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Hyundai 60L-7A, Manual

The Hyundai 60L-7A is a powerful and reliable forklift designed to enhance productivity in various industrial settings. To optimize its performance, it is essential to refer to the user manual. Download this manual for free from our website and unlock the full potential of your Hyundai 60L-7A forklift.

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SECTION  3  POWER TRAIN SYSTEM

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

Group   2  Inspection and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-14

Group   3  Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-22

Group   4  Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-58

Summary of Contents for 60L-7A

Page 1: ...EM Group 1 Structure and function 4 1 Group 2 Operational checks and troubleshooting 4 8 Group 3 Tests and adjustments 4 10 SECTION 5 STEERING SYSTEM Group 1 Structure and function 5 1 Group 2 Operational checks and troubleshooting 5 11 Group 3 Disassembly and assembly 5 13 SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function 6 1 Group 2 Operational checks and troubleshooting 6 15 Group 3 Dis...

Page 2: ...SECTION 8 MAST Group 1 Structure 8 1 Group 2 Operational checks and troubleshooting 8 4 Group 3 Adjustment 8 7 Group 4 Removal and installation 8 10 ...

Page 3: ...ECTION 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 se...

Page 4: ...ion before you start any work Filing method See the page number on the bottom of the page File the pages in correct order Following examples shows how to read the page number Example 1 2 3 Item number 2 Structure and Function Consecutive page number for each item Additional pages Additional pages are indicated by a hyphen and number after the page number File as in the example 1 2 3 Symbol Item Re...

Page 5: ...point one place to the left to convert it to 55mm Carry out the same procedure as above to convert 55mm to 2 165 inches 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 1 2 1 2 3 1 2 3 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...

Page 6: ...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 9...

Page 7: ...2 455 22 719 22 983 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon 1ℓ 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139 8...

Page 8: ...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...

Page 9: ...280 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 233...

Page 10: ...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 ...

Page 11: ...SECTION 1 GENERAL Group 1 Safety hints 1 1 Group 2 Specifications 1 5 Group 3 Periodic replacement 1 13 ...

Page 12: ...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 Flames should never be used instead of lamps Never use a naked flame to check leaks or the lev...

Page 13: ...nce and fall Hand a caution sign in the operator s compartment For example Do not start or Maintenance in progress This will prevent anyone from starting or moving the machine by mistake It is extremely dangerous to try to check the fan belt tension while he engine is running When inspecting the engine is running parts or near such parts always stop the engine first Before checking or servicing ac...

Page 14: ... you have special instructions to the contrary maintenance should always be carried out with the engine stopped If maintenance is carried out with the engine running there must be two men present one sitting in the operator s seat and the other one performing the maintenance In such a case never touch any moving part Always remember that the hydraulic oil circuit is under pressure When feeding or ...

Page 15: ... 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 pers...

Page 16: ...OR COMPONENTS 1 Steering wheel 2 Mast 3 Lift chain 4 Lift cylinder 5 Cluster 6 Backrest 7 Carriage 8 Forks 9 Tilt cylinder 10 Front wheel 11 Bonnet 12 Rear wheel 13 Counterweight 14 Seat 15 LPG tank 16 Clamp 17 Overhead guard 18 Rear combination lamp 19 Turn signal lamp 20 Head lamp 21 Sub bonnet ...

Page 17: ...78 1604 3620 Capacity Load center Weight Unloaded Model Unit 60L 7A 70L 7A Lifting height Free lift Lifting speed Unload Load Lowering speed Unload Load L W T Tilt angle Forward Backward Max height Min height Travel speed Unload Gradeability Load Min turning radius Outside 6000 600 8990 3000 140 420 450 500 1200 150 64 15 10 4275 2515 22 4 44 2 3315 7000 9670 39 4 3360 Fork Mast Body G H I J K M M...

Page 18: ...s rpm kgf m rpm ℓ U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification GM 4 3L V6 4 cycle in line Vertical OHV Water cooling 6 cylinders V6 Push rod actuated overhead valve 101 6 88 39 4 3 48 4294 262 9 4 95 2300 34 1400 6 1 6 220 485 2400 750 12 1 7 12 70A 12 80 10 15 0 4 0 6 Item Type Capacity Rated pressure Rated speed Max Min cc rev bar rpm Fixed displacement gear pump 35 6 27 9 7 6...

Page 19: ...le Rear steer FR RR DE 280 KAPEC 3 Element 1 stage 2 phase 2 25 1 Power shift 2 2 Electrical single lever type 1 2 550 2 1 29 1 2 550 2 1 29 Front wheel drive type fixed location 10 545 8 25 15 14 PR 8 25 15 14 PR Front wheel wet disc brake Rachet wet dis brake Full hydraulic power steering 75 87 to both right and left angle respectively Travel Parking Type Steering angle Overhaul ratio ...

Page 20: ...ring axle mounting bolt nut Front wheel mounting nut Rear wheel mounting nut Counterweight mounting bolt Operator s seat mounting nut Head guard mounting bolt M16 2 0 M10 1 5 M16 2 0 M12 1 75 M10 1 5 M24 2 0 M18 2 0 M22 1 5 M22 1 5 M30 3 5 M 8 1 25 M12 1 75 13 5 4 0 5 7 5 10 1 4 0 5 100 15 41 3 6 2 61 2 61 2 120 15 2 5 0 5 6 2 97 6 28 9 3 6 54 2 72 3 7 2 28 9 3 6 723 108 299 44 8 443 443 1555 239 ...

Page 21: ...2 12 6 19 7 29 8 39 8 60 71 114 121 167 182 247 254 343 356 482 476 709 615 832 1223 1655 1808 2242 lbf ft 8T 10T Fine thread 2 Bolt size M 8 1 0 M10 1 25 M12 1 25 M14 1 5 M16 1 5 M18 1 5 M20 1 5 M22 1 5 M24 2 0 M30 2 0 M36 3 0 kgf m 2 17 3 37 4 46 6 66 7 78 11 58 13 3 18 1 19 9 26 9 28 6 43 6 40 0 54 0 52 7 71 3 67 9 91 9 137 185 192 260 lbf ft 15 7 24 3 32 3 48 2 76 3 83 7 96 2 130 144 194 207 3...

Page 22: ... 7 130 152 253 PIPE AND HOSE ORFS TYPE Thread size 9 16 18 11 16 16 13 16 16 1 3 16 12 1 7 16 12 1 11 16 12 Width across flat mm 19 22 27 36 41 50 kgf m 4 5 9 5 18 21 35 lbf ft 28 9 36 2 68 7 130 152 253 2 3 FITTING Thread size 1 4 3 8 1 2 3 4 1 1 1 4 Width across flat mm 19 22 27 36 41 50 kgf m 4 5 9 5 18 21 35 lbf ft 28 9 36 2 68 7 130 152 253 4 ...

Page 23: ...10 14 0 32 10 50 20 68 30 86 40 104 ATF Engine oil Gear oil 15ℓ 4 0 94 24 8 20 0 25 0 06 21 5 5 7 ISO VG32 SAE 10W 30 API SL class or better ATF DEXRON III Mobil Fluid 424 LPG Azolla ZS10 Hydraulic oil ISO VG10 NLGI No 1 NLGI No 2 ISO VG68 ISO VG46 Ethylene glycol base permanent type 11 5ℓ 3 0 SAE numbers given to engine oil should be selected according to ambient temperature For engine oil used i...

Page 24: ...ith 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 Description Period of replacement Dust seals for master cylinder Brake hose or tube Brake reservoir tank tube Power steering hose Hydraulic pump hose Fuel hose Packing seal and O ring of steering cylinder Lift chain Lift and tilt cylinder ...

Page 25: ...SECTION 2 REMOVAL INSTALLATION OF UNIT Group 1 Structure 2 1 Group 2 Removal and installation of unit 2 2 ...

Page 26: ...c pump 10 Transmission 11 Torque converter 12 Engine 13 Air cleaner 14 Exhaust pipe 15 Steering axle 16 Steering cylinder 17 Rear wheel 18 Tail pipe 19 Radiator 20 Muffler 21 LPG tank 22 Overhead guard 23 Seat 24 Control lever 25 Steering wheel 26 Drive shaft 1 2 3 5 6 22 23 24 25 7 8 9 10 18 21 11 12 13 14 15 16 17 20 26 19 4 60L7AOM23 ...

Page 27: ...s it may be necessary to use a block of wood 1 Center notch Roll pin Knob Spring Pin Fork Carriage Backrest 60L7ARE04 Backrest If necessary Remove bolts securing backrest to fork carriage lift backrest straight up and remove it from carriage 2 Carriage Backrest Bolt 60L7ARE05 Carriage With the mast vertical raise the carriage high enough to place blocks under the load forks This is done to create ...

Page 28: ... over the front of the carriage Carriage Block Mast Lift chain 60L7ARE07 Slowly raise inner mast upright until mast clears top of fork carriage Move carriage to work area and lower the mast Make sure that carriage remains on floor and does not bind while mast is being raised Inspect all parts for wear or damage Replace all worn or damaged parts Carriage Inner mast Lift chain 60L7ARE08 ...

Page 29: ...cylinder Loosen and remove hexagon bolts and washers securing lift cylinders to inner mast Bind the lift cylinder with overhead hoist rope and pull up so that the rope has no slack or binding Make sure the lift cylinder be tightened firmly for safety Loosen and remove hexagon bolts nuts and clamp securing lift cylinders to outer mast Using an overhead hoist slowly raise the inner mast high enough ...

Page 30: ...ch a crane to the stay at the top of the outer mast and raise enough to sustain jacked up machine This operation is carried out under the machine so use a pit or if there is no pit jack up the machine and loosen with an impact wrench Loosen the mounting socket bolts and remove the mast mounting pins Then slowly raise the outer mast 7 8 Outer mast Socket bolt Tilt cylinder pin Tilt cylinder Mast mo...

Page 31: ... 0 04in 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 Mast mounting pin Check the mast mounting pins for wear then install pins into the mast support bracket Jack up the machine so that the front is raised and then using an overhead hoi...

Page 32: ...2 7 Mast Refer to section on mast Page 2 2 1 2 POWER TRAIN ASSEMBLY REMOVAL 1 D503RE04 ...

Page 33: ...1 Drive axle Before removing the drive axle unit drain all of the oil from the axle Loosen hexagonal bolts connecting drive axle to the transmission If there is a pit use the pit for safety Jack up the machine and then put the block under the frame Prepare the truck under the drive axle unit to support it Remove trunnion fixing the axle to the frame and then carefully draw the truck out of the veh...

Page 34: ...connector from the transmission Make sure that the oil be drained from the hose 6 Bolt Cover Torque converter Transmission 60L7ARE18 Torque converter Remove the cover on top face of the torque converter housing then remove the 4 mounting bolts installed on the engine flywheel To rotate the flywheel remove 1 mounting bolt then insert a turning tool in the mounting hole One man must turn the engine ...

Page 35: ...l but be careful of the following points Tightening torque Bolt 1 10 bolts for upper side of flywheel housing 3 5 4 2kgf m 25 3 30 3lbf ft Bolt 2 3 5 4 2kgf m 25 3 30 3lbf ft 1 2 2 Bolt 1 Bolt 2 60L7ARE21 Mounting bolt 60L7ARE19 Mounting bolts holding to flywheel housing Remove the transmission assembly from the engine flywheel by loosening the mounting bolts 8 ...

Page 36: ...nt axle inside the frame then remove the engine assembly REMOVAL 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 1 1 D503RE25 60L7ARE22 ...

Page 37: ... 4 Engine 60L7ARE23 60L7ARE24 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 5 INSTALLATION Installation is the reverse order of removal but be careful of the following points Tighten the engine mounting bolts and nuts Tight...

Page 38: ...77in Air cleaner hose Insert the air cleaner hose securely and fit a clamp Distance to insert hose Air cleaner hose 45mm 1 77in Engine end 60mm 2 36in 3 4 Engine Air cleaner Tail pipe Muffler Loctite 243 Exhaust pipe Exhaust pipe Engine Engine 60L7ARE26 ...

Page 39: ...d 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 Tightening torque 199 30 kgf m 1440 216lbf ft 1 1 60L7ARE27 60L 7A 70L 7A 2690kg 5930lb 3250kg 7165lb ...

Page 40: ...ving them Remove the fitting and then disconnect the hoses 3 Hose Steering axle 60L7ARE29 Mounting bolt Put a block under the 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 There are shims between the support and steering axle to prevent play 4 Steering axle Support Support Mounting bolt 60L7ARE30 ...

Page 41: ...SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and operation 3 1 Group 2 Inspection and troubleshooting 3 14 Group 3 Disassembly and assembly 3 22 Group 4 Adjustment 3 58 ...

Page 42: ...egularly 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 1 POWER TRAIN COMPONENT OVERVIEW STRUCTURE 1 Torque converter 2 T M oil leve...

Page 43: ...t Gear ratio Axle oil Oil quantity Service brake Brake oil Parking brake Gear type Differential type ℓ cc rev ℓ 3 elements 2 phase 1 stage Torque converter POWER SHIFT F2 R2 4 97 1 55 Included DEXRON 3 13 Electric 20 6 2 636 4 10 545 MOBILFLUID 424 12 5 Wet disk brake AZOLA ZS10 Ratchet drum brake Spiral bevel gear 4 pinions FR RR 1 stage FR RR 2 stage Differential Planetary Total Brake SPECIFICAT...

Page 44: ...r comes from the transmission oil pump The oil flows through a small passage in stator support 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 2 TORQUE CONVERTER STRUCTURE 1 2 A B C D Torque converter input plate Torque converter pump gear Pilot boss outer diameter Oil seal outer d...

Page 45: ...uses turbine and the input shaft to turn This sends touque 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 is the same as the speed of impeller stator clutch permits the stator to turn freely with engine rotation but it locks holds to prevent opposite rotation to en...

Page 46: ... and gives two forward and two reverse speeds The transmission has four cluthces that are engaged hydraulically and released by spring force The direction and speed are changed electrically Damage can be caused to the transmission if the truck is moved with the engine not running There will be no lubrication to the transmission components 3 TRANSMISSION 1 Torque converter 2 Input shaft 3 3 P T O g...

Page 47: ...E INPUT 50DF7TA04 Selection of either forward or reverse gear makes all of the parts inside the T M operate 1 Cylinder clutch FR 2 Gear FR 2nd stage 3 Gear FR 1st stage 4 Cylinder clutch RR 5 Gear RR 2nd stage 6 Gear RR 1st stage 7 Gear Output 1st stage 9 Gear Output 2nd stage 10 Output gear TRANSMISSION GEAR ARRAY 3 ...

Page 48: ...f cm2 psi kgf cm2 psi RR 1 2 stage clutch 10 0 13 2 142 2 187 7 10 0 13 5 142 2 192 0 10 0 15 5 142 2 220 5 FR 1 2 stage clutch 10 0 13 2 142 2 187 7 10 0 13 5 142 2 192 0 10 0 15 5 142 2 220 5 T Converter Neutral 4 2 7 2 59 7 102 4 Main line Neutral 10 0 13 2 142 2 187 7 10 0 13 5 142 2 192 0 10 0 15 5 142 2 220 5 Engine rpm Idle 800 1200 1800 2400 2500 TRANSMISSION INPUT PORT 4 Reference Clutch ...

Page 49: ...spider is meshed vertically between 4 pinions 1 and 2 side gear 5 so the engagement become a right angle 3 8 4 DIFFERENTIAL CARRIER ASSEMBLY No 1 2 3 4 5 Item Differential pinion gear inner diameter Spider outer diameter Pinion gear washer Side gear washer Side gear Specification 20 000 20 021 0 787 0 788 19 959 19 980 0 786 0 787 1 92 2 08 0 076 0 082 1 95 2 05 0 077 0 081 Unit mm in mm in mm in ...

Page 50: ... drive axle is composed of differential carrier assy 1 drive shaft 2 and drive wheel 3 The power is transmitted from the engine fly wheel to the transmission The power of transmission is transmitted to the spiral bevel gear through the output gear of the transmission Then the power of differential is transmitted to the wheel through the drive shaft ...

Page 51: ...xle which consists of differential carrier assembly 9 drive shaft 8 and hub assembly 6 transmits the drive force from transmission to the wheels Pinion shaft 11 is connected to transmission output through universal joint 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 8 Side gear 14 and drive s...

Page 52: ...lling resistant Parking brake Brake drum 2 2 0 3kgf m 15 9 2 2lbf ft 12 0 5kgf m 86 8 3 6lbf ft 1 5 0 1kgf m 10 8 0 7lbf ft 1 0 0 2kgf m 7 2 1 4lbf ft 16 0 5kgf m 116 3 6lbf ft 6 0 0 5kgf m 43 4 3 6lbf ft 13 5 0 5kgf m 97 6 3 6lbf ft 18 0 0 5kgf m 130 3 6lbf ft 3 0 0 3kgf m 21 7 2 2lbf ft 20 0 0 9kgf m 144 7 6 5lbf ft 12 0 0 5kgf m 86 8 3 6lbf ft DRIVE AXLE TIGHTENING TORQUE 3 No Item Specificatio...

Page 53: ... adjust of friction plate clearance it s easy to prevent the brake 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 DISK BRAKE 4 1 Spindle 2 Steel plate 3 Disk plate...

Page 54: ...ts to absorb the shock from the ground surface to the machine and at the same time they must rotate in contact with the ground to gain the power which drives the machine Various types of tires are available to suit the purpose Therefore it is very important to select the correct tires for the type of work 1 2 B507AX68 ...

Page 55: ...s detected inside the filter check metallic friction inside the T M or mechanical faults If rubber particles detected check seal or hose defects If Aluminum particles detected check converter or control valve damage If metal or rubber particles found clean all of the T M hydraulic parts Replace damaged parts with the new one DRIVE CHECK Fill T M oil to the proper level before starting the machine ...

Page 56: ... the intake side of the pump Low oil flow through converter Wrong application for vehicle loads are too heavy for the lift truck Too much inching operation slipping the clutch plates and discs Too much stalling of torque converter Cooler bypass valve stuck held open full oil flow does not go through oil cooler Check to oil level Check to mix another oil Check to tightening bolt or changing a contr...

Page 57: ...ve damage Leakage caused by worn or broken seal around metal sealing rings Leakage caused by worn or broken seal around clutch piston Failure of other components Solenoids or related electric components are out of order Engine performance is not correct The one way clutch of the torque converter does not hold Low oil level Air in the oil Clutches slip clutch plates slide in relation to one another...

Page 58: ... are weak or have damage Failure of clutch in the direction the lift truck moves Clutch discs or plates are warped damaged or held together because of too much heat Failure of the valve spool in the direction the lift truck moves The spool stuck held in the engaged position possibly caused by metal burrs particles or dirt Check to clutch assy and then replace to relate with other comonent Replace ...

Page 59: ...rn teeth or clutch plates and or clutch discs and slipping clutch plates and discs noise Failure of the thrust washers Other component parts have wear or damage Air in the hydraulic system Air leakage on suction side of the pump or low oil level that causes aeration Restrictions in oil passage Valve spools movement has restriction Changing is related with other componrent of charging Charging to t...

Page 60: ...w oil level Main regulator valve movement is restricted Transmission pump is worn Inner oil leakage Low oil pressure Main regulator valve stuck open so most of the flow goes to the converter A restriction inside the converter assembly A plugged restriction oil flow passage Main regulator valve movement is restricted plugged Low oil pressure Cooler bypass valve stuck open Restriction plugging in oi...

Page 61: ...pinion or side gears have a defect Thrust washers worn or have a damage Too much clearance backlash between side gears and pinions Leakage through axle hub carrier Too much oi Wrong kind of oil Much restriction on air eather Leakage around pinion shaft Too much oil Wrong kind of oil Much restriction on air eather Oil seal worn or not installed correctly Refueling lubricating oil Exchange lubricati...

Page 62: ...le shaft too short Loose flange studs or nuts Drive gear teeth have been damaged Side gear on differential damaged Differential pinion shaft or spider broken Re assemble wheel bearings Replace drive shaft Tighten studs or nuts Exchange damaged drive gear set Exchange damaged gear Exchange damaged gear 1 2 3 4 a b c ...

Page 63: ...cket bolts 3 and then gear P T O input from the the torque converter 2 D357TM02 4 5 6 35L7ADA22 1 2 3 Remove four bolts 9 and bolts 8 washes oil seal 10 from the housing converter 7 Use loctite 277 to apply to the thread of a screw 8 9 3 35L7ADA23 7 10 9 8 Remove transmission oil from transmission case then remove plug 73 spring 74 screen suction 75 4 50DFTM01 GROUP 3 DISASSEMBLY AND ASSEMBLY 73 7...

Page 64: ...ing 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 50DFTM02 Remove fasten five bolts 23 from fixed stator hub 24 and bearing plate In this time Use the plastic hammer 8 D357TM06 24 20 19 21 22 23 ...

Page 65: ...p gasket 30 then seperate to gear P T O output 25 and ball bearing 90 elbow 27 50DFTM32 Separate to two thrust washers 34 needle bearing 35 gear P T O Idle 36 from front cover 9 50DFTM33 Remove two bolts 38 nine bolts 39 valve gasket 40 valve plate 37 11 Remove eight bolts 41 five socket bolt 42 then separate valve plate 37 from transmission case 12 35L7ADA28 10 21 R2 R1 F1 F2 38 39 37 40 36 34 35...

Page 66: ...hten bolt 46 oil collector 47 then remove output shaft assembly 48 from transmission case Remove input shaft assembly 50 counter shaft assembly 51 intermediate shaft assembly 49 from transmission case 14 15 16 50DFTM05 For high speed forward clutch assembly remove bearing cone 52 with gear pulley tools 17 50DFTM06 43 76 44 77 50 51 47 49 45 48 46 52 ...

Page 67: ...ch discs and three 4T clutch plates 56 six 2T clutch plates 57 one bending plate 59 from the cylinder 20 21 50DFTM08 Push down on the retainer 60 by a jig and remove snap ring 61 with a screwdriver Slowly release the tension on the spring assembly Remove retainer 60 and spring assembly from cylinder Remove piston 62 by using compressed air then remove O ring from the shaft 22 23 24 50DFTM09 54 53 ...

Page 68: ...Slowly release the tension on the spring assembly then remove retainer and spring assembly Remove piston 62 by using compressed air then remove O ring from the shaft Disassembling procedure of input shaft assembly is the same as counter shaft assembly 27 28 29 50DFTM12 For low speed forward clutch assembly remove seal rings 66 from shaft Remove bearing 63 thrust washer 64 gear 65 needle bearing sp...

Page 69: ...3 28 50DFTM13 Remove bearing 67 and gear 68 30 68 67 ...

Page 70: ...earing 69 from output shaft assembly 48 31 Remove plug 71 from the transmission case 33 50DFTM16 Remove bearing cups 70 from the transmission case Put identification on bearing cups to use at assembly 32 50DFTM15 69 48 70 71 ...

Page 71: ...3 30 Remove oil seal 72 from the transmission case 34 50DFTM17 72 ...

Page 72: ...on on the case with the spring loaded lip of the inside seal toward the inside of the transmission case Use loctite 591 to apply to the outer diameter of a oil seal 72 1 2 Install bearing cups 70 in position on the transmission case Put identification on bearing cups to use at assembly 4 Install speed sensor 71 to transmission case 3 50DFTM17 72 50DFTM16 71 50DFTM15 70 ...

Page 73: ...ston with seal ring in cylinder Put spring assembly and retainer 60 in position in the cylinder Put the shaft assembly in a press Push down on the retainer and install snap ring 61 with a screwdriver Install pin and two thrust washes in the counter shaft of low speed clutch side Be extra careful during installation of the piston Broken seal rings can be the result 7 8 9 10 11 69 48 50DFTM13 68 67 ...

Page 74: ... has guide shape on its outside diameter Next install a clutch disc that has teeth on its inside diameter Follow steps 1 and 2 again until all of four the 2T clutch plates and discs are installed in the cylinder Install a 4T clutch plate then install a bending plate In following procedure bending plate shape will be downward Finaly install a 4T cluch plate Use a tool and install snap ring 55 that ...

Page 75: ...in the cylinder Next install a clutch disc that has teeth on its inside diameter Finally Install a clutch plate first that has guide shape on its outside diameter 15 16 1 2 3 4 5 Use a screwdriver and install snap ring 55 that check all of them in position in the cylinder Install three seal rings on the shaft Be careful not to cause damage to the seal rings Install thrust washer and needle bearing...

Page 76: ...haft Output shaft Shim thickness Y X 0 01 Y X 0 05 Y X 0 05 50DFTM20 Select shims to have 0 to 0 05mm 0 to 0 002 inch of axial tightness Assemble transmission case cover and gasket Set up transmission assembly vertically 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 tur...

Page 77: ...til the teeth are in alignment with gears of another shaft assembly Install carefully intermediate shaft assemly 49 and put between the input shaft assembly 50 and counter shaft assembly 51 Install bolt 46 fighten on the cover 47 22 23 24 25 26 27 35L7ADA41 First apply to Loctite 5172 on the transmission case then fixed Install valve plate 37 by using a eight bolts 41 and an five socket bolt 42 28...

Page 78: ...28 by using the jig then install four bolts 29 on the bearing 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 27 rubber hose 26 31 D357TM06 22 23 24 Install the stator hub assembly 24 due to bearing plate assy 21 Install bush 22 piston ring bolt 23 which assembling by each six s Then install bearing plate 32 50DFTM32 21 ...

Page 79: ... in the bearing plate Put bearing cups and their shims in the bearing plate Bearing cups and their shims should be put into their location on transmission cover so as to fit on their shafts in transmission case 33 34 35 36 37 Insert spring 74 oil screen 75 in a hole then install plug 73 38 50DFTM21 Use a plastic hammer when install tube 45 to transmission case Tube direction to charging pump outsi...

Page 80: ...to torque converter then tighten six socket bolts 6 in postion Use loctite 277 to apply to the thread of a screw 6 42 D357TM02 Install torque converter in postion Install flexible plate 1 with six bolts 3 and plate 2 Then Install torque converter housing in position 43 50DFTM22 Install yoke 44 washer 76 cork 77 nut 43 in a output shaft assembly 40 35L7ADA43 35L7ADA22 1 2 43 77 44 76 3 4 5 6 ...

Page 81: ...using and drain oil 1 REMOVAL AND DISASSEMBLY OF WHEEL HUB 1 50D7EDA01 Loosen oil drain plug in planetary housing and drain oil 2 50D7EDA02 Loosen 4 socket head bolts and remove the planetary carrier 3 50D7EDA03 Remove O ring 4 and snap ring 5 from the housing of planetary 4 50D7EDA04 ...

Page 82: ... a plastic hammer 5 50D7EDA05 Remove needle bearing 8 planet gear 7 and thrust washer 9 6 50D7EDA06 Remove sun gear 10 and drive shaft 11 7 50D7EDA07 50D7EDA08 Remove snap ring 12 and then remove sun gear 10 from the shaft 11 8 ...

Page 83: ...e the rolling resistance of tapered roller bearing 9 50D7EDA09 Remove C ring 14 from the ring gear and pull the spindle 15 out of the ring gear 10 50D7EDA10 Pull out bearing inner race on flange using 2 M8 bolts 11 50D7EDA11 Remove wheel hub from the axle housing after loosen 14 bolt and 2 nut 12 50D7EDA12 ...

Page 84: ... adjust 20 form bushing self adjust 19 Then disassemble piston 17 from axle housing 16 After checking 3 pins 23 then finally remove square ring 21 22 Do not reuse damaged square ring 14 Remove bearing cup from the wheel hub by using jig and hammer Shaft seal may be damaged 15 50D7EDA13 50D7EDA14 50D7EDA15 50D7EDA16 ...

Page 85: ...g resistance and record it After loosen 2 bolts 2 and then remove backing plate 3 2 50D7EDA18 Before removing differential assembly from carrier 4 check the location of cap 5 and mark it for reassembly Remove 4 hexagon bolts 6 and cap 5 3 4 50D7EDA19 2 Remove differential assembly from the carrier Disassemble bearing 6 from the differential housing and remove 12 bolts 7 5 6 50D7EDA20 ...

Page 86: ...g 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 8 Remove thrust washer side gears pinion gears and spider and then place them on the clean place 8 Loosen 4 bolts 10 and then remove the drum from the parking brake 50D7EDA21 50D7EDA22 50D7EDA23 50D7EDA24 10 ...

Page 87: ...ful not to damage bevel pinion shaft 11 12 13 Remove shim 16 and spacer 17 from pinion shaft Using a bearing puller disassemble inner race of taper roller bearing from the pinion shaft 12 Remove outer race of taper roller bearing and shim from the housing by using a jig and hammer Do not reuse damaged shims 13 Remove outer race of taper roller bearing on the opposite side 14 50D7EDA25 50D7EDA26 50...

Page 88: ...tacted if needed Adjusting shims of bevel pinion shaft Adjust shim thickness for the bevel pinion shaft with following method Measure E distance on the housing By the equation X E B T C 0 25 define the shim thickness 1 B Mounting dimension of bevel pinion shaft 131 10mm 5 2 in T Height of bearing C Dimension of carved seal on the pinion If there s no carved seal C 0 EX From the housing E 162 85mm ...

Page 89: ...el pinion shaft end Measure shim thickness by following method Dimension Q Distance from bearing outer race surface to spacer surface Dimension S Distance from bearing outer race surface to inner race surface From the below equation define required shim thickness Z Z S Q EX From the bearing S 2 25mm 0 09in From the housing Q 3 15mm 0 12in Needed shim thickness Z 3 50D7EDA32 50D7EDA33 50D7EDA34 P 2...

Page 90: ... 2 Insert pinion shaft into the carrier 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 Tightening torque 45 51kgf m 325 369lbf ft Measure rolling resistance of pinion shaft Rolling resistance 0 20 0 41kgf m 1 4 2 9lbf ft Coke lock nut into the pinion shaft slot 2 ...

Page 91: ... 50D7EDA38 3 Tighten 12 bolts 1 to the differential housing Apply loctite 271 or 277 on the thread of bolt Tightening torque 5 0 7 5kgf m 36 54lbf ft Assemble differential housing Check marks on the housing Match two marks at the same position 3 Assemble ring gear by tightening 12 bolts 2 Apply loctite 271 or 277 on the thread of bolt Tightening torque 12 5 14 5kgf m 90 105lbf ft 4 50D7EDA39 50D7E...

Page 92: ... 6 Confirm that the screw contacts to the bearing After complete assembly of bearing measure rotation backlash once more and readjust with a screw if needed Apply loctite 271 to the thread of bearing cap bolt and then assemble it with tightening torque of 15 0 17 0kgf m 108 123lbf ft Assemble plate with hexagon bolts Apply loctite 271 or 277 to the tapped side of bolt and then assemble it with tig...

Page 93: ... and then assemble it with tightening torque of 11 13kgf m 79 6 94 0lbf ft Close hole 3 with rubber plug 3 4 50D7EDA43 ADJUSTMENT OF PARKING BRAKE The following procedures should be applied for brake shoe adjustment Open rubber plug on 2 Adjuster should be turned according to arrow direction until occurring drum drug Adjuster should be turned opposite direction of the arrow sign by four click At t...

Page 94: ...direction outer side of wheel hub 1 50D7EDA45 6 Install wheel hub assembly to the spindle completely 2 50D7EDA46 Insert the spindle into ring gear and secure with circlip 3 Place heated tapered roller bearing inner race into the spindle until contact take places Install it on the wheel hub after cooling down 4 50D7EDA47 50D7EDA48 ...

Page 95: ...obilfluid 424 Assemble bushing 5 to piston 2 and then assemble piston 2 to axle housing after applying oil sufficiently and then assemble the spring 6 to the bushing 5 Also apply loctite 271 to 4 bolts 7 then assemble them with tightening torque 14 16kgf m 101 3 115 7lbf ft Assemble 3 brake pins 8 to axle housing Check the status of square ring and replace if damaged 6 50D7EDA50 50D7EDA51 50D7EDA5...

Page 96: ...all of the parts completely and remove burrs After assembling confirm that the clearance between the outer plate and the axle housing surface is 2 1 2 6mm 0 08 0 10in 50D7EDA53 50D7EDA54 50D7EDA55 50D7EDA56 Push pre assembled wheel hub to the axle housing until contact take places 7 Tighten the torque plate until the wheel hub assembly has the same rolling resistance as before Apply loctite 271 or...

Page 97: ...anetary carrier assembly to wheel hub and tighten bolt 2 Tightening torque 25 40kgf m 180 9 289 3lbf ft 11 50D7EDA58 50D7EDA59 50D7EDA60 50D7EDA57 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 9 ...

Page 98: ...3 57 Assemble wheel hub and tighten plug 14 Tightening torque 35 60kgf m 253 2 434 0lbf ft 12 50D7EDA61 ...

Page 99: ...The runout must not exceed 0 20mm 0 008inch If runout exceeds specification remove the differential and ring gear assembly from the carrier Refer to Disassembling the differential carrier assembly Check the differential parts including the carrier for problems that may cause the ring gear runout to exceed specifications Repair or replace parts Re install the differential and ring gear into the car...

Page 100: ...tor while rotating the ring gear a small amount in both directions against the drive pinion teeth When you adjust backlash move the ring gear ONLY DO NOT move the drive pinion If the backlash reading is within specifi cation continue checking tooth contact patterns Otherwise adjust backlash Refer to step 6 and check following steps 1 4 Backlash is increased by moving the ring gear away from the dr...

Page 101: ...s toward the toe of the tooth and centered between the top and bottom of the tooth In used gearsets a good contact pattern fills approximately the full length of the tooth The top of the pattern is near the top of the tooth The location should match the wear pattern on the tooth If the contact patterns require adjustment along the width of tooth top bottom follow steps 4 5 If the contact patterns ...

Page 102: ...on bearing cage Low pattern A low contact pattern indicates that the pinion was installed too deep into the carrier To correct move the pinion away from the ring gear by increasing the shim pack between pinion spigot and inner bearing cone Refer to Assembling the pinion bearing cage 4 5 D507AX61 LOW PATTERN D507AX62 GOOD PATTERN IN OPERATION USED GEARS D507AX63 Decrease shim pack D507AX64 Increase...

Page 103: ...sting ring this side Heel pattern Decrease the gearset backlash within specified range to move contact pattern toward toe and away from heel Refer to Adjusting the gearset backlash Toe pattern Increase the gearset back lash within specified range to move contact pattern toward heel and away from toe Refer to Adjusting the gearset backlash 6 7 Move pattern toward toe Move pattern toward heel ...

Page 104: ...SECTION 4 BRAKE SYSTEM Group 1 Structure and function 4 1 Group 2 Operational checks and troubleshooting 4 8 Group 3 Tests and adjustments 4 10 ...

Page 105: ...e 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 GROUP 1 STRUCTURE AND FUNCTION SECTION 4 BRAKE SYSTEM 1 OUTLINE 1 2 Item Type Parking lever stroke Parking cable stroke Ratchet internal expanding mechanical type 82mm 3 2in 16mm 0 62in Specification Item...

Page 106: ...4 2 3 BRAKE PEDAL AND PIPING STRUCTURE 1 2 4 T M control valve 3 Drive axle 60L7ABS03 1 Brake pedal bracket assembly 2 Parking lever assembly 3 Reservoir tank assembly 4 Brake valve 1 ...

Page 107: ...f 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 4 INCHING PEDAL AND LINKAGE 20 25mm 0 8 1 0in 2 4mm 0 1 0 15in 115mm 4 52in 20mm Default Inching link assy Inching cable assy T M control valve Inching spool 60L7ABS04 ...

Page 108: ...um 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 1 Spindle 2 Steel ...

Page 109: ... Push rod 4 Bellows 5 Master piston 6 Lock washer 7 Piston ball 8 Piston ring 9 Servo piston 10 Servo spring 11 U cup seal 12 U cup seal 13 U cup seal 14 U cup seal 15 Relief piston 16 Relief spring 17 Relief plug 18 O ring 19 O ring 20 Ball 21 O ring 22 Spring 23 Gauge 24 Air bent 25 Plug 26 O ring 27 Bolt 28 Spring washer 1 35D7EBV00 ...

Page 110: ...sing 2 servo spring 10 servo piston 9 and master piston 5 2 1 5 9 10 2 35D7EBV02 Remove relief plug 17 with O ring 18 relief spring 16 and relief piston 15 3 Front housing 15 16 17 18 35D7EBV03 Remove O ring 19 check plug 25 with O ring 26 cage 23 check spring 22 check ball 20 and O ring 21 4 Rear housing 26 22 23 21 19 25 20 35D7EBV04 ...

Page 111: ...her with mineral or with hydraulic oil according to their use destination All single parts are to be checked for damage and replaced if required Assembly is in opposite order to disassembly Seal kit XKAU 00176 Use only brake fluid Azola ZS10 into the compensation reservoirs 1 2 3 4 3 ...

Page 112: ...at low speed and check braking effect of parking brake BRAKE PIPING Check pipes hoses and joints for damage oil leakage or interference 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 GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1 OPERATIONAL CHECKS 1 1 2 2 1 2 1 2 15L7ATA19 ...

Page 113: ... Brake valve return port clogged Hydraulic system clogged Wheel bearing out of adjustment Adjust Replace Clean Clean Adjust or replace 2 TROUBLESHOOTING Brake chirps Brake trailing Piston fails to return Disc worn Disc surface roughened See above Brake trailing Replace Replace Repair by polishing or replace Brake squeaks Disc surface roughened Disc worn Excessively large friction between disc plat...

Page 114: ...el filled with hydraulic oil Loosen air vent plug by turning it 3 4 with a wrench Depress brake pedal to drain oil mixed with air bubbles from plug hole Depress brake pedal until no air bubbles come out of air vent plug hole After completion of air bleeding securely tighten air vent plug Install cap on plug 1 2 3 4 5 6 7 Vessel Disk brake Vinyl tube Air vent plug Drive axle 50DF7BS53 2 4mm 0 1 0 1...

Page 115: ...switch stroke when parking brake is applied 2 3mm 0 08 0 1in INCHING PEDAL Pedal height from cross plate Adjust with stopper bolt Pedal height 115mm 4 52in Adjust bolt so that brake pedal interconn ects with inching pedal at inching pedal stroke 20 25mm 0 8 1 0in 2 1 2 20 25mm 0 8 1 0in 115mm 4 52in 60L7ABS07 Microswitchforparkingbrake ifequipped 3 23 82 Knob Parking cable Pin Nut Parking switch P...

Page 116: ...SECTION 5 STEERING SYSTEM Group 1 Structure and function 5 1 Group 2 Operational checks and troubleshooting 5 11 Group 3 Disassembly and assembly 5 13 ...

Page 117: ...ring 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 structu...

Page 118: ...AULIC CIRCUIT 1 6 3 9 4 EF CF LS 13 5MPa T LS P L R T M From Axle To Axle Brake valve MCV 14 60L7ASE02 1 Hydraulic gear pump 3 Steering unit 4 Priority valve 6 Steering cylinder 9 Suction filter 14 Hydraulic tank ...

Page 119: ... 1 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 ...

Page 120: ...olumn 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 machi...

Page 121: ...olumn 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 mac...

Page 122: ...seal 2 Retaining ring 3 Cap seal 4 Thrust bearing 5 Ball 6 Pin 7 Spacer 8 Center spring 9 Washer 10 O ring 11 O ring 12 Rolled screw 13 Gerotor set 14 Bearing race 15 Bore screw 16 Drive shaft 17 End cap 18 Bushing 19 Plate 20 Cap screw 21 Housing 22 Spool 23 Sleeve 24 Plate spring 25 Relief valve 25 1 Plug 25 2 O ring 25 3 Spring seat 25 4 Spring 25 5 Spool 25 6 Bushing 26 Check valve 26 1 Guide ...

Page 123: ...lug 4 End plug 5 Spring 6 O ring 1 OPERATION The oil from the hydraulic gear pump flows to the priority valve The priority valve supplies a flow of oil to the steering system and lift tilt system The steering flow is controlled by the steering unit to operate the steering cylinder The remainder of the oil flow from the pump flows to the main control valve 2 7 Orifice ...

Page 124: ... 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...

Page 125: ...asher 22 Split pin 23 Grease nipple 24 Hub 25 Hub bolt 26 Taper roller bearing 27 Taper roller bearing 28 Oil seal 29 Special washer 30 Lock nut 31 Split pin 32 Hub cap 33 Steering cylinder 35 Cover 36 Hexagon bolt 38 Support 39 Bushing 41 Steer cylinder boot 42 Clamp 43 Hub nut 44 Shim 1 0t 45 Shim 0 5t 46 Hexagon bolt 47 Hardened washer 1 38 2 41 38 4 7 8 9 10 11 13 12 14 15 16 17 19 20 23 24 25...

Page 126: ... m 443 lbf ft 35 1 47 5 kgf m 253 343 lbf ft 50DS7ESE07 Type Structure of knuckle Toe in Camber Caster King pin angle Maxsteeringangleof wheels Inside Outside Tread Unit degree degree degree degree degree mm in Elliott type 0 0 0 0 75 87 51 43 1604 63 1 Center pin support single shaft ...

Page 127: ...in contact with hub and measure camber If camber is not within 0 0 5 rear axle is bent Ask assistant to drive machine at minimum turning radius Fit bar and a piece of chalk at outside edge of counterweight to mark line of turning radius If minimum turning radius is not within 100mm 4in of specified value adjust turning angle stopper bolt Min turning radius Outside 60L 7A 70L 7A 3315mm 131in 3360mm...

Page 128: ... Insufficient or variable oil flow Flow control valve orifice clogged Clean Insufficient or variable dischar ge pressure Piping Pipe from tank to pipe dented or clogged Repair or replace Steering cylinder head leakage Piston rod Packing foreign material Piston rod damage Rod seal damage and distortion Chrome gilding damage Replace Grind surface with oil stone Replace Grind Steering cylinder head t...

Page 129: ... 24 15 50DS7ESE05 1 Dust seal 2 Retaining ring 3 Cap seal 4 Thrust bearing 5 Ball 6 Pin 7 Spacer 8 Center spring 9 Washer 10 O ring 11 O ring 12 Rolled screw 13 Gerotor set 14 Bearing race 15 Bore screw 16 Drive shaft 17 End cap 18 Bushing 19 Plate 20 Cap screw 21 Housing 22 Spool 23 Sleeve 24 Plate spring 25 Relief valve 26 Check valve ...

Page 130: ...5 14 TOOLS Holding tool 2 1 Assembly tool for O ring and kin ring 2 Assembly tool for lip seal 3 Assembly tool for cardan shaft 4 5 69 1 5 69 2 5 69 3 5 69 4 ...

Page 131: ...crewdriver 13mm ring spanner 6 8 and 12mm hexagon socket spanners Plastic hammer Tweezers 6 5 70 1 5 70 2 D353SE23 TIGHTENING TORQUE L Left port R Right port T Tank P Pump 3 Port L R T P Mounting bolt Size 3 4 16UNF 3 4 16UNF 3 4 16UNF 3 4 16UNF M10 1 5 Torque kgf m lbf ft 6 1 0 6 44 4 3 6 1 0 6 44 4 3 6 1 0 6 44 4 3 6 1 0 6 44 4 3 4 0 0 5 29 3 6 ...

Page 132: ...the steering unit in the holding tool Screw out the screws in the end cover 6 off plus one special screw 4 1 Remove the end cover sideways 2 Lift the gearwheel set With spacer if fitted off the unit Take out the two O rings 3 Remove cardan shaft 4 5 72 1 5 72 2 5 72 3 5 72 4 ...

Page 133: ...5 17 Remove distributor plate 5 Screw out the threaded bush over the check valve 6 Remove O ring 7 Shake out the check valve ball and suction valve pins and balls 8 5 73 1 5 73 2 5 73 3 D353SE09 ...

Page 134: ... 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 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 r...

Page 135: ...eir slots in the spool 13 Remove dust seal and O ring 14 Disassembling the pressure relief valve Screw out the plug using an 8mm hexagon socket spanner Remove seal washers Carefully press the spool out of the sleeve 12 5 74 4 5 75 1 5 75 2 D353SE10 15 ...

Page 136: ...tting screw using an 8mm hexagon socket spanner 16 Shake out spring and piston The valve seat is bonded into the housing and cannot be removed 17 The pressure relief valve is now disassembled 18 D353SE11 D353SE12 D353SE13 ...

Page 137: ...h spring slots Place the slots and holes opposite each other so that parts of the holes in the sleeve are visible through the slots in the spool 5 1 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 2 Line up the spring set 3 5 76 1 5 76 2 5 76 4 Guide the spool into the sleeve Make sure that spool ...

Page 138: ...utral position springs into place in the sleeve 5 Line up the springs and center them 6 Guide the ring down over the sleeve The ring should be able to rotate free of the springs 7 5 77 2 5 77 3 5 77 4 Fit the cross pin into the spool sleeve 8 5 78 1 ...

Page 139: ...ttern for standard bearings 1 Outer bearing race 2 Thrust bearing 3 Inner bearing race 4 Spool 5 Sleeve Installation instruction for O ring Turn the steering unit until the bore is horizontal Guide the outer part of the assembly tool into the bore for the spool sleeve 10 5 78 2 5 78 3 5 78 4 ...

Page 140: ...them on the tool 11 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 12 Press and turn the O ring into position in the housing 13 5 79 1 5 79 2 5 79 3 5 79 4 ...

Page 141: ...l with hydraulic oil and place it on the assembly tool 15 Guide the assembly tool right to the bottom 16 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 14 5 80 1 5 80 2 5 80 3 5 80 4 ...

Page 142: ...nit until the bore is vertical again Put the check valve ball into the hole indicated by the arrow 20 Press and turn the lip seal into place in the housing 17 With a light turning movement guide the spool and sleeve into the bore Fit the spool set holding the cross pin horizontal 18 5 81 1 5 81 2 5 81 3 5 81 4 ...

Page 143: ... shaft down into the bore so that the slot is parallel with the connection flange 24 Screw the threaded bush lightly into the check valve bore The top of the bush must lie just below the surface of the housing 21 Grease the O ring with mineral oil approx viscosity 500 cSt at 20 C 22 5 82 1 5 82 2 5 82 3 5 82 4 ...

Page 144: ... the seven through holes match the holes in the housing 27 Fit the spacer if any 28 Place the cardan shaft as shown so that it is held in position by the mounting fork 25 Grease the two O rings with mineral oil approx viscosity 500 cSt at 20 C and place them in the two grooves in the gear rim Fit the gearwheel and rim on the cardan shaft 26 5 83 1 5 83 2 5 83 3 5 83 4 ...

Page 145: ...ghten all the screws and the rolled pin Tightening torque 4 0 0 5kgf m 28 9 3 6lbf ft 31 Place the dust seal ring in the housing 32 Place the end cover in position 29 Fit the special screw with washer and place it in the hole shown 30 5 84 1 5 84 2 5 84 3 5 84 4 ...

Page 146: ...5 30 Fit the dust seal ring in the housing 33 Press the plastic plugs into the connection ports Do not use a hammer 34 5 85 1 5 85 2 ...

Page 147: ...5 31 2 PRIORITY VALVE STRUCTURE 50DS7ESE08 1 Body 2 Spool 3 Spring plug 4 End plug 5 Spring 6 O ring 7 Orifice 1 ...

Page 148: ...4 3 15 D357SE21 1 Tube assy 2 Rod assy 3 Piston seal 4 Wear ring 5 Gland Specifications Cylinder bore 80mm Outer diameter 94mm Stroke half 180mm Rod diameter 55mm 6 DU bushing 7 Rod seal 8 Back up ring 9 Dust wiper 10 Snap ring 11 O ring 12 Back up ring 13 O ring 14 Lock washer 15 O ring 1 ...

Page 149: ...INSPECTION 2 3 1 2 3 4 Check item Remarks Criteria Clearance between piston cylinder tube Clearance between cylinder rod bushing Seals O ring Cylinder rod Cylinder tube Replace piston seal Replace bushing Replace Replace Replace 0 05 0 25 0 002 0 01 0 05 0 18 0 002 0 007 Damage Dents Biting Standard size Repair limit 0 4 0 02 0 3 0 01 mm in ASSEMBLY Install a new piston seal around the groove on t...

Page 150: ...is needed to calk again never calk on the same place 6 D353SE31 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 Install cylinder into trail axle While idling the engine with the rear wheels off the ground operate the steering wheel left and right alternately Then repea...

Page 151: ...her 9 Shim washer 10 Set screw 11 Hexagon nut 12 Gasket 13 Cover 14 Bolt w washer 15 Grease nipple 16 Hexagon bolt 17 Hexagon nut 18 Link 19 Inner race bushing 20 Link pin 21 Special washer 22 Split pin 23 Grease nipple 24 Hub 25 Hub bolt 26 Taper roller bearing 27 Taper roller bearing 28 Oil seal 29 Special washer 30 Lock nut 31 Split pin 32 Hub cap 33 Steering cylinder 35 Cover 36 Hexagon bolt 3...

Page 152: ...m in 50DS7ESE25 Shaft Replace Adjust shim Replace OD of king pin OD of steering cylinder pin Knuckle A1 A2 D1 D2 D3 OD of pin Vertical play ID of bushing OD of shaft ID of bushing 60 2 4 60 2 4 50 2 0 22 0 9 22 0 9 22 0 9 59 5 2 3 59 5 2 3 49 8 2 0 21 9 0 9 21 9 0 9 0 2 0 008 22 5 0 9 OD Outer diameter ID Inner diameter ...

Page 153: ...oil seal Don t use same oil seal twice Repeat the same procedure for the other side Moreover when disassembling is completed part the lock nut in the knuckle to protect the threaded portion 2 3 4 5 6 7 1 Hub cap Spilt pin Lock nut Roller bearing Hub Roller bearing Oil seal Knuckle Washer D353SE24 D507SE26 2 4 10 11 13 12 14 15 5 14 12 13 15 4 5 6 22 21 20 D507SE37 Loosen set screw 10 and nut 11 Lo...

Page 154: ...be sure that the fixed ring of the bearing is placed in position facing the knuckle 2 Hub Mount oil seal 28 and inner race of tapered roller bearing 26 on the knuckle The bearing should be well greased before assembling Install the outer race of the bearing 27 in the wheel center and assemble to the knuckle Put washer 29 in place tighten with nut 31 and locked with split pin 30 In locking with spl...

Page 155: ...SECTION 6 HYDRAULIC SYSTEM Group 1 Structure and function 6 1 Group 2 Operational checks and troubleshooting 6 15 Group 3 Disassembly and assembly 6 20 ...

Page 156: ...F LS TO BRAKE 4 5MPa 13 5MPa T LS P L R T R P T M R GAGE PORT From Axle To Axle 15MPa 14 P 60L7AHS01 1 Main pump 2 Priority valve 3 Main control valve 4 Steering unit 5 Brake valve 6 Steering cylinder 7 Tilt cylinder 8 Lift cylinder 9 Suction filter 10 Return filter 11 Down control valve 12 Down safety valve 13 Flow control valve 14 Hydraulic oil tank ...

Page 157: ...VER IS IN THE LIFT POSITION 1 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 3 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 14 at the same time When t...

Page 158: ...2B 2A 3B 3A 4B 4A GAGE PORT Lower 50DS7EHS03 WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION 2 When the lift control is pushed forward the spool on the first block is moved to lower position The work port 1B 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 ...

Page 159: ... IS IN THE FORWARD POSITION 3 When the tilt control lever is pushed forward the spool on the second block is moved to tilt forward position The oil from hydraulic gear pump 1 flows into main control valve 3 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 14 at the same time ...

Page 160: ...ER IS IN THE BACKWARD POSITION 4 When the tilt control lever is pulled back the spool on the second block is moved to tilt backward position The oil from hydraulic gear pump 1 flows into main control valve 3 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 14 at the same time Whe...

Page 161: ...15 18 17 16 18 17 16 18 17 16 18 17 16 18 17 16 18 17 16 18 17 16 18 60L7AHS06 1 Cover 2 Gear housing 3 Bearing carrier 4 Gear housing 5 Cover 6 Shaft gear set 7 Drive gear set 8 Connecting shaft 9 Thrust plate 10 Lip seal 11 Rubber seal 12 Back up seal 13 Square seal 14 Dowel pin 15 Stud bolt 16 Washer 17 Hex nut 18 Name plate 19 Screw ...

Page 162: ... 7 Spring 8 Seal plate 9 Spring seat 10 Spool end 11 Cap 12 Seal 13 Wiper 14 Plate 15 Screw 16 Spring 17 Poppet 18 O ring 19 Inlet section assy 20 Plug 21 Nut 22 Nut 23 Spool section assy Tilt 24 Spool section assy Lift 25 Main relief valve 26 Cap 27 Plug 28 Spring 29 Outlet section assy 30 Spool section assy Aux 31 Relief valve assy 32 Tie rod 33 Tie rod 34 Spool section assy Aux 1 Port name Inle...

Page 163: ...t 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 D353HS08 ...

Page 164: ... 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 T In lift lower position the fork drops due to its own weight ...

Page 165: ...e 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 ...

Page 166: ... 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 ...

Page 167: ...of the relief unit Procedure 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 4 1 D353HS99 Function 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 a...

Page 168: ...st pilot puppet E This shuts off the oil flow to the area behind relief valve poppet D and causes a low pressure area internally As anti void The anti void unit supplies oil to the high pressure port HP when cavitation has occurred A lower pressure exists in the port HP compared to the low pressure chamber LP The difference between the effective area of diameter A and G causes imbalance of the che...

Page 169: ... 5 TILT CYLINDER 18 17 21 20 19 27 22 7 8 3 11 12 5 6 4 9 10 2 1 14 13 15 16 26 23 24 25 60L7AHS13 1 Tube assy 2 Rod 3 Gland 4 DU bushing 5 Rod seal 6 Back up ring 7 Dust wiper 8 Snap ring 9 O ring 10 Back up ring 11 O ring 12 Lock washer 13 Piston 14 O ring 15 Piston seal 16 Wear ring 17 Set screw 18 Rod eye 19 Hexagon bolt 20 Hexagon nut 21 Spring washer 22 Spherical bearing 23 O ring 24 Dust ca...

Page 170: ...0 minutes and measure hydraulic drift amount forks move down and amount mast tilts forward Hydraulic drift Down Downward movement of forks Within 100mm 3 9in Forward Extension of tilt cylinder Within 5 If the hydraulic drift is more than the specified value replace the control valve or cylinder packing Check that clearance between tilt cylinder bushing and mounting pin is within standard range 1 2...

Page 171: ...triction of oil flow on pump suction side Relief valve fails to keep specified pressure Poor sealing inside cylinder High hydraulic oil viscosity Mast fails to move smoothly Oil leaks from lift control valve spool Oil leaks from tilt control valve spool Excessive restriction of oil flow pump suction side Gear or bearing in hydraulic pump defective Foreign matter jammed between sp ool and valve bod...

Page 172: ...spool of the valve Spool got stuck Leakage in a part of the circuit Defect of relief valve Leakage in a part of the circuit Working with higher pressure than rated pressure Low viscosity of oil Leakage from a part of the circuit Oil leakage in the pump Insufficient suction of the pump Defect of steering relief valve Fit the stop valve on the pipe between valve and cylinder observe the internal lea...

Page 173: ...tings check condition of line Drain reservoir fill with non foaming oil Replace shaft seal Replace drive shaft and seal Cause Remedy HYDRAULIC GEAR PUMP 2 MAIN RELIEF VALVE 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...

Page 174: ...riped O ring damaged Scores on inner surface of tube Unallowable score on the inner surface of tube Foreign matters in piston seal Excessive clearance between cylinder tube and wear ring Insufficient lubrication of anchor pin or worn bushing and pin Bent tilt cylinder rod Replace packing Smooth rod surface with an oil stone Replace dust seal Replace rod Replace O ring Smooth rod surface with an oi...

Page 175: ...19 15 19 19 15 18 17 16 18 17 16 18 17 16 18 17 16 18 17 16 18 17 16 18 17 16 18 60L7AHS06 1 Cover 2 Gear housing 3 Bearing carrier 4 Gear housing 5 Cover 6 Shaft gear set 7 Drive gear set 8 Connecting shaft 9 Thrust plate 10 Lip seal 11 Rubber seal 12 Back up seal 13 Square seal 14 Dowel pin 15 Stud bolt 16 Washer 17 Hex nut 18 Name plate 19 Screw ...

Page 176: ...p the following tools are required Socket wrench set Internal snap ring pliers Shaft seal sleeve Torque 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 ...

Page 177: ...2 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 Disassemble the bearing carrier assy and then remove the connecting shaft 50D7EMP25 50D7EMP26 ...

Page 178: ... and the drive gear set Insert the connecting shaft to the drive gear set and then assemble the bearing carrier assy by fitting of the dowel pin Assemble the drive gear set to another drive gear set by inserting of the hole of connecting shaft Assemble thrust plate and the gear housing by fitting of dowel pin Assemble the cover by fitting of dowel pin When the drive gear sets are removed and assem...

Page 179: ...with tie rods up place O ring into position 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 Position end section on last spool section as shown and hand ...

Page 180: ...f ft Final torque the two 11 16 nuts to 48 5 lbf ft Final torque the 3 4 nut to 74 8 lbf ft Check for proper spool movement 5 Install auxiliary valves and plugs and torque to proper specifications 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 mo...

Page 181: ... 4 Piston seal 5 Back up ring 6 Wear ring 7 Retaining ring 8 Gland 9 DU busing 10 Rod seal 11 Dust wiper 12 O ring 13 O ring 14 Spacer 15 O ring 1 3 4 5 8 15 14 6 7 13 2 9 12 10 11 60L7AHS19 I D O D stroke standard 85 98 1335mm 3 3 3 8 52 6in Rod O D 60mm 2 4in ...

Page 182: ...removed CHECK AND INSPECTION 2 2 1 ASSEMBLY Soak the piston ring in hydraulic oil at a temperature of 40 to 50 C expand the inside diameter and assemble on the piston Install a piston seal Bend the edge of the guide and rotate it to install the guide completely 3 1 Check item Standard size Remedy Repair limit Clearance between cylinder rod bushing Clearance between piston ring tube 0 05 0 25 0 002...

Page 183: ...Washer 13 Piston 14 O ring 15 Piston seal 16 Wear ring 17 Set screw 18 Eye 19 Hexagon bolt 20 Hexagon nut 21 Spring washer 22 Spherical bearing 23 O ring 24 Dust cap 25 O ring 26 Rod bush 27 Grease nipple 23 1 7 8 3 26 22 17 16 13 15 14 11 12 10 9 6 5 4 19 18 21 20 2 27 23 25 24 25 24 27 27 60L7AHS16 I D O D stroke 110 124 338mm 4 3 4 9 13 3in Rod O D 50mm 1 97in ...

Page 184: ...r head and remove the cylinder head from cylinder tube When doing this wind tape round the threaded part of the rod and be careful not to damage the dust seal and rod seal inside cylinder head 2 3 1 Check item Standard size Remedy Repair limit Clearance between cylinder rod bushing Clearance between rod head bushing pin 0 072 0 288 0 003 0 011 0 10 0 35 0 004 0 014 0 5 0 020 0 6 0 024 Replace bush...

Page 185: ...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 ...

Page 186: ...0L7AEL02 1 Work lamp 2 Battery 3 Master switch 4 Tilt alarm 5 Micro switch 6 High horn 7 Back buzzer 8 Beacon lamp 9 License lamp 10 Forward reverse lever 11 Operating panel 12 Head lamp switch Illumination lamp Turn signal switch 13 Horn button 14 Start switch 15 OPSS unit 16 Buzzer 17 Hazard switch opt 18 Relay 19 Fuse box ...

Page 187: ...7 2 1 2 1 2 3 4 ST CL TN BK 5 6 GN RW RB R LW B 1 2 3 4 ST CL TN BK 5 6 GN RW RB R LW B M GROUP 2 ELECTRICAL CIRCUIT 60L7AEL01 ...

Page 188: ...7 3 10MM RING ELECTRIC CIRCUIT FOR LPG FUE KIT 35L7AEL07 ...

Page 189: ...7 4 MEMORANDUM ...

Page 190: ...he positive battery terminal OPERATING FLOW Battery Start motor CN 45 B I conn CN 1 2 Start switch CS 2 3 Fuse box CN 36 No 1 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 1 CHECK POINT 2 Engine OFF Key switch OFF Voltage 12V Check point GND Battery GND Fuse No 1 GND Start key GND Ground ...

Page 191: ...0 GEAR SELECTOR CS 11 CS 12 COMBINATION SWITCH HORN SWITCH CS 5 HAZARD SWITCH CS 41 FLASHER UNIT CR 11 210 310 1 3 2 4 250 CN 55 250 OPSS UNIT CN 113 OPSS BUZZER 332 250 1 2 OPTION CABIN CN 17 260 4 2 3 1 260 35SQ B FUSE BOX CN 36 10A TURN OPSS 5A HEAD TAIL 15A HORN STOP CABIN IG CLUSTER F R SWITCH OPSS SEAT HEATER 5A 10A 15A 10A START RELAY WORK BEACON 1 2 3 4 5 6 7 8 9 10 11 12 5A 5A 5A CABIN B ...

Page 192: ...y switch is in ON position Start switch ON CS 2 4 Fuse box No 5 Combination switch CS 12 5 Illumination relay CR 40 30 Head lamp relay CR 13 30 When start key switch is START position Start switch START CS 2 2 Fuse box CN 36 12 Neutral relay CR 5 30 1 1 2 CHECK POINT 2 Engine Running Key switch ON Voltage 12V Check point GND Battery B GND Fuse box No 5 GND Start key GND Neutral relay GND Ground ...

Page 193: ... BEACON 1 2 3 4 5 6 7 8 9 10 11 12 5A 5A 5A CABIN B 10A 1 2 U 3 G R L B M M B 120 R 35SQ R 35SQ B START MOTOR CN 45 BATTERY 12V MASTER SW ALTERNATOR CN 74 FUEL SYSTEM HARNESS 1 35SQ B 2 120 L M N P A B C D E F G H J K R S ACCEL PADAL 5V EXT ACCEL PEDAL 5V RTN ACCEL PEDAL FPP1 ACCEL PEDAL FFP2 IVS MIL LAMP 12V at CRANK ONLY E G OIL PS WARNING LAMP ECT Gauge CHARGE WARNING LAMP IG VSW 230 1 2 6 7 4 ...

Page 194: ...ch Start switch OPSS unit Beacon lamp Relay Work lamp switch Remark Specification 12V 58AH RC 130min CCA 630 12V 16A 12V 10W 12V 21 5W Tail Stop 12V 21W Turn signal 12V 21W Back up 12V 55W 12V 23 8W 85 10 C M 23W 23W 2 3W 2 12V 80 90dB 120 20C M 12V MAX 3 5A at 12V 100 115dB A at 13V 2m 180A Tail Head DC12V 300mA F R DC12V 300mA DC24V 150mA 12V 16A DC24V 30A 60A 12V 24V MAX 0 5A at 12V DC12V Max 1...

Page 195: ...ine harness license lamp harness Horn Tilt alarm Fuse box Start motor OPSS unit Cluster Cluster Back buzzer OPSS buzzer Forward solenoid 1 Reverse solenoid 1 Forward solenoid 2 Reverse solenoid 2 C O SOL 1 Tilt C O SOL 2 Lift Accel pedal Start switch Horm Gear selector switch Combination switch Parking switch Work lamp switch Beacon switch Hazard switch Tilt switch To seat harness 2 85262 1 368047...

Page 196: ... cleaner switch T M temperature switch Brake oil tank S822 014000 MG640927 S810 003702 MG640927 MG640927 MG640927 MG640927 MG640927 S810 002201 S819 010122 ST730057 2 S819 010122 S814 002100 S822 114000 Connector number Type Destination Connector part No Female Male No of pin CL 7 CL 15 CL 16 CL 21 KET KET KET KET 1 6 6 2 Beacon lamp Combination lamp LH Combination lamp RH License lamp S822 014000...

Page 197: ...gi ne is stopped with starting switch left in ON position Caution lamp defective Caution lamp switch defective Replace Replace Faulty wiring Glow plug damaged Check and repair Replace Faulty wiring Insufficient battery voltage Check and repair Recharge battery Insufficient battery voltage Starting motor defective Recharge battery Replace Insufficient battery voltage Recharge battery Faulty wiring ...

Page 198: ...SECTION 8 MAST Group 1 Structure 8 1 Group 2 Operational Checks and Troubleshooting 8 4 Group 3 Adjustment 8 7 Group 4 Removal and Installation 8 10 ...

Page 199: ... 9 10 8 7 11 Lift cylinder 3 1 4 9 6 5 Lift cylinder Carriage Drive axle 12 60L7AMS01 1 Outer mast 3 Roller bearing 4 Tilt cylinder pin 5 Mast mounting pin 6 Bearing 7 Inner mast 8 Lift chain 9 Anchor bolt 10 Chain sheave bearing 11 Roller bearing 12 Wear plug ...

Page 200: ...ster 3 13 10 4 9 9 10 10 12 2 11 Free Lift cylinder Inner master 11 3 Drive axle 6 Carriage 7 60L7AMS03 1 Outer mast 2 Shim 0 5 1 0t 3 Roller bearing 4 Side roller 5 Tilt cylinder pin 6 Mast mounting pin 7 Bearing 8 Middle mast 9 Chain sheave bearing 10 Anchor bolt 11 Chain 12 Sheave bracket 13 Inner mast 14 Wear plug ...

Page 201: ...8 3 3 CARRIAGE BACKREST AND FORK 2 3 3 4 5 6 7 8 1 60L7AMS04 1 Backrest 2 Carriage 3 Roller 4 Side roller 5 Fork 6 Extension fork 7 Wear plug 8 Knob ...

Page 202: ...fork carriage and between outer mast and inner mast Use these figures to judge if there is any play at roller or rail Front to rear clearance Within 2 0mm 0 08in Left to right clearance Within 2 5mm 0 10in Check that there is an oil groove in bushing at mast support Set mast vertical raise forks about 10cm from ground and push center of lift chain with finger to check for difference in tension If ...

Page 203: ...ormed mast assembly Faulty hydraulic equipment Deformed mast assembly Deformed masts or carriage Faulty hydraulic equipment Damaged load and side rollers Unequal chain tension between LH RH sides LH RH mast inclination angles are unequal Mast assembly is twisted when tilted Disassemble repair or replace See troubleshooting hydraulic pump and cylinders in section 6 hydraulic system Disassemble mast...

Page 204: ...y Difference in height at tip of forks Fatigue failure may result from the fatigue crack even though the stress to fork is below the static strength of the fork Therefore a daily inspection should be done Crack on the fork heel Crack on the fork weldments If the measured value is below the wear limit replace fork If the measured value exceeds the allowance replace fork Repair fork by expert In cas...

Page 205: ...earance between the roller side face and mast at the closest position on the opposite side to the following value by inserting the inner outer mast roller shim Standard clearance A B 0 0 6mm Shim thickness 0 5 1 0mm Distribute the shim thickness equally to the left and right roller Refer to Mast load roller and back up liner removal and Installation After the adjustment check that the inner mast m...

Page 206: ...e side to the following value by inserting the inner and middle mast roller shim respectively Standard clearance A 0 0 6mm Shim thickness 0 5 1 0mm Distribute the shim thickness equally to the left and right roller Refer to Mast load roller and back up liner removal and Installation After the adjustment check that the inner mast moves smoothly in the middle mast and the middle mast moves smoothly ...

Page 207: ...arance at upper middle and lower rollers after loosen the adjust screws from the side rollers Shift the carriage to one side to bring the roller into contact with the inner mast and measure the clearance between the roller side face and mast at the closest position on the opposite side to the following value by inserting the carriage roller shim Standard clearance C 0 0 6mm Shim thickness 0 5 1 0m...

Page 208: ...RRIAGE 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 While supporting lift chains remove the split pin and slide out chain anchor pins from the...

Page 209: ... 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 2 1 2 3 4 CARRIAGE LOAD ROLLER Remove carriage as outlined in the carriag...

Page 210: ...ter 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 Using the overhead hoist lower inner mast until top and bottom rollers and back up liners are exposed Using a pryer remove load rollers from load roller bracket Remove back up liners and shims Thoroughly clean inspect and replace all worn or damaged parts...

Page 211: ...s will create slack in the chains 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 Using a pryer remove load rollers from load bracket Remove back up liners and shims Attach chains or sling to the middle mast section at top cros...

Page 212: ...isconnect free lift cylinder hose Drain hose into a suitable pan or container and cap hose While supporting free lift cylinder assembly remove bolts and washers securing cylinder to mast crossmember Place a sling around free lift cylinder and attach to an overhead hoist Slowly raise and move cylinder to one side Attach chains or sling to the inner mast section at top crossmember Using an overhead ...

Page 213: ...maged parts Reverse the above to assemble and install Use new split pins in chain anchor pins 6 1 Outer mast Chain Carriage Anchor bolt Sheave Inner mast Split pin 60L7AMS19 Carriage Free lift cylinder Inner mast Anchor bolt Chain Chain Middle mast Split pin 60L7AMS14 Rear chain sheave TF mast Raise and securely block carriage and inner mast section Remove the split pin securing the chain anchor p...

Page 214: ...efer to this section for Load chain lubrication and adjustment Carriage chain 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 Place a wooden block under the carriage and lower the carriage o...

Page 215: ...Peened plate edges Oil rusty chains and replace chains with bent or peened components 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...

Page 216: ...ire 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 ...

Page 217: ...t over stretching of chains Prevent chains from jumping off sheaves if they are too loose Adjustment procedure With mast in its fully collapsed and vertical position lower the fork to the floor Adjust the chain length by loosening or tightening nut on the chain anchor After making adjustment on the mast be sure to tighten the nut ...

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