting

2
4 bolts(1).
Apply loctite #271 or #277 to thread of bolt
and then assemble it with tightening
torque of 11~13kgfÂm. 1
(4) Close hole(2) with rubber plug.

35L7ADA08

5) ADJUSTMENT OF PARKING BRAKE

(1) The following procedures should be applied for brake shoe adjustment
Η Open rubber plug on (2).
Θ Adjuster should be turned according to arrow direction until occurring drum drug.
Ι Adjuster should be turned to opposite direction of the arrow sign by four click.
At that case, lining clearance is 0.1~0.25mm.
Κ Check drum drag after operating lever several times.
(Repeat from beginning if drag is occurred)

Brake side adjusting

Expansile direction of
brake shoe adjusting

35L7ADA09

3-32
6) ASSEMBLY WHEEL HUB ASSY
(1) Insert bearing into wheel hub.
Confirm that the bearing and wheel hub
contact completely.
ö Apply grease or oil to shaft seal and then
assemble it with proper direction (Out side
of wheel hub).

D357DA38

(2) Install wheel hub assembly to the spindle

completely.

35L7ADA10

(3) Insert the spindle into ring gear and

secure with circlip.

35L7ADA11

(4) Place heated tapered roller bearing inner

race onto the spindle until contact take
places.
Install it on the wheel hub after cooling
down.

35L7ADA12

3-33
(5) Install the torque plate to fix the spindle.
Apply loctite #5127 to axle housing
surface which contact to the spindle.

35L7ADA13

35L7ADA14

(6) Assemble square ring (2),(3) to the axle 1

housing (1) then apply the oil (Mobil fluid 2 3
#424).
Assemble bushing(5) to piston(2) and then
assemble piston(2) to axle housing after
applying oil sufficiently and then assemble 4
the spring(6) to the bushing(5).
Also, apply loctite #271 to 4 bolts(7) then 5
assemble them with tightening torque :
1.4~1.6 kgfÂm. 7
Assemble 3 brake pins(8) to axle housing
ö Check the status of square ring and 6
replace if damaged.
35L7ADA15

35L7ADA16

3-34
 Assembling plate and inspection 11 12
Η Assemble 4 plates(9) and 3 disks(10)
with spline collar(11) and then lock with
snap ring(12).
Disc must be assembled after the oil
immersion during 12 hours(MOBILFLUID
#424)
Θ Install assembled the spline collar to the
axle housing with the drive shaft.
13 14
Before assembling, clean all of the parts
35L7ADA17
completely and remove burrs.
Ι After assembling, confirm that the
clearance between the outer plate and
and the axle housing surface is
2.1~2.6mm.

35L7ADA18

(7) Push pre-assembled wheel hub to the axle

housing until contact take places.

35L7ADA19

(8) Tighten the torque plate until the wheel

hub assembly has the same rolling 13
resistance as before.
Apply loctite #271 or #277 to thread of
bolt(13) and then assemble it with
tightening torque of 1.8~2.2kgfÂm.

35L7ADA20

3-35
(9) After assemble sun gear to axle shaft and
fix it with a snap ring.
Apply grease on the shaft where bushing
contacts.
Apply grease on teeth of the planetary
gear.

D357DA43

(10)Assemble internal components of

planetary carrier with the reverse order of
disassembly.

D357DA44

D357DA45

(11)Install planetary carrier assembly to wheel

hub and tighten bolt(2)
ÂTightening torque : 2.5~4.0kgfÂm

35L7ADA21

3-36
(12)Assemble the wheel hub and tighten the
plug(14).
ÂTightening torque : 3.5~6.0kgfÂm
14

D357DA47

3-37
3. DISASSEMBLY OF TRANSMISSION
1) Pull torque converter(1) straight forward and
remove from the converter housing. 1

Remove six bolts(3) and flexible plate(1),

plate(2) from the torque converter.

2 3
35L7ADA22

2) Remove six socket bolts (3) and then gear

P.T.O input from the the torque converter. 4 6

5
D357TM02

3) Remove four bolts (9) and bolts(8), washes, 7

oil seal(10) from the housing converter(7).
10

8 35L7ADA23

4) Remove plug (16) and o-ring, spring (18)

and ball (17) from the bearing plate.
5) Remove plug (13) and spring (12),
Valve(14).
6) Remove plug (11).

35L7ADA24

3-38
ö Bearing cups and their shims will be in
cover or on the shafts in transmission case.
Put identification on each of bearing cups
and shims as to their location on
transmission cover or shaft in transmission
case.

35L7ADA25

7) Remove fasten five bolts(23) from fixed

stator hub(24) and bearing plate. In this
time, use the plastic hammer.

22
24

23

D357TM06

8) Remove four socket bolts (21), flange pump 29

27 33
(28) from bearing plate (21).
28 32
Remove a socket bolt (32) and four socket
bolts (33) from flange pump.
Remove charging pump (31) and pump
gasket, then separate to gear-P.T.O output
(23) and ball bearing, 90äelbow (27).
26 31
30
25
D357TM07

3-39
9) Separate to two thrust washers(34), needle
bearing(35), gear- P.T.O idle(36) from 36
34 35 34
bearing plate.

35L7ADA26

10) Remove two bolts(38), nine bolts(39), valve

gasket(40).

35L7ADA27

11) Remove eight bolts(41), five socket bolts

(42), then separate valve plate from
transmission case.

35L7ADA28

12) Remove O-ring, plug(46) then spring(47),

oil screen(48) from transmission case.
13) Remove temperature sensor(45) from
transmission case.
14) Remove plug(43), washer(44).

35L7ADA29

3-40
15)Use the plastic hammer to push tube (49) 49
out of the transmission case. Remove the 50
tube.
16)Remove output shaft assembly (51), input
shaft assembly (50), and counter shaft
assembly (52).

51 52
D357TM14

17)Remove the output gear (53) from the

transmission case.

53
D357TM15

3-41
18)For high speed forward clutch assembly,
remove bearing cone (54) with gear pulley.

35L7ADA30

19)Remove two thrust washers (55) and gear

(56).
20)Remove needle bearings and thrust washer
from the forward shaft of high speed clutch
side.

35L7ADA31

21)Use a screwdriver and remove snap ring

(57) from the cylinder.

35L7ADA32

3-42
22)Remove a five clutch discs and three 4T
clutch plates(58), four 2T clutch plates (60),
one bending plate (59) from the cylinder.

35L7ADA33

23)Push down on the retainer(61) by a press

and remove snap ring(62) with a
screwdriver. Slowly release the tension on
the spring assembly.
24)Remove retainer(61) and spring assembly
from cylinder.
25)Remove piston(63) by using compressed
air, then remove O-ring from the shaft.

35L7ADA34

26)For low speed forward clutch assembly,

remove seal rings (64) from shaft.
Remove bearing (65), thrust washer (66),
gear (67), needle bearing, spacer and
sealing (64).

35L7ADA35

3-43
27)Remove snap ring (57), then remove a five
clutch discs and three 4T clutch plates (58)
and four 2T clutch plates (60), one bending
plate (59) from the cylinder.

35L7ADA36

28)Remove two thrust washes and pin.

29)Push down on the retainer (61) by a press
and remove snap ring (62).
Slowly release the tension on the spring
assembly, then remove retainer and spring
assembly.
30)Remove piston (60) by using compressed
air, then remove O-ring from the shaft.
ö Disassembling procedure of input shaft
assembly is the same as counter shaft
assembly. 35L7ADA37

31)Disassemble input shaft assembly.

32)For output shaft assembly (51), remove the 68
bearing (68) and gear(69).

69

D357TM29

3-44
33)Remove bearing cups (70) from the
transmission case.
ö Put identification on bearing cups to use at
assembly.

70

D357TM25

34)Remove two lip type oil seals (71) from the

transmission case.

35L7ADA38

3-45
4. ASSEMBLY OF TRANSMISSION
1) Thoroughly clean all the parts of the
transmission.
Put clean transmission oil on all of the inner
parts.
2) Put lip type oil seal (71) in position on the
case with the spring loaded lip of the inside
seal toward the inside of the transmission
case and with the lip of the outside seal (71)
toward the outside of the transmission case.

35L7ADA38

3) Install bearing cups (70) in position on the

transmission case.

70

D357TM25

4) Install gear(69) and bearing(68) on the

output shaft assembly(51). 68

69

D357TM29

3-46
5) Install seal ring on the piston(60).
Put clean transmission oil on the seal ring.
6) Install piston with seal ring in cylinder.
ö Be extra careful during installation of the
piston.
Broken seal rings can be the result.

35L7ADA37

7) Put spring assembly and retainer(61) in

position in the cylinder.
8) Put the shaft assembly in a press. Push
down on the retainer and install snap ring
(62) with a screwdriver.
9) Install pin and two thrust washes in the
counter shaft of low speed clutch side.
10) Install needle bearing, spacer, needle
bearing gear(67), thrust washer(66) and
bearing(65) and seal ring(64).

35L7ADA35

3-47
11) Put clean transmission oil on each side of
the clutch plates and clutch discs. Install
four 2T clutch plates, three 4T clutch plates,
five clutch discs and one bending plate in
the cylinder with the following procedure.
(1) Install a clutch plate first, that has guide
shape on its outside diameter.
(2) Next, install a clutch disc that has teeth on
its inside diameter.
(3) Follow steps a and b again until all of four
the 2T clutch plates and discs are installed
in the cylinder.
(4) Install a 4T clutch plate, then install a
bending plate. In following procedure,
bending plate shape will be downward.
(5) Finally, install a 4T clutch plate.

12) Use a screwdriver and install snap ring (57)

that check all of them in position in the 35L7ADA36

cylinder.
13) Install a three seal rings on the shaft.
ö Be carefully, do not damage to the seal
rings on the counter shaft.
14) For the other side of the counter shaft
assembly, follow the procedure in steps 5
through 8.
15) Put clean transmission oil on each side of
the clutch plates and clutch discs. Install
four 2T clutch plates, three 4T clutch plates,
five clutch discs and one bending plate in
the cylinder with the following procedure.
(1) First, install a 4T clutch plate.
(2) Install a 4T clutch plate, then install a
bending plate. In following procedure,
bending plate shape will be downward.
(3) Follow steps a and b again until all of four
the 2T clutch plates and discs are installed
in the cylinder.
(4) Next, install a clutch disc that has teeth on
its inside diameter.
(5) Finally, Install a clutch plate first, that has
guide shape on its outside diameter.

3-48
16) Use a screwdriver and install snap ring (57)
that check all of them in position in the
cylinder.
17) Install three seal rings on the shaft.
ö Be careful not to cause damage to the seal
rings.
18) Install thrust washer and needle bearings
on the counter shaft of high speed clutch
side.

35L7ADA39

19) Install gear (56), thrust washes (55) and

bearing cone (54) with tool.
ö Do not use force to install the gear.
Move the gear backward and forward while
the gear is pushed into the clutch assembly
until the teeth on the clutch discs are in
alignment with the splines on the gear.

35L7ADA40

3-49
20) Assemble input shaft assembly with the
same procedure as counter shaft assembly.
21) Install the gear assembly (53) into
transmission case.

53
D357TM15

22) Carefully put the counter shaft assembly 49

(52) in position in the transmission case. 50
23) Carefully put the input shaft assembly (50)
in position in the transmission case.
Install output shaft assembly (51) into
output gear assembly.
Turn the gear until the teeth are in alignment
with gears of another shaft assembly.
24) Use the plastic hammer and install tube
(49) in the transmission case.

51 52
D357TM14

3-50
25) Install screen (48), spring (47) and plug,
(46), O-ring in the transmission case.
26) Install temperature sensor (45) in the
transmission case.
27) Install plug (43) and washer (44) in the
transmission case.

35L7ADA29

28) First, apply to loctite 5172 on the

transmission case then, fixed.
Install valve plate by using a eight bolts and
an five socket bolt

35L7ADA41

29) Install sticks to gasket on the transmission

case and then install two bolt(38), nine
bolt(39) on the control valve.

35L7ADA27

30) Install two thrust washer(34), a needle

bearing(35), gear-P.T.O idle(36) in the 36
34 35 34
bearing plate(21).

35L7ADA26

3-51
31) Install a gear-P.T.O output(25), two ball 29
27 33
bearings on the flange pump(28) by using
the jig then, install four bolts on the bearing 28 32
plate.
Then, charging pump(31) and gasket(30)
on the flange pump by install a bolt(32) and
four bolts(33). Install a 90 degree Elbow.
26 31
30
25
D357TM07

32) Install the stator hub assembly (24) due to

bearing plate assy (21).
- Install bush(22), piston ring, bolt(23)
which assembling by each sixes.
Then install bearing plate.

22
24

23

D357TM06

33) Install plug (11) and O-ring in the bearing

11 12
plate.
14 13
34) Install valve (14), spring (12), plug (13) and 15
O-ring in the bearing plate.
35) Install plug (15) in the bearing plate. 18 16
17
36) Install ball (17), spring (18), plug (16) and
O-ring in the bearing plate.
37) Put bearing cups and their shims in the
bearing plate.
ö Bearing cups and their shims should be put D357TM04
into their location on transmission cover so
as to fit on their shafts in transmission case.

3-52
 38) When new parts are used, required shim
thickness should be calculated as follows .
(1) Assemble shaft assembly (including taper
bearing cone and cup).
(2) Insert shaft assembly into transmission
case.
ö Use depth gage and block gage because
the height of bearing cup is higher than
surface of transmission case.
ÂMethod of the shaft shim measure :
Measure the dimension "depth" from surface
of bearing plate to bottom of bore where
35L7ADA42
bearing cup is installed.
Item Shim thickness
Input shaft Y-X-0.01
Counter shaft Y-X-0.05
Output shaft Y-X-0.05

(3) Select shims to have 0 to 0.05mm (0 to

0.002 inch) of axial tightness.
(4) Assemble transmission case, cover and
gasket.
(5) Set up transmission assembly vertically.
(6) If you reshim input shaft or counter shaft,
turn transmission input shaft by hand. It
should be turned smoothly. If you reshim
output shaft, turn output shaft by hand. It
should be turned smoothly.
D357TM49
(7) If the input shaft or output shaft does not
turn smoothly, remove shims about 0.025 -
0.05mm.
ö Be extra careful during installation of the
cover. Do not tilt the cover during
installation, damage to the seal rings on
the input shaft can be result.

3-53
39) Install torque converter housing in position.
Install four bolts (9) and washes, oil seal 1 3
(10), four bolts (8) that hold torque
converter housing to the transmission.

2
D357TM52

40) Install gear P.T.O input(5) to torque 4

converter, then tighten six socket bolts (6) in
position.
6

D357TM51

41) Install torque converter in position. Install

flexible plate (1) with six bolts (3) and plate
(2).
Then, Install torque converter housing in
position.

35L7ADA43

3-54
 SECTION 4 BRAKE SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-11
 SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
There are two brake systems, the foot brake system and the hand brake system.
In the foot brake system, oil pressure is generated in the master cylinder by treading on the brake
pedal. This pressure causes the wheel cylinder pistons to extend, expanding the brake shoes and
pressing them against the brake drums to attain braking force.
In the hand (parking) brake system, the brake shoes are expanded by operating the brake lever.
Force from the lever is transmitted to the brake shoes through the hand brake cables and a lever
arm in each disk brake assembly.

2. SPECIFICATION
1) DISK BRAKE
Item Specification
Type Wet disk brake
Brake valve step/bore piston diameter 40mm (1.6in) / 30mm (1.2in)
Pedal height 153~157mm (6.02~6.18in)
Pedal adjustment
Play 5~8mm (0.2~0.3in)
Brake oil Azola ZS10 (SAE 10W hydraulic oil)

2) PARKING BRAKE
Item Specification
Type Ratchet, internal expanding mechanical type
Parking lever stroke 82mm(3.2in)
Parking cable stroke 28mm(1.1in)

4-1
3. BRAKE PEDAL AND PIPING
1) STRUCTURE

lve 4
ol va
ntr
co
T/M

Drive axle

35D7EBS03

1 Brake pedal & bracket assembly 3 Reservoir tank assembly

2 Parking lever assembly 4 Brake valve

4-2
4. INCHING PEDAL AND LINKAGE
The brake pedal serves to actuate the hydraulic brakes on the front 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.

ing stroke)
30~34mm(Inch

5~8mm(Idle stroke)

153~157mm(Pedal height)

T/M control valve

Inching spool

20mm(Default)

Inching link assy

Inching cable assy

35L7ABS04

4-3
5. WET DISK BRAKE
1) STRUCTURE

1 2 3 4 5 6 7

35D7ETA10

1 Spindle 4 Service piston 7 Drive shaft

2 Steel plate 5 Service piston adjust bolt 8 Parking brake
3 Disk plate 6 Spline collar

Sealed up structure of hydraulic multi-disk brake system secures good brake performance even in the
high humid or dusty area.
Because it is possible to use the brake semi-permanently, there is no need to replace or change the
lining as drum type brake do. Also with self-adjust of friction plate clearance, it's easy to prevent the
break performance drop due to friction material wear.
Major components are 3 disk plates (3), 4 steel plates (2), service piston (4) and 4 piston adjust bolts (5).
Braking take places when the discs and plates are pressed each other which make rotation resistance to
the collar (6) and the drive shaft (7).

4-4
6. BRAKE VALVE
1) STRUCTURE

27 28

25 26 24 22 23 21 20 13 12 11 9 10 8 7 6 5 14 4 3

2 19 18 17 16 15 1

35D7EBV00

1 Front housing 11 U-cup seal 21 O-ring

2 Rear housing 12 U-cup seal 22 Spring
3 Push rod 13 U-cup seal 23 Gauge
4 Bellows 14 U-cup seal 24 Air bent
5 Master piston 15 Relief piston 25 Plug
6 Lock washer 16 Relief spring 26 O-ring
7 Piston ball 17 Relief plug 27 Bolt
8 Piston ring 18 O-ring 28 Spring washer
9 Servo piston 19 O-ring
10 Servo spring 20 Ball

4-5
2) DISASSEMBLY
(1) Remove push rod (3), bellows (4), air vent 28 27
(24), bolt (27) and washer (28). 3 4

24
35D7EBV01

(2) Remove front housing (1), rear housing

1 5 9
(2), servo spring (10), servo piston (9) and
master piston (5).

10 2 35D7EBV02

(3) Remove relief plug (17) with O-ring (18),

relief spring (16) and relief piston (15).

18
Front housing

15 16 17

35D7EBV03

(4) Remove O-ring (19), check plug (25) with

O-ring (26), cage (23), check spring (22),
25 22 21 19
check ball (20) and O-ring (21).

26 23 20

Rear housing
35D7EBV04

4-6
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 (Azola ZS10) into the compensation reservoirs.

4-7
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
1) BRAKE PIPING
(1) Check pipes, hoses and joints for damage, oil leakage or interference.
(2) Operate brake pedal and check operating force when pedal in depressed. Check also change in
operating force, and change in position of pedal when pedal is kept depressed.
2) PARKING BRAKE
(1) Operating force of parking lever is 35 - 40
kgfÂm(253 - 290lbfÂft).
2 1
(2) Check that parking brake can hold
machine in position when loaded on 20%
slope. If there is no slope available, travel
at low speed and check braking effect of
parking brake.
15L7ATA19

4-8
2. TROUBLESHOOTING
Problem cause Remedy
Insufficient braking force ÂHydraulic system leaks oil. ÂRepair and add oil.
ÂHydraulic system leaks air. ÂBleed air.
ÂDisk worn. ÂReplace.
ÂBrake valve malfunctioning. ÂRepair or replace.
ÂHydraulic system clogged. ÂClean.
Brake acting unevenly. ÂTires unequally inflated. ÂAdjust tire pressure.
(Machine is turned to one ÂBrake out of adjustment. ÂAdjust.
side during braking.) ÂDisk surface roughened. ÂRepair by polishing or replace.
ÂWheel bearing out of adjustment. ÂAdjust or replace.
ÂHydraulic system clogged. ÂClean.
Brake trailing. ÂPedal has no play. ÂAdjust.
ÂPiston cup faulty. ÂReplace.
ÂBrake valve return port clogged. ÂClean.
ÂHydraulic system clogged. ÂClean.
ÂWheel bearing out of adjustment. ÂAdjust or replace.
Brake chirps ÂBrake trailing. ÂSee above. Brake trailing.
ÂPiston fails to return. ÂReplace.
ÂDisk worn. ÂReplace.
ÂDisk surface roughened. ÂRepair by polishing or replace.
Brake squeaks ÂDisk surface roughened. ÂRepair by polishing or replace.
ÂDisk worn. ÂReplace.
ÂExcessively large friction between ÂClean and apply brake grease.
disk plate.
Large pedal stroke ÂBrake out of adjustment. ÂAdjust.
ÂHydraulic line sucking air. ÂBleed air.
ÂOil leaks from hydraulic line, or lack ÂCheck and repair or add oil.
of oil.
ÂDisk worn. ÂReplace.
Pedal dragging. ÂTwisted push rod caused by improp- ÂAdjust.
erly fitted brake valve.
ÂBrake valve seal faulty. ÂReplace.

4-9
GROUP 3 TESTS AND ADJUSTMENTS
1. AIR BLEEDING OF BRAKE SYSTEM
1) Air bleeding should be performed by two
persons :
One rides on truck for depressing and
releasing brake pedal : the other person is
Vinyl tube
on the ground and removes cap from air
Air vent plug
vent plug on wheel cylinder.
2) Block the front wheel securely and apply
parking brake.
3) Start the engine.
4) Attach a vinyl tube to air vent plug and Disk brake
immerse other end of tube into a vessel
filled with hydraulic oil.
5) Loosen air vent plug by turning it 3/4 with a Drive axle
wrench. Depress brake pedal to drain oil
mixed with air bubbles from plug hole. Vessel

6) Depress brake pedal until no air bubbles

come out of air vent plug hole.
7) After completion of air bleeding, securely
tighten air vent plug. Install cap on plug. 35D7EBS071

2. ADJUSTMENT OF PEDAL
5~8mm
1) BRAKE PEDAL (Idle stroke)
(1) Pedal height from floor plate
152~157mm
Adjust with stopper bolt. (Pedal height)
ÂPedal height : 153~157mm(5.98~6.18in)
(2) Idle stroke
Adjust with rod of brake valve
ÂPlay : 5~8mm(0.2 ~ 0.31in)
35L7ABS05

4-10
 (3) Micro switch for parking brake (if equipped)
23
Η After assembling parking brake and
parking cable, put the parking brake lever 82
P/lever stroke
released. Knob
Θ Loosen the nut for parking brake plate to

Parking cable
stroke 28mm
play up and down.
Ι Move up the plate so that the stopper can
be contacted with the pin and then
reassemble nut. Parking
ÂMicro switch stroke when parking switch

brake is applied : 2~3mm(0.08 ~ 0.1in) Pin

Nut
Parking cable
35D7EBS06

2) INCHING PEDAL
30~34mm
(1) Pedal height from floor plate (Inching stroke
)
Adjust with stopper bolt.
ÂPedal height : 153~157mm(5.98~6.18in) 153~157mm
(Pedal height)
(2) Adjust bolt so that brake pedal interconn-
ects with inching pedal at inching pedal
stroke 30~34mm(1.2~1.3in).

35L7ABS07

4-11
 SECTION 5 STEERING SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
 SECTION 5 STEERING SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE

Steering wheel

Steering cylinder

Steering unit Steering axle

Priority valve
T
L
P
R

Hyd
pump

Hydraulic tank

35DS7SE01

The steering system for this machine is composed of steering wheel assembly, steering unit, priority
valve 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.

5-1
2. HYDRAULIC CIRCUIT

L R
3

T LS P
MCV

4 LS CF EF

12.5MPa

Brake
valve
T/M

9 14

35DS7SE02

1 Hydraulic gear pump 6 Steering cylinder

3 Steering unit 9 Suction filter
4 Priority valve 14 Hydraulic tank

5-2
 1) NEUTRAL

L R
3

G
P

T LS P
MCV

4 LS CF EF

12.5MPa
D
T

Brake
valve
T/M

9 14

35DS7SE03

The steering wheel is not being operated, so control spool(G) does not move.
The oil from hydraulic gear pump(1) enters the port P of priority valve(4) and the inlet pressure oil moves
the spool(D) to the left.
Oil flow into LS port to the hydraulic tank(14).
So, the pump flow is routed to the main control valve.

5-3
 2) LEFT TURN

3 L R

T LS P
MCV

4 LS CF EF

12.5MPa
D
T

Brake
valve
T/M
1

9 14

35DS7SE04

When the steering wheel is turned to the left, the spool(G) within the steering unit(3) connected with
steering column turns in left hand direction.
At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through
the spool(D) of priority valve(4) and flows the gerotor(H).
Oil flow from the gerotor(H) flows back into the spool(G) where it is directed out the left work port(L).
Oil returned from cylinder returns to hydraulic tank(14).
When the above operation is completed, the machine turns to the left.

5-4
 3) RIGHT TURN

L R
3

T LS P
MCV

4 LS CF EF

12.5MPa
D
T

Brake
valve
T/M

9 14

35DS7SE05

When the steering wheel is turned to the right, the spool(G) within the steering unit(3) connected with
steering column turns in right hand direction.
At this time, the oil discharged from the pump flows into the spool(G) within the steering unit(3) through
the spool(D) of priority valve(4) and flows the gerotor(H).
Oil flow from the gerotor(H) flows back into the spool(G) where it is directed out the right work port(R).
Oil returned from cylinder returns to hydraulic tank(14).
When the above operation is completed, the machine turns to the right.

5-5
3. STEERING UNIT
1) STRUCTURE

1
2
18
11

3
14
25-3 4
25-2 14

25-4 5 22
25-1 15
6
23
21

24
8
16
10 24
7
10

19

13
20

17
9
12
20D7SS06

1 Dust seal 11 O-ring 21 Housing

2 Retaining ring 12 Rolled screw 22 Spool
3 Cap seal 13 Gerotor set 23 Sleeve
4 Thrust bearing 14 Bearing race 24 Plate spring
5 Ball 15 Bore screw 25 P-port check valve
6 Pin 16 Drive 25-1 Plug
7 Spacer 17 End cap 25-2 Poppet
8 Center spring 18 Gland bushing 25-3 Spring seat
9 Washer 19 Plate 25-4 Spring
10 O-ring 20 Cap screw

5-6
2) OPERATION
The steering unit is composed of the control valve(rotary valve) and the metering device. The control
valve controls the flow of oil from the pump in the interior of the unit depending on the condition of the
steering wheel. The metering device is a kind of hydraulic motor composed of a stator and a rotor. It
meters the required oil volume, feeds the metered oil to the power cylinder and detects cylinder’s
motion value, that is, cylinder’s motion rate.
When the steering wheel is turned, the spool turns, the oil path is switched and the oil is fed into the
metering device. As a result, the rotor is caused to run by oil pressure, and the sleeve is caused to run
through the drive shaft and cross pin. Therefore, when the spool is turned, the spool turns by the
same value in such a manner that it follows the motion of the spool. Steering motion can be
accomplished when this operation is performed in a continuous state.
If the hoses of the steering system are incorrectly connected, the steering wheel can turn very
rapidly when the engine is started. Keep clear of the steering wheel when starting the engine.
The centering spring for the spool and sleeve is provided to cause the valve to return to the neutral
position. It is therefore possible to obtain a constant steering feeling, which is transmitted to the hands
of the driver. Return to the center position occurs when the steering wheel is released.

5-7
 4. STEERING AXLE
1) STRUCTURE
ö Do not remove the stopper bolt unless necessary.

1-22

1-29 1-26
1-25
1-6 1-24
1-35 1-30
1-7 1-10
1-31
1-38 1-26
1-27
1-5 1-32
1-28 1-23
1-12 1-25 1-27
1-13 1-28
1-3
1-11
1-10 1-21
1-4
1-2 1-33 1-14

1-1
1-9 1-34 1-15
1-8 1-44 1-16
1-11 1-35
1-43
1-12 4
1-5
1-19 1-36
1-40 1-37
1-41
1-42 1-17
1-18
1-39
1-35 1-34 1-20
1-7
1-6

1-33 1-44
1-43
1-35 3
2

35DS7SE06

1-1 Steering axle 1-12 Dust seal 1-23 Link-LH 1-34 Bushing
1-2 Knuckle-RH 1-13 Snap ring 1-24 SPH plain bearing 1-35 Grease nipple
1-3 Knuckle-LH 1-14 Hub 1-25 Thrust washer 1-36 Hexagon bolt
1-4 King pin 1-15 Oil seal 1-26 Clevis pin 1-37 Spring washer
1-5 Taper roller bearing 1-16 Taper roller bearing 1-27 Plain washer 1-38 Upper cover
1-6 Hexagon bolt 1-17 Taper roller bearing 1-28 Split pin 1-39 Lower cover
1-7 Spring washer 1-18 Slotted nut 1-29 Steering cylinder 1-40 Shim(0.1t)
1-8 Special bolt 1-19 Split pin 1-30 Pin 1-41 Shim(0.15t)
1-9 Spring washer 1-20 Hub cap 1-31 Lock plate 1-42 Shim(0.3t)
1-10 Grease nipple 1-21 Serration bolt 1-32 Hexagon bolt 1-43 Snap ring
1-11 Collar 1-22 Link-RH 1-33 Support 1-44 Shim

5-8
2) GREASING AND SPECIFICATION

74
.8

Stroke 91.5mm(3.6in) Stroke 91.5mm(3.6in)

.8
53

35kgf. m(253lb.ft)

Apply loctite #277.

16.7~22.5kgf.m(121~163lb.ft)

35DS7SE07

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(Inside/Outside) degree 74.8/53.8
Tread mm(in) 1140(45)

5-9
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
Check item Checking procedure

Steering wheel  Set rear wheels facing straight forward, then turn steering wheel to left and right.
30-60mm Measure range of steering wheel movement before rear wheel starts to move.
(1.2-2.4 in)
Range should be 30~60mm at rin 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 0Ü0.5ä; rear axle is bent.
 Ask assistant to drive machine at minimum turning radius.
 Fit bar and a piece of chalk at outside edge of counterweight to mark line of
turning radius.
 If minimum turning radius is not withinÜ100mm (Ü4in)of specified value, adjust
turning angle stopper bolt.
Min turning radius(Outside)
35L-7A 2770mm(109in)
40L-7A 2830mm(111in)
45L-7A 2890mm(114in)
50L-7A 2950mm(116in)

Hydraulic pressure of power Remove screw coupling from CF port of priority valve and install oil pressure gauge.
steering Turn steering wheel fully and check oil pressure.
ö Oil pressure : 125kgf/cm2 (1780psi)

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

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

5-11
GROUP 3 DISASSEMBLY AND ASSEMBLY
1. STEERING UNIT
1) STRUCTURE

1
2
18
11

3
14
25-3 4
25-2 14

25-4 5 22
25-1 15
6
23
21

24
8
16
10 24
7
10

19

13
20

17
9
12
20D7SS06

1 Dust seal 11 O-ring 21 Housing

2 Retaining ring 12 Rolled screw 22 Spool
3 Cap seal 13 Gerotor set 23 Sleeve
4 Thrust bearing 14 Bearing race 24 Plate spring
5 Ball 15 Bore screw 25 P-port check valve
6 Pin 16 Drive 25-1 Plug
7 Spacer 17 End cap 25-2 Poppet
8 Center spring 18 Gland bushing 25-3 Spring seat
9 Washer 19 Plate 25-4 Spring
10 O-ring 20 Cap screw

5-12
2) TOOLS
(1) Holding tool.

5-69(1)

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

5-69(2)

(3) Assembly tool for lip seal.

5-69(3)

(4) Assembly tool for cardan shaft.

5-69(4)

5-13
(5) Assembly tool for dust seal.

5-70(1)

(6) Torque wrench 0~7.1kgfÂm

(0~54.4lbfÂft)
13mm socket spanner
6, 8mm and 12mm hexagon sockets
12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon socket spanners
Plastic hammer
Tweezers 5-70(2)

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

D353SE23

Port Size Torque [kgfÂm(lbfÂft)]

L 3/4 - 16UNF 6.1Ü0.6 (44Ü4.3)
R 3/4 - 16UNF 6.1Ü0.6 (44Ü4.3)
T 3/4 - 16UNF 6.1Ü0.6 (44Ü4.3)
P 3/4 - 16UNF 6.1Ü0.6 (44Ü4.3)
Mounting bolt M10Ý1.5 4.0 Ü0.5 (29Ü3.6)

5-14
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).

5-72(1)

(2) Remove the end cover, sideways.

5-72(2)

(3) Lift the gearwheel set(With spacer if fitted)

off the unit.
Take out the two O-rings.

5-72(3)

(4) Remove cardan shaft.

5-72(4)

5-15
(5) Remove distributor plate.

5-73(1)

(6) Screw out the threaded bush over the

check valve.

5-73(2)

(7) Remove O-ring.

5-73(3)

(8) Shake out the check valve ball and suction

valve pins and balls.

D353SE09

5-16
(9) Take care to keep the cross pin in the
sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and thrust
bearing will be pushed out of the housing
together.

5-73(4)

(10) Take ring, bearing races and thrust

bearing from sleeve and spool. The outer
(Thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.

5-74(1)

(11) Press out the cross pin. Use the special

screw from the end cover.

5-74(2)

ö A small mark has been made with a

pumice stone on both spool and sleeve
close to one of the slots for the neutral
position springs(See drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.

5-74(3)

5-17
(12) Carefully press the spool out of the sleeve.

5-74(4)

(13) Press the neutral position springs out of

their slots in the spool.

5-75(1)

(14) Remove dust seal and O-ring.

5-75(2)

Disassembling the pressure relief valve

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

D353SE10

5-18
(16) Unscrew the setting screw using an 8mm
hexagon socket spanner.

D353SE11

(17) Shake out spring and piston. The valve

seat is bonded into the housing and
cannot be removed.

D353SE12

(18) The pressure relief valve is now

disassembled.

D353SE13

5-19
5) ASSEMBLY
(1) Assemble spool and sleeve.
ö When assembling spool and sleeve only
one of two possible ways of positioning
the spring slots is correct. There are three
slots in the spool and three holes in the
sleeve in the end of the spool / sleeve
opposite to the end with spring slots.
Place the slots and holes opposite each 5-76(1)

other so that parts of the holes in the

sleeve are visible through the slots in the
spool.

(2) Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place (see
assembly pattern).

5-76(2)

(3) Line up the spring set.

5-76(4)

(4) Guide the spool into the sleeve. Make

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

5-77(1)

5-20
(5) Press the springs together and push the
neutral position springs into place in the
sleeve.

5-77(2)

(6) Line up the springs and center them.

5-77(3)

(7) Guide the ring down over the sleeve.

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

5-77(4)

(8) Fit the cross pin into the spool / sleeve.

5-78(1)

5-21
(9) Fit bearing races and needle bearing as
shown on below drawing.

5-78(2)

ö Assembly pattern for standard bearings

1
1 Outer bearing race 2
2 Thrust bearing 3
3 Inner bearing race
4 Spool
5 Sleeve 4

5
5-78(3)

Installation instruction for O-ring

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

5-78(4)

5-22
(11) Grease O-ring with hydraulic oil and place
them on the tool.

5-79(1)

5-79(2)

(12) Hold the outer part of the assembly tool in

the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.

5-79(3)

(13) Press and turn the O-ring into position in

the housing.

5-79(4)

5-23
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.

5-80(1)

Installation instructions for lip seal

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

5-80(2)

5-80(3)

(16) Guide the assembly tool right to the

bottom.

5-80(4)

5-24
(17) Press and turn the lip seal into place in the
housing.

5-81(1)

(18) With a light turning movement, guide the

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

5-81(2)

(19) The spool set will push out the assembly

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

5-81(3)

(20) Turn the steering unit until the bore is

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

5-81(4)

5-25
(21) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.

5-82(1)

(22) Grease the O-ring with mineral oil approx.

viscosity 500 cSt at 20ä
C.

5-82(2)

(23) Place the distributor plate so that the

channel holes match the holes in the
housing.

5-82(3)

(24) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.

5-82(4)

5-26
(25) Place the cardan shaft as shown - so that
it is held in position by the mounting fork.

5-83(1)

(26) Grease the two O-rings with mineral oil

approx. viscosity 500 cSt at 20ä C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.

5-83(2)

(27) Important
Fit the gearwheel(Rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.

5-83(3)

(28) Fit the spacer, if any.

5-83(4)

5-27
(29) Place the end cover in position.

5-84(1)

(30) Fit the special screw with washer and

place it in the hole shown.

5-84(2)

(31) Fit the six screws with washers and insert

them. Cross-tighten all the screws and
the rolled pin.
ÂTightening torque : 4.0 Ü 0.5kgfÂm
(28.9 Ü 3.6lbfÂft)

5-84(3)

(32) Place the dust seal ring in the housing.

5-84(4)

5-28
(33) Fit the dust seal ring in the housing.

5-85(1)

(34) Press the plastic plugs into the connection

ports.
ö Do not use a hammer!

5-85(2)

5-29
2. STEERING CYLINDER
1) STRUCTURE

6
12
11
13
14

7 1
8
9
10

15
2

3
4

10
9
8
7
5

14
13
11 ö Specifications
12 ÂCylinder bore : 80mm
6 ÂOuter diameter : 94mm
ÂStroke(half) : 180mm
ÂRod diameter : 55mm
D357SE21

1 Tube assy 6 DU bushing 11 O-ring

2 Rod assy 7 Rod seal 12 Back up ring
3 Piston seal 8 Back up ring 13 O-ring
4 Wear ring 9 Dust wiper 14 Lock washer
5 Gland 10 Snap ring 15 O-ring

5-30
2) DISASSEMBLY
ö Before disassembling steering cylinder, release oil in the cylinder first.
(1) Put wooden blocks against the cylinder tube, then hold in & vice.
(2) Remove the cover by hook a wrench in the notch of cylinder head and turn counter-clockwise.
(3) Remove the cylinder rod and piston from the tube.
(4) Check wear condition of the sealing parts(O-ring, oil seal, dust seal, U-packing, bush). If there
are some damage, replace with new parts.
3) CHECK AND INSPECTION mm(in)
Criteria
Check item Remarks
Standard size Repair limit
Clearance between piston 0.05~0.25 0.4 Replace piston seal
& cylinder tube (0.002~0.01) (0.02)
Clearance between 0.05~0.18 0.3
Replace bushing
cylinder rod & bushing (0.002~0.007) (0.01)
Seals, O-ring Damage Replace
Cylinder rod Dents Replace
Cylinder tube Biting Replace

4) ASSEMBLY
(1) Install a new piston seal around the groove on the
piston.
ö Be careful not to scratch the seal too much during
installation or it could not be seated properly.

D353SE27

(2) Install the rod seal to the position in the gland

applying a slight coat with grease prior to install.

D353SE28

5-31
(3) Install the dust wiper to the gland using a special
installing tool. Coat the dust wiper with grease
slightly before installing.
(4) Using a special tool, install gland assembly into
the cylinder tube.

D353SE29

(5) Using a hook spanner, install the gland ass-

embly, and tighten it with torque 60Ü6kgfÂm
(434Ü43lbfÂft).

D353SE30

(6) After the gland assembly was installed to the

cylinder tube, calk at the tube end into the groove
on the gland to prevent screw loosening.
ö If it is needed to calk again, never calk on the
same place.

D353SE31

(7) Move the piston rod back and forth several times for the full distance of its stroke. This helps to
seat the ring and seals before applying full hydraulic pressure to the cylinder.
(8) Install cylinder into trail axle.
(9) While idling the engine with the rear wheels off the ground, operate the steering wheel left and
right alternately.
ö Then, repeat the above operation at gradually increasing engine rpm. This releases air from the
system and completes preparation for operation.
(10) Stop the engine, lower the floating rear wheels, and check pump joints for oil leaks and looseness
and retighten, them as required.

5-32
 3. STEERING AXLE
1) STRUCTURE
ö Do not remove the stopper bolt unless necessary.

1-22

1-29 1-26
1-25
1-6 1-24
1-35 1-30
1-7 1-10
1-31
1-38 1-26
1-27
1-5 1-32
1-28 1-23
1-12 1-25 1-27
1-13 1-28
1-3
1-11
1-10 1-21
1-4
1-2 1-33 1-14

1-1
1-9 1-34 1-15
1-8 1-44 1-16
1-11 1-35
1-43
1-12 4
1-5
1-19 1-36
1-40 1-37
1-41
1-42 1-17
1-18
1-39
1-35 1-34 1-20
1-7
1-6

1-33 1-44
1-43
1-35 3
2

35DS7SE06

1-1 Steering axle 1-12 Dust seal 1-23 Link-LH 1-34 Bushing
1-2 Knuckle-RH 1-13 Snap ring 1-24 SPH plain bearing 1-35 Grease nipple
1-3 Knuckle-LH 1-14 Hub 1-25 Thrust washer 1-36 Hexagon bolt
1-4 King pin 1-15 Oil seal 1-26 Clevis pin 1-37 Spring washer
1-5 Taper roller bearing 1-16 Taper roller bearing 1-27 Plain washer 1-38 Upper cover
1-6 Hexagon bolt 1-17 Taper roller bearing 1-28 Split pin 1-39 Lower cover
1-7 Spring washer 1-18 Slotted nut 1-29 Steering cylinder 1-40 Shim(0.1t)
1-8 Special bolt 1-19 Split pin 1-30 Pin 1-41 Shim(0.15t)
1-9 Spring washer 1-20 Hub cap 1-31 Lock plate 1-42 Shim(0.3t)
1-10 Grease nipple 1-21 Serration bolt 1-32 Hexagon bolt 1-43 Snap ring
1-11 Collar 1-22 Link-RH 1-33 Support 1-44 Shim

5-33
 2) CHECK AND INSPECTION

D1 C A1,A2 B

D2

35DS7SE08

unit : mm(in)
Criteria
No. Check item Remarks
Standard size Repair limit
A1 OD of shaft 55(2.2) 54.5(2.1)
A 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)
D1 OD of pin 20(0.8) 19.5(0.8)
D Knuckle
D2 Vertical play - - Adjust with shims

ÂOD : Outer diameter

ÂID : Inner diameter

5-34
3) DISASSEMBLY
ö Servicing work on the knuckle part can be carried
out without removing the axle assy from chassis.
The work can be done by jacking up the counter
weight part of the truck. Hub
Hub nut
nut
(1) Loosen the hub nut and take off the steering
wheel tire.

D353SE24

(2) Remove Hub cap.

(3) Pull out split pin and remove lock nut.
Hub cap
(4) Using the puller, take off the hub together with
Spilt pin
the roller bearing. Lock nut
ö Be very careful because just before the hub
comes off, tapered roller bearing will fall out.
(5) After hub is removed, take off the inner race of
roller bearing.
(6) Pull out oil seal. Knuckle
ö Don't use same oil seal twice. Oil seal
Roller bearing
(7) Repeat the same procedure for the other side. Hub
Moreover, when disassembling is completed, Roller bearing
part the lock nut in the knuckle to protect the
threaded portion.
35DS7SE09

(8) Loosen special bolt(1-8) and spring washer(1-9).

(9) Remove hexagon bolt(1-6) and upper cover(1- 1-5

38). 1-6
1-7
(10) Push out the king pin(1-4) without damaging the 1-38
knuckle arm(1-2). 1-2 1-26
1-4
(11) If defect is observed in taper roller bearing(1-5),
1-9
pull it out by using extractor. 1-8

(12) Remove spilt pin(1-28), plain washer(1-27) and

clevis pin(1-26). 1-27
1-28

1-5

35DS7SE10

5-35
4) ASSEMBLY
ö 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.
1-6
Perform the disassembly in reverse order. 1-7
1-38
(1) Tighten the special bolt(1-8) and washer(1-9) of
1-4
king pin(1-3).
(2) There is a notch in the middle of the king pin(1- 1-5
4), make sure that this notch is on the special
bolt side.
(3) Do not hammer to drive in taper roller bearing(1- 1-9
1-3
5) because it will break. 1-8

Always use drive-in tool.

Be sure that the fixed ring of the bearing is 1-5
placed in position facing the knuckle(1-3).
(4) Hub
Η Mount oil seal(1-15) and inner race of taper
roller bearing(1-16) on the knuckle. The 1-21 1-14
bearing should be well greased before
assembling.
Θ Install the outer race of the taper roller 1-15
1-16 4
bearing(1-17) in the wheel center and assemble
1-36
to the knuckle. 1-37
Ι Tighten nut(1-18) and lock with split pin(1-19). In 1-17
locking with split pin, locate the hole for the split 1-18 1-19
pin by turning the nut back 1/6 of a turn. 1-20

Adjust the preload of bearing.

Κ Mount the hub cap(1-20) and tighten with bolt
(1-36).
Bearing should be well greased before assem- 35DS7SE11

bling.

5-36
 SECTION 6 HYDRAULIC SYSTEM

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

Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-17
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22
 SECTION 6 HYDRAULIC SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. HYDRAULIC CIRCUIT

6
8 7
3 L R

11 12

2 B1 A2 B2 A3 B3 A4 B4

X
X

X
X
T LS P

P T

X
4 LS CF EF
R

1
T/M

TO BRAKE
10
9
13

35L7AHS01

1 Hydraulic gear pump 8 Lift cylinder

2 Main control valve 9 Suction filter
3 Steering unit 10 Return filter
4 Priority valve 11 Down safety valve
5 Brake valve 12 Down control valve
6 Steering cylinder 13 Hydraulic oil tank
7 Tilt cylinder

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

8 7

11 12

2 B1 A2 B2 A3 B3 A4 B4

X
X

X
X
P T
Steering syetem
Lift

X
Load check valve
4 LS CF EF

Steering return line

G

Brake syetem

1
Brake return line T/M

10
9
13

35DS7HS02

When the lift control lever is pulled back, the spool on the first block is moves to lift position.
The oil from hydraulic gear pump(1) flows into main control valve(2) through the priority valve(4) and
then goes to the large chamber of lift cylinder(8) by pushing the load check valve of the spool.
The oil from the small chamber of lift cylinder(8) returns to hydraulic oil tank(13) at the same time.
When this happens, the forks go up.

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

8 7

11 12

2 B1 A2 B2 A3 B3 A4 B4

X
X

X
X
Lower

P T
Steering syetem

X
4 LS CF EF

Steering return line

G

Brake syetem

1
Brake return line T/M

10
9
13

35DS7HS03

When the lift control is pushed forward, the spool on the first block is moved to lower position.
The work port(B1) and the small chamber and the large chamber are connected to the return
passage, so the lift will be lowered due to its own weight.

6-3
3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION

8 7

11 12

2 B1 A2 B2 A3 B3 A4 B4

X
X

X
X
P T
Steering syetem

X
4 LS CF EF

Steering return line

G

Brake syetem

1
Brake return line T/M

10
9
13

35DS7HS04

When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward
position.
The oil from hydraulic gear pump(1) flows into main control valve(2) through the priority valve(4) and
then goes to the large chamber of tilt cylinder(7) by pushing the load check valve of the spool.
The oil at the small chamber of tilt cylinder(7) returns to hydraulic tank(13) at the same time.
When this happens, the mast tilt forward.

6-4
4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION

8 7

11 12

2 B1 A2 B2 A3 B3 A4 B4

X
X

X
X
P T
Steering syetem
Tilt

X
backward

Load check valve

4 LS CF EF

Steering return line

G

Brake syetem

1
Brake return line T/M

10
9
13

35DS7HS05

When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward
position.
The oil from hydraulic gear pump(1) flows into main control valve(2) through the priority valve(4) and
then goes to the small chamber of tilt cylinder(7) by pushing the load check valve of spool.
The oil at the large chamber of tilt cylinder(7) returns to hydraulic tank(13) at the same time.
When this happens, the mast tilt backward.

6-5
2. HYDRAULIC GEAR PUMP
1) STRUCTURE

14

9
11
12
1

10
5 15
17
14 16
18 4

19
11
12

14 8
3

9
13

35L7AHS06

1 Cover 8 Connecting shaft 15 Stud bolt

2 Gear housing 9 Thrust plate 16 Washer
3 Bearing carrier 10 Lip seal 17 Hex nut
4 Gear housing 11 Rubber seal 18 Name plate
5 Cover 12 Back up seal 19 Screw
6 Shaft gear set 13 Square seal
7 Drive gear set 14 Dowel pin

6-6
 3. MAIN CONTROL VALVE
1) STRUCTURE (2 Spool)

Port name Size

Inlet port 1-5/16-12UN-2B

Outlet port 1-5/16-12UN-2B
Gauge port PF1/4
D 3 Work port 1-1/16-12UN-2B

6 4
Inlet port
14
3 15
D

B B

5 SECTION B - B
1

23 22 31
Outlet port 3 Work ports
28
25 29
20
32
27
30 21
Gauge port

A
A

7 12

13

2
19
18
17
VIEW D - D 33
16 8 9 10 11
SECTION A - A 35DS7HS07

1 Special nut 12 Outlet section assy 23 Spool end

2 Main relief valve 13 O-ring 25 Spring seat
3 Aux relief valve 14 Poppet 27 Spring
4 Tie rod 15 Spring 28 Spring
5 Tie rod 16 Screw 29 Piston
6 Special nut 17 Seal plate 30 Spool end
7 Inlet section assy 18 Wiper 31 Spool end
8 Spool section-lift 19 Spool seal 32 Spool cap
9 Spool section-tilt 20 Spool cap 33 Solenoid valve
10 Spool section-A1 21 Screw cap
11 Spool section-A2 22 Screw cap

6-7
2) LIFT SECTION OPERATION
(1) Lift position

D353HS08

When the lift control lever is pulled back, the spool moves to the right and the neutral passage is
closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into lift cylinder port(B1).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off
of the neutral passage.
The return oil from cylinder flows into the tank.

6-8
(2) Lower position

D353HS09

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 (B1)ĄT.
In lift lower position the fork drops due to its own weight.

6-9
3) TILT SECTION OPERATION
(1) Tilt forward position

D353HS10

When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is
closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into tilt cylinder port(A2).
The pump pressure reaches proportionally the load of cylinders and fine control finished by closing
the neutral passage.
The return oil from cylinder port(B2) flows into the tank through the hole of the tilt lock spool.

6-10
(2) Tilt backward position

D353HS11

When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is
closed.
The oil supplied from the pump pushes up the load check valve(1) and flows into tilt cylinder
port(B2). The pump pressure reaches proportionally the load of cylinder and fine control finished by
shut off of the neutral passage.
The return oil from cylinder port(A2) flows into the tank via the low pressure passage.

6-11
4) MAIN RELIEF VALVE
(1) Pressure setting
A good pressure gauge must be installed in
the line which is in communication with the
work port relief. A load must be applied in a
manner to reach the set pressure of the relief
unit.
Procedure
Η Loosen lock nut.
Θ Set adjusting nut to desired pressure
setting.
Ι If desired pressure setting cannot be
achieved, add or remove shims as required.
Κ Tighten lock nut.
Λ Retest in similar manner as above.
35DS7HS10

(2) Function
Η As work port relief
The relief valve is in communication
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the
differential area between diameters A
and B relief valve poppet D and check
valve poppet K are tightly seated as
shown. D353HS18

The oil pressure in the high pressure port

HP has reached the setting of the pilot
poppet spring force and unseats the pilot
poppet E and oil flows around the poppet
through the cross drilled holes and to the
low pressure area LP.

D353HS19

6-12
 The loss of oil behind poppet C, effected
by the opening of pilot poppet E, causes
poppet C to move back and seat against
pilot puppet E. This shuts off the oil flow
to the area behind relief valve poppet D,
and causes a low pressure area
internally.

D353HS20

The imbalance of pressure on the inside

as compared to that of the high pressure
port HP, forces the relief valve poppet D
to open and relieve the oil directly to the
low pressure chamber LP in the valve.

D353HS21

Θ As anti void

The anti-void unit supplies oil to the high

K G
pressure port HP when cavitation has
occurred. A lower pressure exists in the A
port HP compared to the low pressure
chamber LP. The difference between the HP
effective area of diameter A and G
causes imbalance of the check valve
LP

poppet K which unseats, thus allowing oil

from the low pressure chamber LP to 7406S6-28(1)
enter the port HP and fill the void.

6-13
4. LIFT CYLINDER

9 10 8 14 13 12 11 2 1 15 16 7 6 4, 5 3

D357HS12

1 Tube assy 7 Retaining ring 13 DU busing

2 Rod 8 Gland 14 O-ring
3 Piston 9 Dust wiper 15 Spacer
4 Piston seal 10 Rod seal 16 O-ring
5 Back up ring 11 O-ring
6 Wear ring 12 Guide

5. TILT CYLINDER

18 19 20, 21, 22 7, 8 3 11 12 5, 6 4 9, 10 2 1 13 16 14 15 17

23

D357HS13
1 Tube assy 9 O-ring 17 Nylon nut
2 Rod 10 Back up ring 18 Rod eye
3 Gland 11 Lock washer 19 DU bushing
4 DU bushing 12 O-ring 20 Hexagon bolt
5 Rod seal 13 Piston 21 Hexagon nut
6 Back up ring 14 Piston seal 22 Spring washer
7 Dust wiper 15 Wear ring 23 O-ring
8 Snap ring 16 O-ring

6-14
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS
1) CHECK ITEM

Within 100mm(3.9in)
(1) Check visually for deformation, cracks or
damage of rod.

(after 10min)
(2) Load maximum load, 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). 35L7AHS11
ÂH Hydraulic drift
- Down(Downward movement of forks)
: Within 100mm(3.9in)
Within 5
- Forward(Extension of tilt cylinder) (after 10min)
: Within 5Á
If the hydraulic drift is more than the
specified value, replace the control valve
or cylinder packing.
(3) Check that clearance between tilt cylinder
bushing and mounting pin is within
standard range. mm (in)
35L7AHS12
Standard Under 0.6 (0.02)

2) HYDRAULIC OIL
(1) Using dipstick, measure oil level, and oil if Hot Filter Dipstick
necessary. Normal
Cold
(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
1200 hours) 35D7EHS18

3) CONTROL VALVE
(1) Raise forks to maximum height and
measure oil pressure.
Check that oil pressure is 210kgf/cm2.
(2990psi)

6-15
2. TROUBLESHOOTING
1) SYSTEM
Problem Cause Remedy
Large fork lowering speed. ÂSeal inside control valve defective. ÂReplace spool or valve body.
ÂOil leaks from joint or hose. ÂReplace.
ÂSeal inside cylinder defective. ÂReplace packing.
Large spontaneous tilt of ÂTilting backward : Check valve defec- ÂClean or replace.
mast. tive.
ÂTilting forward : tilt lock valve defect- ÂClean or replace.
ive.
ÂOil leaks from joint or hose. ÂReplace.
ÂSeal inside cylinder defective. ÂReplace seal.
Slow fork lifting or slow mast ÂLack of hydraulic oil. ÂAdd oil.
tilting. ÂHydraulic oil mixed with air. ÂBleed air.
ÂOil leaks from joint or hose. ÂReplace.
ÂExcessive restriction of oil flow on ÂClean filter.
pump suction side.
ÂRelief valve fails to keep specified ÂAdjust relief valve.
pressure.
ÂPoor sealing inside cylinder. ÂReplace packing.
ÂHigh hydraulic oil viscosity. ÂChange to SAE10W, class CD engine
oil.
ÂMast fails to move smoothly. ÂAdjust roll to rail clearance.
ÂOil leaks from lift control valve spool. ÂReplace spool or valve body.
ÂOil leaks from tilt control valve spool. ÂReplace spool or valve body.
Hydraulic system makes ÂExcessive restriction of oil flow pump ÂClean filter.
abnormal sounds. suction side.
ÂGear or bearing in hydraulic pump ÂReplace gear or bearing.
defective.
Control valve lever is locked ÂForeign matter jammed between sp- ÂClean.
ool and valve body.
ÂValve body defective. ÂTighten body mounting bolts uniform-
ly.
High oil temperature. ÂLack of hydraulic oil. ÂAdd oil.
ÂHigh oil viscosity. ÂChange to SAE10W, class CD engine
oil.
ÂOil filter clogged. ÂClean filter.

6-16
 Problem Cause Remedy
Actuator(cylinder or motor) Â Shortage of oil in oil tank. Â Check the oil level in the oil tank.
works slowly or does not  Decrease of relief valve pressure.  Install pressure gauge on the circuit,
operate. and check the pressure with it by
handling the lever.
 Spool got stuck.  Check that manual lever moves
smoothly.
 Check that lever stroke is enough.
 Shortage of oil flow to the valve.  Check that oil flow of the pump is
within specified rate.
Cylinder lowers considerably  Internal leakage of cylinder happens  Fit the stop valve on the pipe
under normal circumstance. frequently. between valve and cylinder, observe
the internal leakage of cylinder.
 Excessive leakage from spool of the  Check the oil viscosity is not too low.
valve.
 Spool got stuck.  Check that manual lever moves
smoothly.
 Leakage in a part of the circuit.  Check the circuit.
 Observe leakage from pipes.
Pressure does not increase  Defect of relief valve.  Check the relief valve.
sufficiently. Â Leakage in a part of the circuit. Â Check the circuit.
 Observe leakage from pipes.
Temperature rising of the  Working with higher pressure than  Check the flow pressure.
hydraulic oil. rated pressure.
 Low viscosity of oil.  Check the sort of oil and viscosity.
 Leakage from a part of the circuit.  Check if the circuit is relieved at all
times.
 Oil leakage in the pump.  Check if the temperature of pump
surface higher 30ÁC than oil tempera-
ture.
 Insufficient suction of the pump.  Check the oil tank volume.
 Check if the suction strainer is
blocked.
Steering force is heavy. ÂDefect of steering relief valve. ÂCheck the steering relief valve.

6-17
 2) HYDRAULIC GEAR PUMP

Problem Cause Remedy

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

3) MAIN RELIEF VALVE

Problem Cause Remedy

Can’t get pressure ÂPoppet D, E or K stuck open or ÂCheck for foreign matter between
contamination under seat. poppets D, E or K and their mating
parts. Parts must slide freely.
Erratic pressure ÂPilot poppet seat damaged. ÂReplace the relief valve.
ÂPoppet C sticking in D. ÂClean and remove surface
marks for free movement.
Pressure setting not correct ÂNormal wear. Lock nut & adjust ÂSee øHow to set pressure on work
screw loose. main relief.
Leaks ÂDamaged seats. ÂReplace the relief valve.
ÂWorn O-rings. ÂInstall seal and spring kit.
ÂParts sticking due to contamination. ÂDisassemble and clean.
ø A good pressure gauge must be installed in the line which is in communication with the main relief. A
load must be applied in a manner to reach the set pressure of the main relief unit.
Then, follow these steps:
 Loosen lock nut.
 Set adjusting nut to desired pressure setting.
 If desired pressure setting cannot be achieved, add or remove shims as required.
 Tighten lock nut.
 Retest in similar manner as above.

6-18
 4) LIFT CYLINDER

Problem Cause Remedy

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

6-19
GROUP 3 DISASSEMBLY AND ASSEMBLY
1. MAIN PUMP
1) STRUCTURE

14

9
11
12
1

10
5 15
17
14 16
18 4

19
11
12

14 8
3

9
13

35L7AHS06

1 Cover 8 Connecting shaft 15 Stud bolt

2 Gear housing 9 Thrust plate 16 Washer
3 Bearing carrier 10 Lip seal 17 Hex nut
4 Gear housing 11 Rubber seal 18 Name plate
5 Cover 12 Back up seal 19 Screw
6 Shaft gear set 13 Square seal
7 Drive gear set 14 Dowel pin

6-20
2) GENERAL INSTRUCTION
(1) Cleanliness
Η Cleanliness is the primary means of assuring satisfactory hydraulic pump life.
Components such as flanges and covers are best cleaned in soap and hot water, then air dried.
Gears should be washed in solvent, air dried, and oiled immediately.
Certain cleaning solvents are flammable. Do not allow sources of ignition in the area when
using cleaning solvents.
Θ Protect all exposed surfaces and open cavities from damage and foreign material.
ö Gear journals and gear faces are super finished. Take care not to touch these surfaces after oil
and solvent.
(2) Lubrication of moving parts
During assembly, all running surfaces(Bearing and wear plate) must be lightly lubricated with a
clean oil or aerosol lubricant.

3) DISASSEMBLE

When disassembling and assembling the pump, the following tools are required.
ÂSocket wrench set
ÂInternal snap ring pliers
ÂShaft seal sleeve
ÂTorque wrench
Take action the following preparation prior to disassembly and assembly for the pump.
-It is very important to work in a clean area in order to prevent the inside of the pump from getting
into the foreign material, dirt and debris etc.
-Clean and wash properly with solvent for the exterior of the pump and plug ports.
-Removed port plugs and drain out the hydraulic oil from the pump.
-Mark a line across the mounting flange, gear housing and end cover using a permanent mark pen
in order to confirm proper assembly and rotation of the pump after completion of work.

(1) Rear section

Η Loosen and remove the stud bolts,
washer and nuts by using a socket
wrench.
If it is available of using jaw vice to
disassemble the pump, clamp mounting
flange for the pump in a protected jaw
vice with pump shaft facing down.
50D7EMP21

6-21
Θ Remove the rear end cover along with
dowel pin to facilitate removal of the thrust
plate.

50D7EMP22

Ι Carefully disassemble gear housing

assembly which is composed of thrust
plate, drive gear set(drive gear and driven
gear) and gear housing.
Disassemble the thrust plate, drive gear
set and gear housing.

50D7EMP23

Κ Disassemble the bearing carrier assy and

then remove the connecting shaft.

50D7EMP25

50D7EMP26

6-22
 Λ Remove the drive gear set and
disassemble the gear housing from end
cover.
Μ Clean and dry all parts throughly prior to
inspection. Check all parts where are
happened damage deformation, crack,
broken or severe wear or not.

50D7EMP27

4) ASSEMBLY
Assembly procedure of the pump is the reverse order of the removal procedure.
(1) Cover
Η Throughly clean the bore surface to be fitted shaft seal, rubber seal and back up seal for the
cover and inserting holes for the dowel pins.
When installing the seals and the back up seals, apply a slight coat with oil prior to installation.
Θ Fit the shaft seal, rubber seal and back up seal.
Ι Assemble the gear housing by fitting of the dowel pin and the drive gear set.
Κ Insert the connecting shaft to the drive gear set and then assemble the bearing carrier assy by
fitting of the dowel pin.
Λ Assemble the drive gear set to another drive gear set by inserting of the hole of connecting shaft.
Μ Assemble thrust plate and the gear housing by fitting of dowel pin.
Ν Assemble the cover by fitting of dowel pin.
ö When the drive gear sets are removed and assembled, take particularly care not to happen
damage or scratching for inside of gear housing.
The drive gear sets should be removed and assembled for gear housing as straight as possible
so that they can not prevent from damage or scratching.
Throughly clean the components of the pumps so that any dirt or dust can not be entered into the
hydraulic systems.
If they are entered into the hydraulic system, it shall be happened severe damage to the hydraulic
components.

6-23
2. MAIN CONTROL VALVE
1) Lay out valve components on a clean, flat
working surface. The inlet assembly will
include an O-ring, and the spool section(s)
include an O-ring, a load check poppet and
a load check spring. Tools required for
basic valve assembly include 3/4 and 11/16
open or box end wrenches and a torque
wrench with thin wall sockets.

7406S MCV05(1)

2) Assemble tie rod nuts to one end of each

tie rod with one or two threads showing.
Insert tie rods through tie rod holes of inlet
(Large tie rod at top). Lay inlet on end with
tie rods up, place O-ring into position.

7406S MCV05(2)

3) Place first spool section(O-ring side up) on

inlet section, position O-ring and insert load
check poppet(Nose down) and spring
(Behind poppet) into load check cavity as
shown. Repeat this procedure for each
spool section ; The load check springs are
compressed by the following sections
during assembly.

7406S MCV05(3)

4) Position end section on last spool section

as shown and hand tighten tie rod nuts. The
end section on picture is a "turn around"
section without ports. Universal outlet
/power beyond section and power beyond
and closed center sections are also used
as end sections. These end sections do
not have O-ring grooves.

7406S MCV05(4)

6-24
5) Position valve assembly with the mounting
pads of the end sections on a flat surface.
To obtain proper alignment of end sections
relative to the spool sections apply
downward pressure to the end sections ;
Snug tie rod nuts to about 10lbfÂft.
Final torque the two 11/16 nuts to 48Ü5
lbfÂft ; Final torque the 3/4 nut to 74Ü8 lbfÂ
ft. Check for proper spool movement.
7406S MCV06(1)

6) Install auxiliary valves and plugs and torque

to proper specifications.
ö General assembly notes:
A. Lever assemblies can be installed on
section before or after complete valve
assembly.
B. The load check and spring may be
omitter from assembly in certain circuit
conditions(i.e., motor spools).
7406S MCV06(2)

6-25
4. LIFT CYLINDER
1) STRUCTURE

9
6
8

3
10

14 4

5
13

12

11
16

15

 I.DÝO.DÝstroke(standard)
73Ý65Ý1335mm
7 (2.9Ý2.6Ý52.6in)
 Rod O.D : 50mm(2.0in)

D357HS19

1 Tube assy 9 Dust wiper

2 Rod 10 Rod seal
3 Piston 11 O-ring
4 Piston seal 12 Guide
5 Back up ring 13 DU busing
6 Wear ring 14 O-ring
7 Retaining ring 15 Spacer
8 Gland 16 O-ring

6-26
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 in again and
the guide can be removed. D503HS20

2) CHECK AND INSPECTION mm(in)

Check item Standard size Repair limit Remedy

Clearance between cylinder rod & 0.05~0.25 0.4 Replace

bushing (0.002~0.01) (0.0015) bushing
Clearance between piston ring & 0.05~0.35 0.5 Replace
tube (0.002~0.013) (0.02) piston ring

3) ASSEMBLY
(1) Soak the piston ring in hydraulic oil at a
temperature of 40 to 50Á C , expand the
inside diameter and assemble on the
piston. Install a piston seal.
Bend the edge of the guide and rotate it to
install the guide completely.

D503HS21

6-27
5. TILT CYLINDER
1) STRUCTURE

12
11

5
6
7
8

2
24
22
23 24

21

18 1
19
20

17
16
15

13

14
 I.DÝO.DÝstroke :
4 90Ý102Ý220mm
9 (3.5Ý4.0Ý8.7in)
10 Â Rod O.D : 45mm(1.8in)

35DS7HS16

1 Tube assy 9 O-ring 17 Nylon nut

2 Rod 10 Back up ring 18 Rod eye
3 Gland 11 Lock washer 19 Spherical bearing
4 DU bushing 12 O-ring 20 Retaining ring
5 Rod seal 13 Piston 21 Hexagon bolt
6 Back up ring 14 Glyd ring 22 Hexagon nut
7 Dust wiper 15 Wear ring 23 Spring washer
8 Snap ring 16 O-ring 24 O-ring

6-28
2) DISASSEMBLY
(1) Hold the parallel parts of the cylinder tube
bottom in a vice and mark the rod head
end to show how much it is screwed in,
then remove the rod head. Next, hook a
wrench into the notch at the cylinder head
and remove the cylinder head from
cylinder tube.
When doing this, wind tape round the D503HS23
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 cylinder rod & 0.072~0.288 0.5

Replace bushing
bushing (0.003~0.011) (0.020)
Clearance between rod 0.10~0.35 0.6
Replace bushing
head bushing & pin (0.004~0.014) (0.024)

6-29
 SECTION 7 ELECTRICAL SYSTEM

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

Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
 SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION

1
9

2
3

4
5

6 10 11 12 13 14

- +

C H 000000 E F
HYUNDAI

LPG

15 16 17 18 19

35L7AEL02

1 Work lamp 8 Beacon lamp 13 Horn button

2 Battery 9 License lamp 14 Start switch
3 Master switch 10 Forward-reverse lever 15 OPSS unit
4 Tilt alarm 11 Operating panel 16 Buzzer
5 Micro switch 12 Head lamp switch 17 Hazard switch (opt)
6 High horn Illumination lamp 18 Relay
7 Back buzzer Turn signal switch 19 Fuse box

7-1
GROUP 2 ELECTRICAL CIRCUIT
REAR SUPPORT HARNESS

REAR (OP)
F/COMBI H/LAMP F/COMBI H/LAMP R/COMBI LH R/COMBI RH
WORK BEACON
LH LH RH RH

M
190 W

190 W
120 R

180 Y
CLUSTER START KEY S/W

ST RW

ST RW
BK LW

BK LW
CL RB

CL RB
B

B
TN R

TN R
C

C
L T

L T
E

E
B BR R1 R2 C ACC

GN

GN
W

W
W

ENGINE CHECK LAMP

B

B
B

B
HT

WATER SEPARATOR

CL-16
CL-15
OFF

3
4
5
6

3
4
5
6
2

2
BRAKE OIL LEVEL

E/G TEMP GAUGE

CL-23
1 2 3 4 5 6 7 8 9 10 11 12

TURN SIGNAL LH
TURN SIGNAL RH
PARKING BRAKE

CL-7
ON

EARTH(GAUGE)

10A

15A
10A

10A

5A
10A
GLOW LAMP(+)

5A

15A
5A

5A
5A
CHARGE LAMP

ANTI-RESTART
GLOW LAMP(-)

ILLUMINATION

-
T/M OIL TEMP
ST

FUEL GAUGE
FUEL EMPTY
ENG. OIL PS

390 RW

390 RW
HEAD LAMP

354 LW

354 LW
340 RB
312 RY

340 RB
SEAT BELT

AIR FILTER

000 B

000 B
314 R
112 W

112 W
106 L

106 L

370 W
R W L Y

EARTH
OPSS

WORK/BEACON

280 R
000 B
START RELAY
IG

HORN/STOP

F,R SWITCH

FUSE BOX
-

HEAD/TAIL
133 W

133 W
000 B

000 B

CLUSTER

CABIN
CABIN
CN-56

CN-36
CN-57

OPSS
TURN

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

1
2
3
4
5
6
7
8

CS-2
CN-4

CN-5
4 3 2 1

-
2

2
4

1
3

456 LgR
450 GW

230 BrR

205 WG
330 WR

280 RW
340 WY
312 LW

448 GR

240 WL
250 RB

260 RY

190 W
430 YB

314 LB

120 R
180 Y
334 Gr

000 B

000 B
328 Br

446 Br

452 Br
330 WR

330 WR
340 WY

340 WY

210 G
200 R

290 R
312 LW

270 V

458 Y

270 V

220 L
314 LB

390 RW
000 B

354 LW
312 RY

340 RB
000 B

370 W
280 R

314 R

000 B
CN-7
CN-8
190 W

3
4
5
6
CD-2

2
1
120 R 000 B
2
458 Y

280 RW
1

370 WL

390 RW
340 WY
312 LW

354 LG
314 R

000 B
FUEL SENDER CN-19
4
458 Y
CL-21 3
WG 340 340 WY
2
B 000 000 B CD-29
1
450 GW
LICENSE LAMP

S/W TM TEMP
CD-10
000 B
Pa CS-73
CN-26 446 Br 460 YB
1
358 L 000 B SWITCH SEAT
AIR CLEARNER 2
290 R
SWITCH
TILT ALARM
CN-25 CN-121
200 R 336 Or
CN-17 1 2 CUTOFF SOL1
260 RY 380 W 000 B (TILT/LIFT)
1 2 1
290 R
2 HORN
340 WY
3
000 B
4 CN-131
336 Or
OPTION(CABIN) 2 CUTOFF SOL2
000 B
1 (LIFT DOWN)
COM
CR-11 NC CS-72
310 Or L 358 L
L 1 NO 2
G 210 G B 000 B
B 2 NO NC COM 1
000 B
E 3 TILT SWITCH
FLASHER UNIT CN-65
354 LG R
000 B B
CR-5 CD-4
220 L 390 RW
3 4 4
000 B
Pa 200 R
BACK-UP BUZZER
3
320 Or
2 BRAKE S/W
350 P
1 2 1 CN-132
352 L
RELAY NEUTRAL 1
362 W FWD-2
CN-2 CN-2 2
380 W 380 W
CR-13 1 1 HORN 1 SWITCH HORN 1
330 WR 200 R 200 R
3 4 4 2 2 HORN/BRAKE SW 2 FUSE BOX(B+) 2 CN-122
000 B 446 Br 446 Br 352 L
3 3 3 S/W A/CLEANER 3 CLUSTER 3 1
230 BrR 458 Y 458 Y 364 Br FWD-1
2 4 4 FUEL SENDER 4 CLUSTER 4 2
360 GB 450 GW 450 GW
1 2 1 5 5 S/W T/M TEMP 5 CLUSTER 5
460 YB 460 YB
RELAY HEADLAMP 6 6 SEAT SWITCH 6 OPSS UNIT 6
336 Or 336 Or
7 7 CUTOFF SOL 7 RY CUTOFF 7 CN-123
352 L 352 L 354 LG
CR-50 8 8 F-SOL 8 F.R SWITCH 8 1
355 RW 354 LG 354 LG 361 Or REV-1
86 30
87a 9 9 R-SOL/BZ/LAMP 9 F.R SWITCH 9 2
322 G 280 RW 280 RW
85 10 10 BECON LAMP 10 FUSE BOX(ON) 10
312 LW 312 LW
87 11 11 LAMP TURN LH 11 S/W COMBI 11 CN-133
205 WG 314 LB 314 LB 354 LG
85 87 87a
86 12 12 LAMP TURN RH 12 S/W COMBI 12 1
326 W 370 WL 370 WL 363 P REV-2
30 13 13 LAMP WORK 13 S/W WORK LAMP 13 2
340 WY 340 WY
RY TRAVEL CUT 14 14 ILLUMINATION 14 COMBINATION SW 14
356 GR 356 GR
15 15 LOW SPEED 15 LOW SPEED 15
357 YB 357 YB
CR-51 16 16 HIGH SPEED 16 HIGH SPEED 16 DO-5
336 Or 364 Br
86 30
87a 1
324 P 356 GR
85 CN-1 CN-1 2 DIODE(L)
190 W 190 W 361 Or
87 1 1 F/KIT INTERFACE 1 KEY SWITCH 1 3
205 WG 120 R 120 R
85 87 87a
86 2 2 START MOTOR B+ 2 KEY SWITCH 2
205 WG 456 LgR 456 LgR
30 3 3 F/KIT INTERFACE 3 CLUSTER 3 DO-4
452 Br 452 Br 362 W
RY ATTACH CUT 4 4 F/KIT INTERFACE 4 CLUSTER 4 1
448 GR 448 GR 357 YB
5 5 F/KIT INTERFACE 5 CLUSTER 5 2 DIODE(H)
363 P
6 6 - 6 - 6 3
430 YB 430 YB
CS-17 7 7 F/KIT INTERFACE 7 CLUSTER 7
NO NC Br 328 Br
NC 3 8 8 - 8 - 8
W 326 W 320 Or 320 Or
NO 2 9 9 F/KIT INTERFACE 9 RY NEUTRAL 9
B 000 B
COM COM 1 10 10 - 10 S/W CUTOFF 10
SWITCH PARKING 11 11 - 11 S/W CUTOFF 11
12 12 - 12 - 12
358 L 358 L
13 13 TILT ALARM 13 TILT ALARM 13
000 B 000 B
CS-21 14 14 MAIN EARTH 14 EARTH 14
000 B 000 B 000 B
10 10 15 15 MAIN EARTH 15 CLUSTER 15
9 370 WL
9
8
8
6 7 CN-74
2
6 2 R
7 280 RW FUEL SYSTEM INTERFACE U
5 5 1 L
1
4 IG(VSW) A
190 W ~
448 GR 3 G
3 CHARGE WARNING LAMP B B+
456 LgR
2 ECT Gauge C
370 WL ALTERNATOR
1 - D
452 Br
SWITCH REAR WORK E/G OIL PS WARNING LAMP E
320 Or
FUEL SYSTEM
12V at CRANK ONLY F HARNESS CN-45
430 YB
CS-41 MIL LAMP G M
9 10 10
000 B
- H
M
340 WY 346 P
9 ACCEL PEDAL(FFP2/IVS) J
344 G 120 R
8 ACCEL PEDAL(FPP1) K B+
8 345 BW
6 7 ACCEL PEDAL(5V RTN) L START MOTOR
2 310 Or 342 R
6 MAIN EARTH ACCEL PADAL(5V EXT) M
7 310 Or
5 5 - N
1
4 - P
3 - R
314 LB 35SQ(B)
2 - S
312 LW 35SQ(R) 35SQ(B)
1 CN-6
SWITCH HAZARD BATTERY
12V MASTER SW

ACCEL PEDAL
230 BrR
355 RW

340 WY
356 GR
240 WL

312 LW
357 YB
354 LG

314 LB

310 Or
380 W

000 B
350 P

000 B
352 L

360 GB
360 GB

G 6
205 WG

3
250 RB

2
460 YB
354 LG

Y
334 Gr

328 Br
000 B
322 G
324 P

332 V
352 L

- 5
P.D 1
SENSOR

346 P
AMP IVS 4
CS-11

CS-12

P
SW 342 R
2

5
6
7
8
9

3
2

5
6
7

1
1

Vdc R
3
4
3
4

CN-55

PS
344 G
10
11
12
13
14

SIG G 2
1
2
3
4
5
6
7
8
9

6 4 345 BW
2-TRH(LB)
2-FWD(L)

1-REV(LB)

250 RB

G(sig) 1
3-HO(W)
7-Lo(Gr)

8-Hi(G)

1-TLH(L)
5-H(Y)
6-L(G)

332 V
4-N(B)

6-ILL(Y)

B
Or

Gr

Br
W

R
Y

P
B

CN-124
L
380 W
000 B

CN-113

>
1
2
CS-5

GND
IGN

RELAY2

RELAY3
OPS-LAMP
FWD S/W
REV S/W

BRAKE S/W
TRAVEL CUT
SEAT S/W
4-HO(B)

000 B
000 B
000 B
000 B
BATT(+)
PARK'G S/W
BUZZER(-)

3-C(W) 7-C(R) 9-C(Or)

5-C(Br)

HORN
SWITCH
GEAR SELECTOR COMBI.SWITCH OPSS
BUZZER
35L7AEL01
STEERING COLUMN SWITCH OPSS UNIT
MAIN EARTH

7-2
35L-7A : # 482~, 40L-7A : # 385~, 45L-7A : # 710~, 50L-7A : # 497~

7-2-1
ELECTRIC CIRCUIT FOR LPG FUE KIT

10MM RING

35L7AEL07

7-3
MEMORANDUM

7-4
1. POWER CIRCUIT
The negative terminal of the battery is grounded to the machine chassis.
When the start switch is in the off position, the current flows from the positive battery terminal.
1) OPERATING FLOW
Battery(+) Start motor [CN-45(B+)] I/conn [CN-1(2)]
Start switch [CS-2(3)]
Fuse box [CN-36] (No.1) I/conn [CN-2(2)] Horn [CN-25(1)]
Brake switch [CD-4]
(No.2) OPSS buzzer [CN-113(2)]
OPSS unit [CN-55(12)]
(No.3) Flasher unit [CR-11(2)]
(No.4) Cabin [CN-17(1)]

2) CHECK POINT

Engine Key switch Check point Voltage

Η - GND (Battery(+))
OFF OFF Θ - GND (Fuse No.1) 12V
Ι - GND(Start key)
öGND : Ground

7-5
 POWER CIRCUIT

120 R
START KEY S/W
B BR R1 R2 C ACC
HT 1 2 3 4 5 6 7 8 9 10 11 12

10A

15A
10A

10A
OFF

10A

15A

5A
5A

5A

5A
5A

-
ON
ST

WORK/BEACON

START RELAY
W
R

HORN/STOP
L

F,R SWITCH

FUSE BOX
HEAD/TAIL

CLUSTER

CABIN
CABIN
CN-36
CN-74

OPSS
TURN

OPSS
2 R

-
CS-2

U
1 L
2
4

1
3

~
3

R/B
G

G
B+

260 RY
R

200
250
210
FUEL SYSTEM ALTERNATOR
4
120

HARNESS
2 3 CN-45
M
CN-1 M
1
120 R 120 R 120 R
2 B+
3 START MOTOR
4
5
CN-17 260 RY 6
1 7
35SQ(R) 35SQ(B) 35SQ(B)
2 8
3 9
4 10
BATTERY MASTER SW
OPTION(CABIN) 11 12V
12 1
13
14
CR-11 15
310 Or
L 1
G 210 G
B 2 CN-113
3 250 RB
E 2
332 V OPSS
FLASHER UNIT 1 BUZZER

CN-55
W
1 IGN
Y
2 SEAT S/W
Or
3 REV S/W
L
GEAR SELECTOR 4 FWD S/W
G
5 TRAVEL CUT
CS-11 P
2-FWD (L) 6 RELAY2
3-C (W)

1 B
4-N (B) 7 GND
2 Gr
8 OPS-LAMP
1-REV (LB) 3 332 V V
9 BUZZER(-)
4
10 BRAKE S/W
5
7-C (R)

6-L (G) P
STEERING COLUMN SWITCH

6
11 RELAY3
250 RB R
5-H (Y) 7 12 BATT(+)
Br
13 PARK'G S/W
5-C (Br)

14

6-ILL (Y) OPSS UNIT

CS-12
1
7-Lo (Gr)
2 CN-2 CN-25
380 W 380 W 380 W 380 W
3 1 2
8-Hi (G)
200 R 200 R 200 R HORN
4 2 1
5 3
6 4
9-C (Or)

1-TLH (L) 7 5 CD-4

8 6 200 R Pa BRAKE
2-TRH (LB) 310 Or S/W
9 7
4-HO (B) 3-HO (W) 8
9
10
11
COMBINATION
Or
Or

SWITCH 12
13
310
310

380

14
15
CS-41

CS-5
10

5
4

1
6

16
9

3
10

HORN SWITCH
9

7
8
2

HAZARD SWITCH

35L7AEL03

7-6
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Start motor [CN-45(B+)] I/conn [CN-1(2)] Start switch [CS-2(3)]
ö 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] Combination switch [CS-12(5)]
(2) When start key switch is START position
Start switch START [CS-2(2)] Fuse box [CN-36(12)] Neutral relay [CR-5(4 Ą2) ]
I/conn [CN-1(9)] Fuel system interface [CN-6(F)]

2) CHECK POINT

Engine Key switch Check point Voltage

Η - GND (Battery B+)

Θ - GND (Fuse box No.5)
Running ON 12V
Ι - GND (Start key)
Κ - GND (Neutral relay)
öGND : Ground

7-7
 STARTING CIRCUIT

START KEY S/W 180 Y

B BR R1 R2 C ACC
190 W 190 W
HT
OFF
120 R
ON
ST

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

W
R

Y
L

10A

15A
10A

10A

10A

15A

5A
5A

5A

5A
5A

-
WORK/BEACON

START RELAY
HORN/STOP

F,R SWITCH

FUSE BOX
CS-2

HEAD/TAIL

CLUSTER
2
4

1
3

CABIN
CABIN
CN-36

OPSS
TURN

OPSS
W
R
Y

-
3
190
120
180

BrR

L
2 2 2

230

270

220
CN-74
2 R
U
1 L
~
3 G
B+

FUEL SYSTEM ALTERNATOR

HARNESS
CN-45
M
CN-1 M
1
120 R 120 R 120 R
2 B+
CN-57 3
270 V START MOTOR
IG 1
4
- 2
5
E/G TEMP GAUGE 3
6
- 4
7
FUEL GAUGE 5 35SQ(R) 35SQ(B) 35SQ(B)
8
- 6 320 Or
MAIN 9
ANTI-RESTART 7
EARTH 10
EARTH(GAUGE) 8 BATTERY MASTER SW
CLUSTER
11
12
1 12V
4 13
14
CR-5 220 L
3 4 15
4
000 B
3
320 Or
2
350 P
1 2 1

RELAY NEUTRAL CN-6

A IG(VSW)
B CHARGE WARNING LAMP
C ECT Gauge
GEAR SELECTOR
D -
E E/G OIL PS WARNING LAMP
2-FWD (L) CS-11 320 Or
12V at CRANK ONLY
3-C (W)

F
1
4-N (B) G MIL LAMP
2 H -
1-REV (LB) 3
350 P J ACCEL PEDAL(FFP2/IVS)
4
K ACCEL PEDAL(FPP1)
5
7-C (R)

6-L (G)
L ACCEL PEDAL(5V RTN)
STEERING COLUMN SWITCH

6 M ACCEL PADAL(5V EXT)

5-H (Y) 7
N -
P -
5-C (Br)

R -
6-ILL (Y) S -

CS-12 FUEL SYSTEM INTERFACE

1
7-Lo (Gr)
2
8-Hi (G) 3
000 B
4
230 BrR
5
6
9-C (Or)

1-TLH (L) 7
8
2-TRH (LB)
9
4-HO (B) 3-HO (W)

COMBINATION
SWITCH

35L7AEL04

7-8
GROUP 3 COMPONENT SPECIFICATION

No Part name Qty Specification Remark

1 Battery 1 12V80AH, RC : 30min, CCA : 630

2 Working lamp 1 12V, 55W
3 License lamp 1 12V, 3.4WÝ2
4 Combination lamp 2 12V, 21W (T/S) 12V, 10W (Back)
12V, 5W (Tail)
12V, 21W (Stop)
5 Head lamp 2 12V, 55W
6 Flasher lamp 2 85Ü10 C/M, (23W + 23W)Ý2 + 3W Ý 2
7 Flasher unit 1 12V, (21WÜ21W) Ý 2 3W(Flasher)
130W(Harzard)
8 Back horn 1 12V, 90Ü5dB, 60Ü10C/M
9 Horn 1 12V, MAX 3.5A, 105 ~ 120 dB
10 Master switch 1 180A
11 Combination switch 1 Tail, Horn : 5A, F/R : 8A, Etc : 7A
12 Hazard switch 1 12V, 16A
13 Start switch 1 30 ~ 60A
14 OPSS unit 1 12V/24V, MAX 0.5A(at 12V)
15 Relay(4P) 2 12V, 20A
16 Relay(5P) 1 12V, 20A
17 Work lamp switch 1 12V, 16A

7-9
GROUP 4 CONNECTOR DESTINATION

Connector No. of Connector part No.

number Type Destination
pin Female Male
CN-1 AMP 15 I/conn(Frame harness-dashboard harness) 2-85262-1 368301-1
CN-2 AMP 16 I/conn(Dashboard harness-frame harness) 368047-1 368050-1
CN-4 KET 4 LH support harness S810-004201 -
CN-5 KET 4 RH support harness S810-004201 -
CN-7 AMP 6 I/conn(RR support harness-frame harness) 174262-2 174264-2
CN-8 AMP 2 I/conn(RR support harness-frame harness) S816-002002 -
CN-17 KET 4 Option S810-004201 -
CN-19 AMP 4 Option - S816-104002
CN-25 MOLEX 2 Horn 35825-0211 -
CN-26 KET 1 Tilt alarm S822-014000 S822-114000
CN-36 - - Fuse box 21HF-10500 -
CN-45 RING TERM 2 Start motor S820-308000 -
CN-55 KET 14 OPSS unit S814-014100 -
CN-56 AMP 20 Cluster 368511-2 -
CN-57 AMP 8 Cluster 368540-2 -
CN-65 KET 2 Back buzzer S822-014000 S822-114000
CN-113 KET 2 OPSS buzzer S814-002100 -
CN-121 AMP 2 C/O SOL 1 S816-002002 -
CN-122 DEUTSCH 2 Forward solenoid 1 S812-002001 -
CN-123 DEUTSCH 2 Reverse solenoid 1 S812-002001 -
CN-124 AMP 6 Accel pedal 174262-2 -
CN-131 AMP 2 C/O SOL 2 S816-002002 -
CN-132 DEUTSCH 2 Forward solenoid 2 S812-002001
CN-133 DEUTSCH 2 Reverse solenoid 2 S812-002001 -
Switch
CS-2 KET 4 Start switch S810-004201 -
CS-11 AMP 7 Gear selector switch S811-007002 -
CS-12 AMP 9 Combination switch S811-009002 -
CS-17 KET 3 Parking switch S810-003201 -
CS-21 KET 10 Work lamp switch 593757 -
CS-41 KET 10 Hazard switch 593757 -
CS-72 KET 2 Tilt switch S814-002100 -
Lamp
CL-7 KET 2 Beacon lamp S822-014000 S822-114000
CL-15 DAEDONG 6 Combination lamp-LH 110-6PR -
CL-16 DAEDONG 6 Combination lamp-RH 110-6PR -
CL-21 KET 2 License lamp S822-014000 S822-114000

7-10
Connector No. of Connector part No.
number Type Destination
pin Female Male
CL-23 KET 2 Rear work lamp S822-014000 S822-114000
Relay
CR-5 KET 4 Neutral relay S810-004201 -
CR-11 - 3 Flasher unit relay S810-003702 -
CR-13 KET 4 Head lamp relay S810-004201 -
CR-50 AMP 6 Travel cut relay S810-006202 -
CR-51 AMP 6 Attach cut relay S810-006202 -
Sensor and pressure switch
CD-2 KET 3 Fuel sendor S810-003201 -
CD-4 AMP 1 Brake switch S819-010122 -
CD-10 KET 1 Air cleaner switch ST730057-2 -
CD-29 AMP 1 T/M temperature sensor S819-010122 -

7-11
GROUP 5 TROUBLESHOOTING

Trouble symptom Probable cause Remedy

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

7-12
 SECTION 8 MAST

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

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5
Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8
Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11
 SECTION 8 MAST
GROUP 1 STRUCTURE
1. 2 STAGE MAST(V MAST)

13
3
2
12

8
10

9 Lift cylinder

Carriage

6 Frame

13
11
35DS7MS01

1 Outer mast 6 Bearing 11 Roller bearing

2 Shim(0.5, 1.0t) 7 Inner mast 12 Back up liner
3 Roller bearing 8 Lift chain 13 Shim(0.5, 1.0t)
4 Tilt cylinder pin 9 Anchor bolt
5 Mast mounting pin 10 Chain sheave bearing

8-1
 2. 2 STAGE MAST(VF MAST)

13
3

Outer mast

2
4
11
Inner mast

10
9
1
9

12

Lift cylinder 5
Free lift
cylinder

10

Carriage
8

7 Frame
13
3
6

D357MS02

1 Outer mast 6 Mast mounting pin 11 Chain

2 Shim(0.5, 1.0t) 7 Bearing 12 Sheave bracket
3 Roller bearing 8 Inner mast 13 Shim(0.5, 1.0t)
4 Backup liner 9 Chain sheave bearing
5 Tilt cylinder pin 10 Anchor bolt

8-2
 3. 3 STAGE MAST(TF MAST)

14
3
2
4
Outer mast
14
3
11

9
10

2
4 1
11
Inner mast

10
9 8 5

9
Lift cylinder
12
13
Free lift
cylinder
10

Middle mast 14
Carriage 3 7 Frame

14
3

D357MS03

1 Outer mast 6 Mast mounting pin 11 Chain

2 Shim(0.5, 1.0t) 7 Bearing 12 Sheave bracket
3 Roller bearing 8 Middle mast 13 Inner mast
4 Backup liner 9 Chain sheave bearing 14 Shim(0.5, 1.0t)
5 Tilt cylinder pin 10 Anchor bolt

8-3
3. CARRIAGE, BACKREST AND FORK

7
2 3

7
7
3

5 35DS-7E ONLY
5

35DS7MS04

1 Backrest 5 Fork
2 Carriage 6 Extension fork
3 Roller 7 Shim(0.5, 1.0t)
4 Side roller

8-4
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
1) FORKS
(1) Measure thickness of root of forks and
check that it is more than specified value.
EX : ˶=1200mm(47in)
mm(in)
STD Fork assy Applicable model Standard Limit
S173896-02 35L-7A 50(2.0) 45(1.7) Thickness

F13710010 40L-7A 50(2.0) 45(1.7) D507FK01

F17393603 45L-7A 50(2.0) 45(1.7)

F14710011 50L-7A 60(2.4) 54(2.1)

2) Set forks in middle and measure out of

parallel and difference in height at the top of
forks.
Model Fork length Height
difference
equal or
3mm
All below 1200
above 1200 6mm Difference in height
at tip of forks

D255FK02

3) Most force is concentrated at root of fork

and at hook, so use crack detection method
to check cracks.

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

8-5
2. TROUBLESHOOTING
1) MAST
Problem cause Remedy
Forks fail to lower. ÂDeformed mast or carriage. ÂDisassemble, repair or replace.
Fork fails to elevate ÂFaulty hydraulic equipment. ÂSee troubleshooting hydraulic pump
and cylinders in section 6, hydraulic
system.
ÂDeformed mast assembly. ÂDisassemble mast and replace
damaged parts or replace complete
mast assembly.
Slow lifting speed and ÂFaulty hydraulic equipment. ÂSee troubleshooting hydraulic pump
insufficient handling capacity. and Cylinders in section 6, hydraulic
system.
ÂDeformed mast assembly. ÂDisassemble mast and replace
damaged parts or replace complete
mast assembly.
Mast fails to lift smoothly. ÂDeformed masts or carriage. ÂDisassembly, repair or replace.
ÂFaulty hydraulic equipment. ÂSee Troubleshooting Hydraulic
Cylinders pump and control valve in
section 6, hydraulic system.
ÂDamaged load and side rollers. ÂReplace.
ÂUnequal chain tension between ÂAdjust chains.
LH & RH sides.
ÂLH & RH mast inclination angles ÂAdjust tilt cylinder rods.
are unequal. (Mast assembly is
twisted when tilted)
Abnormal noise is produced ÂBroken load roller bearings. ÂReplace.
when mast is lifted and lower- ÂBroken side roller bearings. ÂReplace.
ed. ÂDeformed masts. ÂDisassemble, repair or replace.
ÂBent lift cylinder rod. ÂReplace.
ÂDeformed carriage. ÂReplace.
ÂBroken sheave bearing. ÂReplace.
Abnormal noise is produced ÂInsufficient lubrication of anchor ÂLubricate or replace.
during tilting operation. pin, or worn bushing and pin.
ÂBent tilt cylinder rod. ÂReplace.

8-6
 2) FORKS

Problem cause Remedy

Abrasion Long-time operations causes the fork to If the measured value is below the wear
wear and reduces the thickness of the limit, replace fork.
fork.
Inspection for thickness is needed.
ÂWear limit : Must be 90% of fork
thickness
Distortion Forks are bent out of shape by a If the measured value exceeds the
number of reasons such as allowance, replace fork.
overloading, glancing blows against
walls and objects, and picking up load
unevenly.
ÂDifference in height at tip of forks

Model Fork length Height

difference
equal or
3mm
All below 1200
above 1200 6mm

Fatigue Fatigue failure may result from the Repair fork by expert.
fatigue crack even though the stress to In case of excessive distortion, replace
fork is below the static strength of the fork.
fork. Therefore, a daily inspection
should be done.
ÂCrack on the fork heel.
ÂCrack on the fork weldments.

8-7
GROUP 3 ADJUSTMENT
1. MAST LOAD ROLLER(V, VF MAST)
1) INNER/OUTER MAST ROLLER CLEAR-
ANCE ADJUSTMENT
(1) Measure the clearance with the mast
overlap at near 480mm.
(2) Shift the inner mast to one side to bring
the roller into contact with the outer mast,
and adjust the clearance between the
roller side face and mast at the closest
position on the opposite side to the L15C3MS04

following value by inserting the inner/outer

mast roller shim.
ÂStandard clearance A, B = 0~0.6mm
ÂShim thickness 0.5, 1.0mm
(3) Distribute the shim thickness equally to
the left and right roller. Refer to Mast load
roller and back up liner, removal and
Installation.
(4) After the adjustment, check that the inner
mast moves smoothly in the outer mast.
L15C3MS05

8-8
2. MAST LOAD ROLLER(TF MAST)
1) INNER AND MIDDLE MAST ROLLER
CLEARANCE ADJUSTMENT
(1) Measure the clearance with the mast
overlap at near 480mm.
(2) Shift the inner mast to one side to bring
the roller into contact with the outer mast
and the middle mast, and adjust the
clearance between the roller side face and
mast at the closest position on the L15C3MS06

opposite side to the following value by

inserting the inner and middle mast roller
shim, respectively.
ÂStandard clearance A = 0~0.6mm
ÂShim thickness 0.5, 1.0mm
(3) Distribute the shim thickness equally to
the left and right roller. Refer to Mast load
roller and back up liner, removal and
Installation.
(4) After the adjustment, check that the inner
mast moves smoothly in the middle mast,
and the middle mast moves smoothly in
the outer mast.

2) OUTER AND MIDDLE MAST UPPER

ROLLER CLEARANCE ADJUSTMENT.
(1) Measure the clearance with the mast
overlap at near 480mm.
(2) Shift the inner mast to one side to bring
the roller into contact with the outer mast
and the middle mast, and adjust the
clearance between the roller side face and
mast at the closest position on the L15C3MS07

opposite side to the following value by

inserting the outer and middle mast roller
shim, respectively.
ÂStandard clearance B = 0~0.6mm
ÂShim thickness 0.5, 1.0mm
(3) Distribute the shim thickness equally to the left and right roller. Refer to Mast load roller and back
up liner, removal and lnstallation.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast, and the
middle mast moves smoothly in the outer mast.

8-9
3) CARRIAGE LOAD ROLLER
Adjust Bring into Outer mast
(1) Measure the clearance when the center of screw contact
the carriage upper roller is 100mm from

100mm
the top of the inner mast.
(2) Measure the clearance at upper, middle
Side
and lower rollers after loosen the adjust roller Carriage
screws from the side rollers. Shift the Bring into
carriage to one side to bring the roller into contact
C
contact with the inner mast, and measure Inner mast
the clearance between the roller side face D255MS08

and mast at the closest position on the

opposite side to the following value by
inserting the carriage roller shim.
ÂStandard clearance C = 0~0.6mm
ÂShim thickness 0.5, 1.0mm
(3) Distribute the shim thickness equally to
the left and right roller. Refer to Carriage
assembly.
(4) After the adjustment, the carriage should
move smoothly along the overall mast
length.

4) MAST BACK UP LINER

(1) Measure the clearance with the 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.
ÂStandard clearance E = 0.2 ~ 0.6mm L15C3MS09

ÂShim thickness 0.5, 1.0mm

(3) After the adjustment, the mast should
move smoothly.

8-10
GROUP 4 REMOVAL AND INSTALLATION
1. FORKS
1) Lower the fork carriage until the forks are
approximately 25mm(1in) from the floor.
2) Release fork anchor pins and slide forks,
one by one, toward the center of the
carriage where a notch has been cut in the
bottom plate for easy fork removal.
3) Remove the fork one by one. On larger forks
it may be necessary to use a block of wood.
4) Reverse the above procedure to install load
forks. L15C3MS10

2. BACKREST
1) Remove bolts securing backrest to fork
carriage. Lift backrest straight up and
remove from carriage. Backrest
2) Position backrest on carriage and lower in
place. Install and tighten bolts.

Carriage Bolt

35DS7RE05

3. CARRIAGE ASSEMBLY
1) CARRIAGE
(1) With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is
done to create slack in the load chains when the carriage is lowered. Lower the carriage all the
way down to the floor. Make sure the carriage is level, this will prevent any binding when the mast
is raised.
(2) While supporting lift chains, remove the split pin and slide out chain anchor pins from the chain
anchors of stationary upright.
(3) Pull the chains out of the sheaves and drape them over the front of the carriage.
(4) Slowly raise elevating upright until mast clears top of fork carriage. Move carriage to work area
and lower mast.
Make sure carriage remains on floor and does not bind while mast is being raised.
(5) Inspect all parts for wear or damage. Replace all worn or damaged pars.
(6) Reverse the above steps to reinstall.
Replace the split pin of chain anchor with new one.

8-11
2) SIDE ROLLER
(1) Remove carriage as outlined in the carriage
Side roller
assembly and removal paragraph.
(2) Loosen and remove nuts, adjust screws
and side rollers from carriage side pate.
(3) Thoroughly clean, inspect and replace all
worn or damaged parts.
(4) Reverse the above procedure to assembly.
ö Adjustment
 Once carriage is properly installed,
loosen nuts and adjust screws, (if not D357MS12

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.
Carriage
(2) Loosen and remove flat head bolts and load roller
plain washers from top load roller bracket.
(3) Using a pryer, remove load rollers from
load roller bracket.
(4) Reverse the above procedure to assemble.
Refer to MAST ROLLER ADJUSTMENT
paragraph.

D357MS15

8-12
4) MAST LOAD ROLLER AND BACK UP
LINER
(1) 2 stage mast(V mast)
Hexagon
Η Remove the carriage assembly and bolt
move them to one side. Chain

Θ Loosen and remove hexagon bolts and

clamps securing lift cylinders to outer Backup
mast. liner
Ι Loosen and remove hexagon bolts and Inner mast
washers securing lift cylinders to inner
mast.
Κ Attach chains or sling to the inner mast
section at top crossmember. Using an
overhead hoist, slowly raise the inner Lift
cylinder
mast high enough to clear lift cylinder.
Mast
Λ After lowering the lift cylinder rods, and load
roller Outer mast
disconnecting lift cylinder hose, tilt the lift
cylinders LH and RH and them with Mast
ropes to the outer mast. load
roller
Μ Using the overhead hoist, lower inner
mast until top and bottom rollers and Clamp
back up liners are exposed.
Ν Using a pryer, remove load rollers from
load roller bracket. Remove back up
liners and shims.
Ξ Thoroughly clean, inspect and replace all
worn or damaged parts.
Ο Reverse the above procedure to 35DS7MS16

assemble. Refer to MAST LOAD

ROLLER ADJUSTMENT paragraph.

8-13
(2) 2 stage mast(VF mast)
Η Remove free lift chain connected
between carriage and free lift cylinder.
Θ Remove the carriage assembly and
move them to one side.
Ι Loosen and remove hexagon bolts and
washers securing lift cylinders to inner
Chain
mast.
Κ Loosen and remove hexagon bolts and
nuts securing lift cylinders to inner mast.
Λ Attach chains or sling to the inner mast Backup
liner
section at top crossmember. Using an
overhead hoist, slowly raise the inner
mast high enough to clear lift cylinder.
Μ 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.
Ν Using the overhead hoist, lower inner
mast until top and bottom rollers and
back up liners are exposed.
Ξ Using a pryer, remove load rollers from
load roller bracket. Remove back up
liners and shims.
Ο Thoroughly clean, inspect and replace all
worn or damaged parts.
Π Reverse the above procedure to assem-
ble. Refer to MAST LOAD ROLLER
ADJUSTMENT paragraph. D357MS17

8-14
(3) 3 stage mast(TF mast)
Η Remove the carriage assembly and
move to one side.
Θ Loosen and remove hexagon bolt
securing bottom cylinder from outer mast.
Ι Loosen and remove bolts and special
washers securing lift cylinders to middle
mast.
Κ Attach chains or sling to the inner and
middle mast section at top crossmember.
Using an overhead hoist, slowly raise the
Chain
uprights high enough to clear lift cylinder.
Λ 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.
Backup
Μ Using the overhead hoist raise inner and liner
middle masts. Place 4 inch block of
wood under the free lift cylinder bracket of
the inner mast then lower mast sections
(this will create slack in the chains).
Ν Remove retaining rings securing chain
sheaves to sheave support brackets.
While support chains, remove chain
sheaves and let chains hang free. The
upper outer and lower middle mast rollers
and back up liners are now exposed.
Ξ Using a pryer, remove load rollers from
load bracket. Remove back up liners and
shims.
Ο Attach chains or sling to the middle mast
section at top crossmember. Using an
overhead hoist, slowly raise the middle
mast until top and bottom rollers are
exposed.
Π Using a player, remove load rollers from
load roller bracket.
Ρ Thoroughly clean, inspect and replace all
worn or damaged parts.
΢ Reverse the above procedure to
assemble. Refer to MAST LOAD
ROLLER ADJUSTMENT paragraph.
D357MS18

8-15
5) ELEVATING MAST
(1) Inner mast (V, VF mast)
Η After completing all necessary steps for load rollers and back up liner removal use an overhead
hoist and sling or chain around upper crossmember of the inner mast section.
Θ Lift inner mast upright straight up and out of outer mast section.
Ι Replace and reverse above procedure to install. Make all necessary measurements and
adjustments.
(2) Inner and middle mast(TF mast)
Η After completing all necessary steps for load rollers and back up liner removal. Remove rear
chains and sheave support if not already done.
Θ Disconnect free lift cylinder hose. Drain hose into a suitable pan or container and cap hose.
Ι While supporting free lift cylinder assembly, remove bolts and washers securing cylinder to mast
crossmember.
Κ Place a sling around free lift cylinder and attach to an overhead hoist. Slowly raise and move
cylinder to one side.
Λ Attach chains or sling to the inner mast section at top crossmember. Using an overhead hoist
slowly raise the upright straight up and out of middle mast section.
Μ Attach chains or sling to the middle mast section at top crossmember. Using an overhead hoist
slowly raise the upright straight up and out of outer mast section.
Ν Replace upright and reverse above procedure to install. Make all necessary measurements and
adjustments.

8-16
6) CHAIN
(1) Chain sheave(V, VF mast)
Η Place a sling around carriage and attach
to an overhead hoist. Lift carriage high
enough so that the tension on the chain
over sheaves is relieved after the carriage
is blocked. Position wooden blocks under
the carriage and lower it.
Θ Remove the split pin securing the chain
anchor pins and discard. While
supporting the chains, remove the chain
anchor pins and drape the chains over the
Ι carriage.
Remove retaining ring securing sheaves
to sheave support. Remove sheaves
Κ with bearings.
Remove bearing retaining ring from
Λ sheave and press bearings from sheaves.
Thoroughly clean, inspect and replace all
Μ worn or damaged parts.
Reverse the above to assemble and install. D357MS19

Use new split pins in chain anchor pins.

(2) Rear chain sheave(TF mast)

Η Raise and securely block carriage and
inner mast section.
Θ Remove the split pin securing the chain
anchor pins and discard. While
supporting the chains, remove the chain
anchor pins from outer mast section.
Ι Remove chains.
Κ Remove retaining ring securing chain
sheaves to sheave support. Pry off
sheaves with bearings.
Λ Remove bearing retaining ring from
sheave and press bearings from
sheaves.
Μ Thoroughly clean, inspect and replace all
worn or damaged parts.
Ν Reverse the above procedure to
assemble and install. Use new split pins
in chain anchor pins.

D225MS14

8-17
(3) Chain wheel bearing support(TF mast)
Η Remove the carriage assembly and move to one side.
Θ After removing bolt to securing chain wheel bearing support assembly to free lift cylinder.
After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support
assembly straight up and off of free lift cylinder. Move assembly to work area.
Ι Remove retaining ring securing chain wheel bearing to chain wheel bearing support.
Κ Remove bearing retaining ring from chain wheel bearing and press bearings from chain wheel
bearings.
Λ Thoroughly clean, inspect and replace all worn or damaged parts.
Μ Reverse the above procedure to install.
(4) Rear chain(TF mast)
Η Remove the carriage assembly and move to one side. Refer to carriage removal and installation.
Θ Raise and securely block truck approximately 6 inches from the floor.
Ι Using a sling or chain around inner mast section attached to an overhead hoist, slowly raise inner
mast until there is enough slack in the chains to remove them. Block inner mast section.
Κ Remove split pins and chain anchor pins securing chains to chain anchor(part of inner mast).
Λ While supporting the chains, remove split and chain anchor pins securing chains to chain
anchors attached to outer mast section.
Μ Remove chains.
Ν Reverse the above to assemble and install. Use new split pins in chain anchor pins. Refer to this
section for Load chain lubrication and adjustment.
(5) Carriage chain
Η Place a sling around carriage front plate and attach to an overhead hoist. Lift and secure
carriage high enough so that split and chain anchor pins on carriage can be easily be removed.
Remove chain anchor pins from carriage and drape chains out over carriage.
Θ Place a wooden block under the carriage and lower the carriage on the block.
Ι While supporting the chains, remove split pins and chain anchor pins from chain anchors.
Κ Remove chains and wash them with solvent. Refer to this section for Load chain inspection and
maintenance.
Λ Reverse the above procedure to assemble and install. Use new split pins in chain anchor pins.
Refer to this section for Load chain lubrication and adjustment.
(6) Load chain inspection and maintenance
After every 200 hours of truck operation, lift chains should be inspected and lubricated inspect for
the following chain conditions :
Η Wear
As the chain flexes on and off the chain wheel bearings, the joints very gradually wear. The
stretch a chain develops in service is due to material being worn off pin outer diameter and pitch
hole inner diameter on the inside plate.
Chain wear can be measured using a wear scale or steel tape. When chains have elongated
2%, they should be discarded. When checking chain wear, be sure to measure a segment of
chain that operates over a sheave. Do not repair chains by cutting our the worn section and
splicing in a new piece. If part of the chain is worn, replace all the chains on the truck.

8-18
Θ Rust and corrosion
Chains used on lift trucks are highly stressed precision components. It is very important that the
“as-manufactured” ultimate strength and fatigue strength be maintained throughout the chain
service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or
roller chain because corrosion causes side plate cracking.
Ι Cracked plate
The most common cause of plate cracking is fatigue failure. Fatigue is a phenomenon that
affects most metals and many plastics. After many repeated heavy loads, the plates may crack
and the chains will eventually break. Fatigue cracks are almost always found through the pitch
holes perpendicular to the pitch line. Contrast this failure mode to the random failures caused by
stress-corrosion cracking. If cracks are present, replace all the chain on the truck. Noise in the
chain indicates that the plate is on the verge of cracking and will be failed before long.
Κ Tight joints
All joints in lift chain should flex freely. Tight joints resist flexure, increase internal friction, thus
increasing chain tension required to lift a given load. Increased tension accelerates wear and
fatigue problems.
Tight joints in lift chains can be caused by :
ÂBent pins or plates.
ÂRusty joints.
ÂPeened plate edges.
Oil rusty chains and replace chains with bent or peened components.
Λ Protruding or turned pins
Heavily loaded chains operating with lube generate tremendous friction between pins and plates.
In extreme cases, the frictional torque in the joint can actually turn pins in the press-fit outside
plates. If chain is allowed to operate in this condition, the pins slowly work out of the chain
causing chain failure. Turned pins can be quickly spotted because the flats on the V heads are
no longer in line. Chains with turned or protruding pins should be replaced immediately. Do not
attempt to repair the chain by driving pins back into the chain.
Μ Chain side wear
A wear pattern on pin heads and outside plates indicates misalignment. This condition damages
chain and sheaves as well as increasing internal friction in the chain system.
Ν Chain anchors and chain wheel bearings
An inspection of the chain system includes a close examination of chain anchors and chain
wheel bearings. Check chain anchors for wear, breakage and misalignment.
Anchors with worn or broken fingers should be replaced. Anchors should be adjusted to
eliminate twisting or other misalignment in the chain. When chain is misaligned, load is not
distributed uniformly between the plates. Prolonged operation will result in premature fatigue
failure. Chain wheel bearings with badly worn flanges and outside diameter should be replaced.
Heavy flange wear indicates chain misalignment.

8-19
 Ξ Chain wear scale
The chain can be checked for wear or stretching with the use of a chain wear scale. Stretching of
a chain is due to the elongation of the pitch holes and wearing of the pin O.D. The greatest
amount of stretching occurs at the areas of the chain that flex over the sheaves most frequently.
Check the chain at this point with a scale. The wear scale has instructions printed on the sides
for use in determining chain stretch and are as follows :
ÂDetermine pitch length of chain using 6 inch scale on one side of wear scale.
ÂIf pitch is 1/2(12.7mm), 3/4(19.05mm), 1(25.4mm), 1-1/2(38.1mm), 2(50.8mm), use side A of scale.
ÂIf pitch is 5/8(15.875mm), 1-1/4(31.75mm) or 2(50.8mm), use side B.
ÂAlign point A or B to center of a pin and note position of the opposite A or B point.
ÂIf other point also lines up with a pin, the chain is worn and should be replaced.
If any of the above conditions exists(cracked plates, turned pins, stretching etc), the chains should
be replaced in pairs as a complete assembly. Order chains by part number to insure the correct
chain length, pitch and material specifications.
(7) Load chain lubrication and adjustment
Η Lubrication
The most important consideration in field maintenance of lift chains is lubrication. Hard working,
heavily loaded chains cannot be expected to give satisfactory wear life without scheduled
periodic re-lubrication. Like all bearing surfaces, the precision manufactured, hardened steel,
joint-wearing surfaces require a film of oil between mating parts to prevent rapid wear. Oil must
penetrate the chain joint to prevent wear. Applying oil to external surfaces will prevent rust, but oil
must flow into the live bearing surfaces for maximum wear life. Frequency of re-lube will vary with
operating conditions and environment, the best estimate of lube period is 200 hours. Trucks
parked outdoors or trucks in extremely severe service, may require more frequent re-lube to
maintain an oil film on all chain surface.
ÂWipe off the old oil with a clean cloth and blow out the remaining dirt with compressed air.
Wear eye protection.
ÂWith a clean brush, apply EP-140 extreme pressure lubricant or heavy motor oil(40W).
Θ Replacement
Replace chains as a pair. It will be virtually impossible to maintain uniform loading between the
strands if a new chain is put into service opposite an old chain. The joints in the old chain will be
greater than that on the new chain, greatly complicating the problem of maintaining equal chain
tension. The new chain will wear more slowly causing it to bear the major portion of the load
resulting in premature wear and fatigue failure. Don’t steam clean or decrease new chains.
The manufacturer’s grease is effective in reducing wear and corrosion. If the original factory lube
is dried out or wiped off, soak the new chain in heavy engine oil for at 1/2 hour prior to installing
on truck. After the old chains have been stripped from the mast, very carefully inspect chain
anchors and chain wheel bearing. Broken, cracked or worn anchor must be replaced using the
new anchor pin and split pin. Do not paint newly replaced chain after it has been installed.

8-20
Ι Adjustment
Chain adjustments are important for the following reasons :
ÂEqual loading of chain.
ÂProper sequencing of mast.
ÂPrevent over-stretching of chains.
ÂPrevent chains from jumping off sheaves if they are too loose.
Κ Adjustment procedure
ÂWith mast in its fully collapsed and vertical position, lower the fork to the floor.
ÂAdjust the chain length by loosening or tightening nut on the chain anchor.
After making adjustment on the mast, be sure to tighten the nut.

8-21